energy cost reduction study at

DSCL ENERGY SERVICES COMPANY LTD2nd Floor, Kanchenjunga, 18 Barakhambha Road, New Delhi 110001

Tel. 0091 11 23316801 Fax 0091 11 23319062

Draft Presentation 23-09-05

Energy Cost Reduction Studyat

ContentsAccepted Energy cost reduction measures for implementationStatusWay forward

Accepted measures but to be decided after trialEnergy cost reduction measures on ‘Hold’Way forward

Summary of savings

Summary of savingsMost Likely SavingsMost Likely Savings Possible SavingsPossible Savings Investment Investment

(Rs. Lacs)(Rs. Lacs)PayPaybacbackk

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

II Measures of Less than 6 months PaybackMeasures of Less than 6 months Payback

Sub TotalSub Total 207 69 10 108 22

2 87 10 121 35 41 3-4

IIII Measures of Greater than 6 months paybackMeasures of Greater than 6 months payback

Sub TotalSub Total 135

267 66 115 13

5288 66 125 58 60 7-8

TOTALTOTAL 342

336 76 22

3357

375 76 246 93 100

IIIIII Accepted Project but to be decided after trialsAccepted Project but to be decided after trialsSub TotalSub Total - - - 15 - - - 15 2 2 2

IVIV Project on holdProject on holdSub TotalSub Total 20 44 - 51 30 44 - 58 40 41 8

TotalTotal 362

380 76 28

9362

419 77 319 135 129

Long Term ProjectsTotalTotal - - - 418 - - - 434 700 800 22

Grand TotalGrand Total 362

380 76 70

7362

419 77 753 835 929

Measures of Less than 6 months Payback

List of Energy Saving List of Energy Saving MeasuresMeasures

Most Likely SavingsMost Likely Savings Possible SavingsPossible Savings Investment Investment (Rs. Lacs)(Rs. Lacs)

PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

1.1. Installation of higher Installation of higher Efficient bigger BFW PumpEfficient bigger BFW Pump 93 - - 31.

5 93 - - 31.5 5 5 2

2.2.Utilization of Steam Utilization of Steam

instead of using Electrical instead of using Electrical Heaters in Power House for Heaters in Power House for

F.O. pre-heatingF.O. pre-heating- - - 22 - - - 22 10 10 5

3.3.Installation of screen to Installation of screen to

avoid re-crushing of fines avoid re-crushing of fines before crusher and to before crusher and to

reduce unburnts.reduce unburnts.5.2 43 - 10.

7 5.2 61 - 14.8 5 5 6

4.4. DG Cooling Tower Pump DG Cooling Tower Pump Efficiency ImprovementEfficiency Improvement 14 - - 4.8 14 - - 4.8 2 2 5

5.5. High Efficiency Low Head High Efficiency Low Head Pump for DM Water supplyPump for DM Water supply

11.4 - - 3.8

511.4 - - 3.85 2 2 6

6.6.Chemtech Cooling Tower Chemtech Cooling Tower

pump Efficiency pump Efficiency ImprovementImprovement

11 - - 3.28 11 - - 3.28 1.5 1.5 5

7. 7. Floorwise segregation of Floorwise segregation of cooling watercooling water 48 - - 16.

3 63 - - 25 6 12 6

8.8.Return water from top 3 Return water from top 3 segments of Fermenters segments of Fermenters directly to CT instead of directly to CT instead of

sumpsump24 - - 8 24 - - 8 2 2 3

Accepted Energy Conservation Measures:

Measures of Less than 6 months Payback



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

9.9. Chiller condensate Chiller condensate recoveryrecovery - - 10 1.1 - - 10 1.1 Nil Nil

Immediate

110.0. Arresting steam LeakagesArresting steam Leakages - 26 - 6.6 - 26 - 6.6 1 1 2

SUB- TOTALSUB- TOTAL 207 69 10 10

8222 87 10 121 35 41 3-4


Measures of Greater than 6 months Payback



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

1.1. Efficiency improvement of Efficiency improvement of 03 area CT pumps03 area CT pumps 15 - - 5 18 - - 6 3 3 7

2.2.Segregation of HP and LP Segregation of HP and LP

Lines for Raw Water supply Lines for Raw Water supply from sumpfrom sump

9 - - 3 9 - - 3 4 4 16

3.3.Bigger high efficient raw Bigger high efficient raw

Water supply pumps to RO Water supply pumps to RO PlantPlant

14.7 - - 4.5 17.

7 - - 6 3 4 8

4.4.Installation of smaller low Installation of smaller low head RO pump for starch head RO pump for starch

preparationpreparation4 - - 1.5 8 - - 2.7 2 3 9

5.5. Low head pump for soft Low head pump for soft water tankwater tank 7.5 - - 2.5 8.5 - - 3 2 3 8

6.6. Main CT Fans - Power Main CT Fans - Power Consumption OptimizationConsumption Optimization 19 - - 5.3 19 - - 5.3 3.5 3.5 8

7. 7. DG and Chemtech CT Fans DG and Chemtech CT Fans

- Power consumption - Power consumption OptimizationOptimization

4 - - 1.35 4 - - 1.35 1.4 1.4 12

8.8. Chilled water distribution Chilled water distribution systemsystem 14 - - 4.7

5 14 - - 4.75 3 3 8

9. 9. Flash steam recovery from Flash steam recovery from

the flash tank in the the flash tank in the Dextrose Plant + saving of Dextrose Plant + saving of

RO WaterRO Water- 20 5 6.2

5 - 20 5 6.25 5 5 10


Measures of Greater than 6 months Payback



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

110.0.

Condensate Recovery of Condensate Recovery of Mycelium Broth PHEMycelium Broth PHE - 22.

4 37 8.2 - 22.4 37 8.2 6 6 9

111.1.

Cooling Water return from Cooling Water return from seal pot and de-seal pot and de-

composition vessel directly composition vessel directly to Fermenter sumpto Fermenter sump

9.73 - - 3.2

89.73 - - 3.28 2 2 7

112.2.

Usage of RO Rejects for Usage of RO Rejects for the Backwashing of MGF, the Backwashing of MGF,

ACF, Sidestream Filter and ACF, Sidestream Filter and Plant CleaningPlant Cleaning

- - - 2.5 - - - 2.5 5 5 24

113.3. Line condensate RecoveryLine condensate Recovery - 18 24 2.6 - 18 24 2.6 2 2 9

114.4.

Lighting Energy Lighting Energy conservationconservation

2.55 - - 0.8

62.55 - - 0.86 1.2 1.2 17

115.5. WHRB Steam UtilizationWHRB Steam Utilization 36 20

7 - 63 36 207 - 69 15 15 3

SUB-TOTALSUB-TOTAL 135

267 66 11

5135

288 66 125 58 60 7-8


On HOLD



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

1.1.ETP Final Discharge ETP Final Discharge

Pumps: Gravity flow or Pumps: Gravity flow or Installation of high Installation of high

efficiency pumpefficiency pump20 - - 3 30 - - 10.3 2 2 4-8

2.2.Condensate & Flash Heat Condensate & Flash Heat

Recovery during Recovery during sterilization of PF and IFsterilization of PF and IF

- - - 17.3 - - - 17.3 15.4 15.4 11

3.3.

Crystallizer and Crystallizer and Evaporators condensate Evaporators condensate

Utilization in the De-Utilization in the De-aerator instead of using in aerator instead of using in

Ion-Exchange columnsIon-Exchange columns

- 44 - 11 - 44 - 11 8 8 9

4.4.Usage of Raw Water Usage of Raw Water

instead of Soft water in instead of Soft water in the Dextrose Plant CTthe Dextrose Plant CT

- - - 0.41 - - - 0.41 Nil Nil

Immediate

5.5.Usage of Raw Water Usage of Raw Water

instead of Soft water in instead of Soft water in the 03 Area CTthe 03 Area CT

- - - 1.02 - - - 1.02 Nil Nil

Immediate

6.6. Wheeling of Power to GridWheeling of Power to Grid - - - 18 - - - 18 15 15 10

SUB-TOTALSUB-TOTAL 20 44 - 51 30 44 - 58 40 41 8

Projects on hold

To be decided after trials



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

1.1. Zero BOD stream to be Zero BOD stream to be taken directly to Clarifiertaken directly to Clarifier - - - 15.

47 - - - 15.47 2 2 7

Projects to be decided after trials

Long Term Projects



PaybPaybackack

kW Kg/hr

CM/day

Rs. Lacs

kW Kg/hr

CM/day

Rs. Lacs

Most Likely

Possible

Months

1.1. Co-Generation Co-Generation Opportunities:Opportunities:

Option 1: Running of CFB Option 1: Running of CFB at 28 TPH Load and install at 28 TPH Load and install a Back pressure STG and a Back pressure STG and Utilization of 7.5 kg/cm2 Utilization of 7.5 kg/cm2

steam for the Jet cooker + steam for the Jet cooker + Installation of suitable Installation of suitable Electrical CompressorElectrical Compressor

- - - 418 - - - 418 700 700 20

Option 2: Running of CFB Option 2: Running of CFB at 32 TPH and install a at 32 TPH and install a

Extraction cum condensing Extraction cum condensing Turbine and fulfill Turbine and fulfill

10kg/cm2 requirement 10kg/cm2 requirement thro' PRDS + Installation of thro' PRDS + Installation of

suitable Electrical suitable Electrical compressorcompressor

- - - 434 - - - 434 800 800 22

Long term projects – Cogeneration option

Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB

OBSERVATIONOBSERVATIONCombined efficiency of 2 BFW pumps: 33%Combined efficiency of 2 BFW pumps: 33%

OPPORTUNITYOPPORTUNITY Replacing these 2 pumps with a single high Replacing these 2 pumps with a single high

capacity high efficient pump. capacity high efficient pump. BENEFITSBENEFITS

Power savings – 93 KW Power savings – 93 KW Annual savings – Rs. 31.5 lacsAnnual savings – Rs. 31.5 lacs

Investment – Rs. 5 Lacs (Including motor)Investment – Rs. 5 Lacs (Including motor)Payback: : 2 monthsPayback: : 2 months

ISSUES:ISSUES:Hydraulic testing of the boilersHydraulic testing of the boilers

SOLUTIONSOLUTIONUse the existing pumps during the hydraulic testsUse the existing pumps during the hydraulic tests

Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB

STATUSSTATUSAgreed, Pump specifications frozen and Enquiry Agreed, Pump specifications frozen and Enquiry

floatedfloatedSPECIFICATIONSSPECIFICATIONS

PROCESS OWNERPROCESS OWNER

New pump Design specs

Flow (cum/hr) Head (m) Motor(KW)

45 570 110

CFB-BFWP: Existing System

Design Flow (cum/hr)

Head (m) Power (KW)

27.9 640 90

Power:86.7 KWDesign Eff: 55%Actual eff:33%

Power:87.1 KWDesign Eff: 55%Actual eff:33%

Two pumps with a total capacity of 55.8 Cum/hr is operated.Two pumps with a total capacity of 55.8 Cum/hr is operated.Design Efficiency of each pump: 55%Design Efficiency of each pump: 55%

Combined system efficiency:33% Combined system efficiency:33% Opportunity for shifting to a single high capacity high efficient pumpOpportunity for shifting to a single high capacity high efficient pump

Total flow: 33.8 cum/hr

Discharge pressure: 56 kg/cm2

Suction pressure: 1.1 kg/cm2

CFB-BFWP: Installation of efficient, bigger Pump

New pump Design specsFlow (cum/hr)

Head (m)

Motor(KW)

45 570 110

Total flow: 33.8 cum/hr

Discharge pressure: 56 kg/cm2

Suction pressure: 1.1 kg/cm2

New bigger sized pump

Power:80 KWDesign Eff: 70%

The combined efficiency of both the pumps is 33%s The combined efficiency of both the pumps is 33%s Replacing these 2 pumps with a single high capacity high efficient pump . For hydraulic Replacing these 2 pumps with a single high capacity high efficient pump . For hydraulic

testing the old pump can be used.testing the old pump can be used.Power savings – 93 KW Power savings – 93 KW

Annual savings – Rs. 31.5 lacsAnnual savings – Rs. 31.5 lacsInvestment – Rs. 5 Lacs (Including motor)Investment – Rs. 5 Lacs (Including motor)

Payback: : 2 monthsPayback: : 2 months

Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO

preheatingOBSERVATIONOBSERVATION

184 kW electrical heaters are used for FO pre-184 kW electrical heaters are used for FO pre-heating at the power househeating at the power house

OPPORTUNITYOPPORTUNITY Electrical heaters may be replaced with steam Electrical heaters may be replaced with steam

heatersheatersBENEFITSBENEFITS

Savings in energy cost: 22 Lac Rs. Per annum Investment: Rs 10 Lacs

(Investment to be revalidated taking into account automation sensors and other controls)

Payback:5 monthsISSUES:ISSUES:

Investment to be revalidatedInvestment to be revalidated

STATUSSTATUSAgreed and already in touch with vendors for Agreed and already in touch with vendors for

freezing the investmentfreezing the investment


DSCL ES RoleDSCL ES RoleWould revalidate the investment required and the Would revalidate the investment required and the

cost benefit analysiscost benefit analysis

Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO

preheating

Usage of Steam instead of Electrical Heaters in power house

In the HFO Separator 72 kW Heaters (one standby) are used presently for heating of F.O.Booster Heaters are also of 72 kW(one standby) rating each.One Electrical Lube Oil Heater of 40 kW is also in operation.

Total Steam Requirement: 4.5 to 4.8 TPDSaving Possible: 22 Lac Rs. Per annum

Investment: Rs 10 Lacs(Investment to be revalidated taking into account

automation sensors and other controls)Payback:5 months

Usage of Steam instead of Electrical Heaters in power house

Actual consumption:45.2 KWA.C:30.1 KW

Lube oil heater:A.C: 20.1 KW

Project-3: Installation of screen before crusher to reduce unburnts

OBSERVATIONOBSERVATION30 to 50% of coal fed into the crusher is –6 mm size 30 to 50% of coal fed into the crusher is –6 mm size and fines. More than 50% of coal fed into the boiler and fines. More than 50% of coal fed into the boiler is less than –2 mm. Average unburnts in ash is 15%is less than –2 mm. Average unburnts in ash is 15%

OPPORTUNITYOPPORTUNITY Reduction of fines in coal by installing a screen Reduction of fines in coal by installing a screen before the crusher and reduction of unburnts in before the crusher and reduction of unburnts in

ashashBENEFITSBENEFITS

Coal savings – 43 kg/hr to 61 Kg/Hr Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacsAnnual savings – Rs. 10.2 to 14.3 lacs

Savings due to crusher load reduction: 5.2 KWSavings due to crusher load reduction: 5.2 KWAnnual savings:0.48 LacsAnnual savings:0.48 Lacs

Total savings: Rs. 10.7 to 14.8 LacsTotal savings: Rs. 10.7 to 14.8 LacsInvestment – Rs. 5 LacsInvestment – Rs. 5 Lacs

Payback: 5.6 monthPayback: 5.6 month

ISSUES:ISSUES:NilNil

STATUSSTATUSAgreed and already quotation for the screen has Agreed and already quotation for the screen has

been obtainedbeen obtained


Project-3: Installation of screen before crusher to reduce unburnts

Installation of screen before crusher to reduce unburnts

10*10 cm

8*8 mm

Requirement: (-)6 mm to +2mm

As per samples taken on 19th & 20th

25.9%25.4%

53.3%37.2%

44.1%32%

Rejects

5.1%33.4%

5 mm sieve


10*10 cm

8*8 mm

Unburnts increase because of fines. Provision of screens at the Inlet to hammer mills.

As per samples taken on 14h & 20th

43.03%

22.48%

63.2%

Rejects

0.85%2 mm sieve

Requirement: (-)6 mm to +2mm


Proposed schemeProposed scheme 6*6 mm screen

Possibility of maintaining the fines from 5 to 10% in imported coal


Sample size: 1.5 kgAverage fines (-2mm) in raw coal : 18.8%Average fines (-2mm) to coal bunker: 60%- 2 mm sieve coal increases from 18.8 units to 60 unitsAvg unburnts in ash: 15.47%

25% of the total fines generated at crusher25% of the total fines generated at crusher

Limit fines Generation at crusher by installation of screen at inlet to the crusher. Limit fines Generation at crusher by installation of screen at inlet to the crusher. This Will help reduce the unburnts in ash and reduce power consumption at the crusherThis Will help reduce the unburnts in ash and reduce power consumption at the crusher

Maintaining unburnts from 5 to 8%Maintaining unburnts from 5 to 8%Coal savings – 43 kg/hr to 61 Kg/Hr Coal savings – 43 kg/hr to 61 Kg/Hr

Annual savings – Rs. 10.2 to 14.3 lacsAnnual savings – Rs. 10.2 to 14.3 lacsSavings due to crusher load reduction: 5.2 KWSavings due to crusher load reduction: 5.2 KW

Annual savings:0.48 LacsAnnual savings:0.48 LacsTotal savings: Rs. 10.7 to 14.8 LacsTotal savings: Rs. 10.7 to 14.8 Lacs

Investment – Rs. 5 LacsInvestment – Rs. 5 LacsPayback: 5.6 monthPayback: 5.6 month

05

10152025

31 30 29 28 27 26 25 24 23 22 20 19 18 17 14 1August

unbu

rnt %

var

iatio

n

Unburnt % variation

energy cost reduction study at

Documents

months paybacklist of

ro water

water supply11

return water

high efficiency low

soft water tank7

lacsmost likelypossiblemonths1

lacsmost likelypossiblemonths9