1.

0 Energy Efficiency
Concept & Fundamentals

A. K. SINHA

National Productivity Council - India

 Energy classification

Primaryand Secondary energy

Commercial and Non commercial
energy

Renewable and Non-Renewable
energy
Primary and Secondary Energy
Major primary and secondary sources
Source Extraction Processing Primary energy Secondary
Energy
Open Steam
Coal or deep Grading Coal
mines
purification Coke

Hydro

Nuclear Power
Mining Enrichment station Electricity

Natural gas
Gas well Treatment Natural gas

LPG
Petroleum Cracking Petrol
Oil
and refining Steam
well Diesel/fuel oils
Petrochemical
 Commercial and Non-
commercial Energy

Commercial energy is energy available
at price

Examplesare electricity, coal, lignite, oil,
and natural gas

Non-commercial energy is energy not
available in market for a price

Examples are firewood, cattle dung and
agricultural wastes, solar energy, animal
power, wind energy
Renewable & Non-renewable
Energy
 Global Energy Reserves (End
2008)

Global coal reserves
8,26,001 million tonnes

1258 billion barrels of
oil

185 trillion cubic • World oil and gas
metres of gas reserves are
estimated to last 43
years and 60 years
respectively.
• Coal is likely to last a
little over 122 years
Global Primary Energy
Consumption
 Primary energy consumption-
Some developing and developed countries

Table-1.1 : Primary Energy consumption at the end of 2008

Country Million tones of oil equivalent( Mtoe )
OIL COAL Natural Gas Nuclear Hydro Total
USA 884.5 565 600.7 192 56.7 2298.9
Canada 102 33 90 21.1 83.6 329.7
France 92.2 11.9 39.8 99.6 14.3 257.8
Russian
130.4 101.3 378.2 36.9 37.8 684.6
Federation
UK 78.7 35.4 84.5 11.9 1.1 211.6
China 375.7 1406.3 2.3 15.5 132.4 1932.2
India 135 231.4 37.2 3.5 26.2 433.3
Japan 221.8 128.7 84.4 57 15.7 507.6
Malaysia 21.8 5 27.6 0 1.5 55.9
Pakistan 19.3 6.7 33.8 0 6.3 66.1
49.9 66.1 8.3 34.2 0.9
Singapore 159.4
Total World 3927.9 3303.7 2726.1 619.7 717.5 11294.9
 Energy Pricing

Pricing influenced by economic, social

and political compulsions

Cross-subsidies: Diesel, LPG and
Kerosene subsidized by Petrol

Agricultural and domestic users
subsidized by Industrial and commercial
users
 Energy Security

High energy demand growth rate projected.

Many developing nations has to depend on
import of oil and coal to meet domestic
energy requirement .

Developing nations are vulnerable to external
price shocks and supply fluctuations

Need to reduce dependence on import and
diversify supplies
 Energy Security

Building stock piles

Diversification of energy supply sources

Increased capacity of fuel switching

Demand restraint,

Development of renewable energy sources.

Energy efficiency

Sustainable development
 Energy Conservation and its importance

60% of world
resources
consumed so far

85% of raw energy

comes from non-
renewable sources
and hence not
available for future
generation
Energy Conservations Vs
Energy Efficiency
Energy Efficient Equipment uses less energy
for same output and reduces CO2 emissions

Incandescent Lamp Compact fluorescent Lamp

60 W 15 W

CO2 Emission – 65 g/hr CO2 Emission – 16 g/hr

Figure 1.14
 Energy Strategy for the Future
Energy Strategies-Immediate

Rationalizing tariff structure of various energy

sources

Efficiency in production, reduction in
distribution losses

Promoting R&D and use of energy efficient
technologies and practices

Promoting energy efficiency standards
 Energy Strategies-Medium

Demand side management

Optimum fuel mix

Increased dependence on economic
mode of transportation system for
goods and passenger movement.

Recycling and waste minimisation

Shift to inexhaustible sources of energy
such as solar, wind and biomass energy
 Energy Strategies-Long

Optimum utilization of domestic fuel

sources

Improved energy infrastructure

Enhancing energy efficiency

Legislation towards energy efficiency
improvement.
 Energy Management

“The judicious and effective use of energy to maximize

profits (minimize costs) and enhance competitive
positions”
“The strategy of adjusting and
optimizing energy, using systems and
procedures so as to reduce energy
requirements per unit of output while
holding constant or reducing total costs
of producing the output from these
systems”
 Objective of Energy Management

To achieve and maintain optimum energy

procurement and utilization, throughout
the organization

To minimize energy costs / waste without

affecting production & quality

To minimize environmental effects.

 Energy Audit

Energy Audit is defined as

“the verification, monitoring and analysis of

use of energy including submission of
technical report containing recommendations
for improving energy efficiency with cost
benefit analysis and an action plan to reduce
energy consumption “
 Need for Energy Audit
Three top operating expenses are energy (both
electrical and thermal), labor and materials.
Energy would emerge as a top ranker for cost
reduction
primary objective of Energy Audit is to determine
ways to reduce energy consumption per unit of
product output or to lower operating costs
Energy Audit provides a “ bench-mark”
(Reference point) for managing energy in the
organization
 Types of Energy Audit

Preliminaryenergy audit

Detailed energy audit

Type of energy audit chosen depends

on

Function and type of industry

Depth to which final audit is needed

Potential and magnitude of cost
reduction desired
 Preliminary Energy Audit
Methodology
Preliminary energy audit uses existing, or easily
obtained data

Establish energy consumption in the organization

Estimate the scope for saving
Identify the most likely areas for attention
Identify immediate ( no-/low-cost) improvements
Set a ‘reference point’
Identify areas for more detailed
study/measurement
 Detailed Energy Audit

Evaluates all energy using system,

equipment and include detailed energy
savings and costs

Carried out in 3 phases

Pre-audit Phase

Audit Phase

Post-Audit
 Ten Steps Methodology for
Detailed Audit
Step
PLAN OF ACTION PURPOSE / RESULTS
No
Phase I –Pre Audit Phase

Step 1 • Plan and organise • Resource planning, Establish/organize a

• Walk through Audit Energy audit team
• Informal Interview with • Organize Instruments & time frame
Energy Manager, Production • Macro Data collection (suitable to type of
/ Plant Manager industry.)
• Familiarization of process/plant activities
• First hand observation & Assessment of
current level operation and practices

Step 2 • Conduct of brief meeting / • Building up cooperation

awareness programme with • Issue questionnaire for each department
all divisional heads and • Orientation, awareness creation
persons concerned (2-3 hrs.)
 Phase II –Audit Phase
Step 3 • Primary data gathering, • Historic data analysis, Baseline data
Process Flow Diagram, & collection
Energy Utility Diagram • Prepare process flow charts
• All service utilities system diagram
(Example: Single line power distribution
diagram, water, compressed air & steam
distribution.
• Design, operating data and schedule of
operation
• Annual Energy Bill and energy consumption
pattern (Refer manual, log sheet, name plate,
interview)
Step 4 • Conduct survey and • Measurements :
monitoring Motor survey, Insulation, and Lighting
survey with portable instruments for
collection of more and accurate data.
Confirm and compare operating data with
design data.
Step 5 • Conduct of detailed trials • Trials/Experiments:
/experiments for selected - 24 hours power monitoring (MD, PF,
energy guzzlers kWh etc.).
- Load variations trends in pumps, fan
compressors etc.
- Boiler/Efficiency trials for (4 – 8
hours)
- Furnace Efficiency trials
Equipments Performance
experiments etc

Step6 • Analysis of energy use • Energy and Material balance & energy
loss/waste analysis

Step 7 • Identification and • Identification & Consolidation ENCON

development of Energy measures
Conservation (ENCON)  Conceive, develop, and refine ideas
opportunities  Review the previous ideas suggested by unit
personal
 Review the previous ideas suggested by
energy audit if any
 Use brainstorming and value analysis
techniques
 Contact vendors for new/efficient
technology
Step 8
• Cost benefit analysis • Assess technical feasibility, economic
viability and prioritization of ENCON
options for implementation
• Select the most promising projects
• Prioritise by low, medium, long term
measures

Step9 • Reporting & Presentation to Documentation, Report Presentation to the top

the Top Management Management.
Step10 Phase III –Post Audit phase

• Implementation and Follow- Assist and Implement ENCON recommendation

up measures and Monitor the performance
 Action plan, Schedule for
implementation
 Follow-up and periodic review
 Identification of Energy
Conservation Opportunities

Energy generation

Energy distribution:

Energy usage by processes:

Fuel substitution:
 Technical and Economic
feasibility
Technology availability, space, skilled manpower, reliability,
service,Impact of measure on safety, quality, production or
process. Maintenance requirements and spares availability
Sample Worksheet for Economic Feasibility
Name of Energy Efficiency Measure
i. Investment 2. Annual operating costs 3. Annual savings
a. Equipments • Cost of capital • Thermal Energy
b. Civil works • Maintenance • Electrical Energy
c. Instrumentati • Manpower • Raw material
on • Energy • Waste disposal
d. Auxiliaries • Depreciation
Net Savings /Year (Rs./year) Payback period in months
= (Annual savings-annual operating costs) = (Investment/net savings/year) x 12
Energy Audit Reporting Format
 Energy
Audit
Reporting
Format
 Understanding energy costs

Typical summary of energy bill by a company

Table-3.4
Original units Equivalent
Type of energy Unit cost Monthly bill INR
cost US$
Electricity 5,00,000 kWh Rs. 5.00/KWh 25,00,000 50,000
Fuel oil 200 Kl RS. 20,000/KL 40,00,000 80,000
coal 1000 tons RS.2,000/ ton 20,00,000 40,000
Total 85,00,000 1,70,000

Conversion to common unit of energy

Electricity (1 kWh) = 860 kcal/kWh (0.0036 GJ)

Heavy fuel oil (calorific value, GCV) =10.000 kcal/litre ( 0.0411 GJ/litre)
Coal (calorific value, GCV) =4000 kcal/kg ( 28 GJ/ton)
Benchmarking parameters for
Energy Performance

•Gross production related

e.g. kWh/MT clinker or cement produced (cement plant)
e.g. kWh/MT, kCal/kg, paper produced (Paper plant)
e.g. kCal/kWh Power produced (Heat rate of a power plant)
e.g. Million kilocals/MT Urea or Ammonia (Fertilizer plant)

•Equipment / utility related

e.g. kWh/ton of refrigeration (on Air conditioning plant)
e.g. % thermal efficiency of a boiler plant
e.g. kWh/NM3 of compressed air generated
e.g. kWh /litre in a diesel power generation plant.
 Electrical Measuring Instruments:
These are instruments for measuring
major electrical parameters such as kVA,
kW, PF, Hertz, kvar, Amps and Volts. In
addition some of these instruments also
measure harmonics.

These instruments are applied on-line i.e

on running motors without any need to
stop the motor. Instant measurements
can be taken with hand-held meters,
while more advanced ones facilitates
cumulative readings with print outs at
specified intervals.

Energy Audit Combustion analyzer:

This instrument has in-built chemical

Instruments cells which measure various gases such

as CO2, CO, NOX, SOX etc

Fuel Efficiency Monitor:

This measures Oxygen and temperature
of the flue gas. Calorific values of
common fuels are fed into the
microprocessor which calculates the
combustion efficiency.

Fyrite:

A hand bellow pump draws the flue gas

sample into the solution inside the fyrite.
A chemical reaction changes the liquid
volume revealing the amount of gas.
Percentage Oxygen or CO2 can be read
from the scale.
Contact thermometer:

These are thermocouples which measures

for example flue gas, hot air, hot water
temperatures by insertion of probe into
Energy Audit
the stream.

For surface temperature a leaf type probe

Instruments
is used with the same instrument.

Infrared Pyrometer:

This is a non-contact type measurement

which when directed at a heat source
directly gives the temperature read out.
Can be useful for measuring hot jobs in
furnaces, surface temperatures etc.

Pitot Tube and manometer:

Air velocity in ducts can be measured

using a pitot tube and inclined manometer
for further calculation of flows.

Ultrasonic flow meter:

This a non contact flow measuring device

using Doppler effect principle. There is a
transmitter and receiver which are
positioned on opposite sides of the pipe.
The meter directly gives the flow. Water
and other fluid flows can be easily
measured with this meter.
 Speed Measurements:

In any audit exercise speed measurements

are critical as thay may change with
frequency, belt slip and loading.

A simple tachometer is a contact type

instrument which can be used where
direct access is possible.

More sophisticated and safer ones are

non contact instruments such as

Energy Audit Tachometer Stroboscope

stroboscopes.

Instruments Leak Detectors:

Ultrasonic instruments are available

which can be used to detect leaks of
compressed air and other gases which are
normally not possible with human
abilities.

Lux meters:

Illumination levels are measured with a

lux meter. It consists of a photo cell
which senses the light output, converts to
electrical impulses which are calibrated
as lux.
Thank You for your kind attention