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Table 3-11: Energy cost and intensity Indian and global energy reservesIndustry Energy cost (% of manufacturing cost) Energy intensity (%)India Developed nations IndiaIron & Steel 8.0-9.5 4-6 36.1-57.6Cement 1.0-4.4 0.6-0.9 30.0-59.0Aluminium 16-20 13-15 36.1-71.2Considering the above aspects of power production in India, it is recommended that allmeans of energy conservation be pursued. One approach, for example, is to examinethe various components of the power production system to ascertain which componentcan be tweaked to save power.Centrifugal pump, a common equipment in almost all industries, forms one suchcomponent. In general, centrifugal pumps account for 40-60 per cent of the total powerconsumption in processing plants. By adopting appropriate measures related tocentrifugal pumps, at least 25 per cent energy saving is possible. An audit of thepumps in the system will help identify the issues by examining aspects such as:• Wrong selection – under- or over-selection;• Over-design;• Improper equipment layout;• Usage of old, inefficient pumps;• Usage of multiple smaller-than-required size pumps; and• Systematic engineering principles ignored in pump selection.EMS-ERDA has conducted several such audits and successfully helped conserveenergy in a variety of industries.114