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ENERGY  CONSERVATION  DRIVE    

as  we  believe  

“ENERGY  CONSERVED  IS  ENERGY  GENERATED”  

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About  THE  COMPANY  

■  Name  :  TESLABLUE  PVT  LTD  

■  Objec:ve  :      Providing  end  to  end  solu:on  to  customers  in  energy  sector  is  the  main    objec:ve  of  this  venture.    Thrust  is  to  enhance  efficiency  of  energy    u:liza:on.  

■  Ac:vi:es  :  Waste  heat  recovery  systems,  Solid,  Liquid  and  Gaseous  fuel  fired  Boilers,    Cogenera:on  systems,  Condensate  and  Flash  steam  recovery  systems,  Economisers,  Air  heaters,  Pollu:on  control  equipments  etc.,    Opera:on  &  Maintenance  contracts  &  Energy  audits.    

■  Opera:on  :  Catering  to  the  energy  needs  of  our  customers  in  India  and  abroad  with  revolu:onized  technology  and  product.  

GREEN ENERGY…. How?

■  Heat recovery from exhaust gases of Boilers, Generators, Furnaces, Incinerators, Coolers..

■  Efficient distribution and usage of steam..

■  Efficient condensate recovery system..

■  Utilization of flash steam..

■  Incidental power generation with micro turbines..

■  Periodic energy audits for proper accountability..

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BRIEF  DESCRIPTION  OF  OUR    

INITITAIVE  

 TOWARDS  GREEN  POWER  

RECOVERABLE HEAT WASTED

■  Flue gas exhaust temperature from Boilers are normally at 240°C - 250°C which can be safely brought down to around 130°C, thereby recovering tremendous amount of energy.

■  Flue gas outlet temperature of Gensets is around 450°C, normally wasted in Radiators and Cooling towers, which can be converted into useful energy.

■  Flue gas temperature of exhaust from Furnaces are at very high temperature, sometimes around 900°C - 1000°C, huge quantity of heat energy dumped to atmosphere – Tremendous scope for power generation.

■  Heat removed from Process Coolers are dissipated in Cooling towers, which can be put into useful use by designing adequate heat recovery system.

■  Heat generated at the flue gas outlet of Incinerators carry enormous heat energy either let out to the atmosphere or wasted at scrubber and other pollution control equipments.

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WASTE HEAT RECOVERY

■  An efficient Heat recovery system can be customised for flue gases from Boiler and Gensets, thereby recovering heat which can be used to preheat Boiler feed water and reduce Boiler fuel consumption.

■  Alternatively, an Air heater can be integrated in the system to preheat the combustion air before entering the Furnace, thereby reducing Boiler fuel consumtion.

■  Heat recovered from furnaces are at very high temperature and ideal for power generation.

■  Heat recovered from Incinerators can be used for steam generation and power generation.

■  Recovered heat can cater to various application depending on the process and industry either through hot water or hot air. Customization to suit process requirement is essential.

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DISTRIBUTION & USAGE OF STEAM

We help our customers in..

■  Pipeline sizing for optimal steam velocity.

■  Stress analysis and structural support designs.

■  Design of distribution network of headers, branches, gadgets and overall plant piping.

■  Expansion loops and condensate removal system from long pipelines.

■  Insulation of pipelines and other steam generating and using equipments.

■  Trouble shooting of existing systems for condensation, pressure drops, heat losses etc.,

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CONDENSATE AND FLASH STEAM RECOVERY

■  Design of condensate recovery system, wherein process condensate which are normally at temperature around 100°C is fed back to the boiler feed water tank without the help of pumps.

■  This will increase the feed water temperature before feeding into the boiler. Fuel required for sensible heat is reduced to great extent.

■  Flash steam is normally 12% of the total condensate in most of the process industries. This escapes when the condensate from steam traps falls into the open collection tank. A flash steam recovery system can be customized to recover it.

■  Collected flash steam can be used for low steam pressure application or can be fed to the main steam line using a thermo compressor.

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Schematic of Condensate recovery system

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■  IPG   stands   for     “INCIDENTAL   POWER   GENERATION”.       It   is   termed   so  because  it  aims  at  conserving  the  unu:lized  pressure  energy  in  a  process  plant  PRV/PRDS,  that  is  otherwise  simply  throWled.  

■  The  nozzle  of  IPG  func:ons  the  same  way  as  a  PRV  in  a  process  plant.   It  reduces   the   steam  pressure   to   the   required   process   (Back)   pressure.   In  addi:on,   it   converts   this    pressure  energy   to  high  velocity   that  gives  an  impulse  to  rotate  the  Turbine  wheel  (bolted  with  the  high  speed  sha[)  at  a  speed  of  12,000  RPM.    

■  This   high   speed   is   reduced   through   a   reduc:on   gear   box   to   1500/3000  RPM  depending  upon  the  ra:ng  of   the  generator   to  generate   Incidental  clean,  Green  Electric  Power.  

■  The  system  can  be  a  stand  alone  or  a  Grid  synchronous  system.    

INCIDENTAL  POWER  THRO’  MICRO  GENERATION  

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 IPGs  are  Custom  Designed  for  ConHnuous  OperaHon  with  the  following  range  of  Steam  Parameters:  

■  ANY  Inlet  Pressure  from  4  kg/cm²  (g)  to  60.0  kg/cm²(g)  ■  ANY  Back  Pressure  up  to  14.0  kg/cm²(g)  ■  ANY  Inlet  Temperature  up  to  460°  C  ■  ANY  Flow  Rate  up  to  50.0  TPH  

IPG  –  The  Range  

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   IPG  Type:  (Based  on  Steam  Requirement  for  Process)  

■  Back  Pressure  ■  Extrac:on  Cum  Back  Pressure  ■  Straight  Condensing  ■  Extrac:on  Cum  Condensing  ■  Extrac:on  Bleed  Cum  Condensing  

Types  of  IPG  

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                                                                               Images  of  IPG  

Case study in a Ricemill

■  Type            :  Single  stage  boiled  ■  Capacity  per  hour      :  12  ■  Parboiling  capacity      :  128  tons  ■  Drier  capacity        :  32  tons  /batch  X  4  units  ■  No  of  tanks  (Soaking/steaming)    :  32  ■  Water  requirement      :  1,60,000  litres  ■  Steam  requirement  for  Steaming  :  3,200  Kg/hr  ■  Steam  requirement  for  drying    :  4,800  Kg/hr  ■  Power  requirement      :  110  KW  

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Case study in a Ricemill

Total  electrical  load  :  Parboiling  &  Drier  :  110  KW          :  Boiler(  5  TPH  average)  :    49  KW            Total    :  159  KW  

Considering  only  drier  steam  flow  of  4,800  kg/hr  @  4  Kg/cm²  pressure  Steam  pressure  in  boiler  if  maintained  at  17  Kg/cm²  instead  of  10  Kg/cm²  Incidental  power  generated  when  passed  through    IPG    is  153  KW      

It  may  be  noted  that  the  whole  Drier,  Parboiling  and  Boiler  unit  is  by  and  large  self  sustaining  in  terms  of  power  generated  and  consumed.  

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Case study in a Textile Dyeing unit

■  Type    of  Process        :    Washing  &  Dyeing  ■  Boiler  capacity        :  14  Tons/Hr  ■  Boiler  working  pressure      :  10  Kg/cm²  ■  Process  quan:ty  and  pressure  requirement  :    10,000  Kg/hr  @  2  Kg/cm²

If  IPG  installed  parallel  to  the  Pressure  reducing  sta:on  (PRS)    

■  Incidental  power  genera:on        :  340  KW  ■  Working  hours  (2  Shi[s)      :  20  hours  ■  Self  consump:on  of  power  @  2%    :  6.8  KW  ■  NeW  exportable  power  per  day      :  6,664  KWH    

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BEFORE  IPG   AFTER  IPG  

340 kW Free, Green, Clean Electric Power!

IPG

LP Steam Header

HP Steam Header

PRV

Sat Steam @ 9.5 kg/cm2 (g) 10 TPH, 182 C

Sat Steam @ 2 kg/cm2 (g) 10 TPH, 133 C

LP Steam Header

HP Steam Header

PRV

Sat Steam @ 9.5 kg/cm2 (g) 10 TPH, 182 C

Sat Steam @ 2.0 kg/cm2 (g) 10 TPH, 133 C

IPG  –  A  Clean,  Green  CoGen  SoluHon  

Case study in a paper manufacturing unit

■  Paper manufacturing capacity : 100 Tons/day ■  Steam requirement : 8.5 Tons/hr @ 2.5 Kg/cm² ■  Working hours : 24 hours (3 shifts)

If IPG installed ■  Boiler capacity : 10 Tons/hr ■  Boiler working pressure : 17.5 Kg/cm² ■  Power generated thro’ IPG : 400 KW ■  Self consumption @ 2% : 8 KW ■  Cumulative daily power generation : 9,408 KW

Pl note this power is incidental and generated literally free, which otherwise would have got wasted in throttling at Pressure reducing station.

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System working principle

■  Proposed  IPG  will  have  an  INDUCTION  GENERATOR  coupled  to  the  prime  mover  in  place  of  an  alternator.  

■  Induc:on  generator  is  modified  version  of  alternator  which  works  both  as  an  alternator  and  motor.  

■  The  system  shall  ini:ally  draw  power  from  the  grid    which  will  be  supplemented  by  the  induc:on  generator  as  the  turbine  starts  rota:ng.  

■  The  controls  and    internals  of  the  Induc:on  generator  are  such  that  depending  on  the  steam  flow,  power  genera:on  varies  propor:onately  with  minor  varia:on  in  efficiency.      

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Draw back of this system

■  STG  will  trip  if  Grid  power  supply  fails.  STG  cannot  be  put  into  opera:on  unless  Grid  power  is  restored.  

■  Induc:on  generator  will  work  only  if  the  Grid  connected  load  is  3  :mes  that  of  IG.    Which  means  in  a  100%  Power  consump:on  of  plant,  only  30  to  40%  can  be  met  by  IG  and  balance  70%  has  to  come  from  Grid  as  reac:ve  power  and  excita:on  voltage  has  to  be  supplemented  from  the  Grid  always  during  IG  opera:on.  

■  IG  efficiency  varies  as  compared  to  Synchronous  generator.  Further,  at  part  load  efficiency  is  poor.  

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COST BENEFIT ANALYSIS

■  Process steam requirement : 10 TPH @ 2 Kg/cm² ■  Working hours : 2 Shifts of 20 hours ■  Grid power cost : Rs 6.5 per KWH

With IPG installed ■  Power generation : 340 KW ■  Cumulative power generation/day : 6800 KWH ■  Value of IPG generated power/day : Rs. 44,200 ■  Investment on the system : Rs 60 Lacs ■  Operation & Maintenance manpower cost : Rs 1,000 / day ■  Equipment maintenance cost assumed : Rs 1,370 / day ■  Interest on investment @ 12% : Rs 1,975 / day ■  Simple pay back period : 6 months approximately

To be on the safer side as there are lot of variants like plant steam fluctuations, break downs, maintenance, lets consider the payback period to be around 1 year.

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OUR PROPOSAL TO CUSTOMERS

■  Investment shall be done by our company. ■  Operation and maintenance shall be done by us with our own manpower. ■  Cost of spares during the contract period shall be to our account.

Customer’s obligation ■  Customer to pay us for the energy saved / generated through our equipments and

systems on monthly basis as per mutually agreed terms. ■  Contract shall be for a minimum period of 3 years after that the equipment shall be

transferred to the customer for residual value. ■  Mutually agreed minimum amount to be paid to us incase of non utilization of our

equipments and services for any reasons not because of us. ■  Providing free space and access for our equipment and personnel. ■  Security for our equipments and personnel. ■  All civil and other structural work required for the equipments. ■  We should be allowed to take the equipments out of the premises for maintenance,

alterations etc., without any hindrance.

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■  Eligible  for  Renewable  Energy  Credits  

■  Eligible  for  85%  Deprecia:on  in  the  first  year  

■  Fully  Automated  through  PLC  

■  Less  than  10  Months  Payback  

■  Lowest  Maintenance  Cost  

IPG  –    The  Benefits  

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Every   Industry   using   Power   and   Process   Heat  with   Steam   as   the   Fluid   can  benefit  from    IPG    through  Cogenera:on.    

Process  Industries  benefited  through  IPG  

Chemical/Petro  Chemical  

Paper  Manufacturing  

DisHlleries    &  Breweries  

PharmaceuHcals  &  Bulk  drugs  

Rayon  Manufacturing  

Solvent    ExtracHon    

TexHle  Dyeing  &  Sizing  

UHlity/CapHve  Power  Gen  

Agro    Processing  

Ricemills  &  other  Food  Processing   Milk  Dairies  

Effluent    treatment          plants  

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JUST  IMAGINE  THE  REDUCTION  OF  LOAD  

ON  THE  NATIONAL  GRID  IF  ALL  PROCESS  INDUSTRIES  GO  FOR  

IPG  SYSTEM.  

THIS  WOULD  BE  A  MAJOR  

CONTRIBUTION    IN  COUNTERING  

GLOBAL  WARMING  AND      CO2  EMISSION    

IPG  –  The  future    

How does a Turbine work ?

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Green  Power  -­‐  The  Need  of  the  Hour  

Conclusion  

TeslaENERGY PRIVATE LIMITED