01 Technical Session One

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

TECHNICAL SESSION I

ENERGY CONSERVATION & MANAGEMENT

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

• • • CONTENT • • • TECHNICAL SESSION I 1.

Energy Conservation, Universities and Carbon Footprint

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Mr. Biswas, Mr. Gautam, Mr. Maheshwar, Ms. Shabana 2.

Energy conservation opportunities in pasteurization process of milk in Dairies

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Mr. Amit Kumar Mandal. 3.

Energy Conservation, Conversion and Management

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Ms. Amrit Pal Kaur 4.

Energy Audit And Waste Heat Recovery Opportunities In Shree Cements Ltd, Beawar

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Mr. P.C. Tiwari 5.

Energy Efficient Approach for Alkyd Resin Manufacturing

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Mr. Ranjeet Neve, Mr. Aniket Bodale, Mr. B.B. Gogte, A. Sachin 6.

Energy Conservation Opportunities In Pharmaceutical Plant Air Conditionign

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Prof. D.K. Joshi 7.

Free Cooling As Energy Conservation Measure

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Er. Balbir Singh, Er. V.K. Sethi 8.

Feasibility Study Of Installation of VFD For Id Fans In Thermal Power Plant

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Mr. Santosh Mahadeo Mestry 9.

Industrial Economics

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Mr. L. Manickavasagam 10. Domestic (Human factors)

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Mr. Arunachalam Pillai. A 11. Design and Development of 100 kWp Stand Alone Photo Voltaic Power Plant

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Ms. Madhu Sharma, Dr. S.J. Chopra, Dr. S.P. Singh, Dr. R.N. Singh 12. Eco At Gail , Vijaipur Township, Guna

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Amita Tripathy

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13. Power Optimization In Refrigeration Air Conditioning

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Mrs. Snehlata Soni, Dr. G.S. Sharma, Brijesh Sharma 14. R&D Innovations towards Energy Efficiency in SAIL

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Suresh Prasad, P. Kumar, M Sen, T S Reddy and D Mukerjee

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Energy Conservation, Universities and Carbon Footprint Biswas, Gautam, Maheshwar, Shabana Amrita School of Business, Amritapuri, Kerala

Introduction As of 2009, India has 20 central universities, 215 state universities, 100 deemed universities, 5 institutions established and functioning under the State Act, and 13 institutes which are of national importance.1 There are 16885 colleges with 99.54 lakh students and 4.57 lakh teachers.2 In a country like India where there are so many students, and teachers, it is essential that the future citizens of this planet receive adequate information and resources to ensure that they live with the limited resources and explore for better means of utilization to meet the needs. The practices have to be planted into this generation, so that they carry it over to the work places and eventually across the whole planet.In view of the deteriorating status of the environment, the Supreme Court has recognized the need for basic knowledge about the environment among the youth population. Under the direction of the Honorable Supreme court, UGC has made it mandatory that all University/colleges in India should have a core course in Environmental studies3. This is a welcome move, as knowledge about the deteriorating environment will induce a need for its protection among the youth. Broad and deep understandings of the ways and means to deal with environmental issues have to be addressed and practiced from the universities, where they can learn the best. Resources are limited and the needs are growing, a fact to be admitted. The future generation has to deal with the limited energy resources unless a suitable substitute is found. It has to be understood and accepted that reducing the needs or smarter utilization of resources will help in reducing the demand for growing energy needs. Implementation and propagating the practices of smart utilization in universities result in a better environment and also help the future citizens to live better.

Carbon footprint- A brief insight This paper gives a brief idea for the smart utilization of energy, emphasizing on the carbon footprint produced by each university. A carbon footprint is "the total set of greenhouse gases (GHG) emissions caused by an organization, event, product or person".4 The carbon footprint is not only a direct indicator to the amount of pollution that is being spewed into the planet, but also and indirect indicator of the amount of energy that is being consumed. This can serve as an effective yard stick for universities to gauge their consumption of energy and accordingly reduce it. There are two ways to measure the carbon footprint. One is the bottom-up approach 1

http://en.wikipedia.org/wiki/Education_in_India#cite_ref-I09RA-237_43-1

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http://www.education.nic.in/higedu.asp

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http://www.nlsenlaw.org/resources/ugc-formulates-new-course-on-environmental-studies Wiedmann, T. and Minx, J. (2008). A Definition of 'Carbon Footprint': In: C. C. Pertsova, Ecological Economics Research Trends: Chapter 1, pp. 1-11, Nova Science Publishers, Hauppauge NY, USA. https://www.novapublishers.com/catalog/product_info.php?products_id=5999. 4,4

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 or Process Analysis (PA); the other is the top-down approach or Environmental Input-Output analysis (EIO).5 The detailed methodology to calculate the carbon footprint is beyond the scope of this paper. There are many online tools that help in this calculation. But, it is essential for universities to know their carbon footprint for them to set targets that can be achieved by significantly reducing them, thereby reducing the energy requirements.

Buildings and Carbon footprint: With an average area ranging from 4000sqm to 29212120sqm, every university has separate departments, different buildings that come up to almost an average30% of the area.6 Though carbon emission and buildings might seem unrelated in the first look, a detailed insight will show us that they are actually very closely related. American Institute of Architects (AIA) National Government Advocacy Team has pointed out: “the largest source of greenhouse gas emissions and energy consumption in America, as well as around the world, is buildings. Buildings account for an estimated 48% of all greenhouse emissions (in fact buildings consume more than 40% of all the energy produced in the world!)7

The term “CO2 emissions from buildings” is a misnomer as it is not directly like CO2 from vehicles. But they are responsible as the power plants that provide the electricity to run these buildings produce for tonesof CO2. That’s where most of the CO2 emissions attributed to buildings are coming from.

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www.amrita.edu/about/infrastructure.php .The percentage is calculated on the basis of area of campus to buildings ratio of Amrita Vishwa Vidyapeetham. 7 http://www.treehugger.com/files/2006/05/buildings_accou_1.php Energy Conservation & Management

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The main difference between CFC’s and CO2 is that the people would not feel that they are contributing something to CO2 emission while using electricity. But at the same time while using a refrigerator they know that this would produce CFC’s. In the life time of an average building most energy is consumed, not for construction, but during the period when the building is in use. Typically more than 80% of the total energy consumption takes place during the use of buildings and less than 20% during construction of the same. A building needs a lot of energy to keep its occupants safe, comfortable and productive. It has to keep warm in the winter and cool in the summer, provide lighting, power security systems and heat water, among many other things That is, the energy used for heating, cooling, lighting, cooking, ventilation and so on. Significant gains can be made in efforts to combat global warming by reducing energy use and improving energy efficiency in buildings. The right mix of appropriate government regulation, greater use of energy saving technologies and behavioral change cansubstantially reduce carbon dioxide (CO2) emissions from the building sector, says the report from the United Nations Environment Program (UNEP) Sustainable Construction and Building Initiative (SBCI)8.

Government regulations Many countries have developed their own standards for green building or energy efficiency for buildings. In India we have Indian Green Building council (IGBC) or GRIHA(Green Rating for Integrated Habitat Assessment)9. GRIHA attempts to minimize a building’s resource consumption, waste generation, and overall ecological impact to within certain nationally acceptable limits / benchmarks. Along with that they quantify the aspects like energy consumption, waste generation, renewable energy adoption, etc. GRIHA has also a rating tool that helps people assess the performance of their building. It will evaluate the environmental performance of a building holistically over its entire life cycle to provide definitive standards for a

‘Suzlon One Earth’- Suzlon group global headquarter based at Pune. It received provisional Five Star Rating under GRIHA green building rating system

‘green building’. The rating system, based on accepted energy and environmental principles, will seek to strike a balance between the established practices and emerging concepts, both national and international. For a free and democratic country like India we cannot impose regulations forcefully as it may put a large part of the population in difficulty, especially those who are financially backward. But for universities it would not 8 9

http://www.unep.org/Documents.Multilingual/Default.asp?DocumentID=502&ArticleID=5545&l=en http://www.sustainable-buildings.org/index.php?option=com_cstudy#featured Energy Conservation & Management

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be a problem if it is made mandatory. So governments can lead the way by providing a ratings and recognitions for green buildings and make green buildings for all government related buildings. Government can also go for a tax exemption to promote green buildings.

Greater use of energy saving technologies Thermal insulation, solar shading and more efficient lighting and electrical appliances, as well as the educational and awareness campaigns should be welcomed for this. Simple solutions can include sun shading and natural ventilation, improved insulation of the building envelope, use of recycled building materials, adoption of the size and form of the building to its intended use etc. Of course we can achieve even better result ifwe go for more sustainable construction system solutions, like intelligent lighting and ventilation systems, energy pricing and financial incentives that encourage reduction in energy consumption. It also emphasizes that the building sector stakeholders themselves, including investors, architects, property developers, construction companies, tenants, etc. need to understand and support, such policies in order for them to function effectively.

Carbon Neutral Buildings In 2006 the US Conference of Mayors proposed a Resolution which sets a goal for carbon neutral buildings by 203010. Opportunities exist for governments, industry and consumers to take appropriate actions during the life span of buildings that will help mitigate the impacts of global warming.

How does a building becomes carbon neutral? New green building products and procedures enable us to utilize natural resources and provide power and heating to buildings. By using green building technologies we can reduce your carbon footprint and along with energy-efficient products we can make our scheme or building Carbon Neutral. Green Building Design ranges from the siting and orientation for passive solar gain to the building form and external environment. Important considerations for any build are crucial when determining green building design. The concept of living in a low carbon or carbon neutral house was once thought to be costly and impractical, especially in the colder climates of the world. However with new green building design and breakthroughs in sustainable living this conception can now be realized through Carbon Neutral Building. This is the green Lighthouse which is the first CO2 neutral public building in Denmark. It demonstrates that sustainable design is not a question of stuffing the building with brazen, expensive high-tech gadgets, but that it starts with good old fashioned common sense. In

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 fact, 75% of the reduction of the energy consumption is the direct consequence of architectural design11 Only form Europe, more than one-fifth of present energy consumption and up to 45 million tons of CO2 per year could be saved by 2010 by applying more green standards to new and existing buildings. (According to UNEP’s buildings and climate change, Status, Challenges and Opportunities report, 2007)Along with cleaner and renewable forms of energy generation, the energy efficiency is one of the key factors that determine the emission of the CO2. The savings that can be made right now are potentially huge and the costs to implement them relatively low if sufficient numbers of governments, industries, businesses and consumers act. By investing in energy efficiency in buildings, it not only reducing CO2 emission, but better life, wealth and in fact more jobs!! The WWF estimates that 280,000-450,000 jobs can be created in the building sector alone by 2020, just by making our existing building stock more energy efficient and by constructing new buildings according to the best available technologies12.

According to architecture2030.org, by 2035 approximately 75% of the Built Environment Will be Either New or Renovated.

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http://karmatrendz.wordpress.com/2010/01/03/green-lighthouse-carbon-neutral-faculty-building-bychristensen-co-arkitekter/ 12

http://wwf.panda.org/wwf_news/?167022/Going-green-is-where-the-jobs-are-new-study Energy Conservation & Management

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Green buildings in India In India the Energy and Resource Institute plays a very important role in developing green building capacities in the country. The government has recently adopted the rating system of TERI called GRIHA as the National Green Building Rating System for the country. It aims at ensuring that all kinds of buildings become green buildings. THE CESE building in IIT Kanpur became the first GRIHA rated building in the country and it scored 5 stars, highest in GRIHA under the system13. It has become a model for green buildings in the country. It has proved that with little extra investment, tremendous energy and water savings are possible. There are various projects which are the first of their kinds to attempt for green building ratings like apartment residential buildings and non-air conditioned buildings. We can say that though the numbers of Green buildings are less in India the awareness is increasing. People are slowly recognizing the need and necessity of green buildings. According to Biodiversity Conservation [India] Limited (BCIL), a green home can reduce the energy demand load by 45 per cent, water consumption by 75 per cent and CO2 emissions by 22,000 tons annually — as compared with a conventional home. The partial lists of green buildings are listed in Wikipedia (http://en.wikipedia.org/wiki/List_of _energy _efficient _buildings_ in_ India)

More on reducing Carbon footprint Apart from the buildings, other measures can also be adopted to reduce the carbon footprint.

Recycling: There are many items used at a university that can be recycled. Papers, plastics and cardboard boxes are items that are most frequently used at a university and are then thrown out. Collecting these items and reusing or recycling them will help reduce so much of wastage and can bring down the carbon footprint of the university to a very low level. Cardboard boxes can be reused for storage, one-sided assignment papers can be used as scrapbooks or for rough work. Most common plastics seen around college campuses are the soft drink bottles, plastic covers and other packing material. Aluminum cans also contribute to the waste heap. All this can be collected to be given away to recycling units. Conducting a recycling drive inside the campus will increase the sense of awareness and also gives an opportunity to students to perform their bit of service to Mother Earth. Amrita Vishwa Vidyapeetham has set up a system of recycling where every student separates their own waste in to organic and non-organic. The recyclable materials are dealt with separately. At the Ecological department of the Mata Amritanandamayi Math, recyclables like soft plastic bags, potato chip covers etc. are converted into

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http://en.wikipedia.org/wiki/Green_building_in_India Energy Conservation & Management

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useful items like Shopping bags, purses and pouches. Bio degradable substances are converted into compost which is used to manure vegetable gardens. Efforts are made to create a closed loop system in the campus

Transportation: For large campuses, commuting between locations inside the campuses becomes a major source of carbon emission. Using energy saving vehicles like bicycles will help reduce the pollution inside the campus. Encourage walking for better health and better environment. Other vehicles should be strictly banned inside the campus.

Lighting: Students and staff need to be encouraged to use lesser lights when there’s ample daylight available. It is the easiest way to save electricity. Classrooms need to be designed in a way that they let in enough daylight and wind in to save costs on lighting, fans or air-conditioning. Students need to be encouraged to switch off lights that are not needed in their hostel rooms Timers could be built into the switchboards to ensure that there is no light left on after class hours. Also CFLs are a good way of reducing electricity wastage as they use less energy.

Alternate Sources of Energy: Universities like the Arizona State University, USA, have started using this alternate source of energy which is easy to procure14. Entire college roofs can be converted into a power station by installing solar panels on every available space. This will give energy enough for many computers and devices to function, helping in reducing the carbon footprint and consumption of energy by significant levels. Also campuses can also exploit the wind energy to generate energy if applicable.

Energy saving devices: Use energy saving devices in office and hostel. When purchasing electronic devices (like checkingtheir Renewable Energy certificates15) certifications help in conserving energy.

Save water: Reduce wastage of water. People need to be encouraged to develop water and energy saving habits like reducing use of hot water for washing and bathing, not letting the water run free when you are brushing, shaving etc. Some major universities have waste water treatment plants. The water treated from these plants is used for watering gardens.

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http://www.upi.com/Science_News/2008/06/10/ASU-boosts-solar-power-on-campus/UPI82991213153860/ 15 http://www.epa.gov/greenpower/gpmarket/rec.htm Energy Conservation & Management

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Avoid ornamental gardening: Many universities are of the habit of making huge ornamental gardens and lawns with exotic plants that consume so much water and need constant care. Using native plants in gardening can significantly reduce the usage of large amounts of water and other gardening chemicals like fertilizers. Turf grass, the most commonly used groundcover requires much effort and energy constantly to be grown well. While native plants require only the initial costs of establishment. Most native plants use less water because they are adapted to the rainfall in the area. Growing herbal gardens in the campus increases the air quality of the area and helps absorb carbon emissions.

Paperless campus: The greatest source of paper wastage in campuses comes from assignments, exams and records made in paper. The energy wastage that happens when all this paper is thrown away after use is enormous. One way to prevent this wastage is to recycle the paper. Or better even, reduce the use of paper. Many universities, like AmritaVishwa Vidyapeetham’s Amrita University Management System (AUMS)16, now have their own intranet or other licensed software that helps in keepingrecords from the office or library and helps in faculty to student online communication. This can be taken into advantage and the whole system can be converted into an online mode. Exams, assignments can be conducted online. Also, all records can be kept electronically, preventing so much of wastage and thereby reducing carbon footprint.

Organic Food: A large amount of energy goes into the preparation of food and the same is wasted when food is wasted in large amounts as is common in some universities. This wastage must be curbed. Educating the need for conservation of energy by reducing the wastage of food and using the waste materials for making compost, which can be recycled as manure, will help in energy conservation and reducing carbon footprint. Universities can grow the vegetables that they need in the campuses with the help of students. This is a great opportunity for students and staff to come together and interact. This also gives them a sense of being part of the greater energy conservation movement. Student organic farms can be developed. The experience will stay with the students even when they move out of campus. Amrita Sanjeevani, the seva association, at the Amrita Vishwa Vidyapeetham thrusts on students’ responsibility to the nature.17

Planting trees: Planting trees in the campus is always a fun way of being part of the energy conservation movement. Trees are an amazing way to purify air and refresh the ambience. Tree planting drives bring together students. Campuses such as the IIMs and the IISC are known for their greenery.

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http://www.amritatech.com/amritavidya.htm http://www.amrita.ac.in/amritasanjeevani/ Energy Conservation & Management

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Energy conservation opportunities in pasteurization process of milk in Dairies Amit Kumar Mandal [email protected]

Abstract In dairy industries , milk is to be pasteurized by heating it to a temperature around 78ºC and than keeping the milk for 15ºC and than sudden cooling it to a temperature of 6ºC. Thus , this process ensure killing of the microorganisms which are harmful for human health and the milk can be kept for a long time by refrigeration . The actual killing of the microorganisms takes place in the heating process of the milk . The time taken for cooling of milk in case milk is not exposed to surroundings after heating , do not have so much impact on the quality of the pasteurization .Generally , for pasteurization , milk is first heated through an heat exchanger , passed through a milk holder so that it can take 15 seconds to pass and to retain the hot temperature for 15 seconds . After milk holder , the hot milk is directly cooled to 6ºC by an another heat exchanger . There is a potential saving of heat by regeneration of the hot milk coming out of the heat exchanger and the cold milk entering inside the hot heat exchanger .

Keywords – Pasteurization of milk , hot heat exchanger , cold heat exchanger, regeneration of heat . Pasteurization process in milk industry Milk coming from the milk silos or the day tanks is sent to a hot plate type heat exchanger. The temperature of entrance of the milk is 5-6 ºC. The milk is brought to temperature of around 80 ºC( for example 78 ºC in a typical industry in Jaipur dairy, Rajasthan , India). The milk as soon as been reached to desired hot temperature is been sent to a milk holder . The milk holder is a long duct coiled in shape , makes the milk to pass through it in 15 -16 seconds . In this period almost all harmful bacteria’s are been killed . After passing through milk holder the milk is directly cooled in an another plate type heat exchanger in which the heat conveying fluid is chilled water . Thus there is potential saving of

heat and refrigeration load by refrigeration of heat by the

incoming fluid at 6 ºC and the milk coming out from the milk holder . For heat transfer , a plate type heat exchanger can be used .

Method The circuit diagram of the existing method of pasteurization in most of dairy industry is given in fig 1 , similarly the improved method of pasteurization for energy conservation is given in fig 2 . We can observe

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in fig 1 that milk is coming at 6 ºC and heating to temperature of 80 ºC in hot heat exchanger . After passing through hot heat exchanger , the milk is passed through a milk holder where it takes the milk to pass out in 15 seconds at 80ºC . The milk is than passed through a cold heat exchanger where it is again brought to 6ºC.In fig 2 , the hot milk coming out from the milk holder is been sent to a heat exchanger for regeneration . The incoming milk at 6 ºC is been passed through regenerative heat exchanger as a cold fluid in . Similarly the hot milk coming out from the milk holder is going inside the regenerative heat exchanger as a hot fluid in . The cold fluid comes out by recovering the heat of hot milk coming out from the milk holder . The hot milk of the milk holder also becomes cool by this process .The base of doing such arrangement is pasteurization is process of heating the milk above 80ºC and keeping it for sufficient time so that the cell wall of the bacteria rupture and been killed . Once the bacteria’s are been killed ,the milk can be kept refrigerated for long time without any harm . In dairy processes , the milk is heated in heat exchanger and it is not exposed to atmosphere anywhere after heating it . Thus the regenerative process can work out and an huge amount of energy can be saved .

fig (1)

Fig (2) Observation and measurement Energy Conservation & Management

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In a typical dairy in India, it is found that milk flow rate of 8.2 ltr/sec is to be pasteurized .The processing is done almost 24 hrs/day . Since the milk coming from the inner silo is at 6ºC to hot heat exchanger . So after coming out from the hot heat exchanger , the milk at 80 ºC can be passed through an regenerator which heats up the cold milk of silo reducing the hot heat exchanger duty , similarly the milk of 80 ºC will becomes cooler after coming out from the regenerator reducing the cold heat exchanger duty .In case the milk is brought to temperature of 40ºC in regenerator and the cold milk of silo is also brought to 40 ºC in regenerator than :Heat saving = 8.2×4.2 ×(40-6)=1170KW =879223Kg FO/yr=21980575rs/yr Similarly refrigeration saving = 8.2×4.2 ×(40-6)=1377.6KW Taking COP= 2.5 Electrical power consumption = 550KW (Electricity cost – INR 4.51/KWH) Thus saving of 21729180 INR /yr is there .In case we save the half of the above calculated amount , still a significant energy and monitory saving is there .

Results There is a potential saving of heat and refrigeration load . As calculated above for 8.2kg/sec mass flow the saving in a typical dairy industry may be 21729180 INR /yr running 24 hrs/day .

Conclusions The process of regeneration can prove a great saving of energy as well as carbon emission to the environment .The investment as compared to the benefits is quite less comparatively .

References •

www.foodscience.uoguelph.ca/dairyedu/pasteurization.html,

•

http://books.google.co.in/books?id=6ROLbW8klRsC&pg=PA196&lpg=PA196&dq=regeneration+in+pasteurizati on&source=bl&ots=17aaGQrPv&sig=yKf4sUJsmVnNkGEmIk8xT3l4BYs&hl=en&ei=H6gITbnPDJDNrQeeqsn VDg&sa=X&oi=book_result&ct=result&resnum=9&ved=0CE0Q6AEwCA#v=onepage&q=regeneration%20in% 20pasteurization&f=false,

•

http://www.medindia.net/patients/patientinfo/pasteurizationofmilk_htst.htm,

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http://www.wikipatents.com/US-Patent-5266343/pasteurization-process-for-dairy-products

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Energy Conservation, Conversion and Management The future 5: savior of energies Ms. Amrit Pal Kaur [email protected]

Abstract Energy is one of the major inputs for the economic development of any country. In case of the developing countries the energy sector assumes a critical importance in view of the ever increasing energy needs requiring huge investments to meet them. also another major concern of the time is the ever increasing global warming and its effects. Now is the time to raise alarms and work towards a better future. This can be achieved by the following five energy technologies.

HVAC: The goal for a Heating, Ventilation and Air Conditioning (HVAC) system is to provide proper air flow, heating, and cooling .The HVAC considers all the interrelated building systems while addressing indoor air quality, energy consumption, and environmental benefit.

Cogeneration: Cogeneration (also combined heat and power, CHP) is the use of a heat engine or a power station to simultaneously generate both electricity and useful heat. Cogeneration is a thermodynamically efficient use of fuel.

Fusion Energy Fusion produces no greenhouse gas emissions. Fusion is suitable for the large-scale electricity production required for the increasing energy needs of large cities. A single fusion power station could generate electricity for two million households.

Carbon Capture And Storage: This technology is the best solution to the rising earth’s temperature. CO2 storage is simply the process of taking captured CO2 and then placing in a location where it will not be in contact with the atmosphere for thousands of years.

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Plastic Solar Cell: The plastic material uses nanotechnology and contains the first solar cells able to harness the sun's invisible, infrared rays. A new type of plastic cell that can harness some 30 percent of the energy falling on it, up from an industry standard of 6 percent. The key is a thin layer of nanoparticles. KEY WORDS: global warming, HVAC, Cogeneration, fusion, plastic solar cell

Introduction The current energy scenario has forced us to think of alternatives for the present energy sources. Thus new advanced energy technologies are the need of time. Another serious issue engulfing our planet is global warming which is spreading like wild fire. Thus we must propose to develop new technologies keeping in mind the present situation.

HVAC An HVAC system provides adequate indoor air quality by: conditioning the air in the occupied space of a building in order to provide for the comfort of its occupants; diluting and removing contaminants from indoor air through ventilation; and providing proper building pressurization. The goal for a Heating, Ventilation and Air Conditioning (HVAC) system is to provide proper air flow, heating, and cooling to each room. HVAC is sometimes referred to as "climate control" and is particularly important in the design of medium to large industrial and office buildings such as sky scrapers and in marine environments such as aquariums, where humidity and temperature must all be closely regulated whilst maintaining safe and healthy conditions within. HVAC systems have a significant effect on the health, comfort, and productivity of occupants. Issues like user discomfort, improper ventilation, and poor indoor air quality are linked to HVAC system design and operation and can be improved by better mechanical and ventilation systems.

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In general, outside (“supply”) air is drawn into a building’s HVAC system through the air intake by the air handling unit (AHU). Once in the system, supply air is filtered to remove particulate matter (mold, allergens, dust), heated or cooled, and then circulated throughout the building via the air distribution system, which is typically a system of supply ducts and registers. In many buildings, the air distribution system also includes a return air system so that conditioned supply air is returned to the AHU (“return air”) where it is mixed with supply air, re-filtered, re-conditioned, and recirculated throughout the building. This is usually accomplished by drawing air from the occupied space and returning it to the AHU by: (1) ducted returns, wherein air is collected from each room or zone using return air devices in the ceiling or walls that are directly connected by ductwork to the air-handling unit; or (2) plenum returns, wherein air is collected from several rooms or zones through return air devices that empty into the negatively pressurized ceiling plenum (the space between the drop ceiling and the real ceiling); the air is then returned to the air-handling unit by ductwork or structural conduits.

HVAC is one of the largest consumers of energy in the hospitality industry, Constituting approximately 30 percent or more of total costs. Because HVAC systems account for so much electric energy use, almost every Facility has the potential to achieve significant savings by improving its control of HVAC Operations and improving the efficiency of the system it uses through proper design, Installation and scheduled maintenance.

Advantages 1) Quieter, and therefore more likely to be turned on or left on by teachers and staff. 2) Less drafty due to multiple supplies and a return that is away from occupants. 3) Better at controlling humidity and condensed moisture drainage. 4) Easier to maintain due to reduced number of components and few units to access. 5) More space around units and can be accessed without interfering with class activities. 6) Space for higher efficiency air filters, and more surface area. Energy Conservation & Management

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Cogeneration Cogeneration (also combined heat and power, CHP) is the use of a heat engine or a power station to simultaneously generate both electricity and useful heat. Cogeneration is a thermodynamically efficient use of fuel. In separate production of electricity some energy must be rejected as waste heat, but in cogeneration this thermal energy is put to good use. Co-generation is the concept of producing two forms of energy from one fuel. One of the forms of energy must always be heat and the other may be electricity or mechanical energy.

Need for cogeneration The major source of loss in the conversion process is the heat rejected to the surrounding water or air due to inherent constraints of different thermodynamic cycles employed in the power generation. In a cogeneration plant, very high efficiency levels, in the range of 75%–90%, can be reached. A number of environmentally positive consequences flow from this fact: Power tends to be generated close to the power consumer, reducing transmission losses, stray current, and the need for distribution equipment significantly. Cogeneration plants tend to be built smaller, and owned and operated by smaller and more localized companies than simple cycle power plants. As a general rule, they are also built closer to populated areas, which causes them to be held to higher environmental standards

Combined cycle system 1) The engine cooling circuit can be sent to a heat reservoir, from which hot water and space heating is produced. 2) The amount of heat recovered is roughly equal to the amount of electric power produced. , this is sufficient to cover the hot water needs free of charge.

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3) When the heat reservoir is full, excess heat is classically dissipated by the engine radiator. An optional heat exchanger further recovers exhaust heat, doubling the amount of heat recovered and pushing thermal efficiency to 90%. 4) This enables to cover free of charge the heating needs of a sufficiently insulated house.

Advantages of Cogeneration 1) In separate production of electricity some energy must be rejected as waste heat, but in cogeneration this thermal energy is put to good use. 2) Since co-generation can meet both power and heat needs, it has other advantages as well in the form of significant cost savings for the plant and reduction in emissions of pollutants due to reduced fuel consumption. Even at conservative estimates, the potential of power generation from co-generation in India is more than 20,000 MW

Fusion Energy In a fusion power plant most of the energy produced by the reactions in the plasma is carried by the neutrons. These high energy neutrons (14 MeV) are captured and their energy used to generate electricity.

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The energy of the neutrons is absorbed in the structures lining the plasma chamber walls. The remaining energy in the helium (4He) particles maintains the high plasma temperature. In a fusion power plant the plasma would be confined in a large vacuum vessel surrounded by a neutron absorbing breeding blanket. The breeding blanket has a dual function: it converts the energy of the neutrons into thermal energy and it ‘breeds’ new tritium from lithium to provide more reaction elements.

How can fusion produce electricity in a future power plant? The fusion reaction can be simply written as: Tritium (3H) + deuterium (2H) >> Helium (4He) + a high-energy neutron (n)

The main challenge in fusion is to maintain the high temperature of the plasma for long periods of time. In burning plasma the energy of the Helium nuclei are the main contributors to heating the plasma. However, the plasma is constantly being cooled by impurities picked up from the vessel wall.

The deuterium-tritium or D-T reaction is the most promising because of the forces between nuclear particles. At very short distances, nuclear particles attract each other through the strong force, and the neutron in tritium adds to this attractive force, thereby promoting the fusion reaction. In the D-T reaction, each neutron carries off about 14 million electron volts of energy, roughly 80% of the released energy (an electron volt is the energy acquired by an electron in moving through a potential difference of one volt).

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These energetic neutrons constitute a considerable radiation hazard, so a fusion reactor will need a one-meter thick lithium blanket to absorb neutrons and breed more tritium. To some degree, quantum mechanics provides a way around the electrostatic repulsion of the protons, because it is possible for the two nuclei to “tunnel” through this barrier and thereby considerably reduce the necessary collision energy. To keep the fusion reaction going, the deuterium and tritium must be heated sufficiently that the ions’ thermal motion will produce sufficiently energetic collisions. In this case the ions must be hot enough that they will form plasma. As plasma moves, its electric currents produce electromagnetic forces that act back on the plasma, so controlling and confining the plasma is a daunting challenge.

Cost of fusion energy An obvious concern with fusion energy is the cost of electric power. A fusion plant must be competitive with both conventional and fission plants in order to be economically viable. As the shown in the above figure which was assembled from several cost comparison studies, IFE plants driven by heavy ion accelerators may produce electricity at a 20-30% cost advantage and may also be competitive with fossil-fuel plants and advanceddesigned fission plants.

Advantages of fusion energy 1) Fusion is an almost limitless fuel supply. Deuterium is abundant and can be extracted easily from sea water. Lithium, from which tritium can be produced, is a readily available light metal in the Earth’s crust. 2) Fusion produces no greenhouse gas emissions. Fusion power plants will not generate gases such as carbon dioxide that cause global warming and climate change, nor other gases that have damaging effects on the environment. 3) Fusion is suitable for the large-scale electricity production required for the increasing energy needs of large Zities. 4) Waste from fusion will not be a long-term burden on future generations. Any radioactive waste generated will be small in volume and the radioactivity will decay over several decades with the possibility of reuse after about 100 years 5) No transport of radioactive materials is required in the day-to-day operation of a fusion power station, as the intermediate fuel tritium is produced and consumed within the power plant. 6) The abundance of raw materials, their wide distribution, and the environmental acceptability of fusion are augmented by the expectation that fusion energy will be an economical source of electricity generation.

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A single fusion power station could generate electricity for two million households.

Carbon Capture And Storage To prevent the carbon dioxide building up in the atmosphere (possibly causing global warming and definitely causing ocean acidification), we can catch the CO2, and store it. As we would need to store thousands of millions of tons of CO2, we cannot just build containers, but must use natural storage facilities CO2 storage is simply the process of taking captured CO2 and then placing in a location where it will not be in contact with the atmosphere for thousands of years. Storage of the CO2 in underground sites beneath a layer of impermeable rock (cap rock) which acts as a seal to prevent the CO2 from leaking out is the most popular option at present.

Carbon capture and storage (CCS) encompasses the processes of capture and storage of CO2 that would otherwise reside in the atmosphere for long periods of time. CCS involves the separation and capture of CO2 at the point of emissions followed by storage in deep underground geologic formations. There are three main types of proposed underground storage sites: 1) Depleted Oil and Gas Reservoirs CO2 can be pumped into the reservoirs to fill the empty spaces left by removal Of hydrocarbons. 2) Deep Saline Aquifers CO2 can also be stored in deep salt water-saturated rock formations.

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3) Deep Unminable Coal Seams CO2 can be stored in deep coal seams where it will be held in the pores on the surface of the coal and in fractures.

Saline Aquifer

Four steps are required for CCS: 1. Capture of CO2 from a power plant. 2. Transport of the CO2 gas to a suitable storage facility. 3. Injection of CO2 gas into an underground reservoir. 4. Monitor the reservoir. While a lot of research on CCS technology has already been done, an overall regulatory framework is still being developed.

Nanotechnology To Generate Electricity

A new type of solar cell uses layers of two different types of conducting polymers to increase the device’s efficiency. The design has achieved a record high efficiency for photovoltaics that use conductive polymers to generate electricity. A new process for printing Plastic solar cells boost the power generated by the flexible and cheap form of photovoltaics.

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How Plastic Solar Cells Turn Sunlight Into Electricity?

When the film is exposed to light, each photon excites an electron in the polymer. If an interface between the polymer molecule and the functionalized buckminsterfullerene exists, a current can be produced. The film is exposed to light using ultra short laser pulses. Not only does this technology make sense from a financial standpoint but it can also be the catalyst, which will make solar power attractive and affordable for the masses.

High- performance and low-cost plastic solar cells: A solar cell that includes a high efficiency thin film plastic (polymer) as the active material. The active material includes a mixture of a semi-conducting polymer and an ionic electrolyte. The semi-conducting polymer is made up of a p-type polymer and an n-type electron acceptor. The ionic electrolyte is present in said mixture in an amount ranging from 0.01 to 5 weight percent.

Konarka technology solar cells

Solar company Konarka has developed technology to create rolls of plastic that can convert light to electricity. Inkjet printing is a commonly used technique for controlled deposition of solutions of functional materials in specific locations on a substrate. It can provide easy and fast deposition of polymer films over a large area. Energy Conservation & Management

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Advantages 1) Reduced Cost 2) Flexibility 3) Lesser Weight 4) Working in cloudy days 5) Utilizing Infrared light 6) Easy to manufacture

Conclusion: The paper discusses that the above five energy technologies are the foremost means to help survive through the energy crisis in the present and the future. Also global warming, environmental degradation is sure to be curbed.

Bibliography: www.nottingham.ac.uk Modern Refrigeration and Air Conditioning (August 2003) by Althouse, Turnquist, and Bracciano, GoodheartWilcox Publisher. Fusion as an energy source-a guide from institute of physics. Fusion science and technology www.geos.ed..ac.uk Cogeneration- Wikipedia. The free encyclopedia www.solarmer.com, www.universityofcalifornia.com

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Energy Audit And Waste Heat Recovery Opportunities In Shree Cements Ltd, Beawar Mr. P.C.Tiwari Cement Manufacturing Process Details :The history of Portland Cement may be said to date back to the time when it was found that by burning limestones containing clay and silica, a cementing agent was produced which hardened under water and after hardening was not soluble in water. As this end product somewhat resembled Portland stone in colour and character, it was named Portland Cement. Earlier cements were incompletely burnt as the material was not heated to a temperature sufficiently high for sintering to occur. It was soon found that higher strengths could be obtained by burning the material more completely i.e. beyond decarbonising and upto sintering which is a stage immediately preceding the melting of the mix. Basically, the ground raw mix containing suitable mixture of calcium oxides, silicon oxides, aluminium oxides and iron oxides respectively occurring as limestone, sand, clay, bauxite, laterite etc. is after fine grinding and blending subjected to burning process inside the kiln. As the temperature rises, carbon dioxide is first evolved at temperatures between 700 deg and 900 deg C transforming the calcium carbonate into lime. Lime being strongly basic reacts with other materials in the raw mix when the temperature further rises and calcium carbonate into lime. Lime being strongly basic reacts with other materials in the raw mix when the temperature further rises and in this way silicates of calcium, aluminium and iron, which are basic constituents of Portland Cement, are formed. At a temperature of 1350 deg C the process of sintering begins inside the kiln and is normally completed between 1400 deg and 1450 deg C. At this stage the material which by now has acquired a greenish black colour is converted into what is known as clinker. This clinker after cooling is ground in finish mills along about 5% gypsum to give the finished product known as Ordinary Portland Cement (OPC).

Raw Material Preparation Limestone of differing chemical composition is freely available in the quarries owned by Shree Cement Limited. This limestone is carefully blended before being crushed. Crusher installed is single rotor impactor of 800TPH capacity and motor 950kW, 1000 rpm, 6600VRed mineral is added to the limestone at the crushing stage to provide consistent chemical composition of the raw materials. Once these materials have been crushed and subjected to online chemical analysis they are blended in a homogenized stockpile. The Stacker used having luffing, slewing and travelling and can pile upto 125m length and storing capacity of 2x30,000MT. A Bridge Scrapper reclaimer 700TPH capacity is used to recover and further blend this raw material mix before transfer to the raw material grinding mills.

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Raw Mill Transport belt conveyor transfers the blended raw materials to ball mills where it is ground. The chemical analysis is again checked to ensure excellent quality control of the product. The resulting ground and dried raw meal is sent to a homogenizing and storage silo for further blending before being burnt in the kilns. The Raw Mill is vertical roller mill with 300TPH capacity, 4.75m dia grinding table, 13 Nos. larger segment, 26 Nos. smaller segment, grinding track dia is 3.75m. there are 3 Nos. grinding rollers with 2.65m diameter 12 Nos. segmented, the roller material is MU18 Chromium Cast Steel. The power requirement is 2400kW and mill speed is 23-37 RPM. Drive Main Gear box is having ration of 64.5:1. motor is 2710kW, BHEL make, 1000 RPM, 6600V HT motor. The Raw Mill fan has a 2400kW, 1000 RPM motor. Silo has a capacity of 20,000 ton and 50.7m height with effective dia of 20m.

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Fuels The heat required to produce temperatures of 1,800°C at the flame is supplied by ground and dried petroleum coke and/or fuel oil. The Petcoke is imported via the companies' internal wharf, stored and then ground in dedicated mills. Careful control of the mills ensures optimum fineness of the Petcoke and excellent combustion conditions within the kilns system. Coal Mill is having capacity of 38TPH.

Burning The raw meal is fed into the top of a preheater tower equipped with 6 cyclone stages. The Preheater contains Pyro string and kiln string cyclones. The Pyro string preheater is type PR7044, 6-stage, cyclone dia stage 2-6 is 7300mm, twin cyclone dia 4600mm, the kiln string preheater type PR6742, 6-stage, ccyclone dia stage 2-6 is 6700mm, twin cyclone dia 4200mm. The pyro-clone precalciner is 3.7m dia and 60m long. As it falls, the meal is heated up by the rising hot gases and reaches 800°C. At this temperature, the meal dehydrates and partially decarbonizes. The meal then enters a sloping rotary kiln, which is heated by a 1,800°C flame, which completes the burning process of the meal. The kiln has a dimension of 4.4m dia, 60m length, 3.5% inclination in length and speed 0.35 to 3.5 RPM. The motor used is 550kW, 1000 RPM, VFC drive with auxiliary drive of 30kW, 1500 RPM motor.The pyrojet burner is having overall thermal capacity 262GJ/hr, burner pipe dia 457.2 x 14.2mm length of total burner 13.602m. The meal is heated to a temperature of at least 1,450°C. At this temperature the chemical changes required to produce cement clinker are achieved. The dry process kiln is shorter than the wet process kiln and is the most fuel-efficient method of cement production available.

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Air Quenched Cooler The clinker discharging from the kiln is cooled by air to a temperature of 70°C above ambient temperature and heat is recovered for the process to improve fuel efficiency. Some of the air from the cooler is dedusted and supplied to the coal grinding Plant. The remaining air is used as preheated secondary air for the main combustion burner in the kiln. Clinker is analyzed to ensure consistent product quality as it leaves the cooler. Metal conveyors transport the clinker to closed storage areas. The AQC is a grate cooler capacity 3500 TPD, cooling area 92m2 with 12 Nos. grate plates, and it is a stepped grate single stage type. The Reciprocating grate is having 11 nos. of hopper and one drag chain with double pendulum flap 300/22. There are 3 Nos. of grate drives of 40kW capacity each with speed 150-1500 RPM and 2.38-23.81 strokes per minute, and stroke length 140mm.

Filters : Air Pollution Control Devices Dedicated electrostatic precipitators dedust the air and gases used in the Clinker Production Line Process. In this way, 99.9% of the dust is collected before venting to the atmosphere. All dust collected is returned to the process. The ESP’s are rated for 280 degree Celcius temperature, 525000m3/h gas quantity, static pressure 150mmWC, raw dust content 37.1g/Nm3, clean gas dust content 75mg/Nm3, 9787.5m2 collecting area, single chamber 3 Nos. field, operating pressure -200mmWC, pressure drop across ESP is 2.5mbar, 0.37kW geared motor for collecting/emitting rapping.

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Cement Mill (clinker grinding): The ball mill is designed for clinker grinding, inner dia 4.6m, 14.7 RPM, 4200kW power requirement, grinding path 13m, grinding media size 25mm motors of 2x2400kW, 993RPM with 216 teeth girth gear & 29 teeth pinion gear of 30mm module.

Constituents Different types of cement are produced by mixing and weighing proportionally the following constituents:

¾ Clinker ¾ Gypsum ¾ Limestone addition ¾ Fly ash for PPC Grades The grade 43 and 53 in cement mainly corresponds to the average compressive strength attained after 28 days ( 672 hours) in mega pascals (Mpa) of at least three mortar cubes ( area of face 50 cm squared) composed of one part cement, 3 parts of standards and ( conforming to IS 650:1966) by mass and P/4 ( P is the percentage of water required to produce a paste of standard consistency as per IS standard) + 3 percentage ( of combined mass of cement plus sand) of water , prepared, stored and tested in the manner described in methods of physical test for hydraulic cement.

Case Study # 1 Replace the existing HT Motor of Raw Mill ESP fan with HT motor 450kW 450 RPM with HT VFD in plant-2 (4500TPD) Raw Mill ESP Fan was observed for its performance and it was found that the fan is operating at 355 rpm against rated 468 rpm and generating a pressure rise of 80mmWG at flow rate 172.66 m3/sec. The HT Slip Ring Induction motor rated for Output power of 710kW and a speed of 740 rpm is driving the fan at 355 rpm which is normal speed required for process requirement. The speed of the fan is being controlled by inserting delta connected external Grid Rotor Resistance where the significant power is lost. The fan installed is Energy Efficient Fan with estimated efficiency of 79% at the operating pressure rise and flow but the motor is operating at only 43% efficiency. The Power loss in GRR is estimated and measured to be 193kW. Air kW generated by the Fan is only 135kW and fan shaft Power required by the fan is 135kW/(0.79 x 0.9 ) which is equal to 190kW. Keeping the other plant operations in view for extreme conditions, an energy efficient HT motor of 450kW, 450 RPM with HT Variable Frequency Drive (VFD) is proposed for driving the fan.

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Also the CGR & GRR requires 5 Nos.X 2.2kW blowers for cooling and 11kW power can be saved in new scheme.

Operating Parameters: Motor Input power = 392kW, Motor Speed = 355 rpm, Slip = 52.19% Air Gap Power = 373kW, Total Cu Loss in Rotor = 373kW X 52.19% = 195kW Motor efficiency at operating load = 43%

Power Saving potential = Total Rotor Cu Loss – Cu loss in rotor winding + Power wasted in Cooling Blowers = (195kW3X2002X0.016/1000 + 11kW) = 204kW Energy Saved=204kWX24Hrs./dayx330 days/ annum=16,15,680 kWh Amount Saved = 16,15,680 kWh X Rs.6/kWh = Rs.96.94 Lacs Investment required = 70 Lacs, Simple Payback period = 9 Months Reduction in CO2 emission=2x0.204MWx24 hrs.x330days/annum =3231 tCO2/annum Saving in cost of Generation=2x0.204MWxRs.600Lacs/MW=Rs.244Lacs

Case Study # 2 Remove damper from the Raw Mill ESP fan suction Unit-2 (4500TPD) Raw Mill ESP Fan was observed for its performance and it was found that a damper is provided for flow control. It was found that the pressure drop across the damper is 11mmWC for the 100% open position and flow is 172.66m3/s. It is proposed to remove damper from the duct as it is wasting an air power of 19kW.

Operating Parameters: Draft before damper = -101mmWC Draft after damper = -90mmWC Draft at fan outlet = -10mmWC Pressure drop across damper = -90 – (-101) = 11mmWC Power loss due to damper = 172.66m3/s X 11mmWC/102 = 19kW Energy Saved = 19kW X 24 Hrs./day x 330 Operating days/ annum = 1,50,480 kWh Amount Saved = 1,50,480 kWh X Rs.6/kWh = Rs.9.02 Lacs Energy Conservation & Management

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Investment required against Labour cost = 0.2 Lacs Simple Payback period = 8 days Reduction in CO2 emission = 2 x 0.019MW x 24hr. x 330days/ annum =301tCO2/Yr. Saving in Cost of power generation = 2 x 0.019MW x Rs.600Lacs/ MW = Rs.22.8Lacs

Case Study # 3 Replace the existing HT Motor of Sepax ESP fan wih HT motor 500kW 988RPM with HT VFD in plant-2 (4500TPD) Sepax Fan was observed for its performance and it was found that the fan is operating at 650 rpm and generating a pressure rise of 424mmWG at flow rate 63.06 m3/sec. The HT Slip Ring Induction motor rated for Output power of 1110kW and a speed of 988 rpm is driving the fan at 650 rpm which is normal speed required for process requirement. The speed of the fan is being controlled by inserting delta connected external Grid Rotor Resistance where the significant power is lost. The fan installed is Energy Efficient Fan with estimated efficiency of 81.35% at the operating pressure rise and flow but the motor is operating at only 59.78% efficiency. The Power loss in GRR is estimated and measured to be 193kW. Air kW generated by the Fan is only 135kW and fan shaft Power required by the fan is 262kW/(0.81 x 0.94 ) which is equal to 343kW. Keeping the other plant operations in view for extreme conditions, an energy efficient HT motor of 500kW, 988 RPM with HT Variable Frequency Drive (VFD) is proposed for driving the fan.

Operating Parameters: Motor Input power = 539 kW, Motor Speed = 650 rpm, Slip = 34.34% Air Gap Power=508 kW, Total Cu Loss in Rotor = 508kW X 0.3434%=174.3kW Motor efficiency at operating load = 59.78% Power Saving potential = Total Rotor Cu Loss – Cu loss in rotor winding = (174.3kW-3X1702X0.02/1000) = 174.3-1.734= 172.61kW Energy Saving potential= 172.61kW X 24Hrs./ day x 330 days/ annum =13,67,071 kWh Amount Saved = 16,15,680 kWh X Rs.6/kWh = Rs.82 Lacs Investment required=70 Lacs, Simple Payback period = 11 Months CO2 emission Reduction=2 x 0.1726MW x 24hr. x 330days/ annum = 2734 tCO2/Yr. Saving in cost of Generation=2x0.1726MWxRs.600Lacs/MW=Rs.207Lacs

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Case Study #4 Remove damper from the Sepax fan suction Unit-2 (4500TPD) Sepax Fan was observed for its performance and it was found that a damper is provided for flow control. It was found that the pressure drop across the damper is 12mmWC for the 100% open position and flow is 63.06m3/s. It is proposed to remove damper from the duct as it is wasting an air power of 7.4kW.

Operating Parameters : Draft before damper = -548mmWC Draft after damper = -560mmWC Draft at fan outlet = -12mmWC Pressure drop across damper = -560 – (-548) = 12mmWC Power loss due to damper = 63.06m3/s X 12mmWC/102 = 7.4kW Energy Saved = 7.4kW X 24 Hrs./day x 330 Operating days/ annum = 58,608 kWh Amount Saved = 58,608 kWh X Rs.6/kWh = Rs.3.5 Lacs Investment required against Labour cost = 0.2 Lacs Simple Payback period = 21 days CO2 emission Reduction = 2 x 0.074MW x 24hr. x 330days/ annum =117tCO2/Yr. Saving in Cost of power generation=2 x 0.0074MW x Rs.600Lacs/ MW =Rs.4.4Lacs

Investment Risk Barrier In Indian cement industry, this technology has not been implemented so far owing to the following reasons: Non-availability of proven technology indigenously. Non-availability of installation or their operating experience in India resulting in lack of confidence. Special design requirements of waste heat recovery boiler suiting to high dust load. Large capital requirement and financial constraints owing to depressed cement marketing scenario Dust content of the exit gases from the cement manufacturing process, is as high as 100 g/Nm3. Most of the dust particles are sticky at high temperatures. This makes waste heat recovery very difficult as large amount of dust collects at heat transfer surfaces and leads to complete choking of the heat exchanger. In the project scenario the dust content in the preheater exit gases are expected to be as high as 80-100 g/Nm3 which pose a real threat to the success of the project activity which entails high up front-cost. The feature of the dust in exit gases from AQC is the strong hardness which shall make the heat exchanger surfaces of AQC boilers abraded quickly. If anti-wear measure of the AQC boiler is in appropriate, the normal running of AQC boilers shall be influenced. The anti-wear measure of domestic equipment is less efficient than that of advanced foreign equipment, thereby also forming a barrier to the project activity. Energy Conservation & Management

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Energy Efficient Approach for Alkyd Resin Manufacturing Ranjeet Neve1, Aniket Bodale1, B B Gogte2 and Sachin A Mandavgane1 1

Department of Chemical Engineering, Visvesvaraya National Institute of Technology, Nagpur, 440010, India.

2

Retd Professor, Department of Oil Technology, Laxminarayan Institute of Technology, Nagpur,440010, India. [email protected]

Abstract Alkyd resin is a key ingredient of all surface-coating products like paints, primers, adhesives, printing ink etc. Conventional alkyd resin uses petroleum-based products (50-70%) like phthalic anhydride (35-50%) and organic solvents (30%). In the present work, a novel alkyd resin was developed containing renewable vegetable product (50-70%) petroleum based products (25%). Volatile organic compounds (VOC) content of conventional alkyd resin is 40% while the new alkyd resin was 14%. The novel alkyd resin manufacturing temperature was around 200 oC for 7-8 hours as compared to conventional resin (225-240oC for 12 hours) thus saving energy and time. The physicochemical and film properties of resin have been studied and compared with commercial sample. The cost of the present product is less than the conventional product.

Keywords Alkyd resin, Agro base, Energy efficient, short oil, surface coating products.

Introduction Worldwide the paint and coating industry represents some $50+ billion market with predicted yearly growth rate of 2-5% over the next 10 years. Surface coating materials (paints, primer, printing inks) contain three major ingredients: pigments (including extenders), binder/ film former (alkyd resin) and solvent (or thinner). Alkyd resins are polyester polymers of fatty acids and responsible for the mechanical properties, drying speed and durability of surface coating materials. Alkyd resins (Lambourne 1987) are essentially polyesters of polyhydroxyl alcohols and polycarboxyl acids chemically combined with the acids of various drying, semidrying, non drying oils in different proportions. The basic reaction involved in the preparation of alkyd resin is esterification. The reversible reaction can be shown as; R-COOH + ROH → RCOOR + H2O Two general processes can make alkyd resin are: a) fatty acid process and b) monoglyceride process (two-stage process). In fatty acid process, the ingredients are placed in the reaction kettle and heated at temperature ranging from 410°c to 450°c or higher. The batch is held at reaction temperature until the desire acid value and viscosity have been reached. In monoglyceride process, drying oil is first made to react with glycerol, and an intermediate Energy Conservation & Management

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product called a monoglyceride is obtained, which can then react with phthalic anhydride at 250-280°C, to form a homogenous alkyd resin. Kharkate et. al. (2005) synthesized alkyd resin binder based on renewable vegetable resources like soyabean oil and rosin by heating at 210-245oC for 8-9 hrs. Sathe et. al. (1999) developed a new type of alkyds using substantial proportion of styrene ( 30-50%) , a low percentage of polyols and anhydride by heating at 230-240oC for 8-9 hrs. Kulkarni et. al. (1994) reported preparation of sorbitol based alkyd by heating at 230-240oC for 8-9 hrs. Vaidyabthan et. al.(1988) prepared ‘CASTRO’ alkyds by cooking mainly castor oil and rosin at 275°C. Gogte et. al. (1981) reported preparations alkyd resin by using epoxidised karanja oil by selecting appropriate temperature (200°C). In the present work a novel alkyd resin is prepared at very low temperature (200-220 oC for 7-8 hrs) as compare to convention process (225-240oC for 12 hours) thus saving energy.

2. Materials and Methods Materials used in the present experimental work; linseed oil, glycerol, maleic anhydride, benzoic acid, rosin, sodium bisulphate, sodium bisulphate, red oxide, talc, whitting and tween 20.

2.1 Experimental setup The preparation of alkyd resin was carried out in a glass reactor. The reactor consists of two parts. Lower part of the reactor is round bottom vessel with very wide mouth. The capacity of the flask is about two liters. The upper part of the reactor is its lid, having four necks with standard joints. Figure 1 shows the experimental setup. Out of these four necks, a motor driven stirrer was inserted in the rector through the central neck while another neck was used for the thermometer. A condenser was fitted with the reactor through the third neck. And the fourth neck was use for introducing the chemicals into the reactor. The reaction vessel and its lid were tied together with the help of clamps. The reactor was heated by an electric heating mantle having automatic thermostat for smooth control of the temperature of the reactor within +2°C. The speed of the stirrer was controlled by a regulator.

Figure 1. Experimental setup

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2.2 Synthesis of alkyd resin For synthesis of alkyd resin (Payne 1961), mixture as given in Table 1 was charged and reacted in a standard glass reactor (2l). Xylene, butanol and toluene (1:1:1) were used as solvent. The order of addition of raw material and heating schedule for making eco-friendly resin was standardized (Table 2). After completion of reaction, solvent was removed from product by vacuum evaporation at 200 mm Hg. Physiochemical properties of pale yellow alkyd resin are reported in Table 3.

Table 1. Composition Alkyd Resin

Ingredients

Composition

(by

wt%)

Linseed Oil

20

Glycerol

15

Maleic anhydride

10

Benzoic acid

1

Rosin

53

Sodium bisulphite

0.5

Sodium bisulphate

1.5

Table 2. Heating schedule of alkyd resin

Order of addition of reactants

Time H:min

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Linseed

oil,

glycerol,

maleic

03:00

anhydride, benzoic acid, rosin, sodium bisulphate, sodium bisulphite

Heat at 220

0

00:30

Heat at 210

0

00:30

Heat at 205

0

00:30

Heat at 200

0

02:00

C

C

C

C

Total heating time

06:30

0

02:00

Cool to 80

C,added solvent &

removed the product

Table 3. Physiochemical properties of alkyd resin

Properties

RI

Acid Value

37.38

% Solid

86.33

Color

Pale yellow

Stability

Six moths

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2.3 Applications of alkyd resin The alkyd resin thus prepared was used in surface coating product formulations like screen ink (Mandavgane et. al. 2007a), primer (Mandavgane et. al. 2007b,c), paint (Mandavgane et. al. 2007d), detergents (Mandavgane et al 2006e) and floor cleanser (Mandavgane et al 2006f). The products were found to exhibit properties at par with commercial samples.

3. Results and Discussion Alkyd resin polymeric composition with short oil length (20%) was prepared with the use of chain stoppers and catalysts. Due to gelation, it becomes very difficult to synthesis alkyd resin with oil content less than 30%. Conventional alkyd resin is long oil resin (40-50%). The novel alkyd resin manufacturing temperature was around 200 oC for 7-8 hours as compared to conventional resin ( 225-240oC for 12 hours) thus saving energy and time. Novel alkyd resin contains agro (50-70%) and petroleum (25%) base raw materials as compared to conventional resin containing 50-70% petroleum based products, which is to be imported. The agro products used are non edible oil and rosin. Rosin imparts the mechanical strength, helps in smooth propogation of polymerization and gives high molecular weight polymer (higher the molecular stronger the polymer). Volatile organic compounds (VOC) content of conventional alkyd resin is 40% while the new alkyd resin was 14%. The gram of VOC per liter in the developed surface coating formulations is 370 well within the limits (Gloss and semi gloss architectural coatings: 380)

4. Conclusion Alkyd resin manufacturing is highly energy intensive. The conventional process involves 10-12 hrs heating at 225-250oC. The success rate of each batch is also low because of over polymerization and gelation resulting in loss of energy and material. Here a formulation and method is developed which has brought down the heating schedule to just 8 hrs at around 210 oC and risk of over polymerization has been avoided using chain stopper. Very short oil alkyd resin thus developed is highly hydrophilic and can be used in Emulsion Polymers. Emulsion Polymers since uses water as a solvent; instead of organic solvents the Volatile Organic Compounds (VOC) of surface coating products prepared using such polymers is very low. The cost of novel alkyd resin is less than the commercial it uses more agro base products and less energy. The alkyd resin thus developed is novel, energy efficient, ecofriendly and agro based. ANN Modeling (Mandavgane et al 2006g) of parameters like composition, heating schedule and physical properties can make the results generalized.

5. References •

Gogte B. B. and Dabhade S. B. 1981, Alkyds based on non-edible oils Karanja oil (Pongamia glabra), Paint India, 3-5. Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 •

Kharkate S. K. and Gogte B. B. 2005, A novel eco-friendly short oil rosinated alkyd binder, Paint India, 129-138.

•

Kulkarni R. D. and Gogte B. B. 1994, ‘SORBO’ alkyd emulsion paste for primers and synthetic enamels, Paint India, 41-44.

•

Lambourne R. L. 1987, Paint and Surface Coatings: Theory and Prctice, Ellis Horwood Publisher, Chichester,75-79.

•

Mandavgane S. A., Gogte B. B. and Subramanian D. 2007, Sulphonated lignin based screen ink formulations, Indian Jr of Chemical Technology, 14, 321-324

•

Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2007, Development of steel primer from spent black liquor and short oil alkyd resin, Jr Sci Indus Res, 66,407-410.

•

Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2006, Development of eco-friendly primer from spent black liquor and linseed oil based novel alkyd resin, Proc of CHEMCON 2006, Bharuch, India, Dec 26-31, 2006.

•

Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2007, Synthesis of eco-friendly paint from kraft lignin and rice bran oil based novel alkyd resin, Indian Jr. of Chemical Technology, (communicated)

•

Mandavgane S. A., Gogte B. B. and Subramanian D. 2006, Some spent black liquor based powder detergents cum stain removers, Jr Sci Indus Res, 65,760-764.

•

Mandavgane S. A., Vivek, Pawar S., Gogte B. B. and Subramanian D. 2006, Development and study of floor cleanser from modified black liquor, Chem Engg. World, 41,66-68.

•

Mandavgane S. A. and Venkateshwarlu K., Modeling of Biomass Briquetting Using Artifial Neural Networks, Proc of Advances in Energy Research 2006, IIT Bombay, 2006.

•

Payne H. F.1961, Organic Coating Technology, vol 1,John Wiley & Sons, New York, 87-106,

•

Sathe P. D. and Gogte B. B. 1999, Primer and synthetic enamel compositions based on new type of styrenated alkyds, Paint India, 129-138.

•

Vaidyabthan K. S. and Gogte B. B. 1988, High gloss enamel paints based on ‘CASTRO’ alkyds, Paint India, 25-28.

Acknowledgements SAM is greatful to Department of Science and Technology (SSD/TISN/020/2009), New Delhi, India for Financial support and encouragement for the research project. Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Case Study Energy Conservation Opportunities In Pharmaceutical Plant Air Conditioning D.K.Joshi [email protected]

Abstract Evaluation of energy saving opportunities in a typical pharmaceutical unit using VAM (Vapor Absorption Machine). Capacity of vam depends upon efficient working of cooling Tower( Temperature of the sumpwater).

Key words : Vapor absorption, Coefficient of performance I.Introduction Basically Air conditioning is used in Pharmaceutical plant to control followings The major areas of consumption in air conditioning pharmaceutical plants are:

¾ Refrigeration chillers (High side). ¾ Primary &Secondary Pumps. ¾ Air handling units (AHU) (Low side). ¾ Cooling tower

(a).

Temperature

As per USFDA (United States Federal drug Agency) the temperature requirement is NMT 250C. Which is needed for some product stability.Certain products are more stable in the above said temperature range. Temperature is maintained by circulating chilled water in. AHU(Air HandlingUnit) (b).

Humidity

Humidity is also an important factor for product and human comfort. It should be in the range of 55% but it also varies from product to product. As per USFDA it should be NMT 55 % (c)

Contamination.(in term of Particulate Matter)

Temperature and humidity for human comfort and product requirement and to Avoid Contamination for product purity.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

To get space conditioned, Centralized chilled water system with a combination of Air handling unit fitted with different types of filters is achieved

2. Methodology and Model description. Vapor absorption technology is based on using Heat Energy, instead of Electrical/Mechanical Energy as in vapor compression system, in order to change the conditions of the Refrigerant, external source of heat (Steam) is required. Steam required for generating 1 TR (Tone of Refrigeration) = 4.5 Kgs (steam).[1] Vapor absorption system is most Economical where Steam is available as by- Product or waste heat is available as in case of Exothermic Reactions.

Figure -1 Vapor Absorption Machine having a Capacity of 250 TR (Steam Operated)

3. Observations and Measurements 3.1

Details of Chillers. Table 1

S.NO

Type

Make

Refrigerant

Cws

Cwr

Chws

Chwr

1

VapourAbsortion

Thermax

Cr +Li Br

320C

320C

320C

320C

2

VapourAbsortion

Thermax

Cr +LiBr

320C

320C

320C

320C

3

VapourAbsortion

Thermax

Moly+LiBr

320C

320C

320C

320C

4

VapourAbsortion

Thermax

Moly+LiBr

320C

320C

320C

320C

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

3.2

Readings on Chillers. Table 2

S.NO

Description

Chiller 1

Chiller 2

Chiller -3

Chiller -4

1

CHW-R

Not

Not

120C

120C

2

CHW-S

-

7.20C

7.50C

3

CHW-S. Prs.

-

1.5 kg/ cm2

1.5 kg/ cm2

4

CHW-R Prs

0.5 kg/ cm2

0.5 kg/ cm2

5

C.Water-S

320C

330C

6

C.Water-R

370C

370C

7

C.Water-S Prs

1.5 kg/ cm2

1.5 kg/ cm2

8

C.Water-R Prs

0.5 kg/ cm2

0.5 kg/ cm2

9

Steam pressure

4.0 kg/ cm2

6 kg/ cm2

10

Valve

98

3.3

Opening

97

Capacity loss due to high temperature of cooling water

Design temperature for chiller operation at optimal capacity is under Cooling water supply temperature = 290 C Cooling water return temperature = 340 C But we are getting Cooling water supply temperature = 320 C i.e. 30 C higher From OEM[1] data 10 C rise will loose 9% of it’s capacity Present cooling tower is of 250 TR capacity which is equals to Chiller Capacity.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

4. Calculations (1)

For losses

First

10 C rise = 250 TR x 9 %

= 22.5 TR loss, 227.5 TR available

0

= 20.47 TR loss, 207.03 TR available

0

= 18.63 TR loss , 188.4 TR available

Second 1 C rise = 227.5 x 9% Third 1 C rise = 207.03 x9% Total loss

= 61.6 TR

To produce 61.6 TR Cost will be

= 61.6 x 4.2 x Rs 1.60

= Rs 414 / hr on single chiller On four chiller annual loss will be = 4 No x Rs 414 x20 hrs x300days = Rs99, 36,000 per annum.

(2)

For savings

If we install four Energy efficient cooling tower of having capacity 350TR[2] This will cost Rs 5, 20,000/-each i.e. Rs 20,80,000/That will save loss in capacity of chillers

(3)

Pay back

Pay back

=

Investment

=

20,80,000 / 99,36,000

=

/

savings

3 Months

5. Results and Discussions Cooling tower sump temperature play a vital role in operation of VAM, as we have seen that every 10 C rise of sump temperature water will loose9% of its capacity and the cooling capacity of the cooling tower was just equal to the capacity of chiller. We must have capacity of cooling tower to be slightly higher that that of chiller and at the same time a proper maintenance of cooling tower should be done to avoid it’s detoriate its rated capacity.

6. Conclusions The above case study is done in a leading pharmaceutical unit near Indore, It was also pointed out to the management that cooling tower is in very shape it requires immediate attention, for getting full advantage of rated capacity of VAM. Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

To operate VAM on fossil fuel is now a days very costly, if we use any Renewable source of energy to run VAM will be a financial and technically sound gooddecision.

7. References 1

Thermax [1]

2 Mihir cooling tower[2]

operation& maintenance of vpour absorption machine specification of cooling towers

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Free Cooling As Energy Conservation Measure Er. BALBIR SINGH, IES Chief Engineer (E), BSNL, Haryana.

Er. V.K.SETHI Sub Divisional Engineer (E), BSNL, Yamuna Nagar.

Majority of the air conditioning systems are based on re-circulated air system, in which irrespective of the outside ambient conditions, the conditioned space/equipment area is to be air conditioned by maintaining the temperature at desired level. The required fresh air and return air are cooled by refrigeration compressors. All the telephone exchanges, major & small, function under controlled conditions and are air conditioned. The temperature is required to be maintained at certain level throughout the year. The major exchanges are temperature sensitive and temperature is required to be maintained in the range of 23 +3˚C, There are around 100 air conditioning plants in BSNL in the State of Haryana and the capacity of Air Conditioned plants normally ranges between 21 TR to 50 TR. The majority of Air Conditioned plants are of 21 TR capacity. The Air Conditioned plants consume energy in bulk and there is a great potential of ENERGY CONSERVATION in air conditioning. This is to be noted that even decrease of indoor temperature by 1˚C result in increase of 4% energy consumption.

CONCEPT: In Northern India the outside temperature during winter (November to February) is quite low. These favorable outside conditions can be used for maintaining the Switch Room/ equipment room temperature by pumping outside cold air into the equipment room through plant room by running the blowers of package AC units. This concept is known as FREE COOLING. The normal temperature of cool air at canvas connection of Package AC unit is 13 to 14˚C. So when the outside temp is < 14˚C than no package AC unit is required to be run. When out side temperature is upto 20˚C, the temperature in switch room/ equipment room can be maintained by pumping more air.

Design And Metholody: CFM [Cubic feet per minute] requirement for free cooling for a particular AC plant is calculated on the basis of average running of number of AC package units during the winter season for e.g. one package unit means 5000 CFM. Free air from outside is pumped in the package room and further supplied in the switch room through blowers of AC package units. The hot air from the switch room is thrown out using exhaust fan/ damper or by door opening as feasible. The system can be Manual or Automatic. Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Manual: The system is operated by the operative staff. The free cooling system is started manually and the dampers are adjusted accordingly.

The system is operated when outside temperature is < 20˚ C.

The

components used are as follows: 24 SWG GI duct with mechanical filter, 600 mm Axial fan, damper, contactor and cables etc.

(b) AUTOMATIC: Free cooling will be working as and when outside temperature goes

< 20˚C and will be OFF when

temp inside switch room is below 25.5˚C, also the compressors will be ON only when free cooling is not working due to fault or outside conditions are not favorable. In this system, the louvers of the inlet and outlet fans shall work automatically with the thrust of the air. The components used are as follows: 24 SWG GI sheet duct with mechanical filter, 600 mm dia Axial fan, 450 mm exhaust fan, dampers, louver, Digital temperature controllers, contactors, relays, control wiring and cable etc.

Implementation: PILOT AUTOMATED PROJECT UNDERTAKEN: The project has been undertaken with automated system at Telephone Exchange Building, Yamuna Nagar (Haryana) Desired inside temperature: 25˚C In this project, 10,000 CFM is required to cool the conditioned space i.e. Switch Room/ equipment room containing C-DoT and OCB exchange equipment. 2 No: 5000 CFM fans with mechanical filters with suitable duct work have been provided to push the air into the existing AC plant room and 4 Nos 18” exhaust fans with shutters in the return air path to exhaust the air into the atmosphere have been provided. Whenever the outside temp is below 20˚C, The fresh air and exhaust air fans start working through temp sensor, sensing the outside ambient temp. This forced air is sucked by the package units and supplied into the conditioned space, where after taking the heat of the equipment; it is exhausted by the exhaust fans. Temperature sensor has also been provided in the switch room so that the when the temp is about to go below 25˚C the system stops to work and is only ON when the desired temperature is about to increase from 25˚C. This also adds to further savings by switching off the inlet and outlet air fans. The general layout of the system with and without free cooling is as shown as per annexure attached at ‘A’ and ‘B’. The Control circuit is at Annexure ‘C’ Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

The free cooling concept has been concept has been successfully implemented in around 90 AC plants in BSNL, Haryana. Thereby resulting in reduction of energy consumption, as detailed below:

Sr. No.

Description

Result

(i)

No. of AC plants in which free cooling concept

90

implemented

(ii)

Reduction in running of package AC units [at least one

7 TR x 90 = 630 TR

package of 7 TR in each plant]

(iii)

No of working hours [round the clock]

24 Hours

(iv)

Power consumption

1.8 KW / TR

(v)

Period of operation of free cooling [ Oct. to March] – restricted to 3 months for calculations purpose 90 days x 24 Hrs = 2160 Hrs

(vi)

Reduction in energy consumption in units

630 x 1.8 x 2160 = 24,49,440 KWH

(vii)

Units consumed for running free cooling system @ 1.50

1.50 x 90 x 24

KW per free cooling system [in units] = 3,240 KWH [which is negligible]

From the above, it is observed there is huge potential of energy conservation by using Free cooling concept as an ‘Energy Conservation Measure’. As per our practical experience, it has been observed that actual running of the free cooling concept is around 4½ months.

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Benefits: ¾ Reduction in compressor run hours. ¾ Increased compressor life ¾ Less energy cost. ¾ Less CO-2 emission. ¾ Lot of energy conservation measures have been initiated & ¾ implemented. In appreciation of the achievement in ENERGY CONSERVATION in the Office buildings sector, BSNL Haryana has won three National Energy Conservation Awards - 2010. The awards have been presented by Honorable

Minister

of

Power,

Sh.

Shushil

Kumar

Shinde

on

14th

December,

2010.

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

ANNEXURE ‘A’

LAYOUT PLAN OF AC PLANT AT T.E. YAMUNANAGAR (AIR CIRCUIT NORMAL)

OMC AC PLANT

Switch room OFFICE

OFFICE

X-MISSION BTS

GREEN (SUPPLY AIR) RED

(RETURN AIR)

BLACK ( CONDENSOR AIR CIRCUIT)

CONDENSOR

C O N DE NS O RS

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

ANNEXURE ‘B’

LAYOUT PLAN OF AC PLANT AT T.E. YAMUNANAGAR (FREE COOLING)

OUTER COLD AIR

OMC AC PLANT

Switch room OFFICE

OFFICE

X-MISSION BTS

GREEN (FREE OUTER COLD AIR)

CONDENSOR

RED

AC PACKAGE

(HEATED EXHAUST AIR)

RETURN AIR PATH

5000CFM AIR INLET FAN

C O N DE NS O RS

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

ANNEXURE ‘C’

• TEMPERATURE CONTROLLER FOR FREE AIR COOLING IN WINTER (SCHEMATIC DAIGRAM)

----

OUTSIDE TEMP. SENSOR TC-2 TC-1

NEUTRAL

FREE AIR

EXHAUST

INDOOR TEMP SENSOR

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Technical Paper on Feasibility Study Of Installation Of VFD For Id Fans In Thermal Power Plant Santosh Mahadeo Mestry [email protected], [email protected]

1. Introduction:The function of Induced Draft fan is to suck the gases out of furnaces and throw them into the stack. Boiler is provided with two nos. of Induced Draft Fans. Each ID fan is provided with regulating damper control and scoop control for controlling the loading on fans.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

3. Principle of Hydraulic Coupling:The ID fans are controlled with VFC control. The variable fluid coupling works on the principle of hydrodynamics. It consists of an impeller and rotor(runner) enclosed in a Casing. The impeller is connected to the prime mover, while the rotor is connected to the driven machine. The coupling is filled with fluid, usually mineral oil. The speed of the driven equipment is varied by varying the quantity of fluid Supplied between the impeller and the runner.

3.1 Slip:A difference between input & output speed is essential in a fluid coupling in order to enable it to transmit torque. Difference between input & output speed is normally expressed as percentage of the input speed & refereed to as slip.

(I/P speed- O/P speed) Slip %

= - ------------------------------ *100 I/P speed

4. Hydraulic Coupling Losses:There are two Types of Losses of power in VFC.

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

4.1 Hydraulic Losses :Since the regulation is based on slip regulation, evidently there is slip loss occurred which heat up the working oil & must therefore be removed by a heat exchanger. The amount of loss depend upon the run- of Char. & slip required to attain the desire O/P speed.

4.2 Mechanical Losses :Mechanical losses occurred due to friction in the bearings, ventilation losses & losses in the oil circulating system which usually do not exceed 1% and are therefore of little significance.

Loss in a typical VFC can be shown graphically as below.

Hydraulic Losses Mechanical Losses

Speed (RPM)

(W.R.T. Slip)

(W. R. T. Speed)

Slip (%)

Losses (KW)

5.0 Hydraulic Losses Calculation:5.1 Heat Loss Method:The heat gained by the cooling water supplied to the VFC is an indication of the Power loss. The energy loss in VFC is estimated by measuring the cooling water flow and the temperature difference between the inlet and outlet cooling water. Cooling water flow rate is measured by ultrasonic flow meter & ECW temp. gain is obtained from infrared thermometer. Energy Conservation & Management

55

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 The calculations related to VFC loss are given below Total heat loss (KW) =

ECW flow in m3/h x ECW Temp. Gain in 0C x 1000 ---------------------------------------------------------

860 Kcal/hr Hydraulic loss :-

UNIT-1 SR. NO.

PARAMETER

UNIT-2

UNIT

ID FAN-1A

ID FAN-1B

ID FAN-2A

ID FAN-2B

AVERAGE

M3/Hr,

104

78

89

105

94

Celsius

2.2

2.6

3

2.8

2.65

%

55

54

53

54

54

KW

266.04

235.81

310.46

341.861

288.54

Cooling Water Flow of Working Oil Cooler

A

Temp. Rise of CW Across WO B

Cooler

C

Scoop Position

Deg.

Total Heat Loss D=(A*B*1000)/860

in VFC

The above calculation of Hydraulic Loss by heat loss method is validated by Slip Loss calculation. It is given below.

5.2 SLIP Loss Method:Some technologist regarded Fluid coupling as the hydraulic analog of the AC squirrel cage induction motor as the motor torque is developed by interaction between the magnetic field at synchronous speed created by the stator current, and the field created by the current it generates in the rotor cage, which in turn is slightly lower speed equivalent to the slip. Speed measurement is done by Stroboscope. Current & Voltage values are from PMS.

O/P Power I/P Power

=

---------------(1- Slip)

Hydraulic Loss by Slip Loss method is shown in following table.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

5.3 Validation of Hydraulic loss by slip loss calculation:UNIT-1

SR. No. A

UNIT-2

ID FAN-

ID FAN-

ID FAN-

ID FAN-

PARAMETER

UNIT

1A

1B

2A

2B

AVERAGE

Motor I/P Power

KW

1224.00

1243.00

1257.00

1289.00

1253.25

ID fan Motor B

Efficiency

%

96.00

96.00

96.00

96.00

96.00

C

Scoop Position

%

55.00

54.00

53.00

54.00

54.00

D

Motor Speed

RPM

733.00

734.00

731.80

733.50

733.08

E

Fan Speed

RPM

574.00

576.10

568.20

573.00

572.83

F=100*(F-G)/F

Slip

%

21.69

21.51

22.36

21.88

21.86

G=A*B/100

VFC, I/L Power

KW

1175.04

1193.28

1206.72

1237.44

1203.12

Fan Shaft I/L H=G*(1-F/100)

Power

KW

920.15

936.58

936.95

966.67

940.09

I=G-H

VFC Loss

KW

254.89

256.70

269.77

270.77

263.03

6.0 Efficiency Aspect:Efficiency of variable fluid coupling is= 1- slip. Fan driving system efficiency can be improved by regulating fan speed by digital Variable Frequency Drive(VFD) instead of VFC. Fan driving system efficiency ηdriving= ηmotor*

MOTOR

I/P Power P

ηmotor= 96%

ηVFC = ηmotor*(1-slip)

VFC

ηVFC= 1-slip

FAN

I/P Power at Fan Shaft P*

ηmotor%* ηVFC%

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

6.1 Present Efficiency Calculation:Average Slip of VFC =21.86%.

PRESENT EFFICIENCY ( ηold) SR. NO.

PARAMTER

UNIT

ηold

A

ηmotor

%

96

B

slip

%

21.86

C=(1-B/100)100

ηvfc

%

78.14

D=A*C/100

ηdriving

%

75.0144

7.0 Recommendation:Installing a Variable Frequency Drive for this variation in flow requirements will result in substantial energy savings. The speed of the fan can be varied to attain the desired flow.

There are two options. 1.

To install variable frequency drives for the ID fans with VFC in place.

2.

In this case, fan speed is varied by VFD keeping VFC scoop 100% open.

Design VFC slip at scoop 100%: - 3.4% NEW EFFICIENCY (ηnew) SR.NO.

PARAMTER

UNIT

ηnew

A

ηmotor

%

96

B

slip

%

3.4

C=(1B/100)100

ηvfc

%

96.6

D=A*C/100

ηdriving

%

92.736

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 1.

To install variable frequency drives for the ID fans & remove VFC .

In this case VFC slip loss is nil since slip =0 NEW EFFICIENCY SR.NO.

PARAMTER

UNIT

ηnew

A

ηmotor

%

96

B

ηdriving

%

96

HT VFD of this capacity is running in several plants

8.0 Cost-Benefits:(New Efficiency-Old efficiency) % Energy Saving = ---------------------------------- *100 New efficiency

SR. NO.

PARAMETER

UNIT

Value

AVERAGE MOTOR I/P A

POWER

B

ηold

A

1253.25 %

75.01 VFD WITH VFC OPERATING

C

ηnew

VFD

AT FULL SPEED

WITHOUT

(SCOOP=100%)

VFC

%

92.73

96

%

19.10

21.86

KW

239.48

274.02

ENERGY D=100*((C-B)/C)

SAVING

E=A*C/100

KW SAVING

In DTPS, there are 4no. ID fans. Above energy saving calculation is for one fan.

Energy Conservation & Management

59

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 If cost of unit- 3.50 Rs/KWH & annual Operating Hrs. =8200 Hr, benefit & simple payback period is shown in the following table.

VALUE

SR. NO.

PARAMETER

UNIT

VFD WITH VFC

VFD

OPERATING AT FULL

WITHOUT

SPEED(SCOOP=100%)

VFC

ENERGY A

SAVING/FAN

KW

B

NO.OF FAN

No

239.48

274.01 4

TOTAL ENERGY C=A*B

SAVING

KW

957.92

1096.04

D

COST/UNIT

Rs.

3.5

3.5

E

TOTALINVESTMENT

Rs.CR.

5.6

5.6

ANNUAL F

OPERATING HRS

Hrs.

8200

8200

G=C*D*F

ANNUAL SAVING

Rs CR

2.74

3.14

Month

24.44

21.36

SIMPLE PAYBACK F=12*(E/G)

PERIOD

Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

Industrial Economics Mr. L.Manickavasagam. Managing Director & Energy Auditor.

Introduction:Most of the industries especially textile industries are located in the rural areas and the up to date technology is not reaching at the level of electrical engineers in all industries about various factor like energy saving, energy auditing etc.

Case study 1 (Example): In leading industries like heavy Automobile industries maximum demand is 8000 KVA. But Maximum units per hour consumption are 4000 KWA only. The PF in the metering pointer is 0.995. The Power factor at load point is varying from 0.45 to 0.85. This result of load factor is 50 %.

Case study 2 (Example): In another light vehicle automobile industries located in north is having a maximum demand of 12MVA. But the consumption is 6 MWH Units/ Hour. The electrical engineer is having a problem of locating a fault if it is in tail end due to shortage of labor. This result 6MVA is not pumped in to the cables and 1000 Unites / hour is waste.

Case Study 3 :2.1 Methodology:A textile industries a compressor motor 200 HP/ 150 KWh having a PF of 0.82 after 6 months of time duration the PF come down to 0.75. The capacitors are not helping to improve beyond 0.85. The reason found is that the inductance in 3 phases varies. This could happen in rewind motors. A remedial measure that Compressor motor is fed by VFT with a result of energy saving 20% , PF UPF and KVA reduction of 440 KVA. 1.2 In Text tile industries is having a MD of 2600KVA in Tamilnadu .The unit consumption is 1600 KW /hour. Due to power cut in Tamilnadu the TNEB permitted only 1200KVA. The balance load is balanced by DG sets 2*750 KVA . The monthly energy charges including Diesel cost around 75 Lakes. The PF at the meter point is 0.995. 1.3 Executive summary and methodology:

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 All machine tail end PF measured and corrected unity PF due to this 700 KVA reduces. One generator put off with a saving of Diesel charges 10 LAKS per month secondly one of the DG set running was operated at 440 Volt 50 cycle with PF 0.8 .The corrective measure taken to operate 400 Volt 48.5 Cycle and unity PF . This result reduces 200 KVA and a saving of 20 % diesel

2.4. An additional load of 500 KVA received from EB.DG set get off. The electric city bill rise in to 50 lakes only with a saving of 25 lacks per month and 3 cores per annum. The industries is getting loss of 5 cores in book value and 3 cores recovered from energy charges leaving 2 cores. Action is being taken to avoid failure of equipment and labor problem to improve production.

2.5 The harmonics is taking major role in poor PF and failure of Motors. One of the association raised voice to ban in condition bulb and available bulb to be replaced by CFL. In the same way we need to raise a voice 3 phase convector in VFT extra. To be ban which has used mainly in chloride industries textile industries, cement industries, etc. the harmonics produced in the convector result low PF and remise the PF. The Total KVA increases continuous power loss in capacitors and degrading of capacitor. In leading manufacturer of VFT is giving only 0.9 PF. An additional harmonics filter is to be installed to get the unity PF. BEE should take steps to provide 5 star rating for VFT even though in ported one , eddy current control motors and voltage vector control motors.

3.1 Conclusion: Capacitors are used in industries mostly in control room where ever MD Is exceeded average units by more than one times should be penalized even 5 to 10 times. So the industries come forward to provide the quality capacitor in the motor end with help of energy consultant. Our national maximum demand can be utilized in beneficially the loss in generation transmission and distribution, utilization is now 50 % to 100%. This will be reducing considerably 220%.

3.3.2 In Tamilnadu agriculture service connection serviced with free energy efficiency Motor by replacing the exciting motor. This will considerably reduce the maximum demand by 800 MA in Tamilnadu grid. This can be extended to all India level not only agriculture but also in industrial services.

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3.3.3 A quality capacitor cost about rupees 450 to 500. Govt of India and state government should get the technology high quality capacitor( This is per /KVA watt consumption , Durability not to be degrade cost) should be manufacture and supplies and not to be imported. The subsidy can be given to capacitors this will make reduction of KVA in national level MD and this MD can be utilized beneficially without incurring a huge amount on generation as a short term measure.

3.3.4 A cement industries is consuming 67 unites /ton where international standard is 91 units / ton. The reduction of units is due to very simple technology. The horizontal rotary kiln converted in to vertical rotary . Energy consumption reduces by 26 % this would be implemented in all cement industries by giving all assistant.

3.3.5 The board should supply the quality of voltage and without harmonics current, Over voltage, under voltage, transcend voltage, surge voltage and Un intersectional supply. This will ensure the increase in production.

Request: This message should reach the people consent people. The summit will help expertise.

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Domestic (Human factors) Mr.Arunachalam Pillai Introduction : In all India domestic consumers are meeting high energy charges . This is due to the electrical engineer is not at all involving the design. An electrician is the taking a major role in deciding wiring and equipment etc. he didn’t know energy saving or energy conservation in domestic services. This submit will help to educate the domestic consumer on energy saving.

Capital out lay : Methodology:Most of the houses are constructed in apartment or flats in metro, state capital etc, where the land value is very high. In multi story building natural lighting near hall rooms are big question? It should be design and implemented by MMDA .In AC rooms the height of the room should maintain at 2.5 Meter only. Normally rooms are designed 3.5 meter height. The fall selling should be provided at a height of 2.o meter to 2.5 meter. This will save the 30 % energy. In normal house having a ground floor only 75 square meter or provided with refrigerator , water pump with motor , electrical oven , heater, Cooker , vacuum motors and lightings.

Executive summary:A tube light to be used with energy efficiency lamp .This energy consumption will be 30 watts with servo stabilizer of 195 Volt. This will save 15 watts lower than 45 watts CFL with same light energy. This will save 30% of energy. The power circuit should be provided with 225 V to 230 V output always. This will save the equipment, life, energy saving.

2.2.3 A water pump should be used with level limiting switches.

2.2.4 A water tank should be providing with each floor level.

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2.2.5 For gardening GLR should be used.

2.2.6 A five star refrigerator and Air conditioner should be used. Thermal switch checked for it is sound for 6 months once. The refrigerator should used of it is full accommodation this will increase the efficiency in the refrigerator. When the refrigerator is empty the thermo material should be provided inside. This will avoid cooling of the air in side.

2.2.7 Fan should be used capacitor type regulator only. The consumer should be educated to use the regulator only in off condition while reducing the speed. This will avoid failure of regulator.

2.2.8 The wiring to be checked in a year for good insulation. When the earth to natural voltage increase more than 1.5 V . The electronic devices light, computer, printer, scanner will be get damaged.

2.2.9 When the inventor or UPS used the harmonic should be used below than 5 %. This should be checked at the level of UPS and Inventor by the license authority.

2.2.10 The consumer have to be educated to penalize supplier in the consumer court ,when the voltage fluctuate more than 5%.

Conclusion: To achieve this with the consumer the awareness to be made. In syllabus of 10th and12th subject of Physics, energy efficient should be including. In ITI, Polytechnic , Engineer colleges the energy saving, energy conservation , energy efficiency to have a one subject as a mandatory . In TV wide publicity should give about energy saving and energy conservation. I hope this submit will open the eye of the customers and Government to implement all recommitting.

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“Design and Development of 100 kWp Stand Alone Photo Voltaic Power Plant at University of Petroleum and Energy Studies, Dehradun” Ms. Madhu Sharmaa, Dr. S.J.Chopraa, Dr. S.P. Singhb, Dr. R.N.Singhb a

University of Pertroleum and Energy Studies, Dehradun ([email protected]) b

School of Energy and Environment Studies, DAVV, Indore

Need & Justification of the Project India is the sixth largest and one of the fastest growing energy consumers in the world. Economic growth at 80/o to l0% % over the next few decades, will lead to a substantial increase in demand for Energy in general and petroleum products in particular. India is relatively poor in oil and gas resources. It meets nearly 72% of its petroleum products demand through imports. With depleting crude oil reserves globally, we have to look at ways other than hydrocarbon resources to satiate our energy appetite. Solar energy is a good option & has a great potential. The University consumes about 40,000 Lts of diesel annually for our DG set for the emergency supply of electricity. By replace emergency generation of electricity from diesel based to solar will help to save a huge amount of petro energy and also money.

Objective of this project Keeping above things in mind the following are the objectives of the project 1.

To use the most effective and environmental friendly power saving methods in the UPES campus at Dehradun.

2.

Shift entire day time lighting load to Solar Power

3.

Replacing the DG set with solar system.

4.

Develop solar PV based demo system..

Introduction In the coming centuries of the decline of the World’s fossil Energy Stocks, a electricity production mix will established which will be inevitably dominated increasingly by the direct & Indirect use of Solar Energy. Except Nuclear, all common energy carriers like coal & Oil are indirectly solar energy carriers, for their genius is basically due to prehistoric solar irradiation on earth. Over the last few decades a strong public desire to introduce rapidly sustainable energy conversion technologies with a minimum of harmful impacts on society & Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Environment developed & proved its realization in various projects worldwide. The design of a Sun power station depends mainly on the basic technology of its energy conversion system. Solar PV is a renewable energy system which uses Photovoltaic modules on the roof or façade area of a building to convert light into electricity. Voltaic cells are made up of thin layers of Semi Conducting material (Usually Crystalline Silicon) which generate an electrical charge when exposed to direct light. SAPV system design is very dependent on the geographical location of the system since the amount of electricity generated varies with the irradiance and temperature but also with the consumed energy in general. Balance-Of-Systems (BOS) : The PV system includes not only the source circuits or subarrays, but also the associated power conditioning, protection & safety equipment, and support structures. All these components come under the one category named ‘Balance of Systems’. The BOS is defined as everything except the PV modules and the load. The BOS includes module support structures, external wiring & connection boxes, Power Conditioning equipment, inverter, charge controllers, transformers, Safety & Protective equipment- diodes, switches, lighting protection, circuit breakers, ground rods and cables , Energy Storage batteries, Utility Grid Interface and Connective devices, Wretches monitoring instruments and associated sensors (pyranometers, thermometers, anemometer etc), Data acquisition equipment for monitoring & evaluating the PV system performance.

Materials and methods UPES has a campus of 25 acres (approximately 2 Lakh sq Feet) of space and has an electrical load connected 250 KW by the state electricity department. Beside this 4*125 KVA & two sets 65 KVA DG sets are running for emergency power supply to our Class rooms, Hostels, Mess hall. Faculty seating which include Computers, LCDs, Exhaust Fans, Lighting fixtures etc

4.1

Arrangement of Finances

As per document No. 32/01/2009-10/PVSE, Government of India of MNRE, Solar Photovoltaic Group, University is eligible for applying the financial assistance as per article 7 of the document i.e. Rs.100 / watt .

4.2

Solar Energy Potential in Dehradun

Solar Energy resource assessment is the primary & essential exercise for solar energy projects because of its intermittent nature. The maximum possible values of solar radiation on earth are solar Constant (1367 W/m2). To know the Solar Energy Potential in Dehradun average of sunshine hours, wind speed, rainfall, ambient air temperature, maximum solar radiation, ,minimum solar radiation, solar radiation on Horizontal Surface, rage solar radiation on tilted surface as resources have been used.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Collection of meteorological data ( Source : NASA)

Parameters for Tilted Solar Panels:

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Minimum Radiation Incident on an Equator-pointed Tilted Surface (kWh/m2/day) Lat

30.5

Direct

Tilt 0

Tilt 15

Tilt 30

Tilt 45

January

6.13

3.35

4.18

4.77

5.10

February

5.50

3.46

3.96

4.26

4.34

March

7.07

4.88

5.32

5.49

5.37

April

7.62

5.98

6.17

6.04

5.60

May

7.40

6.46

6.36

5.94

5.23

June

5.56

5.67

5.50

5.09

4.44

July

3.43

4.51

4.42

4.15

3.70

August

2.62

3.87

3.88

3.72

3.42

September

4.65

4.24

4.45

4.46

4.25

October

6.93

4.40

5.04

5.40

5.48

November

7.28

3.73

4.60

5.22

5.54

December

6.64

3.17

4.05

4.70

5.08

Annual Average

5.90

4.48

4.83

4.94

4.80

Lon 78.5

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

4.3

Project Site Details

Location/Address - University of Petroleum & Energy Studies, Bidholi, Dehradun Altitude -

30 o 19’ N, Longitude

2237 feet (682 m), Latitude o

o

20” E, Av rainfall -

2073.3 mm, Temperature - Summer - Max 36 C and Min 16.7 C, Winter - Max 23.4 C and Min 5.2 oC.

4.4

o

- 78

o

Determining electrical load and identify the location

The very first step in designing a PV system must be a careful examination of electrical loads because sizing of the system components is dependent on the electricity and power demand. Based on the lighting load calculations in different buildings at University campus and available roof top / façade area to install arrays and battery banks , 4 independent sites were selected to install the 25 KW Solar Photovoltaic System each.

Location to install PV Generator S.No.

Location

Location for PV generator

Lighting Load(kW)

1.

Parijat -building

Rooftop 35.5*

2.

New Building

Rooftop

3.

Chitrakoot

Flat facade area

22.55

4.

Hostel block – A

Slightly sloped facade area

14.2

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 *For the first two buildings the inverter room and battery room is common and load can be distributed either way.

4.5

Designing of PV Generator

A PV generator comprises modules, fixation material, mounting structure, bypass diodes, blocking diodes, fuses, cables, terminals, overvoltage/lightning protection devices, circuit breakers and Junction boxes. Module selection - After collection of Meteorological data different PV modules were compared according to their type, rated power, efficiency, Fill factor, protection level, life and anufacturing standards (IEC) for selection. PV modules based on thin film technology are not considered as their efficiency is less and there is probability of breakage. Around 5 % of breakage has been reported as per different case studies. CEL has been selected to supply and commission proposed solar pack and modules of 156 Wp have been considered.

PV Array size The key factors affecting system sizing are Load Size, Operation Time, Location of the system (solar radiation), Possible sizing safety margin, Available roof or façade area can restrict the PV array size. PV modules are combined by series and parallel connection to form an electrically and mechanically larger unit, the PV Generator. The number of series connected modules i. e. string determines the system voltage, which corresponds to the input voltage of the connected inverter. The number of strings connected in parallel determines the system power. Module voltage decreases with increasing temperature. The maximum power point of the string must be calculated to be in the range of the designed system voltage for all operating temperature.

Calculation of Maximum no. of modules in string In our case as per module characteristics Temperature dependence Voltage coefficient

- 0.34

% / oC

Current coefficient

+ 0.04

% / oC

As per inverter specification Minimum input voltage

120 V o

Maximum input voltage

220 V

Minimum site temperature 5 C

Maximum site temperature

Nmax =

Nmin =

=

=5

=

37oC

=4

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Total 5 numbers of modules in a string is considered. Specification of string S.No.

Parameters

Specifications

Units

1

Total modules in series

5

Nos.

2

Voc

214

V

3

Vmp

170

V

4

Imp

4.4

A

Calculation of number of string to be paralleled to the inverter Inverter maximum input current = 146 A String current = 4.4 A

= 33

Nstring

Number of strings considered to be paralleled = 32 Five Modules connected in series to make a string 4.6

Orientation of PV array and shadow analysis

Orientation of the PV array is south facing at a tilt angle of 25o to have the optimum output throughout the year at 30.33o latitude and 78o longitude Shadow Analysis Latitude,

= 30.33o

Tilt angle, β = 25o

Day no., N = 355

(on 21st December sun - at lowest height & shadow of string – largest)

Declination angle, δ = -23.45o

Panel Width, b = 4 m

Panel length, L = 1.58m

Hour angle, Solar altitude angle,

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Module row distance, d Tilt height, h

h = b Sin β = 1.6

Frame distance, d2

d2 =

(i.e. distance between two rows)

8:00

8:30

9:00

10:00

AM

AM

AM

AM

2:00 PM

3:00 PM

4:00 PM

4:30 PM

5:00 PM

-60

-52.5

-45

-30

30

45

60

67.5

75

Altitude,

24.82

31.26

37.51

48.94

48.94

37.51

24.82

18.21

11.5

d2 (m)

3.28

2.63

2.08

1.39

1.39

2.08

3.28

4.86

7.86

Time

Hour angle,

Solar

Panel

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

4.7

Area required

As already discussed above the selected locations to install PV Generators are S.No.

Location

Location for PV generator

1.

Parijat -building

Rooftop

2.

New Building

Rooftop

3.

Chitrakoot

Flat facade area

4.

Hostel block – A

Slightly sloped facade area

1 & 2. Parijat Building & New building

For the first two above location available roof area is sufficient. 3.

Chitrakoot

Array matrix has been designed as 1st row -

6 structures, 2nd row

- 5 structures, 3rd row

- 5 structures

Each structure is of two strings. Total no. of strings = 32 Structure size = 3.2 x 4 m2 Space between structures = 0.5 m Distance between rows = 2.25 m (Calculated by shadow analysis) Length of the row = 3.2 x 6 + 0.5 x 5 = 21.7 m Width of the structure = 4 x cos 30 = 3.464 m Total width required = 3.464 x 3 + 2.25 x 2 = 15 m Area required = 21.7 x 15 = 326m2 = 3510 square feet 4.

Hostel block – A

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 All the structures installed in one row. Required length = 3.2 x 16 + 0.5 x 15 = 58.7 m, Required width = 4 x cos 30 = 3.5 m Area required = 58.7 x 3.5 = 206 m2 = 2217 square feet

4.8

Bypass diodes - A bypass diode provides a current path around a module or a part of a module. It

protects the bypassed cells in the module, e.g. under partial shading conditions, from operation in a load mode and possible destruction. The need for bypass diodes depends on the system configuration and module specifications.

4.9

Blocking diodes - Blocking diodes prevent current flow backwards into a string. However, using

modern "protection class II" modules and "ground fault proof and short circuit proof' wiring virtually eliminates the occurrence of such a failure. Blocking diodes of 10 A has been selected. 4.10

Fuses - Fuses protect cables from over current. In PV generators they should be used only if a large

number of strings is connected in parallel and the generator's short circuit current could exceed the cable's rated current in one string. Fuse of 10 A with HRC base has been selected.

4.11

Cables - The cable cross section is sized in accordance with the maximum current. The maximum

current that may flow through the module or string cable is the generator short circuit current minus the short circuit current of one string. 1.

Sizing of the cable has been done as per IS

2.

Interconnection of modules in series-parallel combination as per following

3.

Each source circuit to have 5 modules in series to make one string

4.

Output of the string to be taken to PJB’s using 1 x 4 mm2 single core wires

5.

From 32 PJBs to 6 FJBs using 2 x 4 mm2

6.

32 sets of strings to be paralleled in 6 FJBs using 2 x 10 mm2 cables

7.

Output from 6 FJB’s to be taken to one MJB

8.

Output from MJB to be connected to charge controller terminal of the 25 kW PCU, using 2 x 16 mm2 cable.

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Wiring Diagram From

To

Cable (mm2)

Module

Module

1x6

Module

PJB

1x4

PJB

FJB

2x4

FJB

MJB

2 x 10

MJB

PCU

2 x 16

PCU

B/B

2 x 25

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4.12

Overvoltage/lightning protection devices - Over Voltage Protection against atmospheric lightning

discharge to the PV array is provided.

4.13

Circuit breakers - Circuit breakers between the PV generator and the inverter or charge controller are

needed to remove the PV generator's voltage from the main DC line. They must be rated for the generator's nominal short circuit current and open circuit voltage and for DC. The above-mentioned components are located and electrically connected in one or more junction boxes. This box must be suited for the mounting location in terms of IP-protection, temperature rating, UV-resistance etc. It should be easily accessible to regularly check the fuses and the overvoltage protection devices and to open the DC circuit breaker(s).

4.14

Junction boxes

Series boxes - To connect modules in series box is used. Total no. of series boxes required = 5 x 32 = 160 for each unit Panel Junction Box (PJB) - Panel JB is used to run the electrical supply cables for the cell strings from the embedding material to the outside. Selected panel junction box Hensel make having two nos. of terminals 4 mm2 and ½ “gland (one for entry and another for exit) With IP 65 protection Quantity required 32 x 4 = 128 sets

one for each string

Field junction box - Field junction box is a device which is used to parallel the different module strings. Terminal blocks are provided for paralleling +ive & -ive electrical output from series junction boxes. Sizing of junction box depends on the voltage and current rating and also on the number of strings which it can parallel. The module junction boxes must have minimum protection to IP 54 and protection class II when mounting; care should be taken to avoid any water penetration.

Selected Field junction Box FJB-I

FJB-II

Type

Hensel make

Hensel make

Parallel connection

6 nos.

5nos.

Blocking diode

10 A 12

6 nos.

5 nos.

HRC fuse with fuse base

10 A each

6 nos.

5 nos.

MOVs

500 volts rating each

3 nos.

3 nos.

IP 65

IP 65

Protection Quantity sets

2 x 4 = 8 sets+ 4 sets spare

4 x 4 = 16

= 12 sets

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Main junction box ( Array junction box) - This is for paralleling all +ve and all –ve points from the individual field junction boxes. A bus bar is provided with suitable studs and lugs for paralleling electrical outputs from field junction boxes. Selected MJB is of Hensel make. Copper bus bar

capacity – 200 A

Protection

IP 65

one pair

Quantity

4.15

4 sets

Mounting structure - The mounting structure holds the modules in place. It must take all mechanical

loads, potential wind loads and thermal expansion/ contraction with an expected lifetime of at least 20 years. In building applications water tightness is often needed as well. Module mounting and wiring should be simple. The replacement of individual modules should be possible without dismantling the whole PV generator. Each structure fabricated from drawn steel and hot dip galvanized should capable of supporting 10 numbers of PV modules and capable of withstanding a horizontal wind speed of 150 km/hr after grouting and installation. The mounting structure design should be such that the frame, on which PV modules are mounted, can be kept inclined at 25o to the horizontal.

4.16

Power Conditioning Unit - Power conditioning unit (PCU) provides uninterrupted AC power using

battery power. DCDB output will be fed to the PCU which mainly consists of MPPT (Max. Power point tracker), Charge Controller & Inverter. The Power Conditioner Units shall convert DC power produced by SPV modules and stored in battery bank, in to AC power. Common Technical Specifications: Type:

Self commuted, current regulated, high

frequency, IGBT based

Output Voltage

:

3Φ, 440 VAC (±10%)

Waveform

:

Pure Sinewave

Output Frequency

:

50 Hz

Continuous Rating

:

25KVA

Nominal DC Input

:

120 VDC

Total harmonic Distortion

:

< 3%

Operating temp. range

:

5° to 50° C

Housing Cabinet

:

IP 20

Inverter Efficiency

:

>90%

4.17

± 3 Hz

Determining Battery bank Size

The battery’s task is to compensate for the mismatch between energy supply and energy consumption. The battery capacity is stated in Ah.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 The nominal cell voltage is 2 V, but the actual open circuit voltage of a fully charged cell is in the range of 2.1 V—2.4 V depending on acid density and temperature.

Depth of discharge (DOD) During discharge, the operating cell voltages decrease from the above average to cut-off between 1.75 V and 1.9 V. This cut-off voltage is very important for the battery lifetime as it defines the depth of discharge (DOD). The DOD is both rate and temperature dependent. This maximum allowable DOD depends on battery type and load profile. For typical lead acid battery DOD is between 0.5-0.8.

Autonomy time Autonomy time varies from case to case and depends on latitude, operation season, required percentage of availability. Reserve days (Autonomy days)

=2

Required energy for 6 hours daily = 25 kW x (2 x 6 hours) = 300 kWh

Battery capacity =

=

= 2500 Ah

Selection of battery bank Exide made Maintenance free Tubular lead-acid batteries Conform to

:

IS 1615 standard

Nominal capacity

:

2500 Ah @ 27oC

Total number of cell per battery bank

:

60

Float voltage

:

2.25 + 0.01 Vpc @ 27oC

Boost voltage

:

2.30 + 0.01 Vpc @ 27oC

Guaranty

:

5 years

4.18

Sizing of Inverter

The requirements for a stand- alone inverter are best fulfilled by sine wave inverters. These devices work on the principle of pulse width modulation. They are suitable even for operating sensitive electronic equipment. Compared with trapezoidal inverters, sine wave inverters are higher in price on account of the greater complexity of their circuitry. In stand-alone application sizing of the inverter is very critical. Care must be taken to avoid over sizing the unit because it will not deliver as peak efficiency when operated at only fraction of its rated power.

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 High Conversion efficiency is essential for the use in autonomous system with battery storage. The slope of the output wave form is an indication of the quality & cost of the inverter.

System Concept The inverter power is approximately equal to the PV generator. The following power range has been used for design 0.8 * Ppv < Pinv < 1.2

Ppv

For this system we have chosen inverter of 25 KW rating for each system. Selected Inverter The models should have qualification as per IEC 61683, IEC 62109-2 & IEC 62093 The Power Conditioner Units (25KVA) shall convert DC power produced by SPV modules and stored in battery bank, in to AC power.

Common Technical Specifications: Rating

120 V ,25 KW Pure Sine-wave

Mounting

Inside Control Room, Floor/Wall Mounted

No. of Inverters

1 (for each system)

Enclosures

Indoor

4.19

Charge Controller & MPPT

The power available from the solar array varies with module temperature and solar insolation. The inverter has to extract the maximum power out of the solar array. Therefore it is equipped with a device called ‘Maximum Power Point Tracer (MPPT-Unit). With the help of the MPPT unit the inverter input stage varies the input voltage until the maximum power point on the arrays IV Current is found. In the stand-alone systems, the system voltage of the PV generator must be matched to accumulators. The charge voltage must be higher than the battery voltage. Energy Conservation & Management

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 Advantages of using MPPT charge controller: There is greater flexibility in selecting modules and batteries In case of very long wires from PV generator to battery, much higher generator operating voltage can be chosen than the battery voltage, resulting lower currents and wiring losses.

Selection of MPPT charge Controller The safe charging of the battery is ensured by using pulse width modulation (PWM) for the charge current. Operational Voltage range - 150 V to 410 V, Rating - 120 V pulse width modulated Mounting - Inside control room, The current will be fed to the charge controller and MPPT should preferably confirm to IEC 62109-3, IEC 62093 and IEC 62509 standards.

5

SAPV system maintenance

The standard maintenance schedules is followed for the SAPV system mentioned by the Solar PV Training Programme Field Technician Manual prepared by the Central Electronics Centre, IIT Madras in association with SIEMENS in the year 2001 (SIEMENS and Central Electronics Centre IIT Madras, 2001).

6

Estimation of CDM Benefit

Unit generated = 1, 14,750 kWh GEI for North Zone = 0.8 kg of CO2 / kWh GEI = 1, 14,750 x 0.8 = 91,800 kg of CO2 / annum 1 CER = 1000 kg of CO2, No. of CERs = 91,800 / 1000 = 91.8 1 CER = 10 $ CDM benefits / year = 91.8 x 10 x 45 = Rs.41, 310 Approximate cost involved in availing (consultant, validator, registration) CDM benefits is much higher than possible benefits. May be taken as extra benefit.

7. Calculation of IRR The discount rate which achieves a net present value of zero is known as the Internal Rate of Return (IRR). The higher the IRR, the more attractive the project.

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8. Conclusions Based upon the detailed studies following conclusion has been drawn: 1.

100 kWp SAPV power plant has been designed and developed

2.

As per the load requirement and availability of land 4 different buildings are identified to install PV system and occupied 4 x 300 sq meters area at selected location.

3.

The capital cost for 1kWp SAPV power system is INR 2.75 lacs / kWp.

4.

The total amount of CO2 emissions mitigated due to the SAPV supply in its life span (i.e. 20 years) is estimated at 1836 tons.

5.

It can be safely concluded that, the PV power systems can play a major role which has a potential to convert sunlight energy directly to electrical energy at low operating and maintenance costs and would

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 help to save already degraded environment. Developed solar based power system would be ecofriendly, reliable and a sustainable solution for the near future of the World.

9. Suggestions 1.

The PV system is an efficient source of power and its system cost goes down with improvement in material research and PV module efficiency through research and development of PV system design.

2.

The PV system is most suitable for remote village locations where there are frequent power cuts or grid extension is a costlier option.

10.References •

Photovoltaics In Buildings A Design Handbook for Architects and Engineers Published by – James & James, London

•

Planning and Installing Photovoltaic Systems Published by – James & James, London

•

Solar Energy Principals of Thermal Collection and Storage –by S P Sukhatme & J K Nayak, 2008

•

Sizing and Cost estimation methodology for stand-alone PV power System –Chel A, Tiwari G.N., Chandra A Int. J. Agile Systems and Management, Vol. 4, Nos. 1/2, 2009

•

Optimal sizing of solar array and inverter in the grid connected photovoltaic systems -Source springerlink

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Title of the research paper/ Case study: Eco At Gail , Vijaipur Township, Guna. Amita Tripathy [email protected]

Abstract Heading: Energy Conservation Opportunities Lighting is an essential service in all the townships. The power consumption by the lighting varies between 2 to 10% of the total power depending on the type of township. Innovation and continuous improvement in the field of lighting, has given rise to tremendous energy saving opportunities in this area. Lighting is an area, which provides a major scope to achieve energy efficiency at the design stage, by incorporation of modern energy efficient lamps, luminaries and gears apart from good operation. The Township of GAIL, Vijaipur is spread over an area of 150 acres. The power requirement of this complex is catered through it’s own CPP of 2X2.7 MW

(GTG’) and power import from utility grid ( MPSEB.) having

contract demand of 3.5 MVA. The main power distribution is through 6.6 KV system and utility grid is hooked up at 132 KV.

Key Words: Lighting, bill analysis, solar water heaters, leds

I.Introduction: GAIL (India) Ltd (Erstwhile Gas Authority of India Ltd), India’s principal gas transmission and marketing company, was set up by Government of India in August 1984 to create gas sector infrastructure for sustained development of gas market in the country. Today GAIL has expanded into Gas Processing, Petrochemicals, Liquefied Petroleum Gas Transmission and Telecommunications. The company has also extended its presence in power, Liquefied Natural Gas Re-gasification, City Gas Distribution and Exploration & Production through equity and joint ventures participations. GAIL (India) Ltd is having it’s one of the gas processing complex at Vijaipur, Dist. Guna, M.P.

1.1 Township Of Vijaipur: The Township of GAIL, Vijaipur is spread over an area of 150 acres with 170 A- Type , 230 B -Type, 120C Type, 68 D -Type residential quarters, 48 bedded guest house, two hostels with 45 rooms, hospital, club building swimming pool, Administrative building and two shopping complexes.

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2.Methods And Materials 2.1energy Scenario: The power requirement of this complex is catered through it’s own CPP of 2X2.7 MW

(GTG’) and power

import from utility grid ( MPSEB.) having contract demand of 3.5 MVA. The main power distribution is through 6.6 KV system and utility grid is hooked up at 132 KV. Major loads include motors up to 665KW, lighting system and heater. For emergency power back up there is DG Set of 1.35MW, 415V and 4nos UPS of ratings from 50-75KVA and small size UPS of 5-10KVA.

2.1.1Electricity bill analysis •

POWER FROM GRID – 3.5 MVA at 132KV from MPSEB.

•

CAPTIVE GENERATION- 2x2.7MW Gas Turbine Generator.

•

EMERGENCY BACK UP SUPPLY- 1X1.35MW DEG •

SUB STATION- 6 NOs IN PLANT •

3 NOs IN TOWNSHIP

In th e electrical b ill analysis, a wid e variation is in th e kWh (Un its) consu mp tion on a mo n th ly basis . Th e r a tio of ma x imu m to min imu m consump tion is abou t1.75 . Max imu m Pow er Consu mp tion : 196812.5kW h for the Mon th of May. H er e d e ma nd r eg ister ed for th e same mo n th is 400 kVA . Min imu m Pow er Con sump tion : 112110kW h pow er con sump tion and. dema nd r eg ister ed w as 457 kVA for th e mon th of Augu st.

2.1.2 Demand Analysis

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FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011 6000000 5000000 4000000 3000000 2000000 1000000 0 A pr- May- J un- J ul08 08 08 08

A ug- S ep- O c t- Nov- Dec - J an- F eb08 08 08 08 08 09 09

E NE R G Y C HA R G E S

DE MA ND C HA R G E S

2.1.3POWER FACTOR ANALYSIS

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TTOT OTAALL EE NE NE RRG G YY CC ONS ONS UME UME D D IN IN CC OL OL ONY ONY 220000 220000 200000 200000 180000 180000 160000 160000 140000 140000 120000 120000 100000 100000 AAprpr- MayMay- JJunun- JJulul- AAugug- SSepep- OOcct-t- NovNov- Dec Dec-- JJanan- FFebeb08 08 08 08 08 08 08 08 08 09 09 08 08 08 08 TO08 08 08 08 08 09 09 TOTA TALL EENE NERRGGYY CCOONS NSUME UMEDD IN IN CCOOLLOONY NY

2.1.4 ELECTRICITY TARIFF contract demand=3.5 MVA Tariff charges =Rs.130/KVA Kwh charges: Rs.2.90>50% load factor : Rs.3.50