Energy Efficiency Optimization (For Process and Power Plants)

Energy Efficiency Optimization(For Process and Power Plants)Dr.G.G.RajanCochin – IndiaPhone: 0091-484-2782158Cell: 098470 45158email: ggrajan@vsnl.comWeb: http://business.vsnl.com/ggrtech05/03/2008

05/03/2008About Energy EfficiencyOptimization• Energy efficiency optimization refers to theapplication of mathematical / statistical / operationsresearch techniques to minimize energyconsumption, energy cost and loss reductionwithout loss of production quantity / quality.• A basic mathematical background is desirable toknow the theoretical concepts.• It is possible to carry out energy efficiencyoptimization, by using simple tools – e.g.optimization and modeling software.

WHY ENERGY EFFICIENCYOPTIMIZATION ?Energy efficiency optimization is the best route tomeet the energy demand at minimum cost withoutloss of production / output of the system.In conventional Energy demand management, usersare guided by their own intuitive decisions, whichmay not be optimum.For meeting the energy demand effectively atminimum cost and meeting all the imposedconstraints, EEO is the apt solution.05/03/2008

05/03/2008Energy efficiency optimization –Auditing approach.• To carry out Energy Efficiency Optimizationusers must know, which are the subsystems /equipments responsible for overall energyefficiency and what parameters need to bemonitored and controlled to achieve theobjective.• In real life situations this may include EnergyConsumption / Utilization of all forms of energysuch as Fuel , Steam , Electricity , ThermalEnergy etc related to the process under study

ENERGY AUDITING05/03/2008•Energy auditing of the system /subsystem helps to bring down thetotal energy consumption by losscontrol and efficiency improvement ofthe right items.•For achieving this, a systematicEnergy Auditing of the total system isessential.

05/03/2008Prioritization of Energy costcentres• Prioritization of Energy cost centres is done using Pareto’stheory.• In this process , the total system is divided into a number ofsubsystems and elements and energy input / output datacollected for analysis.(design and observed energyquantities.)• Energy consumption data analysis reveals intensive energyconsumers requiring tight control and sets monitoringpriorities.• At unit level, this may cover energy consumingdevices.(e.g.boilers/heaters/turbines etc)• At macro level, analysis of total industrial sector is required.

Pareto’s Theory related toEnergy Efficiency .05/03/2008• About 7 to 10% of the total equipmentconsume 70 to 75% of Total Energy Input tothe system.( Class A)• About 30% of the equipment consume 10%of Total Energy Input (class B)• The balance 60 to 70 % of equipmentconsume 6 to 7% of Total Energy Input(class C)• Same concept may be applicable for Macosystem as well.

% Energy70605040302010005/03/2008Typical Pareto’s ModelA (10%) B (20%) C(70%)% Equipments

Energy System Analysis05/03/2008• Energy System Analysis is the first activityto identify class A, Class B and class C subsystems/ equipment of the total system forPerformance Monitoring and Optimization• This concept may be applied to very largemacro systems such as national thermalpower plants, refineries, petrochemical unitsetc.• Using the data collected during the auditingprocess, it is possible to develop PerformanceModels for the sub systems ( individualplants in case of macro systems) forcorrective action.

Advantages of EnergyAuditing• offers fast track solutions to EnergyEfficiency Management.• Monitors performance effectively• Identifies specific problem area in a veryshort time.• Offers tangible solutions.• Reduces operating cost and• Increases profit margin drastically.05/03/2008

05/03/2008Organizing Technical Audit• Technical Audit for Process & Power plants ,covers the following conventional energy centers.– Utility system (water/steam/air)– Boilers– Pumps– Compressors– Turbines ( Gas turbines & Steam turbines )– Turbo Generators– Heat Exchangers / Condensers– Miscellaneous applications– Systems analysis and MIS

Types of Energy Audit05/03/2008• Walk through energy audit• Total system analysis ( intensive )• Heater / Boiler Audit• Steam system Audit• Electrical system Audit• Loss control ( auditing process /handling losses )• Auditing rotating equipments• Heat exchanger system audit

05/03/2008Energy Audit findingsOffer : Energy resource break-up ( steam /power / fuel )List of class A , class B and Class CequipmentsCurrent energy efficiency of equipmentsList of equipments with lower energyefficiencyEnergy resource utilization and loss areas

Developing Energy Efficiency Models• Energy efficiency models may be designed toevaluate the energy efficiency of all energyintensive equipment for continuous performanceevaluation and monitoring .• This must cover all type of Energy input resourceslike Fuel , Steam , Power and Thermal Energy.• Energy efficiency Models are the key toPerformance Evaluation of the equipment ,system and sub systems for taking correctiveactions in the right direction.05/03/2008

ExampleSteamPowerFuelUnit I Unit II Unit III Unit IV05/03/2008

Energy wise System Analysis Using the Energy Data, Techno Thermanalyses the entire system Energy wise andoffers information such as• unit wise Steam consumption.• unit wise power consumption• unit wise fuel consumption• total energy input analysis.• Energy cost , losses etc05/03/2008

Energy type – Break-up8 %32 %60%05/03/2008 Fuel Steam Power

Unit wise Energy Consumption454035302520151050I II III IVunits%05/03/2008

Total Analysis6050403020100I II III IV05/03/2008Steam Fuel Power

Advantages of Energy Efficiencyoptimization05/03/2008Continuous use of Energy EfficiencyOptimization helps to• Identify the type of parameters to bemonitored for corrective action .• Identify the sub system performance• Identify the equipment / element responsiblefor poor performance.• identify the process parameter or othersresponsible for poor performance

An effective tool for Energy ManagementDecisions.This approach is very useful tool for taking fastEnergy Management Decisions such as• Is the system performance okay ? What is theproblem ?• Which parameters are responsible ?• What is the best alternative to improveperformance05/03/2008Could also be used to identify efficiencydeterioration using various models.

Users of Energy Audit• Operating staff – process and power plants• Process Engineers / Managers• Chief Executives / Directors• Energy Management Consultants• R & D organizations• Energy Equipment manufacturers.• Thermal Power stations / power industry.05/03/2008

Cost - Benefit Analysis• Use of Energy Efficiency Optimization oncontinuous basis pays off in a few days toweeks.• Identifies equipment deterioration.• Longer run lengths / higher production /power generation of units could be achieved.• Energy costs could be minimized• Net profit could be increased.05/03/2008

Useful for MIS users• In tailored form, this could be usedto generate MIS for top executiveswho can use the information forequipment maintenance /replacement decisions at the righttime.• Substantial savings could beachieved by this.05/03/2008

POWER PLANT APPLICATIONS• This concept may be used very effectively inPower plants for evaluating and monitoring theefficiency of• Power boilers• Steam turbines• Gas Turbines• Power losses• Performance evaluation etc.05/03/2008

TYPICAL EXAMPLE• In the case of Thermal Power plants, theoverall efficiency of power generation isdetermined by• Boiler efficiency• Turbine efficiency and• Generator efficiency• Built-in modules have the capability toevaluate each parameter separately forcorrective action.05/03/2008

MIS FOR Power Plant PerformanceMonitoring and Control05/03/2008• This is a very powerful tool for Corporate / Unit level EnergyManagement for taking corporate and operational decisions atthe right time and cost.A typical MIS gives• Energy efficiency of individual plant vs target• Break-up of energy losses• Cost of power generation and control centres• Transmission losses unitwise vs norms• Specific power consumption etcfor corrective action at the Right time and Right Cost.

Capacity Utilization vsEfficiencyCapacity utilization plays an important role onsystem efficiency.In normal case, higher the capacity utilization,higher is the efficiency. This is known as systemcharacteristics.Operational capacity must be optimized to achievehighest possible efficiency of the total system toreduce operating cost.Energy efficiency models are used to quantify thisinformation and arrive at optimal solutions.05/03/2008

Flexi target setting05/03/2008* Energy Management of a large system calls foridentifying the parameters responsible for affecting theoverall performance of the system.* This requires thorough analysis and development ofperformance models which set flexi-targets for theenergy performance under various operatingparameters.* This is achieved by customization.* This also explains the reasons for performancedeviation scientifically.

OnEnergy Efficiency Optimization05/03/2008

Questions on using EnergyEfficiency ModelsHow effectively can these models be used in theabsence of proper flow measurements for fuel andit’s properties ?05/03/2008Indirect method is used for determining theefficiency of heaters / boilers etc which does notrequire flow data . Parameters used in the programare flue gas analysis , stack temperature , ambienttemperature, Relative humidity and setting losses.This tallies very much with direct method ofefficiency determination.

Example - Equipment Maintenance /Replacement Decisions.• These models may be usedfor taking EquipmentMaintenance /Replacement Decisions tominimise the Total Cost ofOperation whichdetermines the profitabilityand productivity of theindustry.05/03/2008140120100806040200I II III IV Voprtg fixd total

Failure Prediction of Equipment /components These models in combinationwith Maintenance andCorrosion software may be usedeffectively to predict equipment/ component failure due tocorrosion, scaling, pitting,vibration etc using powerfulmodels.05/03/2008

Economics of InsulationRs'0000001816141210864201 2 3 4yearheat loss opr.cost savings• This approach evaluatesHeat loss from varioussections of theequipment, whichcould be used toidentify the source ofloss for takinginsulation retrofitdecisions.05/03/2008

INNOVATIVE IDEAS05/03/2008CogenerationCombined heat power cycle optimizationTrigenerationOrganic rankine cycleWaste heat recoveryUsing Energy efficient equipments etc

Thank YouAny Questions ?05/03/2008