‘Cleaner Production Audit’

at
a Printing Press

NEW SENSE

J. Nagesh Kumar
Director
Centre for Energy, Environment and Productivity (CEEP)
Chennai
tallkumar@gmail.com  9444882553
 Electricity Tariff
• Tariff category – HT-1(a)
• Sanctioned demand – 450 kVA
• Demand charges – Rs.250/kVA
• Energy charges – Rs.5.25/kWh
• Demand charges in excess of sanctioned demand
– excess demand x Rs.500/kVA
– Excess kWh = [kWh – (kWh x sanctioned demand)/ maximum demand)]
• Example for month of Aug 2016
– Maximum demand – 491 kVA
– Demand charges – (450 x Rs.250) + (41 x Rs.500) - Rs.1,33,000
– Excess energy – [1,25,900 kWh – (1,25,900 x (450/491))] x Rs.5.25(10.5)
= Rs.55,193
– Excess amount paid – (41 kVA x Rs.500) + 55,193 = Rs.75,693
• If maximum demand exceeds sanctioned demand by 20% then
connection will be cut
• MD exceeded sanctioned demand in Aug, Sep and Oct 2016
 Maximum demand, kVA
600

500

400

300

200

100

0
Aug/16 Sep/16 Oct/16 Nov/16 Dec/16 Jan/17 Feb/17 Mar/17 Apr/17 May/17 Jun/17 Jul/17
 Daily Load variation
350

300

250

200

150

100

50

0
Components of Electricity bill
(Aug’16 – Jul’17)

Demand
Charges
Rs.13 Lakhs

Energy
Charges
Rs. 72 lakhs
 Energy Balance
Air compressor Split AC's Lightings Water Pump
6% 4% 2% 2%
Printing machine
plate baking AC's
oven 11%
3%

Post printing
drives
21%

Printing machine
51%
Energy conservation measures
 Improve power factor
300

250

200

150

100

50

0
17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00
 Improve power factor
• Average instantaneous power factor - 0.9
• Average maximum demand – 433 kVA
• Expected maximum demand by improving P.F to 0.99 – (433 x 0.9)/0.99
– 394 kVA
• Annual savings in demand charges – (433 – 394) x Rs.250
– Rs.1.17 lakhs
• Capacitors required – 433 x 0.9 (tan-10.99 - tan-10.9)
– 1062 kVAR
• Investment – 1062 x 100 – Rs.1 lakh
• Pay-back period – 12 months
• If excessive harmonics are present then harmonic filter consisting of an
inductor and reactor in series may be provided for improving the power
factor in lieu of capacitors
 Increasing contract demand to reduce
production losses
• Existing contract demand – 450 kVA
• Existing average demand – 433 kVA
• Peak maximum demand reached in the previous 12 months – 498 kVA
• Expected average demand after improving the power factor – 394 kVA
• Minimum billable demand – 75% of contract demand
• Suggested contract demand (C.D) – 500 kVA
• Minimum billable demand after increasing C.D – 375 kVA
• Estimated production losses due to stoppage of printing machines
• Annual savings – Not Quantified
 Avoid rarely utilised hired DG set after
increasing the contract demand
• Average demand after enhancing the power factor – 394 kVA
• Plant’s own DG set available – 320 kVA
• This is sufficient for operating the plant load without UV process
• With increase in contract demand and power factor the 320 kVA DG set
+ grid power will be sufficient to operate the entire plant with UV.
• Hence, it is suggested to stop hiring of 400 kVA DG set
• Annual savings – Rs.40,000 x 12 – Rs.4.8 lakhs
Optimising air-conditioners in 8-colour
printing machine
Optimising air-conditioners in 8-colour
printing machine
 Optimising air-conditioners in 8-colour
printing machine
• There are two air-conditioners 11TR and 5.5TR which are continuously in
operation.
• The air inside is concentrated with solvents and VOC’s
• Machine down-time due to change over is 10 hrs per day
• When machine is not in operation, the AC’s can be switched OFF
• An exhaust fan may be provided to exhaust the stale air during down-time
period
• Energy savings – (11+5.5) x 1.2 kW x 10 x 300 days
– 59,400 kWh
• Annual cost savings – Rs.3.11 lakhs
• Investment – Rs.0.25 lakhs
• Pay-back period – 1 month
• In addition the work environment will be vastly improved
 Optimising air-conditioners in 6-colour
printing machine
• There are 2 air-conditioners 11TR and 5.5TR which are continuously in
operation.
• The air inside is concentrated with solvents and VOC’s
• Machine down-time due to change over is 10 hrs per day
• When machine is not in operation, the AC’s can be switched OFF
• An exhaust fan may be provided to exhaust the stale air during down-time
period
• Energy savings – (11+5.5) x 1.2 kW x 10 x 300 days
– 59,400 kWh
• Annual cost savings – 59,400 x Rs.5.25 – Rs.3.11 lakhs
• Investment – Rs.0.25 lakhs
• Pay-back period – 1 month
• In addition the work environment will be vastly improved
Use of natural day-light in shop floor
 Use of natural day-light in shop floor
• Type of lamps used in shop floor – 40 W FTL with 8 W choke
• No. of lamps used in the shop floor – 130
• Power consumed for lighting – (48 x 130)/1000 – 6.24 kW
• Provide translucent sheets on the roof to make use of natural day-
light
• Annual energy savings – 6.24 x 8 hrs x 300
– 14976 kWh
• Annual monetary savings – 14976 x Rs.5.25
– Rs.78,624
• Investment – Rs.78,000
• Pay-back period – 12 months
 Replace existing lamps with energy
efficient lamps
• Total no. of 40W FTL’s in shop floor and office – 170
• These may be replaced with 20 W LED lamps
• Annual energy savings – (170 x (48 – 20) x 8 x 300)/1000
– 11,424 kW
• Annual monetary savings – 11,424 x Rs.5.25
– Rs.59,976
• Investment – Rs.500/lamp x 170 – Rs.0.85 lakhs
• Pay-back period – 17 months
Keeping the fountain solution chiller
unit outside the printing room
 Keeping the fountain solution chiller
unit outside the printing room
• Capacity of chiller – 1.5 TR
• Total heat liberated from the condenser – 1.8 TR
• Power required for air-conditioner for reducing
this additional heat – 1.8 x 1.2
– 2.16 kW
• Annual energy savings – 2.16 x 24 x 300
– 15,552
• Annual monetary savings – 15,552 x Rs.5.25
– Rs. 81,648
• Investment – Nil
Reduce heat ingress into printing
rooms
 Reduce heat ingress into printing
rooms
• Major portion of the sides are enclosed with glass
• This leads to unnecessary heat gain into the printing room
• It is suggested to provide heat resistant film for the glass
• Annual energy savings – 2 x (11 + 5.5) x 1.2 x 10 x 300 x 0.10
– 11880 kWh
• Annual monetary savings – 5940 x Rs.5.25
– Rs.62,370
• Investment – Rs.0.20 lakhs
• Pay-back period – 4 months
Use free cooling at night for printing
machines
Use free cooling for printing machines
• The night temperatures are below 25oC for atleast
five months in a year
• It is suggested to switch OFF the AC’s between 8.00
pm to 6.00 am and operate the exhaust fan
• Annual energy savings – 2 x (11 + 5.5) x 1.2 x 10 x 300
– 1,11,880 kWh
• Annual monetary savings – 1,11,880 x Rs.5.25
– Rs.6,62,370
Partition the plate-making room and
switch OFF one AC
 Partition the plate-making room and
switch OFF one AC
• In this room only the exposing machine needs air-conditioning
• Hence, it is suggested to provide a partition for the exposing
machine and switch OFF one AC
• Annual energy savings – 1.5 x 1.2 x 9 x 300
– 4860 kWh
• Annual monetary savings – 4860 x Rs.5.25
– Rs.25,515
• Investment – Rs.0.12 lakhs
• Pay-back period – 6 months
 Reduce pressure in compressor
• Existing compressor setting is between 8 – 10 bar
• Pneumatic cylinders and other air requirements need
maximum of 4 bar
• Every 1 bar increase in compressed air pressure will
increase power consumption by 7%
• Higher pressure will also lead to higher leakages
• Hence, it is suggested to change the settings to 6 – 7
bar
• Annual energy savings – 22 kW x 0.21 x 24 x 300
– 33,264 kWh
• Annual monetary savings – 33,264 x Rs.5.25
– Rs.1.75 lakhs
 Provide VFD for air compressor
• Under existing operation the compressor loads for 12 seconds and
unloads for 30 seconds
• The power during loading is 22 kW and during unloading it is 7 kW
• The compressor is unloading 70% of the time because it is over-
sized
• It is suggested to provide a variable frequency drive to match the
supply with demand
• Annual energy savings – 7 kW x 24 x 300 x 0.7
– 35,280 kWh
• Annual monetary savings – 35,280 x Rs.5.25
– Rs.1.85 lakhs
• Investment – Rs.1 lakh
• Pay-back period – 6 months
 Points for discussion
• Optimising the machine speed !
• Baking machine temp and heat loss reduction
• Need for 420 kVA DG set ?
• Exhaust fan in the office for fresh air
• Re-use of punched scrap
• Doors should be provided with luveres
• Windows should be clear of obstructions
• Use of distilled water from ACs @400 litres/day
• Install solar water heater for use in kitchen. Excess
pallets can be sold at Rs.1.5 per kg
• Install a 20 kW solar power plant and connect to LT grid
of the plant. It will generate 100 units per day.
Insulate fountain solution tank
Restore ventilation by removing
obstructions
AC for ink mixing and stores?
Reduce heat loss in baking oven
Boiler fuel?
Punched cutting as a product?
Punched cutting as a product?
Punched cutting as a product?
Punched cutting as a product?
 Solar water heater for canteen
• Hot water can be used for providing boiler feed water for preparing
rasam, sambar, tea, etc.
• Raw cold water is now used which may result in higher energy
consumption in the boiler
• A 200 lpd evacuated vacuum tube collector may be provided at the roof-
top for producing 900C hot water
• Energy savings by using hot water – 200 x 1 x (90 - 30)
– 12,000 kcal/day
• Fuel (pallet) savings in boiler – (12,000/(0.5 x 2000)
– 12 Kg
(boiler efficiency – 50%, calorific value of fuel – 2000 kcal/kg)
• Annual monetary savings – 12 x Rs.1.50 x 300 – Rs.5400
• Investment – Rs. 0.30 lakh
• Pay-back period – 66 months
 Providing a 20 kW solar power plant
• Integrate with local LT grid
• Annual generation = 20 kW * 5 kWh/kW * 300
= 30,000 kWh
• Annual savings = 30,000 * Rs.8 = Rs. 2,40,000
• Investment = Rs. 12 Lakhs
• Pay-back period = 5 Years