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Options for Steam Efficiency

22nd February 2010

Datta Kuvalekar
SFCinProcess
Industry&ourrole

Undertookastudyacrossindustrysegmentstoestablish Best
&AverageforSpecificFuelConsumption&utilities.Published
thestudyinassociationwithCIIin200304.

IdentifiedtheopportunitiesforsavingsineachoftheIndustry
Sectorsfactually.

EstablishingtheCurrentdatatocreateawarenessiskey!
Benchmarks:
Utilityconsumption
Asperthestudyweconductedin200304

Industry Fuel: Electricity: Water:


Percentage Percentagesaving Percentage
savingfromAvg formAvgtoBest savingfromAvg
toBestinsample insample toBestinsample

Brewery 25 35 13

Tyre 22 13 40

Textile 54 77 85

Paper 44 60 90
Benchmarks:SFC

Industry Units Best Average Worst

Brewery FOLit/KLBeer 44 58 75
Tyre FOKg/TonFinishedTyre 162 210 353
Textile CoalKg/1,000Mts 168 390 666
Paper* CoalKg/TonPaper 230 408 574

SEPSoya CoalTon/TonSeedCrushed 47 70 93

SEPRiceBran HuskTon/TonSeedCrushed 100 115 124

Hotels BoilerFuelLtx10/OR 9 30
TheSteamandCondensateLoop

Distribution losses 5-7%

85% 80%

100% Input Boiler Process 60% Process

Boiler losses 15%


20% Condensate
FactorsaffectingSFC

Going ahead with the exercise of benchmarking, the potential of


savings in a plant were distributed into:

- Steam Generation - Distribution & utilization


- Condensate & Flash Recovery - Capacity Utilisation

This enabled to identify priorities to bridge the gap for each


Industry and we published the 2nd Study in 2004-05 in
association with CII.
GoingAhead

WorkedwithplantsineachindustrySegmentto:

1. SpreadAwareness.

2. Shareknowledge&establishedsolutionstoimprove
averages.

3. Comeupwithinnovativesolutionstobridgegapstosetanew
benchmarkinSpecificFuelconsumption.
Benchmarks:Brewery

AspertheCIIForbesMarshallStudy(200405)inBrewery

BestSFC: 41FOLt/KLBeerAvgSFC: 58FOLt/KLBeer

WehaveworkedjointlywiththeIndustrygroups
andhaveauditedand/orconsulted24Breweries.
Brewery:Potential

Savings potential
2.5%
1.5%

13.5% 7%

Condensate & Flash recovery


Steam distribution & Utilization
Steam Generation
Capacity Utilization
Brewery:BeatingtheBest

SFC (FO Lit/KL Beer)

70
58
60
50
50 41
40 36
Avg
30 Best (Prev)
20
10
0
Prev New
Case:Brewery

AtaBreweryinSouthofIndia,

1. SFCimprovedfrom52Lt/KLBeerto48andthento36.
2. Boilerefficiencyimprovedfrom79% 84%
3. O2maintainedinrangeof4%andimprovedfrom711%.
4. Feedwatertempraisedby15c
5. Recovered11,000kgofcondensateandlaterbettereditto
14,000kgs.
6. Reducedblowdownsteamlossby100kg/day.
Benchmarks:Paper

AspertheCIIForbesMarshallStudy(200405)inPaperindustry
BestSSC:1.5ton(steam)/tonAvgSSC:1.9ton(steam)/ton

WehaveworkedjointlywiththeIndustrygroupsandour
systemsarerunningin139paperindustries.
Paper:Potential

Savings potential
10%
15%

3%
8%

Steam Generation Distribution


Condensate & Flash Recovery Utilization
BeatingtheBest:
Paper
SFC (Ton Steam/Ton Paper)

2 1.9
1.77
1.6 1.5
1.4

1.2 Avg
0.8 Best (prev)

0.4

0
Prev New
Case:Paper

IncaseofaPaperplantinNashik,bycontinuouspartnership,
1.In2004: SSC2.2 Production25TPD
SuppliedaBTC,Productionimprovesto30TPDandSSCto1.65

2. In2005: ImplementedOnlineBoilerEfficiencyMonitoring andCRS


Feedwatertempimprovesfrom70to87C
Improveboileroperationandmonitoringhelpsdecidethefuelmix
SOPtoextractbestefficienciesconstantly.

3.Plantexpands.Predriergroupof4cylinderswithonemoreindependent
TCsystemadded.Productionraisesto40TPD
Case:Paper

4.In2008:expandstoproduce70ton/daywithgroupof6postdrier
cylinders
Weredesignthetotalsteamandcondensateconfiguration
InstalledrotaryjointsandSpiraxaccessories
Implementindividualloopsalongwithfinetuningofentiresystem
todeliverrequiredproduction.

Presentlyproductionis75to80ton/dayKraftpaperandGSM
rangeof160to220GSM,steameconomyis1.4to1.5ton/tonof
paper.
Benchmarks:Starch

AtaStarchPlantinMaharashtra,

1. 55TPDproduction(200TPDinstalled)

2. Totalsavings:Rs.20.21lakhs/annumonafuelbillof122lakhs.
%Savings:16.56%

3. 200kg/hrofflashsteambeingutilizedduetoThermo
compressorbasedsystem.
Starch:Potential

Savings potential
7% 7%

13.5%
Condensate & Flash recovery
Steam distribution & Utilization
Steam Generation
Benchmarks:Tyre

AspertheCIIForbesMarshallStudyinTyreIndustry
BestSFC:162kgFO/KLAvgSFC:210FOkg/KL

ForbesMarshalliscurrentlyintheprocessofconductingenergy
auditsformajorTyregroups&partneringthemtoimprove
fuelefficiencyinIndia&SriLanka.
Tyre:Potential

Savings potential

7%
9%

7%
Condensate & Flash recovery
Steam distribution & Utilization
Steam Generation
BeatingtheBest:Tyre

SFC(FO Kg/Ton Finished Tyre)

250
210
190
200
162
140
150 Avg SFC
100 Best SFC

50

0
Previous Current
Case:Tyre

AtaTyreplantinMaharashtra,

1. SFCof187FOkg/tonrubberimprovedto167
2. Plantprocesses62MTofrubber/day
3. Feedwatertemperatureof96 C
Benchmarks:Textile
(Tirupur)

AspertheCIIForbesMarshallStudy(200405)inTextileIndustry
inTirupurcluster,

BestSFC:1.57kgwood/kgclothAvgSFC:2.75
Potential:Textiles

Savings potential
7%
12%

7%
Condensate & Flash recovery
Steam distribution & Utilization
Steam Generation
Benchmarks:Textile
(Tirupur)
SFC(Firew ood Kg/ Kg)

3 2 .7 5

2 .5 2 .2 6

2 1 .5 7
1 .4 6 Best
1 .5
Avg
1
0 .5
0
Prev N ew

ApartfromTirupur,FMhasaudited100+textileprocessingplants&similarly
partneredclustersinBurhanpur,Pali,Ludhiana,Bhilwara,Panipat,Surat.
Benchmarks:SEP

AspertheCIIForbesMarshallStudy(200405)inSEPIndustry
BestSFC:100kghusk/tonseedAvgSFC:115

FMinvolvementinNagpurSEPplantshasimprovedtheBestto80
&averageto110
SEP:Potential

Savings potential to bridge the gap


7.5%
12%

3.5%
3%

Steam Generation Distribution & utilization


Condensate & Flash Recovery Capacity Utilization
BeatingtheBest:
SEP
Rice Bran SFC (Husk Ton / Soya SFC(Coal Ton / Ton
Ton Seed Crushed) Seed Crushed)

140 70 63
115 58
120 111 60
100
100 47 47
50

80 40
61 Best Best
60 Avg Avg
30
40
20
20
10
0
0
Prev New
Prev N ew
Benchmarks:SEP

Plants Customershaving Customers Customerhaving


NoFMInfluence havingtrapping entiresteam&
andcondensate condensate
systemdesigned systems
byFM designedbyFM

RiceBran
Kghusk/ton 142 100 80
Soya
Kghusk/ton 88 66 47
Benchmarks:Pharma

IntheForbesMarshallCIIStudy200405,wetriedtobenchmark
thePharmasector.Howeveratruebenchmarkinthissector
cannotbecreatedas:

1. Theprocessesvarywithformulations.

2. Thevariationinthebulkdrugs
Pharma:Potential

Savings potential
4%
8%

5%
4%

Steam Generation Distribution & utilization


Condensate & Flash Recovery Steam trapping
Pharma:Potential

1. Gapbetweendirect&indirectboilerefficiency
a.OnOffoperationisfrequent
b.RunningofBoileronLowloads
c.Lowfeedwatertemp.

TheavgDirectefficiencyinthesectoris72.4andavg
indirectefficiencyis77.5%
Pharma:Potential

2.Gapbetweentheoretical&actualsteamconsumption

a. Supplysteampressurevariation
b. Impropertrapselection&bypasskeptopen
c. Airventingprovisionmanual
d. Steamflowcontrolmanual
Pharma:Potential

3.Incorrectsteamtrapping:
Only35%ofthetrapsselectedintheindustryarecorrect

4.TheCRFinthesectorvariesfrom0% 60%
a. Multiutilityreactorjackets fearofcondensate
contamination
b. Captiveconsumption
Coilvs.Shell

TheCIIForbesMarshallstudy(200405)onthecomparisonofcoiltype
and3passwetbacksmoketubeboilersreveals:

1. Theefficiencyofthecoiltypeboilerrangesfrom6576%whereas
theshelltypehas8384%

2. Thedrynessfractionofthecoiltypeisinrangeof5070%

3. Thepoorqualityofsteamalsoleadstoextendedbatchtimings.

4. Condensatereturnisnotpossibleincoiltypeboilersdueto
limitationsofpositivedisplacementpump.
Coilvs.Shell

Astudyonthecomparisonofcoiltypeand3passwetbacksmoketubeboilers
reveals:
3passwetback
Parameter CoilBoiler SmoketubeShell Impact
Boiler

Efficiency 65 76% 83 84% Reducedfuelbill


Dryness 5070% 98% Reducedprocess
Fraction time
Condensate Drainedbecauseof Achieved Reducesfuel
return templimitationsof consumptionby
positivedisplacement about10%
pump
Coilvs.Shell

AtasoftdrinksmanufacturingplantinNagpur,

Parameter Unit Before After


(CoilBoiler) (3passwetback
SmoketubeShell
Boiler)

Boilercapacity Kg/Hr 3x600 2000x1


Efficiency % 89
Drynessfraction % 60 98
Fuelconsumption Litres/Annum 1.74lacs 1.2lacs

AsavingofRs.36,00,000/yr!
Coilvs.Shell

AtabottlingplantinGoa,
Parameter Before After
(CoilBoiler) (3passwetbackSmoke
tubeShellBoiler)

BoilerCapacity 600kg/hrx3 2000kg/hrx1


Fuel FurnaceOil FurnaceOil
CondensateRecovery Nil 100%
FeedWaterTemperature Ambient 50C(5KLFWTnot
insulated)
Bottlesproducedperminute 340 500
BPM
SFC(LitofFOpercaseof 0.1 0.0650.075
beverage)
AsavingsofRs.12,00,000/yr!
Coilvs.Shell

AtaCattlefeedandPoultryfeedmanufacturingplantinMaharashtra,thepresent
productioncapacityis40,000Tonsofproductannually.

Parameter Before After


(CoilBoiler) (3passwetbackSmoke
tubeShellBoiler)

BoilerCapacity 1x400kg/hr+1x300 750kg/hr


kg/hr
Fuel LDO FO
Efficiency(NCV) 75% 89%
DrynessFraction 50% 98%
LineTraps Absent TDtraps
ProductionCapacity 40,000Tons 46,000Tons
Coilvs.Shell

ConversionfromCoiltoShell,causedareductioninspecificfuel
consumptionandtherebyincreasedtheproductionform40,000to
46,000.

TheproductioncostpertonofproductimprovedfromRs93to
Rs58.

Duetobetterqualityofproduct(becauseofbettersteam),the
powerconsumptionreducedby4kWhpertonofproduct,=saving
ofRs16pertonofproduct.

AnnualMonetarySavings=Rs.20,40,000/
NumbersSpeak

OureffortsinreducingtheaverageSFCacrosssectorshaveyielded
quantumfuelsavings.Forinstance,

1CroreLitresofFurnaceOilintheBreweriesinIndia

1.5CroreKgsofricehuskintheSEP(RiceBran)inIndia

35,000tonnesofwoodinthetextileclusterofTirupur
Realizedsavings
acrossplants

Manymoresectors,Manymoreindustries

Food,Dairy,Distillery: McCain,Cadbury,Nutrine,Perfetti,Tilaknagar
Distilleries,Metrodairy,

Starch: AnilStarch,MaizeProducts,SahyadriStarch,RiddhiSiddhi,

Oil&Petro: RIL,IOCL,BPCL,HPCL,BRPL,IPCL,Essar,MRL,..

Fertilizers: RCF,Deepakfertilizer,MCF,NFL,KRIBHCO,
Whatitmeans
intheend
1. Monitoringhelpsinidentifyingthepotentialforsavingsand
sustainingit.

2. Everyday,companiesfocusingonsteamenergy
conservationaresavingLakhsontheirannualfuelbills.

3. Ineachofthesectorswehaveworkedcloselywiththe
industryandraisedtheaveragesandimproved
benchmarks.
Partneringalltheway

1. Spreadingbestpracticestobridgethemostcommongaps
Righttrapselection
Linesizing
Condensaterecovery

2. Innovativesolutionsforimprovingthebenchmarks.
Boilerefficiencymonitoring
RecompressionofFlashsteam
Industryspecificsolutions.E.g.BrewMax

3. Sustainthebestbymanagingthesteamsystems.

AwarenessandKnowledgeiskey!
ThankYou