Energy Auditing India
Just as an industry needs to know if it is working efficiently, if it is fully utilising its resorses without wastage -- its water and energy, its raw material, its finances, its man power -- so also a country needs to examine if its resources -- raw material, energy and water, finances and man power -- are being used with least wastage. And yes, what is the scope for reducing the wastage and conserving the resources for sustainable development?
2. Revamp current plant performance
3. Process integration
4. Retraining of manpower
- Inventory Control
- Process details
- Plant and machinery
- Product range and product quality
- Cost and quality of various energy inputs
- Assessing the present energy consumption pattern
- Relating energy inputs and production cost
- Identifying potential areas of energy losses
- Highlighting wastages in major areas
- Fixing of energy savings potential and prioritisation targets
- Qualification improvement programmes
- Vocational courses
- distance education
- Workshops
- Training at OEM’s works.
- Government – National and State level
- Energy Efficiency Agencies
- Equipment manufacturers
- Non Government Organisations (NGOs)
- Ministries / Departments like
- Planning Commission,
- HRD Ministry
- State Technical Education Boards
- Department of Science and Technology
- Ministry of Power
- State Electricity Boards etc.
- Integrated resources planning
- Demand side management
- Policy guidelines and concept
- Vocational training for skill building and skill updation
- Mass education/awareness campaigns on behavioral and attitudinal changes towards energy and environment
- Statutory measures to curb inefficient use of energy and illegal practices like fuel adulteration and environmental protection
TABLE –2
These 2 tables suggest some lines to carry out energy Audit of India and they will be --
Targets for these will have to be set up and measured for providing future direction.
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So if we decided to ENERGY AUDIT India, how would we proceed? This was the question taken up in PCRA (Petroleum Conservation Research Institute) in 2004, while I was in charge of it. We found that there are two facets of this approach -- one was to base the module on same lines as we do in Energy Audits in four major sectors namely Industrial, Agriculture and Domestic sectors and in power-generation plants themselves. Second was to look beyond them.
One of the objectives of PCRA is to function as a “Think Tank” to the Govt. of India for future policies and strategies on energy efficiency, petroleum conservation and environment protection. In 2003-04, PCRA through its various brain-storming sessions, assessed that just on the lines of Energy Audit in industries, we carry out Energy Audit of the country on a fixed frequency – preferably once in five years co-terminus with the plan period. Such a report generated one year before each plan period, shall become a part of plan document.
Energy conservation is a multifaceted activity involving both promotional and regulatory measures. The level of energy efficiency in developing countries is very low. The reasons for this are lack of technical knowledge, non-availability of energy efficient equipment or machinery and wrong energy subsidies. Energy subsidies, particularly those encouraging energy consumption by keeping the energy prices low, result in low efficiency, environmental degradation and increased energy intensity.
As per world energy outlook, India’s Specific Energy Consumption per unit of GDP is higher by 3.7 times that of Japan, 1.4 times that of Asia and 1.5 times that of USA, indicating very high energy wastage and thus potential for substantial energy savings.
In an ideal situation, the Specific Energy Consumption measures how much energy is consumed per unit of GDP growth. In order to analyse the trends in Specific Energy Consumption, it is necessary to separate energy intensity changes into structural and behavioural changes on one hand and technical energy efficiency changes on the other hand. The Specific Energy Consumption is closely related to economies of scale, process technology, instrumentation and control, structural changes, Govt. policies and end users behaviours. Yet, it is a universal scale for bench-marking and setting energy efficiency targets; something, that has been effectively used by the Japanese.
As can be seen from the table given below, in India, the industrial sector consumes 50% of the total commercial energy but contributes only 25% to the country’s GDP growth. Currently, this sector consumes more than 100 MTOE (million tones of oil equivalent), with a growth rate of about 6% per anum. There is need; therefore, to bring about substantial improvements in the efficiency of energy use in the industrial sector, particularly with the Indian economy opening up to the global markets. This alone can enable the Indian industry to compete effectively in the global market and also ensure higher profits. Based on various analyses, a saving potential of around 20% has been identified in the industrial sector without significant investment.
Taking Clue from Energy Audit of an Industry -- To do this let us take a look at how Energy Audit is conducted
An industrial energy audit helps in energy cost optimisation, pollution control, safety aspects and suggest methods to improve the operating and maintenance practices of the system. It prepares for coping up with the situation of variation in energy cost, energy availability, reliability of energy supply, decision on appropriate energy mix, decision on using improved energy conservation equipments, instrumentations and technology. The energy audit provides necessary information base for overall energy conservation programmes and is a vital link in the entire energy management chain. Energy management in turn can be construed as the process of guiding and controlling energy use so as to yield maximum possible output per unit of energy.
To meet the stated objective of Energy Audit in a holistic manner, the overall process of an industrial energy audit can be placed under five broad categories:
1. Minimize
obvious wastages
5. Paradigm shift
1.Minimize obvious wastages such as too much movement of inventory, making 2 trips when 1 is sufficient, non-balancing raw material, using excess water, lighting etc.
2. Current plant performance
For Energy Auditing of any industrial unit, the 1st step is sound knowledge of the current performance of major operating departments, process parameters and key equipments. Using this information, technical analysis is performed to check the present efficiency of energy use at each stage and to identify areas where technical improvement might be made. A good understanding of the parameters affecting the manufacturing process is essential. The cost involved for achieving enhanced performance is determined and financial analysis performed to identify cost effective measures.
This involves detailed study of the following function :
3. Process integration
Process integration always results in energy savings. It is a design tool to optimise energy resources in plants employing conventional technologies. It is common sense that Plants using batch processes would instantly benefit by shifting to continuous processes but the decision is not always easy as it requires considerations of market availability, inventory management, and manpower management too. Where the plant is already having a continuous Process, its intensification is the key. It involves making fundamental changes to processing technologies to yield improved product quality, throughput and energy efficiency. The advent of computers have made such an integration much more accurate than was earlier possible with manual controls.
Process integration is an established technology for continuous processes in the chemical industry. Pinch analysis is the most commonly used integration tool. It involves the use of heat exchanger networks to optimise heat energy by linking hot and cold process streams in the most thermodynamically advantageous way. Other tools take into account all energy flows (eg potential energy, pressure and momentum) using a technique known as exergy analysis. Developments are still needed to improve the analytical tools as well as technologies to recover the waste heat. One of the important areas is integration within a batch process where it can be substituted by continuous process.
As industries are adopting advanced equipment and process technologies for competitiveness, the available manpower also needs to be imparted new knowledge and skills to operate such technologies, for which retraining is very essential. Retraining of manpower can be done through :
One major aspect of training is attitudinal change.
Energy Auditing the Country
For ‘Energy Auditing India’ we can try
to apply the above 5 modules. Reducing obvious wastage has great potential. Careless
use leading to wastage is a routine affair for water, grains, electricity,
fuel, even human beings.
Process Integration
In the context of “Energy Auditing of the Country” the process integration means synergistic role and action of various actors, which include: -
The other issues concerning, process integration which require action oriented approach are :-
Retraining Manpower
For the success of ‘Energy Auditing India’ programme, involvement of people at the grassroots level will be important. This involvement can be ensured by motivation, education and legal liability for compliance. In this regard, the approaches can be as follows :
It is worth listing PCRA's efforts so far in respect of the above three.
i) Vocational training for skill building and skill up-dation
Unfortunately, in India we have excess of qualified engineers but scarcity of competent middle-level skilled persons like plumbers, electricians, carpenters etc. Inspite of Government efforts to open Industrial Technical Institutes (ITIs) in every district HQ and other smaller towns, we have not been able to attract sufficient number of candidates to take advantage of these courses. The simple reason for lack of interest in acquiring ITI qualification is that the poor candidates, belonging to a particular category lack the means and basic qualification to enter these courses. For this category of youth it is much easier to learn the traditional skills from their elders, where no basic qualification is required. Also there is no opportunity for them to update their skill and knowledge due to lack of basic qualification, resources and learning forums.
PCRA has prepared 60 films on vocational training, where persons with such background can update their knowledge to become more competitive. Some of the vocational films, produced by PCRA cover
Carpentry
Domestic Wiring
Masonry
Lathe Machine
Tractor Maintenance
Plumbing
Welding
AC Repair
Motor winding
ii) Behavioural and attitudinal changes through mass media
One of the objectives of PCRA is “To create awareness among masses about the importance, benefits and methods of conserving petroleum products and environment protection by enhancing information sharing and mass awareness.
A number of initiative have been taken by PCRA to bring in attitudinal changes amongst the masses for efficient utilisation of energy.
I) An infotainment radio programme “Boond Boond Ki Baat” is being aired on every Monday at 9.30 am by AIR FM Gold to spread awareness on the issues concerning energy efficiency & environment protection. The important topics covered so far are
o Energy Act
o Coal Bed Methane
o Green House Gases
o Bio-fuels
o Solid waste management
o CNG
o Fuel cells
o Auto fuel policy and energy efficient lighting system etc.
II) A very interesting edutainment programme “Khel Khel Mein Badlo Duniya” is being broadcasted on Doordarshan. The programme has been produced by PCRA and DAVP. The main topics covered in the various episodes of this programme are: -
· Wind Energy
· Solar Energy
· Bio-gas
· Vermiculture
· Transportation of petroleum products
· Vehicle population in metros
· Metro Rail
· Energy saving potential in different industries etc.
III) Regular Press Advertisements are being released by PCRA to achieve maximum reach to the households of the country. Sectoral advertisements on “Oil Conservation” for Transport, Industry, Agriculture and Domestic sectors were released in the leading national/ regional newspapers / magazines all over the country.
IV) PCRA has associated itself with “Lifeline Foundation”, an NGO of Gujrat by sponsoring their unique project, “The Highway Rescue Project” to evacuate highway accident victims within one hour of a distress call. PCRA as a sponsor to this project, displayed its conservation messages on these boards as well as stickers during last year , thereby spreading mass awareness on conservation while associating itself with this noble cause.
V) Films and TV spots are considered to be one of the most effective communicating media for PCRA’s Education Campaign Programmes Over the years, PCRA has developed several educational films and TV spots on the theme of oil conservation & environment protection in various languages that are being screened regularly during various charted activities of PCRA and sponsored in various TV channels.
VI) Large amount of literature giving useful tips for efficient utilization of energy and petroleum products in various sectors of economy is being printed and distributed by PCRA to educate the masses about the importance of efficient utilisation of energy.
iii) Statutory measures to curb inefficient use of energy ,fuel adulteration and environment protection
In addition to persuasive measures it is necessary to introduce statutory measures to curb inefficient utilization of energy. Energy conservation Act 2001 , which makes Energy Audit mandatory for certain types of industries is one step in this direction. As has already been stated, energy intensity in our country remains very high in comparison to developed countries. It is true that we have improved our Energy efficiency to some extent. The good news is that the Indian consumer has progressively become more efficient in consuming the available energy supply. As per the report from the Planning Commission, Energy intensity of our growth has reduced from 1.55 to 0.74 i.e reduction of 50% during the last three decades. To be globally competitive, a demand or need driven programme is more likely to succeed than a supply driven program based on subsidies. Lot is required to be done to create proper strategies for Demand Management Side than for Supply Management Side.
Paradigm
Shift --
For
sustainable Eco and Energy conservation, we need two paradigm shifts. First, adopt
some new visions of development . New
vision, such as using our Optic Fiber Network to provide Rural Tele-Communication
rather than depending on traditional methods,
Developing our next-to-nil research capabilities, Larger thrust on Skill education, Energy-efficient
Urban Planning, and so on. Second, question the sanctity of some of our
developmental models . I can cite 2 examples – Our Agriculture sector consumes
less energy per unit of GDP – why not develop it? Our service sector promotes
too much of non-productive services (such as security guards, super star
hospitals) – why promote them? Let us examine this scenario – the local
municipal corporation supplies water but not potable enough – individuals buy water
purifiers – GDP grows, but these machines necessarily throw away 50 % water –
that had been pumped and brought there. We do not calculate how much water and
energy have been wasted in the process – we focus only on GDP growth brought in
through increased business of individual
water purifiers. Another example, let us look at education of urban children.
Instead of promoting neighborhood school
model, which requires revamping of quality education in all schools, our policy
allows “specialized seven-star schools” requiring daily transportation of
thousands of school children across huge distances in the city leading to
tremendous energy consumption in unproductive activity.
The most
energy-efficient country, namely Japan sets targets for still higher energy efficiency
– and one strategy is by educating children to critically examine various
life-styles and choose what promises to ensure sustained energy efficiency. We too
need to prepare ourselves for such courageous paradigm shifts.
TABLE- 1
Energy Supply Scenario –2002-2003Source Available Quantity
· Coal – 370 MMT [a] Used for Electricity generation- 285 MMT [b] Used directly by industry – 85 MMT
· Petroleum –112 MMT
· Natural gas –97 MMT
· Electricity –107973 MW [a] Thermal- 76607 MW[b] Hydro- 26910 MW [c] Nuclear –2720 MW
· Non-Conventional Energy [a] Biomass – MW [b] Solar – MW [c] Wind – MW [d] Tidal - MW
Sector specific, % energy consumption Vs % contribution to GDP
Sector % Energy Consumption % Contribution to GDP
Agriculture, Forestry and Fishing 5.0 23 %
Industry 49 25 %
Service - 50
Training and consultancy - - ] Not known nor measured.
R and D ] Not known nor measured.
Infrastructure such as Highways and OFCs ] Not known nor measure
Re-emphasize agri and agro industries.
Make industry more energy efficient
Train HR by introducing vocational education
More coordinated efforts for non-conventional energy
Demand-Side Management
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