Vishal oil and gas conservation

3
EMERGENCE OF PCRA
 1973 : OIL CRISIS WORLD OVER
 STUDY
TEAM
: ENGINEERS FROM IOC, NPC, DGTD
ESTIMATED HUGE OIL CONSERVATION
POTENTIAL IN INDUSTRIES & STUs
 STUDY
RESULTS
: CONSERVATION POTENTIAL
OF 20 - 30%
 6th
JAN ’76 : PETROLEUM CONSERVATION ACTION
GROUP (PCAG) FORMED
 10th
AUG’78
: PCAG RECONSTITUTED AS
“PETROLEUM CONSERVATION
RESEARCH ASSOCIATION” (PCRA)
AND REGISTERED AS A SOCIETY
UNDER MOP&NG

4
SECTROAL APPROACH
PCRA
INDUSTRY AGRICULTURE
TRANSPORT DOMESTIC
COMMERCIAL

5
SCOPE OF ENERGY AUDIT
Industry (49%) 171.5
MMtoE
Transport (22%) 77 MMtoE
Agriculture (5%) 17.5 MMtoE
Domestic (10%) 35 MMtoE
Others (14%) 49 MMtoE
0%
20%
40%
60%
80%
100%
1
Sectoral Consumption of Energy (350 MMtoE)
DTP &MDP
Energy Audit
71% of the Energy Consumption comes under the ambit of PCRA

6
S.
No.
Activity Nos.
(Since 1985)
1. Energy Audits, Fuel Oil Studies, SSI, Follow ups 34910
2. Institutional training programme 1102
3. Model Depot Projects 1696
4. Driver Training Programme 4014
5. Rectification of LIPs & footvalves 30212
6. Demonstration Centre 411
7. Exhibitions, Seminars & Consumer Meets 945
8. Action Group Meetings 208
9. Youth Programme 6819
10. Van Publicity 3537
A GIST OF FIELD ACTIVITIES.

7
0
50
100
150
200
250
300
350
400
85-86
86-87
87-88
88-89
89-90
90-91
91-92
92-93
93-94
94-95
95-96
96-97
97-98
98-99
99-00
00-01
01-02
02-03
03-04(P)
QTY
VALUE
YEAR
VALUE
(Rs.Crs.)
QTY
(‘000 TONNES
220
275
INCREMENTAL SAVINGS - ALL SECTORS

8
0
100
200
300
400
500
600
700
800
900
1000
85-86 87-88 89-90 91-92 93-94 95-96 97-98 98-99 99-00 00-01 '01-02 '02-03 '03-
04(P)
QTY
VALUE
YEAR
VALUE
(Rs.Crs)
Qty
(‘000
Tonnes)
952.23
701.00
RECURRING SAVINGS –
INDUSTRIAL SECTOR

9
PHILOSOPHY OF ENERGY AUDIT
 Through energy audit, we optimize the consumption of
fuel i.e. coal, electricity petroleum products etc.
 To spread the benefits obtained through Energy Audit
in any one industry to entire cluster
 To replicate the benefit obtained through Energy Audit
in other industries through Education Campaign and
ITPs
 Sponsor R &D projects identified from Energy Audit.

10
Energy Audits in Clusters
(2001-02 to 2003-04)
Sl.
No.
Name of the Cluster
Industry
No. of
Industries
Audited
Annual Energy
Consumption
(KLOE)
Saving
Potential
Identified
(KLOE)
1 Aluminium 5 13570 936
2 Iron & Steel 62 133677 16276
3 Cement 2 37786 722
4 Pulp and paper 11 58297 3561
5 Sugar 1 1450 290
6 Textile 49 153770 6749
7 Chemical 30 56642 3366
8 Process Industries 131 290718 16882
9 Thermal Power Station 1 1800 257
10 Commercial Buildings 58 19199 1823
11 Hand Tools Industry 28 11020 1888
12 Milk Processing Industry 20 24311 1676
13 Food processing Industry 29 59771 4812
14 Petroleum 80 4930354 82643
15 Engineering 97 1172053 17326
16 Misc. 1 272 17
Total 604 6964417 159206

11
Sl
No
Name of Industry Type Audit
Type**
City *EYC
KLOE
Savings
Identified
(SI) KLOE
% SI/
EYC
1. ONGC Natural Gas P Uran, Mumbai 128891 20834 16
2. IOC Blending Ltd. LO Blending P Vashi,
Mumbai
1750 205 12
3. IOC LPG Bottling LPG Bottling P Bhopal 1000 200 20
4. LPG Recovery
Plant, GAIL
LPG
Recovery
P Lakwa,
Assam
22470 2000 9
5. HPCL, Nagaon
Paper Mill
Paper Mill P Nagaon,
Assam
1600 190 12
6. Vishnu Chem (Units
I & II)
Chemical P Medak, A P 4120 900 22
7. Mother Dairy Dairy P Delhi 1229 43 3
8. India Habitat Centre Office M Delhi 1338 96 7
9. Star Wire India Ltd Steel E Ballabhargh 1247 61 5
10. TELCO Automotive E Jamshedpur 10000 975 10
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited industrioes
MAJOR ENERGY AUDITS
(Since 2001)

12
Sl
No
Name of Industry Type Audit
Type**
City *EYC
KLOE
Savings
Identified
(SI) KLOE
% SI/
EYC
11. TVS Motor Co. Automotive E Hosur,
Karnataka
7920 715 11
12. Security Paper Mills Paper Mill P Hoshangabad,
MP
11300 1840 16
13. JK Pharma Chem
Ltd
Pharma-
ceuticals
P Cuddalore, TN 8000 500 6
14. UPRVUNL Power E Anpara, UP 4776 232 5
15. Ginni Filaments Textile T Chhata, UP 13200 827 6
16. Hans Metals P Ltd. Metal E Kanpur, UP 2000 218 11
17. Hindalco Ind. Ltd Aluminium E Renukoot, UP 4476 498 11
18. Maxlux Glass P Ltd. Glass P Uluberia, WB 2448 345 14
19. Hindustan Iron &
Steel Co. Ltd.
Steel E Kolkata 1400 123 9
20. Britania Industries Biscuit P Kolkata 1920 29 2
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited
MAJOR ENERGY AUDITS
(Since 2001)

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Energy is Life
Conservation is instinct of life
GDP is inseparable from conservation /efficiency
Who are the Stake Holders?

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ATMOSPHERE
ENVIRONMENT HYDROSPHERE
BIOSPHERE
CONSUMERS
GOVERNMENTS
POLICY
LAWS
REGULATORS
MARKETS
INDUSTRY
ASSOCIATIONS
COMMERCE/BUSIN
ESS/TRADE
IMPORTS /
EXPORTS
ECONOMY/
FINANCE/ BANKING
TAXES /
INCENTIVES
PROFITABILITY
FACTORY
PRODUCT MIX
LOGISTICS
PROCESS
MACHINERY
SCALE
QUALITY
SAFETY
STAFF
COMMUNITY
VENDORS
INPUTS

15
Energy is :Energy is :
 Food, Fodder , Fiber, FuelFood, Fodder , Fiber, Fuel
 HealthHealth
 SafetySafety
 ClimateClimate
 Any greater cause than energyAny greater cause than energy
conservation?conservation?

17
 Energy is Consumed forEnergy is Consumed for emotional upliftemotional uplift likelike
consumerism, competition, convenience,consumerism, competition, convenience,
comfort, life style, luxury etc.comfort, life style, luxury etc.
 Energy & energy conservation is an issue ofEnergy & energy conservation is an issue of
1.1. AttitudeAttitude
2.2. ValuesValues
3.3. BeliefsBeliefs
4.4. PracticesPractices

18
 Energy is an Emotion more than KnowledgeEnergy is an Emotion more than Knowledge
• The T&D losses in Mumbai, Calcutta & DelhiThe T&D losses in Mumbai, Calcutta & Delhi
are 10-11%, 18-19% & 30% respectively. Inare 10-11%, 18-19% & 30% respectively. In
certain states it is 50%certain states it is 50%
• Russia took 12 years to ratify Kyoto ProtocolRussia took 12 years to ratify Kyoto Protocol
• USA is not convinced yet to ratify KyotoUSA is not convinced yet to ratify Kyoto
ProtocolProtocol

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 50 years back we knew Drinking Water was50 years back we knew Drinking Water was
free. Today it is NOTfree. Today it is NOT
 Drinking water extraction in future may use oil
drilling like technology and vast process plants to
make the water potable.
 Where is the energy for this future?Where is the energy for this future?
Energy & Resources

20
All of us believe today that Air is Free.Air is Free. WillWill
it follow the route of Drinking Water init follow the route of Drinking Water in
future?future?
For combustion and release of energy, air is
as important as fuel if not more. How many
of us measure and control the combustion
process in totality ?.
Energy & Resources

21
How many of us check the air filter vis-à-
vis the fuel tank level of our automobiles ?
Can you risk to Guess , billions of US
dollars of packaged airpackaged air in future and the
life formslife forms?
Energy & Resources

23
 Enlightened industry is employing OEMs &
Technology suppliers to do Energy Audit at
regular intervals
 MNCs are conducting Energy Audits of their
vendor’s units over decades
 Tea, Salt & Chemical Industry using water
circulators or thermic fluid heaters to preheat air
as a via media
PCRA’s Mixed Experience

24
 Hotels are generating hot water from DG set hot
flue gas. Hotels are using boilers to generate steam
and run vapour absorption refrigeration systems
 A very enlightened salt industry using vacuum
flash for drying salt. Producing pure water &
conserving ground water. A two in one salt
manufacture cum desalination! Or is it Three in
One?

25
Some industries still are ignorant and
secretive. Unwilling to allow the energy
auditors to see the process, plant, quality
control deptt etc. They still believeThey still believe energyenergy
conservation is on boiler floor and motorconservation is on boiler floor and motor
drives onlydrives only

26
 The garbage collector’s van getting filled fastest.
Sometimes some houses remain uncollected. The
garbage collector wades through the traffic in
search of easy / quick dumping grounds. Now theNow the
house holder is waiting in advance for thehouse holder is waiting in advance for the
garbage collector to deposit / dispose off hisgarbage collector to deposit / dispose off his
consumption.consumption.
 An increasing tendency of the industry to consume
wood in boilers/ furnaces in place of oil/ coal

28
PCRA’s Experience
 PCRA does the scoping study, meeting &
discussing with people, process study, equipment
wise study, literature study etc before detailed
energy audit. In a way we establish full
communication by knowing the language of thelanguage of the
industry.industry.
 In a textile spinning mill the exhaust fans were of
overcapacity compared to inlet fans

29
Selection of suitable number of inlet fans,
water spray pumps, exhaust fans along with
relative humidity measurement saved 2.5
lacs KWh/Annum
PCRA’s Experience

30
 Air compressor appears to follow 80:20Air compressor appears to follow 80:20
principle. It delivers only 20% effective outputprinciple. It delivers only 20% effective output
and wastes 80% of the input. Due toand wastes 80% of the input. Due to
- Deteriorated performance of internals- Deteriorated performance of internals
- Compressed air leaks- Compressed air leaks
- Air pressure selection- Air pressure selection
- Single stage operation- Single stage operation
PCRA’s Experience

31
 - Inter stage coolers- Inter stage coolers
- cooling Water Treatment- cooling Water Treatment
- Cooling Tower Performance- Cooling Tower Performance
- Pressure drop- Pressure drop
PCRA’s Experience

25.11.04 32
-- In a dry cell manufacturing plant one ofIn a dry cell manufacturing plant one of
the four compressors could be stoppedthe four compressors could be stopped
-- 5% of the electricity generated in the country5% of the electricity generated in the country
runs air compressorsruns air compressors
 In a foundry the used sand of moulds is recycledIn a foundry the used sand of moulds is recycled
after removal of organic binders and flux. Theafter removal of organic binders and flux. The
dryer used for this purpose was kept over fired todryer used for this purpose was kept over fired to
be on the safe side. An appreciation of qualitybe on the safe side. An appreciation of quality
measurement of fresh and recycled sands reducedmeasurement of fresh and recycled sands reduced
the fuel consumption.the fuel consumption.
PCRA’s Experience

25.11.04 33
A steam less dairyA steam less dairy that uses only hot water
circulation. No boiler, no steam.This dairy
does not have milk powder in the productproduct
mixmix
PCRA’s Experience

34
 Optimizing refrigeration loads in a dairy.
20% of refrigeration loads were reduced by
- off peak operation of refrigeration for
ice build up in IBT
- Sequencing of IBT operation & avoid
unnecessary ice build up with respect
to stocks & expected inputs
PCRA’s Experience

35
- Control of ice build up to maximum 2 inch- Control of ice build up to maximum 2 inch
- Automatic instrumentation for heating- Automatic instrumentation for heating
and chilling to avoid over heating / foulingand chilling to avoid over heating / fouling
& over chilling/ too low suction pressure.& over chilling/ too low suction pressure.
-- optimum insitu cleaning to improveoptimum insitu cleaning to improve
regeneration efficiency. Saveregeneration efficiency. Save
water/chemicals toowater/chemicals too
PCRA’s Experience

36
- Monitoring and adjusting cooling tower- Monitoring and adjusting cooling tower
for the ratedfor the rated range and approachrange and approach.. ThisThis
alone controls the Discharge Pressure ofalone controls the Discharge Pressure of
the compressorthe compressor
- Calculate regeneration efficiency in every- Calculate regeneration efficiency in every
shift. Aim for 90%shift. Aim for 90%
PCRA’s Experience

37
 In a Mirinda Orange Drink Plant found that it’s COIn a Mirinda Orange Drink Plant found that it’s CO22
absorption requirement was half compared to exoticabsorption requirement was half compared to exotic
Coco-Cola. Higher temperature of chilling for the desiCoco-Cola. Higher temperature of chilling for the desi
drinks are enough. Different energy settings fordrinks are enough. Different energy settings for
different product mix.different product mix.
 In a latex plant the OEM has set the chiller at +6In a latex plant the OEM has set the chiller at +6 00
C ofC of
product temperature. The process needed higherproduct temperature. The process needed higher
temperature of 16temperature of 16 00
C! In operation, the product wasC! In operation, the product was
shock chilled and allowed to thaw!! A good example ofshock chilled and allowed to thaw!! A good example of
energy conservation at the interface of the equipmentenergy conservation at the interface of the equipment
and process. The machine needs reset for a productand process. The machine needs reset for a product
outlet temp of 16outlet temp of 16 00
C.C.
PCRA’s Experience

38
An FMCG major was connected from anAn FMCG major was connected from an
agricultural feeder. The voltage fluctuationagricultural feeder. The voltage fluctuation
causing recurrent disruptions. They werecausing recurrent disruptions. They were
running DG sets at 20% load factor andrunning DG sets at 20% load factor and
disconnected the EB feeder. Suggested lockdisconnected the EB feeder. Suggested lock
rotor protection/ re-acceleration after carryingrotor protection/ re-acceleration after carrying
equipment wise no load / part load/ full loadequipment wise no load / part load/ full load
readings. The EB feeder was revived. DG setreadings. The EB feeder was revived. DG set
shutdown.shutdown.
PCRA’s Experience

39
 In an asbestos plant, the asbestos, cement and fly
ash slurry is processed in a vacuum drum filter for
required thickness of sheets. The vacuum pump
discharge temperature is 80 0
C. Suggested to
utilize this waste heat to dry the sheets and reduce
fuel firing and electricity
Amazing, is it not?Amazing, is it not?
Lot of low lying fruits!Lot of low lying fruits!
PCRA’s Experience

25.11.04 40
COMPANY POWER & FUEL
03-04 02-03
%
Ch
P&F/Tot Exp (%)
03-04 02-03
ESSAR STEEL 1108 873 26.9 38.8 38.3
GRASIM IND 889 856 3.9 22.6 23.7
ACC 744 706 5.4 25.6 27.5
RELIANCE IND 725 719 0.8 1.8 2.3
TISCO 668 788 -15.3 9.0 11.8
CHAMBAL FERT 554 481 15.2 30.5 31.7
CENTURY TEXTILES 495 466 6.3 25.5 25.3
GUJ AMBUJA CEM 431 324 32.9 34.2 34.5
BALLARPUR IND 412 384 7.3 26.5 34.0
INDIAN ALUMINIUM 378 347 9.0 27.8 29.3
TOTAL(201) 14780 13694 7.9 8.9 9.6
OPPORTUNINITES GALORE
Ref.Financial Express, Chennai 22.06.04
TOP 10 PRIVATE COS ACCORDING TO POWER & FUEL COST(Rs. Crores)

42
Individual Carbon NeutralityIndividual Carbon Neutrality
Distributed Production for DistributedDistributed Production for Distributed
ConsumptionConsumption
Asymptote Nature?Asymptote Nature?
Production Engages
People + Locations
Ecological
Degradation
Concepts for Future
But ………

43
 Food MilesFood Miles
 Up-gradation / harvesting of low grade energyUp-gradation / harvesting of low grade energy
sources (sun light, low temp.heat of flue gassources (sun light, low temp.heat of flue gas
from boiler, furnace, engines, low velocity windfrom boiler, furnace, engines, low velocity wind
by thermo compressors, heat pumps etc)by thermo compressors, heat pumps etc)
 Awakening onAwakening on common property rightscommon property rights of air,of air,
water, earth, sky….water, earth, sky….
Concepts for Future

44
 Conflict resolution between interest holders ofConflict resolution between interest holders of
food, fibre, fodder, fuelfood, fibre, fodder, fuel
 NPT on automobilesNPT on automobiles
 Nuclear power for HNuclear power for H22 production / desalinationproduction / desalination
 Recycling industries for ferrous/ non-ferrousRecycling industries for ferrous/ non-ferrous
metals, plastics, paper etc.metals, plastics, paper etc.
Concepts for Future

45
 Consumers shall pay for the cost of pollution
(producer shall pay …..is past)
 Press the Best Individuals, Institutions,
Organizations, & Resources for energy
conservation. e.g Brand AmbassadorsBrand Ambassadors of theof the
FMCG, Media, Chartered Accountants etc. ThisFMCG, Media, Chartered Accountants etc. This
will ensure sustainable business as well as lifewill ensure sustainable business as well as life
Concepts for Future

46
ICAI published a book on energy audit and
management.
Concepts for Future

47
Enjoy the interest on the principal ofprincipal of
nature’s bounty.nature’s bounty. Do not treat it as booty.Do not treat it as booty.
Mankind should not be the worst NPAMankind should not be the worst NPA
amongst the life forms.amongst the life forms.
Concepts for Future

Vishal oil and gas conservation

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