whr in msmes experience from world bank-sidbi project · world bank project : financing energy...
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WHR in MSMEs – Experience from World Bank-SIDBI Project
Development Environergy Services Ltd (DESL), New Delhi
At the
Energy Management Action NetworK (EMAK) Workshop Taj Palace Hotel, New Delhi
25 February 2015
Background
World Bank Project : Financing Energy Efficiency in MSME implemented by SIBDI and BEE
SIDBI is leading an activity where services are provided in 5 clusters to MSME units enhancement of energy efficiency
DESL has had the unique experience of conducting energy assessment studies in over 400 MSME units in the Faridabad cluster • The scope of work included Walk Through Audit, Detailed Energy
Audit and providing Implementation Support to the MSME units
• Detailed Energy Audit were conducted in over 260 MSME units in the mixed Faridabad cluster, which included 10 industrial sectors
• The Waste Heat Recovery system was recommended in mainly the forging, foundry, chemical, textile and die casting units
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Efficiency of Forging Furnaces
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METAL
PNG; 100%
METAL
FLUE GAS; 46%
HYDROGEN COMBUSTION; 12%
OPENING LOSS; 4%
SKIN LOSS; 2%
MOISTURE IN AIR; 2%
UNBURNT CARBON; 0.1%
FURNACE (Existing Efficiency:33%)
27 Deg C
1100 Deg C
Major EE recommendations: Waste Heat Recovery, Excess Air Control, Insulation
Improvement ad Opening Loss reduction
Receptiveness to suggestions
Receptiveness Remarks
Excess Air Control Low High manual interface Lowest cost option - sensing of temperature through PID is the most accepted EPIA
Insulation and Opening Loss
High Part of regular O&M measures
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Operating Parameters of Forging Furnaces
The theoretical maximum possible temperature gain ranges from 230 to
550 C
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Issues Faced while designing a WHR system
Draft is not balanced – Flue gas flow from the chimney is found to be very low in many cases
VIDEO
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Schematic of a WHR System & Economics
Furnace Hood
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Gain in air temperature
Weight of recuperator (kg) & Surface area (m2)
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Gain in air temperature
Cost of recuperator INR & Effectiveness %
Cost Effectiveness (% Theoretical)
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Technical Barriers
Waste heat sources at a plant are from non-continuous or batch processes
Seasonal operations and low-volume operations reduce the economic benefits of WHR system
Scenarios of added cost and complexity for integrating the WHR system controls with existing process controls
Space limitations and equipment configurations make WHR systems difficult or impossible to site economically
Lack of back-up service network
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Business Barriers
Industries reluctant to make investment that do not increase production and ensure economic survival and / or Perception about likely negative impact on the production
Risk of financing projects dependent on uncertain future fuel prices and variable electricity rates
Resistance to accept new, unproven technology that would potentially jeopardize existing production processes, despite significant potential benefits
Reliability and operability
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Possible Way Forward
Consolidate success from many ongoing MSME focused programs
Large scale proliferation by making available designs/design tools to vendors and manufacturers
Vendor/Manufacturer incentive program for energy efficient design (eg. Rating of products)
A paradigm shift on how MSME owners view investment in furnaces - Life Cycle Costing (eg. Rs/MT)
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About DESL
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Our Parent Company – VEIC VEIC is the Veolia subsidiary for consulting services in the fields of water and wastewater, energy and waste management services. The structure of companies under VEIC is as follows:
VEIC has over 200 employees and offices located in India, UAE, Oman, Saudi Arabia, VietNam, Togo; Cameroon, Gabon, Benin, Kenya, Tanzania and Algeria (excluding Europe).
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Partner Partner
Common Management
49%
51%
30%
51%
100%
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DESL Milestones (1/2) In a journey of over 15 years DESL has worked in the energy efficiency and renewable energy space all over the world. The service offerings cover the entire range of services including energy audit, energy services performance contract, project management including basic and detailed engineering, procurement, installation and commissioning services for development of energy efficiency and renewable energy projects as well as consulting services on energy policy, regulations and strategy. DESL has estimated that its services have contributed in reducing GHG emission by close to 4 Million Tons CO2 equivalent annually.
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ENERGY EFFICIENCY
Enabled energy saving of approx
200 MW in commercial buildings,
industries and municipal facilities
Designed and Engineered over
500 MW of biomass based
power plants and cogeneration
WTE Designed and
engineered 22 MW solid waste to energy plant
SHP Due Diligence &
Project development for
250 MW of hydropower
SOLAR 400,000 LPD solar water heating in
industrial processes
Distributed SPV systems
DESL Milestones (2/2) DESL is today a globally recognized energy consulting company having worked for many prestigious assignments for Multi & Bilateral organizations such as World Bank, ADB, UNDP, UNEP, UNIDO, USAID, GIZ, and DFID amongst many others.
Projects Executed in USA, Spain, France, Algeria , Kenya Sudan, Ivory Coast , South Africa, Jordan, Egypt, UAE, Tajikistan, Nepal, Bangladesh, Pakistan, Vietnam, China, Mongolia, Japan, Singapore
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Thank you
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Acknowledgement: Small Industries Development Bank of India
Contact Information: 011-40791100
srikantkasturi@deslenergy.com
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