Presentation on Energy saving by Alternative Operations of Aerators - - PowerPoint PPT Presentation

ENERGY SAVING

Presentation on Energy saving

by

Alternative Operations of Aerators

in

ETP and STP Aeration Tank.

Presented By :

• R. S. Patel.

(Head – Engineering)

ARVIND LIMITED

• DIV. ANKUR TEXTILES.

SWADESHI MOVEMENT

Early 1900s

• Swadeshi = “One’s own country",

Self sufficiency

• Boycott British goods
• Indians produce own goods
• Indians school – nationalist education

People boycott the fabric coming from England The Year 1930

• The Lalbhai’s reasoned that the demand for fine and superfine fabrics

still existed.

• Any Indian company that met this demand would surely prosper.
• The three brothers, Kasturbhai, Narottambhai and Chimanbhai,

decided to setup a mill to produce superfine fabric.

• And a company called Arvind Limited was born in 1931

WHAT IS ARVIND ?

Annual Turnover Rs 10,000 Cr

Textiles Garments Retails Engineering Telecom

Composites & Advance materials

Real Estate Brands

TEXTILES….

• Denim
• Woven fabric-Shirting
• Woven Fabric-Bottom Weight.
• Woven fabric –Life Style-Voiles.
• Technical Textiles
• Knits

TEXTILES

Woven fabric –Life Style-Voiles – Ankur Textiles..

• Ankur is one of the oldest working composite Textile mill

in Ahmedabad started in 1914.

• In 1979 Arvind Group take over this unit.
• In last five year our turnover growth is @ 12% and

planned to reach 500 Cr. by FY20.

Turn Over, ₹ in Cr.

PRODUCTION – SP. THERMAL & SP. ELE. ENERGY

15.4 15.0 16.4 13.9 5.2 5.2 5.3 3.4 3,828 3,949 4,037 4,667

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5 10 15 20 25 30 2013-14 2014-15 2015-16 2016-17

Production - Sp.Thermal and Sp.Electrical Energy

• Sp. Thermal Energy in Mil. Kcal/MT

Specific Electrical Energy in Mil Kcal/MT Production in Ton

How to optimize energy consumption..

• Continuous & proactive Efforts.
• Internal Audit Team for Energy

Management.

• Day to day monitoring of all utility

consumption.

• Strong management support.
• Assistance from External teams, i.e.

Thermax, Forbs Marshall, Inspiron, Energy audit services Etc.

Energy Conservation Organogram

ENCON PROJECTS IMPLEMENTED

During the year2014-15, 2015-16 & 2016-17

• No. of Projects

: 30 Total Amount Invested : ₹ 75.34 Million Cost Saving Achieved : ₹ 45.12 Million Electrical Energy Saved : 36.83 Lacs kWh Thermal Energy Saved : 1651 MTOE

Energy Saving Steps – FY14-15

ELECTRICAL Sr. Project Location Energy saving step details ProjectDescription Saving Investment Pay Back Period KWH/Year ₹/Year ₹ Months 1 Invertors on H-Plant Fan Motors Invertors on Spinning H-Plant

• Fans. Total 16 No.

623808 5146416 960000 2.8 Invertors on Weaving & Winding H-Plant Fans. Total 13 No. 225264 1858428 700000 Total For Invertors 849072 7004844 1660000 2 L E D Project 160 No LED fittings in place of fluorescent fitting 74857 617570 368000 7.2 Grand Total (Electric) 923929 7622414 2028000 3.2 THERMAL Sr. Project Location Energy saving step details ProjectDescription Saving of coal Investment Pay Back Period MT/Year ₹/Year ₹ Months 1 Fuel saving by collection of condensate recovery Installation of condensate pump 144 806400 550000 8.2 TOTAL SAVING + INVESTMENT in FY15 144 8428814 2578000 3.7

Energy Saving Steps - FY15-16

ELECTRICAL Sr. Project Energy saving step details ProjectDescription Saving Investment Pay Back Period KWH/Year ₹/Year ₹ Months 1 L E D Project 160 No LED fittings in place of fluorescent fitting 37628 310431 136000 5.3 THERMAL Sr. Project Energy saving step details ProjectDescription Saving of coal Investment Pay Back Period MT/Year ₹/Year ₹ Months 1 Fuel Saving by Effimax Installation of EFFIMAX monitoring system on 8 MT/Hr FBC Boiler 250 1395000 1000000 8.6 2 Fuel saving by replacement of boiler Installation of 8 MT/Hr FBC boiler in place of 6 MT/Hr smoke tube boiler 1418 7912440 8000000 12.1 Total 1668 9307440 9000000 11.6

SAVING + INVESTMENT in FY16 1668 9617871 9136000 11.4

Energy Saving Steps - FY 16-17

ELECTRICAL Sr. Project Energy saving step details Project Description Saving Investment Pay Back Period KWH/Year ₹/Year ₹ Months 1 LED Project 730 Nos of LED fitting in place of Florescent fitting 170767 1314906 548000 5.0 2 Power saving by LED Replacement of 28 Nos of High bay lights

• f 400 Watts by 120 Watts LED fittings

65856 507091 224000 5.3 3 Power saving by LED Replacement of 7 Nos of High bay lights

• f 400 Watts by 120 Watts LED fittings

compound light 8232 63386 56000 10.6 4 Power Saving DC Drive convert to invertor drive in WARPINGM/C 117600 905520 110000 1.5 5 Power Saving Replacement of PUMP in ETP 2NOS 30HP INSTALL 20HP 84000 646800 48000 0.9 6 Power Saving Replacement of compressor motor pulley. 241500 1859550 30000 0.2 7 Power Saving Replacement of Aerators motors in ETP 2Nos 30HP INSTALL 20HP 84000 646800 800000 14.8 Continued…

Energy Saving Steps Electrical- FY17 continued…

Sr. Project Energy saving step details ProjectDescription Saving Investment Pay Back Period KWH / Yr ₹ / Yr ₹ Months 8

Power Saving Installed Doffing motor on Card m/c

21000 161700 48000 3.6 9

Power Saving Installed Invertor on Roll folding m/c.

7000 53900 30000 6.7 10

Power Saving Installed invertors on 8 Stenters for Exhaust

123200 948640 120000 1.5 11

Power Saving REPLACE AUTO CORNER M/C 2NOS (138 were

replaced by X5 mopdel) 161700 1245090 25000000 240.9 12

Power Saving Installed Invertor in Boiler I D Fan 1 Nos M/c

64680 498036 75000 1.8 13

Power Saving Installed Temerature controller in compressor

Cooling Fan -1 no M/C 9450 72765 10000 1.7 14

Power Saving Replaced Auto Corner suction motor pulley in 2

m/cs 30800 237160 10000 0.5 15

Power Saving Installed Invertors 10 Nos SFAN/RFAN in

Winding Dept. 420000 3234000 320000 1.2

Continued…

Sr. Project Energy saving step details ProjectDescription Saving Investment Pay Back Period kwh / Yr. ₹ / Yr. ₹ Months 16 Power Saving Installed Fibre roof for day light in Jet dyeing area. 3528 27166 50000 22.1 17 Install Monitor roof in Godown - removed 24 - 40 W tube lights in top floors 3528 27166 500000 220.9 18 Low eff to high eff. Replaced Low eff. Stenter by High eff. 283073 2179662 19300000 106.3 19 Energy Saving by Alternative operation of ETP and STP Aerators Total 7 nos of Aerators are put on alternative drive. 346302 2666525 175000 0.8 20 Save Energy and water consumption through Water Pressure control To maintain water pressure at 1.5 Kg/cm2 round the clock by installing invertors and pressure transdudar on water supply. Reduced water consumption by 145 KL/day. 89436 688657 60000 1.1 21 Invertors on H Plant fan mptors Invertors on H plant fans- Total 6 nos (Spinning) 252000 1940400 150000 0.9 22 Invertors on H Plant fan mptors Invertors on H plant fans- Total 4 nos (Weaving) 134400 1034880 100000 1.2 SAVING + INVESTMENT Electricals in FY17 2722052 20959800 47764000 27.4

Energy Saving Steps Electrical- FY17 continued…

Energy Saving Steps FY-17

THERMAL Sr. Project Energy saving step details ProjectDescription Saving of coal Investment Pay Back Period ₹/Year ₹ Months 1 Thermal Energy Installed Invertors in Stenter M/c for Exhaust 8 m/c. 824600 200000 2.9 2 Stenter upgradation Replace low efficiency Stenter by high eff. stenter m/c 1543800 15000000 116.6 3 Steam Trap Replacement Replaced 36 No. thermodynamic trap by float type trap, Reduced steam cons. 6% 310000 180000 6.9 4 PRV on Machines Installed 15 No Pressure Reducing Valves on 15 No. comby m/c to reduce steam pressure 5.5 to 3.0 bar 365800 150000 4.9 5 Steam cut off switch on 5

• No. Drying range m/cs.

Installed 5 Nos. of steam cut off switches when m/c is stopped. 1463200 25000 0.2 6 Reuse of Hot Water Started recirculation and reuse hot water 70000 ltr/day. 899000 60000 0.8 7 Collection of condensate water Installed additional pump. 706800 250000 4.2 16-17 : TOTAL SAVING + INVESTMENT (Thermal) 6113200 15865000 31.1 16-17 : TOTAL SAVING + INVESTMENT (Electrical) 20959800 47764000 27.4 16-17 : TOTAL SAVING + INVESTMENT (Ele. + Thermal) 27073000 63629000 28.2

Thought process for power saving

 Micro organisms such as bacteria and protozoa can use the small particles and dissolved organic matter, not removed in primary treatment, as food.  Aeration tank contains “soup" of starved microbes called activated sludge.  They are aerobic organisms so need Oxygen to survive and requirement of dissolve oxygen is proportionate to the input pollutant load.  Design of any aeration tank is done for DO level of 2.5 mg/ltr.  As our input load of COD, BOD is lesser to design load DO was remained 3.5 to 4 mg/ltr.  Excess DO was consuming unnecessary Electrical Energy.  We started thinking various options to reduce DO level.  First option is to reduce Speed of Aerators by installing VFD.

Aeration Tank Details

We have total 3 nos. of aeration tanks for secondary treatment Location Capacity KL HP of each Aerator

• Nos. of

Aerator ETP 1600 25 2 ETP 1200 15 3 STP 1000 20 2

Trials

• Due to reduction in speed, circulation of bottom

part micro organism not found proper. (Turbulence was not proper)

• Droplets formation of water was also not proper

hence absorbing of oxygen was poor and oxygen transfer ratio per KW of power was lower.

• So this trial was not successful.

Trial - 1 To reduce Speed of Aerators by installing VFD.

Trials

Trial – 2 By putting aerators on alternate operations.

• Initially two aerators of ETP Aeration tank put on alternative
• peration..
• Started from 10 minutes interval and kept watch on changes at

micro level for fifteen days.

• We found reduction in DO from 2.0 to 2.5 mg/lts.
• No settling of micro organism found.
• No change in quality of treated water.
• Power saving 50% of Aerators power.

Dis advantage.

• Due to frequent on –off of the motor, possibility to fail motor

winding increases.

Trials

Trial-3

• Increase interval time from 10 to 15 min.
• Observed for fifteen days and we found no change in

quality of treated water.

• Risk for failure of motor decrease but still possibility of

higher rate of motor winding failure.

Trial-4

• Increase interval time from 15 to 20 min.
• Observed for fifteen days and we found no change in

quality of treated water.

• Risk for Failure of motor decreased.

Trials

Trial-5 Increase interval time from 20 to 25 min.

• In seven days we found accumulation of

Activated sludge at all corners of Aeration tank

• To avoid Anaerobic condition of activated sludge,

we again put interval time for 20 minutes.

• In this mode it is running very satisfactorily

through out the year.

• (Video)

Implementation

• After satisfactorily working of three months we

implemented same at aeration tanks of STP and second tank of ETP.

• At STP our input load is very low & we found DO

level even after alternative operation was remaining +3 mg/ltr.

• So VFD were installed on aerators of STP.
• They are operating at 35 Frequency.
• At STP we saved 60 % of Aeration power.

Photographs

Photographs

DATA SHEET

Aeration Tank-1 at ETP Aeration Tank-2 at ETP Aeration Tank at STP Aeration Tank-1 at ETP Aeration Tank-2 at ETP Aeration Tank at STP 1 Nos of Aerators 2 3 2 2 3 2 2 2 HP of each Aerator 25 15 20 25 15 20 20 3 DO (ppm) when both aerators are in working 4 4.2 5.1 2.5 2.25 3.5 2.5 4 MLSS in ppm 4050 4100 1500 3750 3800 1400 1250 5 Aeration inlet COD in ppm 525 505 158 525 505 158 158 6 Output COD 84 86 NIL 85 85 NIL NIL 7 Total power in KW 26.5 25.19 29.2 13.5 12.7 14.4 6.08 8 Power cons. In KWH per day 636 605 550 324 305 346 217

945 344925 26.66 Total saving per day in KWH Power saving KWH per year Saving in Lakh ₹ / year

Sr. No. Details Before Change After Alternative aerator After invertor and alternative aerator working at STP

Care to be taken…

Care to be taken before and after implementation.

• Possible only where input load is lower to

design load.

• To monitor constantly.
• DO level,
• MLSS level
• Inlet and treated water parameters.
• If major change is found all aerators are to be

started simultaneously.

Future Plan

• For smooth acceleration of aerators VFDs are to

be installed on all motors and to run at full speed .

• This will also help in reduce motor burning.
• This case was published in KEP News Letter of

Nov-2017

THANK YOU