October
20 2004
“Energy Auditing India”
Introduction
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 & environment
protection. In 2003-04, PCRA through its various brain storming sessions,
assessed that just on the lines of Energy Audit in industries, there is need to
carry out Energy Audit of the country on a fixed frequency – preferably once in
five years coterminus 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 & 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 /
machinery and 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 & behavioural changes on
the 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 & control, structural changes, Govt. policies and end users
behaviours. Yet, it is a universal scale for for benchmarking and setting
energy efficiency targets.
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 would 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
An
industrial energy audit helps in energy cost optimisation, pollution control,
safety aspects and suggest methods to improve the operating & 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
& controlling energy users 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 three broad
categories:
1. Current
plant performance
2. Process
integration
3. Retraining
of manpower
1. Current plant performance
For Energy Auditing of any industrial unit,
the 1st step in this direction 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 :
¨ Inventory
Control
¨ Process
details
¨ Plant
& machinery
¨ Product
range & product quality
¨ Cost
& quality of various energy inputs.
¨ Assessing
the present energy consumption pattern
¨ Relating
energy inputs & production cost
¨ Identifying
potential areas of energy losses.
¨ Highlighting
wastages in major areas
¨ Fixing
of energy savings potential and prioritisation targets
2.
Process integration
Process integration
always results in energy savings. Process integration is a management /design
tool to optimise energy resources in process plant employing conventional
technologies. Process intensification involves making fundamental changes
to processing technologies to yield improved product quality, throughput and
energy efficiency.
Process integration is
an established technology
for continuous processes in the chemical industry. Pinch analysis is the
most common process 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 analysis tools as well as technologies to recover the waste heat.
One of the important areas is batch process integration..
3.
Retraining of manpower: -
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 :
¨ Qualification
improvement programmes
¨ Vocational
courses/ distance education
¨ Workshops
¨ Training
at OEM’s works.
Energy
Auditing the Country
For Energy auditing of the county, sector
specific approaches covering studies on energy conservation pattern and fixing
energy saving potential of major industries like Aluminium, Steel, Textiles,
Cement, paper, Fertilizers, petroleum and chemical etc. will be required as a
first step.
Process Integration
In the context of
“Energy Auditing of the Country” the process integration means synergistic role
and action of various actors, which include: -
¨ Government – National & State level
¨ Energy Efficiency Agencies
¨ Equipment manufacturers
¨ Non Government Organisations (NGOs)
¨ Ministries / Departments like
o
Planning
Commission
o
HRD Ministry
o
State Technical
Education Boards
o
Department of
Science & Technology
o
Ministry of
Power
o
State
Electricity Boards etc.
The
other issues concerning, process integration which require action oriented
approach are :-
¨ Integrated
resources planning
¨ Demand
side management
¨ Policy
guidelines and concept
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.
¨ Vocational
training for skill building
¨ Mass
education/awareness campaigns on behavioural and attitudinal changes towards
energy and environment
¨ Statutory
measures to curb inefficient use of energy and illegal practices like fuel
adulteration and environmental protection
i)
Vocational training for skill building and skill updation
Unfortunately, in India we have excess of
qualified engineers but scarcity of competent 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, it is much easier to learn the traditional skills from their elders,
where no basic qualification is required. Also there is no opportunity for this
category to update their skill /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. The list of
some of the vocational films, produced by PCRA is given below:-
¨ 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.
¨ 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.
¨ 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.
¨ 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.
¨ 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.
¨ 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.
¨ 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 & 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. Again it is
not true that we have not improved our Energy efficiency at all. 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 completive, a demand/ need driven programme is
more likely to succeed than a supply driven prograame based on subsidies. Lot
is required to be done to improve energy efficiency in the industrial sector.
Fuel adulteration is another area of
concern in our country. Although Hon’ble Supreme Court of India has given
direction to setup 2 fuel testing laboratories to check fuel adulteration in
NCT & NCR, the lack of will in the enforcement agencies is coming in the
way of checking fuel adulteration, which results in environment pollution.
Strict measures are necessary to be undertaken to check the menace of
adulteration.
|
Energy
Supply Scenario –2002-2003 |
|
|
Source
|
Available
Quantity |
|
·
Coal –370 MMT |
a. Used for Electricity generation- 285 MMT b. Used directly by industry – MMT |
|
·
Electricity –107973 MW |
a. Thermal- 76607 MW b. Hydro- 26910 MW c. Nuclear –2720 MW |
|
·
Petroleum –112 MMT |
|
|
·
Natural gas –97 MM 3 |
|
|
·
NCES – MW |
a. Biomass –
MW b. Solar – MW c. Wind – MW d. Tidal - MW |
|
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·
|
c. |
|
·
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d. |
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·
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·
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·
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e. |
TABLE-
1
TABLE
–2
|
Sector specific, % energy consumption Vs % contribution to
GDP |
||
|
Sector |
%
Energy Consumption |
%
Contribution to GDP |
|
Agriculture,
Forestry & Fishing |
5.0 |
23 |
|
Industry |
49 |
25 |
|
Service |
- |
50 |
|
Training
& consultancy |
- |
- |