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