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Electrical Energy Conservation in

Steel Plants

Bhilai Steel Plant


S.Lakshmi,AGM(Energy Cell)
Energy Conservation and its Importance
What is Energy Conservation?
Example:
Replacing traditional light bulbs with Compact
Fluorescent Lamps (CFLs) means you will use
only 1/4th of the energy to light a room.
Pollution levels also reduce by the same amount
i.e Co2 emissions will reduce to 16g/Hr from
65g/Hr.
Energy Conservation and Energy Efficiency
Energy conservation is achieved when growth
of energy consumption is reduced, measured
in physical terms.
Energy efficiency is achieved when energy
intensity in a specific product, process or area
of production or consumption is reduced
without affecting output, consumption or
comfort levels.
Benefits of Energy conservation
Industry:
Reduced energy bills.
Increased Competitiveness
Increased Productivity
Improved Quality
Increased profits
Nation:
Reduced Energy import
Avoided costs can be used for poverty reduction
Conservation of Limited Resources.
Improved Energy Security
Globe-
Reduced GHG & other emissions
--- Maintains a sustainable environment
Energy Strategy for the Future

Immediate-term strategy:
Rationalizing the tariff structure of various energy products.
-- Optimum utilization of existing assets
-- Efficiency in production systems and reduction in distribution losses, including those in
traditional energy sources.
-- Promoting R&D, transfer and use of technologies and practices for environmentally sound
Energy systems, including new and renewable energy sources.

Medium-term strategy:

Demand management through greater conservation of energy


To move away from non-renewable to renewable energy sources viz. solar, wind, biomass energy, etc.

Long-term strategy:
Enhancing energy efficiency
Efficient generation of energy resources
Improving energy infrastructure
Energy Conservation Act
With the background of high energy saving
potential and its benefits, bridging the gap between
demand and supply, reducing environmental
emissions through energy saving, and to effectively
overcome the barrier, the Government of India has
enacted the Energy Conservation Act - 2001.

Energy Conservation Amendment Act 2010 (28 of


2010)
Important features of the Energy
Conservation Act are
w.r.t.applicabilty to SAIL/BSP
Standards and Labeling

Standards and Labeling (S & L) (star rating of


equipment) has been identified as a key activity for
energy efficiency improvement.
The main provision of EC act on Standards and Labeling are:
Evolve minimum energy consumption and performance standards
for notified equipment and appliances.
Prohibit manufacture, sale and import of such equipment, which
does not conform to the standards.
Introduce a mandatory labeling scheme for notified equipment
appliances to enable consumers to make informed choices
Disseminate information on the benefits to consumers
Designated Consumers

The main provisions of the EC Act on designated consumers are:


The government notified energy intensive industries and other
establishments as designated consumers.
Schedule to the Act provides list of designated consumers which
covered basically energy intensive industries, Railways, Port Trust,
Transport Sector, Power Stations, Transmission & Distribution
Companies ,IRON & SLTEEL Industry Commercial buildings or
establishments etc.
The designated consumer to get an energy audit conducted by an
accredited energy auditor.
Energy managers with prescribed qualification are required to be
appointed or designated by the designated consumers;
Designated consumers would comply with norms and standards of
energy consumption as prescribed by the central government.
Penalties and Adjudication
Penalty for each offence under the Act would
be in monetary terms
The initial phase of 5 years would be
promotional and creating infrastructure for
implementation of Act. No penalties would be
effective during this phase.
National Mission for enhanced energy efficiency

Under the National Mission for enhanced energy efficiency, the


Perform Achieve and Trade (PAT) scheme is being introduced to
enhance cost effectiveness of improvements in energy
efficiency in energy intensive large industries and facilities,
through certification of energy savings that could be traded.

their
Designated consumers can meet the energy consumption norms by
own actions, as well as through the purchase of energy
saving certificates. These certificates will, therefore, become an
instrument of compliance for achieving energy consumption norms.
Electrical energy intensive areas in Iron & Steel
Industries
Electric power supply systems
Electric Motors
Compressed Air System
Fans and Blowers
Pumps and Pumping System
Cooling Towers
Lighting System
ELECTRIC POWER SUPPLY SYSTEMS
OR ELECTRICAL UTILITY
Electricity generated at Generating station is carried to the consumer through
transmission and distribution network
IF ONE UNIT IS SAVED AT THE CONSUMER
END WILL LEAD TO SAVING OF 2 UNITS OF
GENERATING STATION.
ELECTRIC MOTORS
MOTORS
Motors convert electrical energy into mechanical energy by
the interaction between the magnetic fields set up in the
stator and rotor windings.
Industrial electric motors can be broadly classified as
induction motors
direct current motors or
synchronous motors
All motor types have the same four operating components:
stator (stationary windings),
rotor (rotating windings),
bearings, and
frame (enclosure)
MOTORS
Two important attributes relating to efficiency of
electricity use by A.C. Induction motors are
efficiency(), defined as the ratio of the
mechanical energy delivered at the rotating
shaft to the electrical energy input at its
terminals, and power factor (PF).
High value for and a PF close to unity are
desired for efficient overall operation in a plant
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN
MOTORS
Properly size to the load for optimum efficiency.
(High efficiency motors offer of 4 5% higher efficiency than standard
motors)
Use energy-efficient motors where economical.
Use synchronous motors to improve power factor.
Check alignment.
Provide proper ventilation
(For every 10C increase in motor operating temperature over
recommended peak, the motor life is estimated to be halved)
Check for under-voltage and over-voltage conditions.
Balance the three-phase power supply.
(An Imbalanced voltage can reduce 3 5% in motor input power)
Demand efficiency restoration after motor rewinding.
(If rewinding is not done properly, the efficiency can be reduced by 5 8%)
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN DRIVES

Use variable-speed drives for large variable loads.


Use high-efficiency gear sets.
Use precision alignment.
Check belt tension regularly.
Eliminate variable-pitch pulleys.
Use flat belts as alternatives to v-belts.
Use synthetic lubricants for large gearboxes.
Eliminate eddy current couplings.
COMPRESSED AIR SYSTEM
COMPRESSED AIR SYSTEM
Air compressors account for significant amount of
electricity used in Indian industries. Air compressors
are used in a variety of industries to supply process
requirements, to operate pneumatic tools and
equipment, and to meet instrumentation needs.
Only 10 30% of energy reaches the point of end-
use, and balance 70 90% of energy of the power
of the prime mover being converted to unusable
heat energy and to a lesser extent lost in form of
friction, misuse and noise.
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN
COMPRESSORS

Use a synthetic lubricant if the compressor manufacturer


permits it.
Be sure lubricating oil temperature is not too high (oil
degradation and lowered viscosity) and not too low
(condensation contamination).
Change the oil filter regularly.
Periodically inspect compressor intercoolers for proper
functioning.
Establish a compressor efficiency-maintenance program.
Start with an energy audit and follow-up, then make a
compressor efficiency-maintenance program a part of your
continuous energy management program.
CHECKLIST & TIPS FOR ENERGY
EFFICIENCY IN COMPRESSED AIR
Minimize purges, leaks, excessive pressure drops, and
condensation accumulation.
( Compressed air leak from 1 mm hole size at 7 kg/cm2
pressure would mean power loss equivalent to 0.5
kW)
Use drain controls instead of continuous air bleeds through
the drains.
Use a small air compressor when major production load is
off.
Take air compressor intake air from the coolest (but not air
conditioned) location. (Every 5C reduction in intake air
temperature would result in 1% reduction in compressor
power consumption)
FANS AND BLOWERS
Fans and blowers provide air
for ventilation and industrial
process requirements

A change in speed (RPM) of


any fan will predictably
change the pressure rise and
power necessary to operate it
at the new RPM.
CHECKLIST & TIPS FOR ENERGY
EFFICIENCY IN FANS AND BLOWERS
Use smooth, well-rounded air inlet cones for fan & blower air intakes.
Avoid poor flow distribution at the fan & blower inlet.
Minimize fan & blower inlet and outlet obstructions.
Clean screens, filters, and blades regularly.
Use aerofoil-shaped fan & blower blades.
Minimize fan & blower speed.
Use low-slip or flat belts.
Check belt tension regularly.
Eliminate variable pitch pulleys.
Use variable speed drives for large variable fan & blower loads.
Use energy-efficient motors for continuous or near-continuous operation
Eliminate leaks in ductwork.
Minimise bends in ductwork
Turn fan & blower off when not needed.
PUMPS AND PUMPING SYSTEM
The first step to achieve energy efficiency in
pumping system is to target the end-use.

A plant water balance would establish usage


pattern and highlight areas where water
consumption can be reduced or optimized.

Good water conservation measures, alone, may


eliminate the need for certain no. of pumps.
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN
PUMPS AND PUMPING SYSTEM

Operate pumping near best efficiency point.


Modify pumping to minimize throttling.
Adapt to wide load variation with variable
speed drives or sequenced control of smaller
units.
Use booster pumps for small loads requiring
higher pressures.
Repair seals and packing to minimize water
waste.
COOLING TOWERS
Cooling towers are a very
important part of many chemical
plants.

The primary task of a cooling


tower is to reject heat into the
atmosphere.

They represent a relatively


inexpensive and Dependable
means of removing low-grade heat
from cooling water.

The make-up water source is used


to replenish water lost to
evaporation.

Hot water from heat exchangers is


sent to the cooling tower.

The water exits the cooling tower


and is sent back to the exchangers
or to other units for further
cooling.
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN COOLING
TOWERS
Use two-speed or variable-speed drives for cooling tower fan control if the fans are few.
Use FRP blades in place of metallic blades.
Stage the cooling tower fans with on-off control if there are many.
Turn off unnecessary cooling tower fans when loads are reduced.
Balance flow to cooling tower hot water basins.
Periodically clean plugged cooling tower water distribution nozzles.
Install new nozzles to obtain a more-uniform water pattern.
Replace splash bars with self-extinguishing PVC cellular-film fill.
On old counter flow cooling towers, replace old spray-type nozzles with new square-spray ABS
practically-non-clogging nozzles.
Replace slat-type drift eliminators with high-efficiency, low-pressure-drop, self-extinguishing, PVC
cellular units.
If possible, follow manufacturer's recommended clearances around cooling towers and relocate or
modify structures, signs, fences, dumpsters, etc. that interfere with air intake or exhaust.
Optimize cooling tower fan blade angle on a seasonal and/or load basis.
Correct excessive and/or uneven fan blade tip clearance and poor fan balance.
Re-line leaking cooling tower cold water basins.
Check water overflow pipes for proper operating level.
Install interlocks to prevent fan operation when there is no water flow.
Establish a cooling tower efficiency-maintenance program. Start with an energy audit and
follow-up, then make a cooling tower efficiency-maintenance program a part of your continuous
Lighting System
Lighting System
Lighting is an essential service in all the industries. The
power consumption by the industrial lighting varies
between 2 to 10% of the total power depending on the
type of industry. Innovation and continuous
improvement in the field of lighting, has given rise to
tremendous energy saving opportunities in this area.

Lighting is an area, which provides a major scope to


achieve energy efficiency at the design stage, by
incorporation of modern energy efficient lamps,
luminaires and gears, apart from good operational
practices.
CHECKLIST & TIPS FOR ENERGY EFFICIENCY IN LIGHTING SYSTEM

Reduce excessive illumination levels to standard levels using switching, decamping, etc.
Aggressively control lighting with clock timers, delay timers, photocells, and/or occupancy
sensors.
Install efficient alternatives to incandescent lighting, mercury vapor lighting, etc.
Efficiency (lumens/watt) of various technologies range from best to worst approximately
as follows: low pressure sodium, high pressure sodium, metal halide, fluorescent, mercury
vapor, incandescent.
Select ballasts and lamps carefully with high power factor and long-term efficiency in
mind.
Upgrade obsolete fluorescent systems to Compact fluorescents and electronic ballasts
Consider lowering the fixtures to enable using less of them.
Consider day lighting, skylights, etc.
Consider painting the walls a lighter color and using less lighting fixtures or lower
wattages.
Use task lighting and reduce background illumination.
Re-evaluate exterior lighting strategy, type, and control. Control it aggressively.
Replace energy efficient displays like LED's in place of lamp type displays in control panels /
instrumentation areas, etc.
Maximise sunlight use through use of transparent roof sheets, north light roof, etc.
Install input voltage regulators / controllers for energy efficiency as well as longer life
expectancy for lamps where higher voltages, fluctuations are expected.
Power Consumption Trend at BSP
Operation Power,MW* BSP Load,MW
Year ABP Actual ABP Actual
2008-09 237.97 231.78 269.9 265.68
2009-10 240.9 229.13 280.0 261.24
2010-11 242.00 237.38** 284.0 271.2
2011 12 249 230.2 309.0 263.42
2012-13:upto 235.42 235.21*** 275.5 276.98
July'12
* Operation Power is used for Calculation of Specific power consumption
** 2010-11: SMS-2- LF2 ,RH2 &M/c6 became fully operational & higher
volumes
*** ASU-4 became operational
Thank You

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