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Advit Foundation_Energy Optimization

  1. 1. 3/11/2013 Energy optimisation – the Cleaner Production (CP) wayFor - Cost reduction - Energy savings - Pollution prevention Rajat BATRA Team member ADVIT Foundation STENUM Asia Sustainable Development Society Gurgaon 1
  2. 2. 3/11/2013 Outline • Sustainable Development • Energy scenario in India • Cleaner Production (CP) approach • Success stories / actual case studies 2
  3. 3. 3/11/2013 Sustainability …..is an Economic system which fulfils the needs of the present generation without compromising the needs of future generations 3
  4. 4. 3/11/2013 Sustainable development the 3 E concept Environmental integrity to have environmental considerations Economic efficiency to have economic success Equity to have fairness to all persons involved in the process A long term win-win approach 4
  5. 5. 3/11/2013 Facts about global warming • The primary greenhouse gas responsible for global warming is carbon dioxide • Scientists estimate that global temperatures are increasing at a rate of 0.3°C every ten years • A temperature rise of just 1 or 2°C can cause flooding, drought, crop failures and stormy weather. • 2000-2009 was the hottest decade on record • Sea levels have risen between 4-8 inches worldwide during the last century, and experts predict they could rise as much 2 feet in the next 100 years • The World Health Organization blames 150,000 deaths per year on the effects of global warming including extreme weather, drought, heat waves, decreased food production and the increased spread of diseases like malaria. 5
  6. 6. 3/11/2013 India’s Energy needs Some facts… • One of the fastest growing economies in the world. Estimated growth 7% on moderate term. • Energy Consumption is 12.6 million BTU. • India energy intensity is higher compared to Japan, USA and Asia as a whole by 3.7, 1.55 and 1.47 times respectively (energy consumption compared to GDP). • This indicates inefficient use of energy • Also substantial scope of energy savings. Note: 1BTU = 3412.142kWh 6
  7. 7. 3/11/2013 Trends in per capita Energy Consumption Sources: Ministry of Statistics and Programme Implementation 7
  8. 8. 3/11/2013 Present installed capacity of India All India generating installed capacity (MW) of power utilities including allocated shares in joint and central sector Utilities. Sources: Central Electricity Authority 8
  9. 9. 3/11/2013 Electricity demand projections Total Electricity Required Installed Capacity (MW) ( Billion kWhr) Year GDP Growth Rate 7% 8% 7% 8% 2011-12 1031 1097 206757 219992 2016-17 1377 1524 276143 305623 2021-22 1838 2118 368592 424744 2026-27 2397 2866 480694 574748 2031-32 3127 3880 627088 778095 Source: Energy Policy Report, Planning Commission, India 9
  10. 10. 3/11/2013 Trends in energy production in India Sources: Ministry of Statistics and Programme Implementation 10
  11. 11. 3/11/2013 Trends in Fuel Price Note: Petrol, diesel and kerosene prices are in rupees per litre, while LPG prices are per cylinder of 14.2 kilogram's. Sources: http://in.reuters.com/ 11
  12. 12. 3/11/2013 ENERGY for the future Some Options… Clean Coal Technologies Usage of renewable energy resource Modernisation of power transmission & distribution system Alternative fuels for surface transportation- bio-fuels, electric vehicles, hydrogen and fuel cell vehicles. Hydrogen has significant potential as a clean energy source Sources: TERI 12
  13. 13. 3/11/2013 Future Challenges Concerns of: Energy access Energy import vulnerabilities Climate change What then are the options & what are the implications of adopting alternative choices to fuel the country’s energy needs? Sources: TERI Scenario based illustrative projections 13
  14. 14. 3/11/2013 What Shape Can The Future Take? Scenario Storyline names Reference Development continues along current paths with autonomous efficiency Energy improvements taking place where feasible and increase in use of Scenario renewable energy carrying on at the same pace; and defined policy (RES) priorities being implemented Sustainable A determined effort is provided here for efficiency improvements both on Energy the supply and demand sides; an accelerated push for renewable energy, Scenario nuclear and new technologies. Energy Security concerns are paramount (SES) in this scenario. This scenario honours the Prime Minister of India’s commitment that Global India’s per capita carbon emissions would never exceed those of the Equity developed world and it is optimistically assumed here that the developed Scenario world would be able to bring down its emissions to a level of 2 (GES) tonnes/capita by 2030 as indicated by IPCC AR4. Stringent This scenario considers that India takes on an extremely aggressive Mitigation approach to energy self-sufficiency also resulting in even more stringent Scenario emissions reductions. (SMS) Sources: TERI 14
  15. 15. 3/11/2013 Primary commercial energy supply 2031 Sources: TERI 15
  16. 16. 3/11/2013 Fossil import dependency Large energy import infrastructure requirements by 2031 in the RES Coal import: ~1400 million tonnes, Oil import: ~750 million tonnes Sources: TERI 16
  17. 17. 3/11/2013 Power generation capacity mix 2031 Sources: TERI 17
  18. 18. 3/11/2013 Main Inferences Directional path of the Global Equity Scenario (GES) most attractive, balances multiple considerations of – minimizing energy imports – optimizing use of India’s substantial renewable energy resources cost effectively, and – efficient use of capital. Sources: TERI 18
  19. 19. 3/11/2013 Macro Inferences Significant short term gains (nearly 30%) are possible by increasing energy efficiencies along the entire value chain. What we do in the short term can benefit from long term opportunities: • Creating a comfort level with emerging technologies • Creating a conducive environment for transformational changes Sources: TERI 19
  20. 20. 3/11/2013 Understanding Cleaner Production approach Waste is generated What is to be done with it ? End of Pipe thinking: Waste Treatment approach Costs money Waste is generated Where does it come from ? What can be done to avoid it ? What can be done to reduce it ? Cleaner Production approach Saves money! 20
  21. 21. 3/11/2013 Understanding Cleaner Production approach Emissions and wastes are raw and auxiliary materials – which have mostly been purchased for a certain amount of money – and have not been transformed into saleable products. ECO-Efficiency is high when nearly all raw and auxiliary materials are transformed to saleable products – minimised waste 21
  22. 22. 3/11/2013 Impact of Cleaner Production approach Reducing wastage of energy in moulding process resulted in lower specific energy consumption 22
  23. 23. 3/11/2013 Structure of a typical CP project • Individual projects (customised, as required) • Cluster projects – Industry Association – Any other cluster • Carried out over 9 to 12 months • Four elements – Training, Consulting, Implementation support, Evaluation and award 23
  24. 24. 3/11/2013 Advantages of CP Reduced production costs Reduced maintenance costs Improved statutory compliance Reduced enviornmental impacts Better work conditions to employees Better cooperation with authorities Enhanced image competetive advantage Preparation or addition to ISO 14001 or ISO 50001 or other standards 24
  25. 25. 3/11/2013 Case Study 1: Reduced waste – auto parts SME in Gurgaon Before After Problem: Losses of brass chips in turning process Improvement: Guard provided on machine to avoid coolant & chips on floor. This results in proper brass chips collection. Savings/a: Rs. 27,600 Cost: Rs. 27,600 ROI: 1.0 25
  26. 26. 3/11/2013 Case Study 2: Reduced energy and water consumption – auto parts SME in Bhiwadi Result: 80% energy and water saving; ROI: 5 Improvement actions: • Insulated top surface of • Saved 43,200 kWh/yr (Approx. Rs. tanks 2 lakhs/yr) • Fresh water saved 67,000 liter/yr 26
  27. 27. 3/11/2013 Case Study 3: Reduced energy consumption - auto parts SME in Manesar After Process: 36 pieces of mirror are placed on a standard brick for convex process in an oven. Savings/a: Rs. 207,000 Cost: Rs. 33,120 Improvement: Number of pieces increased ROI: 6.25 from 36 to 39 per slot. Size of brick altered within the possible regime to occupy more pieces thus saving energy on one hand and enhancing productivity on the other. 27
  28. 28. 3/11/2013 Case Study 4: Reduced energy consumption – confectionary in Manesar Improvement actions: Result: >90% Compressed air was used to blow away empty pouches from the saving; ROI: packing line. A simple low voltage micro-blower was installed to do 118 the job TECHNO-ECONOMICS BEFORE AFTER Orifice size 3 NA Pressure 5 NA No. of orifices 40 40 Operation hours 7,200 7,200 Compressed air 4,059,102 NA (cfm/year) Energy needed 608,865 7,200 (kWh/year) Energy saved (kWh/year) 0 601,665 Equipment cost 0 40,000 Savings 0 4,738,112 Payback period / ROI NA 2.5 d / 118 28
  29. 29. 3/11/2013 Case Study 5: Reduced water consumption – electroplating SME in Gurgaon Improvement actions: Result: 25% saving • Conductivity profile of rinse ROI ∞ tanks monitored over 3 months • Based on this, optimum water flow rate implemented • Operators trained to measure conductivity as a basis for flow rate 29
  30. 30. 3/11/2013 Bhiwadi SME Cluster Project 2010-11 Project results - summary ₹ 1,228,000 ₹ 6,256,949 Annual savings Total investment 30
  31. 31. 3/11/2013 Shimla Hotels Cluster Project 2011-12 Economic evaluation - Actual return on investment INR 1,000,750 INR 2,061,890 Actual savings achieved till date (Rs. per annum) Actual invested till date (Rs.) 31
  32. 32. 3/11/2013 Shimla Hotels Cluster Project 2011-12 Savings - payback period INR 1,902,923 INR 2,259,308 INR 1,181,507 Immediate Less than 1 year 1 to 3.5 years 32
  33. 33. 3/11/2013 STENUM Asia services • Individual consulting projects on Cleaner Production / Resource Efficiency • Advisory and/or training on: – Material flow analysis, mass balancing – Energy analysis, energy audit – Renewable energy – Waste analysis and minimisation – Water treatment and control 33
  34. 34. 3/11/2013 Other services • Advisory and/or training on: – Environmental controlling – Process analysis – Resource management and concepts – CP option implementation – CP system implementation – CP interventions in residences (ECO Home) 34
  35. 35. 3/11/2013 Summary • Sustainability: a long term view • Energy scenario: – Global warming – Energy security – Huge potential for energy efficiency improvements • Cleaner Production (CP): – Low cost savings that work – Methology rather than technology change 35
  36. 36. 3/11/2013 Thank you for your attention For further details, please contact: STENUM Asia Sustainable Development Society SFF 101, Palam Triangle, Palam Vihar, Gurgaon 122017 www.stenum-asia.org Rajat BATRA +91-9811051918, rajat.batra@stenum-asia.org 36

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