Energy Savings

Energy audit report and Evaluation of scope for energy conservation:

Brief summary of Plant energy intake:

Connected load

Peak operating load

Off –peak load

Contract demand

Maximum demand

Average power factor

Objective of the report is to identify and recommend a set of cost-effective energy conservation schemes for the CAPOL plant which will further reduce the overall specific consumption of the electricity and fuels in the plant without actually affecting the production or quality of the products. The implementation of the process should result in improved energy efficiency and should reduce specific energy cost of production and net increase in profitability

Check list of energy intensive equipment:

 Compressed air systems

Water pumping systems and cooling towers]

Thermic fluid heaters

Steam systems

Furnaces

Transformers

Power factor and demand management

Electric motors

Fans and Blowers

Lighting

DG sets

Major focus areas for energy conservation:

• To enforce the usage of operations management for proper capacity utilization
• Boilers are not efficient at part load conditions
• Using right fuel
• Poor insulations on steam lines flanges, valves etc
• Steam trap by passes
• Hexane losses due to poor steam distribution and utilization

Other possible energy recovery options:

• Condensate recovery and recirculation as feed water
• To verify whether flash steam at anywhere useful
• To verify the systems like cooling water circulation systems operating as per the capacity of the plant.

Suggest to make an Energy management policy

• Bench mark the specific energy consumption
• Incorporate energy efficiency equipment in all the project infrastructures
• Conduct regular energy audits
• To adopt the energy conservation practices
• Enhance the skills of the human resources and strengthen the energy management programs
• Capacity utilization maximization – co-generation and waste energy recovery
• Loss prevention of the water, power, steam, coal, compressed air and chilling systems
• Motivating the employees to reduce energy consumption by 1 % per annum.

Other miscellaneous energy saving possibilities:

• Replacement of motors with smaller capacity
• Transparent sheets for the packing section and ware houses for eliminating the lights
• Installation of VFD wherever possible
• Cooling tower blades with superior material
• Energy recovery like using the heat from the steam condensate for heating of oil cake.
• Insulation of the storage tanks

Other energy saving measures:

• Gear box changes
• Energy recovery options
• Prevention of energy losses
• Replacing steam ejectors etc with better pumping systems

Advise:

Implementation of ISO standards and Quality standards: