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SERVICES
PROVIDED :
A) THERMAL ENERGY AUDIT :
Studies are undertaken to determine efficiencies of generation,
distribution & Utilisation of thermal energies. Boiler
efficiency tests are carried out to determine steam generation to fuel
ratio. Condensates coming from coil, jackets, evaporators are collected
to arrive at norms for each operation. Exhausts of furnaces, boilers are
quantified by analyzing them with our set of equipments. Fixed heating
load, start up load & insulation losses are determines. Based on the
above results thermal energy balance is struck for reference period of
one year.
Based on the energy
losses identified in the thermal energy balance, energy conservation
measures are presented with techno economic analysis. The energy saving
areas normally identified are:
Improvement in steam /
power generation efficiency, house keeping measures, waste heat
recovery, optimal choice of fuel, process optimization etc. Time bound
implementation programs are drawn with company manager. We have carried
out eighty such audits, mainly in process industries in India. We have
achieved savings ranging from 4 to 30 % in the thermal energy expenses
of our clients.
B) ELECTRICAL ENERGY AUDIT :
Energy billing patterns are analyzed for relevant penalties or fixed
rates. Amperage, voltage, power factor & KWH on motors are measured.
Actual running hours per batch or per hour out puts are observed.
Illumination levels, refrigeration load & compressed air system are
evaluated for house keeping measures. Electrical energy balance is
prepared with norms for each product.
Based on the energy losses & percentage loading
of rotating equipment, energy conservation measures are presented
with techno economic analysis. The energy saving areas normally
identified are : compression / illumination loads, derating of
blowers / fans, control mechanism, application of motor controllers,
sizing of pumps, usage of TOD tariff etc.
We
have carried out above fifty such audits in India. We have achieved
savings of 2 to 20% electrical energy expenses of our clients.
C) BOILER EFFICIENCY
/ TEST DETERMINATION :
We carry out boiler efficiency tests as per DIN 1942 standards, with our
set of equipments. Both direct & indirect test are carried out. In
direct test, actual fuel fed & water evaporated are measured whereas
in indirect method. O2%, CO2% stack gas temperatures, ash loss, wet gas
loss are determined. Based on these values, efficiency improvement areas
with techno economic analysis are presented. Efficiency improvement
areas implemented include tuning of boilers, sizing of coals, de-rating
of grate, rationalization of coal distribution on grate, proper
preheating of oil, short circuiting of combustion gases, optimal control
of oil firing vis-à-vis required pressure, heat recovery, sizing of
boiler auxiliaries etc.
We
have carried out about one hundred boiler efficiency test with
capacities ranging from 1 to 60 Mt/Hour, both for process & power
generation, We have achieved savings up to 14% on oil / gas fired &
up to 21% / on coal / lignite's / agro residues fired boilers. We have
also been responsible for acceptance tests.
D) IMPLEMENTATION OF
WASTE HEAT RECOVERY SCHEMES
Implementation would normally include details process design, listing of
suppliers & supervision of commissioning. Waste heat recovery
schemes which we have implemented for industries are :
Condensate
recovery system, flash steam trapping condensers, waste heat boilers for
furnaces / kilns, pre-heating of combustion air for direct fired
equipments / boilers, heat exchangers for process streams, heat recovery
from D. C. sets, thermopacs, etc. We have also assisted in development
& testing of waste heat recovery products.
E) CO-GENERATION
STUDIES
Techno economics analysis for co-generation of process steam &
power is analyzed for the industry Studies of the industry" process
steam & power requirements are carried out. Project co-ordination
services for co-generation are provided. Performance evaluation of
existing co-generation plant is carried out. With escalating
electrical energy prices & scarce availability, co-generation of
power for industries requiring process steam seems to be only optimal
energy strategy. Open / Combined cycle co-generation increasing the
power generation in our country. We are providing our services for
additional co-generation projects in sugar mills in Maharashtra. We have
build cogeneration projects from concept to commissioning.
F) STEAM TRAPS STUDY /
SERVICING
On-line study of steam traps is carried out by sound & temperature
measurements. Report indicating condition of the traps, service required
optimal selection of type & size is given. We have tested more than
five thousand steam traps & identified this area as a commonly
neglected steam loser.
G) ENERGY NORMS
FIXATION / PRODUCT COSTING
Specific energy consumption (energy required to manufacture a unit of
the product) norms are established by Condensate measurement, heat &
mass balances, & power measurements. These norms are required by
industry for internal energy monitoring, costing of product price
or for statutory declaration of energy costs.
H) ENERGY MONITORING
& IMPLEMENTATION SERVICES
This service is normally provided to industries where we have carried
out energy audit. The service includes designing energy monitoring
formats, preparing them on a monthly basis, deviation analysis &
report to decrease any rise in energy consumption level observed, with
corrective recommendation. We provide engineering services to implement
our audits recommendation.
We are presently retained by four industries for this service.
NOTE We process all
equipments to provide the above energy conservation services
1) PROCESS PLANT
DESIGN
We have done detailed process design engineering for the following
products. Dry Ice, Sodium Sulphate, Dilute Sulphuric Acid from 98% acid,
Multiple effect evaporation systems for caustic solution (upto seven
effects) & H-acid & Continuous Calcinations.
2) EPC FOR UTILITIES
For new or expansion projects, we provide engineering procurement &
commissioning assistance for utilities including steam generators,
turbines, hot oil units, direct fired equipments, compressors, piping
etc. We have executed such projects in textile, basic chemicals,
tyres, paper, chemicals etc.
3) CONVERSION OF
FURNACE OIL FIRED BOILER TO
BRIQUETTE-FIRED SYSTEM.
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