Coun\ Papen ON EI\ERGY MANAGEMtrNTtr

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TATA ENERGY RESEARCH INSTITUTEBANGALORE

CouNTRY Papen

ON

EI\ERGY MANAGEMtrNT EFFORTS

By

TATA ENERGY RESEARGH INSTITUTEBANGALORE, INDIA

Dr. K V Narasimha Rao, ResearchAssocr'af e, TERI, Bangalore, lndia

About TERI

TERI is an autonomous, not-for-profit, research institute established in 1974.

ln the initial period, the institute concentrated on documentation and

information dissemination activities. Towards the end of 1982, research

activities were initiated in the field of energy, and expanded soon to cover the

environment, biotechnology, forestry, and the whole range of sustainable

development issues.

'This institute studies and seeks solutions to the immense problems that arise

consequent to the rapid depletion of natural resources, and the serious

environmental hazards that result from their use. Every stage of the energy

cycle is examined - extraction, generation, transmission, distribution and

utilisation - with the focus on the environmental impacts at each stage.

TERI, Regional Centre, Bangalore

Established in 1990, TERI, Bangalore has a core group of inter-disciplinary

professionals trained in modern energy conservation concepts and practices.

TERI has so far conducted over 150 detailed energy audits for a wide range

of industries. TERI also undertakes implementation of various energy

conservation measures for its clients.

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TERI also scrutinises project reports for new ventures to incorporate "Energy

Efficiency ParameterS", introducing Energy Management techniques for

implementation and monitoring in that organisation.

TERI also conducts training programmes on 'Practical Energy Audit' for

personnel from various industries. Most recently, (September 26-28, 1996), it

has conducted a training programme on PEA at Goa, lndia.

TERI's Approach:

TERI has a wide range of sophisticated portable, diagnostic & measuring

instruments. These facilitate analyses and measurements, and form a more

reliable basis for identification and quantification of viable energy saving

alternatives. Whiie carrying out energy audit, there would be constant

interaction with plant management to ensure that the proposals evolved are

realistic, practical and implementable.

TERI's experience shows that between 6-200/o energy can be saved by

carrying out systematic energy audits.

IG.IEEIP

lG-lEElP is a recently formed joint technical co-operation project involving

Govt. of lndia, Govt. of Germany, TERI and the GTZ.

TERI has been selected as the implementing Agency for the project known as

'lndo-German lndustrial Energy Efficiency lmprovement Project' funded by

GTZ-Germany with EMC, Govt. of lndia as the co-ordinating body. This

project is focussing its attention on energy uses in the State of Karnataka,

lndia,

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The main mission of the project is to create awareness for the need for

energy efficiency and to identify energy-saving opportunities in the industrial

sector. The demonstration units selected under this project would serve to

implement energy-efficient technologies, comparable to those existing in

'advanced countries, to document the benefits in energy savings, and

facilitate their replication in similar units throughout the country. lt would

therefore contribute to reduce specific energy consumption by the lndian

lndustry at a national level.

The project intends to implement energy efficiency improvement through a

multi-pronged stragegy of energy/technology audits, implementation of

energy optimisation opportunities arising out of the audit studies, information

dissemination, training and demonstrating live industrial situations where

such practicable solutions for improved energy efficienqy have been

successfully employed. Teri has at'its' service several experts who would be

guiding these efforts on short and longterm basis.

The initially selected targe-groups are:

Cement

lron & Steel

Food Processing

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TATA ENERGY RESEARCH INSTITUTE,BAN GA,LOR E

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CASE STUDY

A. Company Background: Brewery in Bangalore, lndia

(i) Established 1885

(ii) Operation : Round the clockProcess (24 hours a day)Bottling ('16 hours a day, generally)

(iii) Products : BeerNormal: 6.5% alcoholExtra Strong '. B-10% alcohol

(iv) Production '. 44,000 kL of Beer

(v) No. of employees : 350

(vi) Present energy consumption status (1995 - 96)

a. Electricity (50 - 55% for Refrigeration & Air-conditioning)Purchased '. 419,622 kwhSelf generated . 213,264 kWh

b. Furnace oil(boilers)

: 176,819 I

c. HSD (self power generation) .741521

(vii) Specific Energy Consumption

a. Electricity : 160 kWh/kl of Beerb Furnace Oil '. 48 ll kL of Beer

(viii) Brief Description of the process

1. Brewinga. Millingb. Mashingc. Wort seperationd. Wort boilinge. Hop seperationf. Wort cooling

2. Fermentatian and Lageringa. Fermentation (7 day process)b. Lagering (21 day process)

3. Bottling M

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B. ENERGY SAVING OPPORTUNITIES

Refrigeration & Air Conditioning

Facility Description:

Vapour (Ammonia) compression = 7 No.

Systems (6 reciprocating, 1 screw)

Secondary refrigerant = Brine (CaClz, 25o/o by weight)at -9 and -4'C

Water (0"C) - one systemexclusively

Total refrigeration requirement = 250 TR

Recommendations:

a. Stop running the fan coil unit in fermentation room; insulate the

hemispherical domes of the fermenting vessels with 1OOmm thick

thermocole.

b. Replace 15 kW condenser water pump (system # 4) with 11.2 kW

pump (similar to the other systems).

c. Bring down the pressure drop across the chiller (system # 6) to 1

kglcm2 (or less) from the present 2kgtcm2 by descaling the chiller.

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Saving Galculations:

a. Do away without fan coil unit in fermentation room

Estimated savings in refrigeration = 8 TR

Correspondingenergysavings = 8kW@1 kWTR

Estimated savings in pumping power = 2 kW

Savings in fan power = 2 kW

Total energysavings = 8+2+2=12kW

Annual energy savings = 8000 x 12

@ 8000 operating hours= 96000 kWh

Annual energy cost savings = 3 x 96000

@ Rs.3.00/kwh= Rs.2880001

b. Replacing Condenser Water Pump # 4 with a Proper Sized One

Possibleenergysavings = 0.8x5x0.746

= 3kW

.Annual energy savings = 24000 kWh

Annual energy cost savings = Rs.72000/-

c. Reducing the Pressure Drop across the Ghiller # 6

Discharge pressure of brine pump = 3.0 kgicm2

Power input to the PumP = 8.5 kW

PXlcomoineox3600Present brine flow rate, 0 =

9.81 x hwhere,

l'lcombined

o9.81 x 30

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= 0.5

8.5x0.5x3600

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TATA ENERGY RESEARCH INSTITUTE

BANGALORE

power required for tjelivering the .same quantity of water

at a lower pressure, @ 1 5 kg/cm2g

51.99x9.81 x15

0.5 x 3600

= 4.25 kW

Difference in power input = 8'5 - 4'25

= 4.25 k\N

Annual EnergY savings = 4'25 x 8000

= 34,000 kWh

'Annual energy cost savings = 34,000 x 3'00

@ Rs.3.00 PLr r.wn= Rs.1,O2,OO0|-

Cost of lmPlementation

a. lnsulation for fermenting vessels

Effective area to be insulated = 6 m2

(per vessel)

Total area = 18 x 6

= 1O8 m2

lnsulation material = 100 mm thick thermocole

lnvestment required @ Rs. 12O0lm2 = 12OO x 108

= Rs.1 ,29,600/-

b. Replacing 15 kW pump with 11.2kW pump

Cost of 11.2kW pump with = Rs.50000 (approx')

energy efficient motor

c. Reducing pressure drop across the chiller

lnvestment required = Rs.30000 (approx')

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Simple payback period

a. S.P.P.

b. s.P.P.

c. S.P.P.


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lnvestment

Annual energy savings

1 29600

S.P.P. =

2,88,000

= 6 months

50000

72040

8.5 months

30000

1,02,000

^, 3.5 months

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