Perform Achieve and Trade

Target Setting

Perform Achieve Trade

2015

Thermal Power Plant - PAT Cycle I

Total No of DCs -144

Threshold Limit:

30,000 tons of oil equivalent

(TOE) per annum

Total Target Set

3.1 MTOE

Thermal Power Plants

[DC :144 Nos]

Coal/Lignite [97] Gas [40]

Diesel [7]

Target Setting in TPPs

Net Design Heat Rate

= Gross Design Heat Rate

1- APC% operative

Net Operative Heat Rate

= Gross Operative Heat Rate

1- APC% operative

Heat Rate Deviation (%)

= (Operating Heat Rate Design Heat Rate) x 100

Design Heat Rate

Heat Rate Deviation

= (Operating Heat Rate Design Heat Rate)

Parameter Unit Plant-1 Plant-2

Gross Heat

Rate (GHR)

kcal/kwh 2500 2500

Auxiliary

Power

Consumption

(APC)

% 8% 10%

NHR = GHR / (1- APC%)

Net Heat

Rate (NHR)

kcal/kwh 2717(= 2500/0.92)

2777(=2500/0.90)

Net Heat Rate Target

Deviation in NetStation Heat Rate from Design Net Heat Rate

Reduction Target for Deviation in Net Station Heat Rate (%)

Up to 5 % 10 %

More than 5% and Up to 10 %

17 %

More than 10% and Up to 20%

21 %

More Than 20 % 24 %

Ex-NHR Calculation % Reduction Target for deviation in NHR

Target in PAT (Manufacturing)

Target is defined as the % reduction of Specific Energy Consumption (SEC) from Baseline value.

Plant System Boundary

All forms of Energy Product

E P

SEC = E / PSEC

Y1 Y2 Y3

Baseline SEC

Target SECReduction in SEC

Expressed in %

Sectoral studies by BEE on Setting Up of Sectoral Bandwidth for DCs have revealed the impact on SEC due to above diversities

Sector Range of SEC

Power plant 2300 3400 kcal / kwh

Fertilizer 5.86 9.11 Gcal/T of Urea

Cement 665 900 Kcal/Kg of Clinker (Thermal)

66 127 KWH/ T (Elect)

Integrated Steel 6.15 8.18 Gcal / tcs

Sponge Iron 4.4 7.6 Gcal / T (Thermal)

72 135 KWH/T (Elect)

Aluminium (Smelter)

Aluminium (Refinery)

15000-16000 KWH/T

3.28 4.12 MKcal / T of Alumina

Pulp & Paper 25.3 121 GJ/T

Textile 3000 16100 Kcal/kg (Thermal)

0.25 10 KWH/Kg (Elect)

Chlor-Alkali 2300 2600 kwh/ T of caustic soda

The energy usage pattern varies widely in industries of a particular sector due to various diversities like-Scale of Production (Installed Capacities) - Use of Raw Material- Process Technology- Vintage - O & M Practices- Type of Product Output etc.

Reasons for Large Energy Usage Bandwidth

Factors of Diversity Most Affected Sectors

a) Raw Material Input Pulp & Paper, Fertilizer, Power Plant, Textile

a) Quality of Raw Material / Fuel All sectors

a) Process & Technology Aluminium, Iron & steel, Chlor-Alkali, Paper

a) Final Product output Textile, Iron & Steel, Aluminium

a) Vintage All Sectors

a) Capacity Utililization All sectors

Approach for Setting Targets Depends upon the Objective of the Scheme

Total Saving Objective - 6.686 mMTOE Setting Sector Targets based on available saving potential of Industries and Program Objectives

SN SectorEnergy

ConsumptionShare of

ConsumptionApportioned Energy

reduction No. of identified

DCs

(mMTOE) (%) (mMTOE)

1 Power (Thermal) 104.56 63.38% 3.211 144

2 Iron & Steel 25.32 15.35% 1.486 67

3 Cement 15.01 9.10% 0.815 85

4 Fertilizers 8.20 4.97% 0.478 29

5 Aluminium 7.71 4.67% 0.456 10

6 Textile 1.20 0.73% 0.066 90

7 Paper & pulp 2.09 1.27% 0.119 31

8 Chlor- Alkali 0.88 0.53% 0.054 22

Total 164.97 100.00% 6.686 478

Example : Target Setting (1)

Plant

Name

Production (in Tonnes) Estimated SEC (in MTOE/ ton)

Relative

SEC

Total

Energy

consumpti

on

(in MTOE)

%

Target

To be

Energy

Saving2005-06 2006-07 2007-08

Average

production

(MT)

2005-06 2006-07 2007-08Average

SEC

Plant1 3,62,793 3,68,867 3,78,157 3,69,939 1.275 1.272 1.277 1.274 1.000 4,71,455 X 4714.55x

Plant2 3,58,954 3,58,734 3,59,213 3,58,967 1.364 1.365 1.362 1.364 1.070 4,89,546 1.07X 5238.14x

Plant3 76,867 2,07,741 2,50,981 1,78,530 1.569 1.355 1.276 1.400 1.098 2,49,920 1.10X 2749.12x

Plant4 66,347 73,008 99,406 79,587 1.425 1.452 1.408 1.428 1.121 1,13,679 1.12X 1273.2x

Plant5 NA NA 37,635 37,635 NA NA 1.780 1.780 1.397 66,995 1.40X 937.93x

Total 13,91,594 14912.9X

Example : Target Setting (2)

Total Saving 14912.94x MTOE

Target

Saving62000 MTOE

X 4.15 %

Plant Name Baseline SEC Target (%) To be SEC To be MTOE

Plan1 1.274 4.15 1.22 4,51,889

Plan2 1.364 4.44 1.30 4,67,806

Plant3 1.400 4.56 1.34 2,38,527

Plant4 1.428 4.65 1.36 1,08,391

Plant5 1.780 5.80 1.68 63,111

Total energy consumption at the end of 3 years (in MTOE) 13,29,725

Total present energy consumption (in MTOE) 13,91,594

Energy saving during the period 61,870

Number of Clusters depend upon the Bandwidth of Baseline SEC

0123456789

10

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7 Plant 8 Plant 9 Plant10

Baseli

ne S

EC

Plant

Cluster 1

0

2

4

6

8

10

Plant 1 Plant 9 Plant 4 Plant 3 Plant 6 Plant 10 Plant 8 Plant 2 Plant 7 Plant 5

Baseli

ne S

EC

Plant

Cluster 3Cluster 2

Thank you