Target Setting
2015
Perform Achieve and Trade
Perform Achieve Trade
Thermal Power Plant - PAT Cycle I
Total No of DCs -144
Threshold Limit:
Thermal Power Plants
[DC :144 Nos]
30,000 tons of oil equivalent
(TOE) per annum
Total Target Set
3.1 MTOE
Coal/Lignite
[97]
Gas [40]
Diesel
[7]
Target Setting in TPPs
Net Design Heat Rate
Net Operative Heat Rate
= Gross Design Heat Rate
1- APC% operative
= 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)
Net Heat Rate Target
Ex-NHR Calculation
Parameter
% Reduction Target for deviation in NHR
Unit
Plant-1
Plant-2
Gross Heat
Rate (GHR)
kcal/kwh
2500
2500
Up to 5 %
10 %
Auxiliary
Power
Consumption
(APC)
8%
10%
More than 5% and Up
to 10 %
17 %
More than 10% and Up
to 20%
21 %
More Than 20 %
24 %
NHR = GHR / (1- APC%)
Net Heat
Rate (NHR)
kcal/kwh
2717
2777
(= 2500/0.92)
(=2500/0.90)
Deviation in Net
Station Heat Rate from
Design Net Heat Rate
Reduction Target for
Deviation in Net
Station Heat Rate (%)
Target in PAT (Manufacturing)
Target is defined as the % reduction of Specific Energy Consumption (SEC) from Baseline
value.
All forms of Energy
S
E
C
Product
Plant System Boundary
SEC = E / P
Baseline SEC
Reduction in SEC
Target SEC
Expressed in %
Y1
Y2
Y3
Sectoral studies by BEE on Setting Up of Sectoral Bandwidth for DCs have
revealed the impact on SEC due to above diversities
Sector
Power plant
Fertilizer
Cement
Range of SEC
2300 3400
5.86 9.11
665 900
Sponge Iron
Gcal/T of Urea
Kcal/Kg of Clinker (Thermal)
66 127
Integrated Steel
kcal / kwh
KWH/ T (Elect)
6.15 8.18 Gcal / tcs
4.4 7.6 Gcal / T (Thermal)
72 135 KWH/T (Elect)
Aluminium (Smelter)
15000-16000 KWH/T
Aluminium (Refinery)
3.28 4.12 MKcal / T of Alumina
Pulp & Paper
Textile
25.3 121 GJ/T
3000 16100 Kcal/kg (Thermal)
0.25 10 KWH/Kg (Elect)
Chlor-Alkali
2300 2600 kwh/ T of caustic soda
Reasons for Large Energy Usage Bandwidth
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.
a)
a)
a)
a)
a)
a)
Factors of Diversity
Raw Material Input
Quality of Raw Material / Fuel
Process & Technology
Final Product output
Vintage
Capacity Utililization
Most Affected Sectors
Pulp & Paper, Fertilizer, Power Plant, Textile
All sectors
Aluminium, Iron & steel, Chlor-Alkali, Paper
Textile, Iron & Steel, Aluminium
All Sectors
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
Sector
SN
Energy
Consumption
Share of
Consumption
Apportioned Energy No. of identified
reduction
DCs
(mMTOE)
104.56
(%)
63.38%
(mMTOE)
3.211
Power (Thermal)
Iron & Steel
25.32
15.35%
1.486
Cement
15.01
9.10%
0.815
85
Fertilizers
8.20
4.97%
0.478
29
Aluminium
7.71
4.67%
0.456
10
Textile
1.20
0.73%
0.066
90
Paper & pulp
2.09
1.27%
0.119
31
Chlor- Alkali
0.88
0.53%
0.054
22
Total
164.97
100.00%
6.686
144
67
478
Example : Target Setting (1)
Production (in Tonnes)
Plant
Name
Estimated SEC (in MTOE/ ton)
Relative
SEC
Total
Energy
consumpti
on
(in MTOE)
%
Target
To be
Energy
Saving
2005-06
2006-07
2007-08
Average
production
(MT)
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
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
2005-06 2006-07 2007-08
Average
SEC
13,91,594
14912.9X
Example : Target Setting (2)
Total Saving
Target
Saving
X
14912.94x
MTOE
62000
MTOE
4.15
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
Plant Name
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
Baseline SEC
Number of Clusters depend upon the Bandwidth of Baseline SEC
10
9
8
7
6
5
4
3
2
1
0
Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7 Plant 8 Plant 9 Plant
10
Plant
Baseline SEC
10
8
6
Cluster 2
Cluster 3
Cluster 1
4
2
0
Plant 1
Plant 9
Plant 4
Plant 3
Plant 6 Plant 10 Plant 8
Plant
Plant 2
Plant 7
Plant 5
Thank you
