pisd-i case studies

8/8/2019 PISD-I Case Studies

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P I S DP I S D -- II

CASE STUDIES

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Textile Sugar Paper Leather

P I S DP I S D II

July-2007 to June-2010

150150 5050 1515 100100


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PISD Services

1. Dissemination and Communication

2. Training and Human Resource Development

3. Cleaner Production and Energy Efficiency Technologies

4. Wastewater Treatment Plants

5. Environmental Management System and Certification

6. Corporate Social Responsibility (CSR)

7. Performance Reports


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PISD Process

Integrated Audit

(I)

Confirmed list of interestedindustries from PSC, I.Aconducted at industry, I.Areport shared withindustry

(O)

I.A report document,Industry got awarenessabout the opportunities

for energy savings andenvironmentalimprovement

Action Plan

(I)

Findings &

recommendation fromI.A report, specificinvestigation, costestimations, cost benefitanalysis, estimation of ROI, discussions withindustry representatives

(O)

Final Action Plandocument, Industry gotawareness about the

actions to be taken forenergy savings andenvironmentalimprovement

CP/CT/ET

(I)

Industry select theCP/CT/ET by itself from the

Action Plan, CPI facilitateby collecting baselineinformation, providing listof vendors and contractors,top supervision duringinstallation, providingtraining to HR on site

(O)

Selected intervention gotimplemented, Industrystarts savings due to theactions taken for energyconservation andenvironmentalimprovement

PerformanceAnalysis

(I)

Monitoring andrecord keepingformats;coordinationbetween industryand CPI

(O)

Continuousmonitoring &record keeping;performance data

P r i m e A c t i v i t i e s

(I) Input (O) Output


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Industry Name Sarena Industries & Embroidery Mills (Pvt.) Ltd. Lahore

PISD Partner since March 2008

PISD Services Availed Integrated Audit, Action Plan, EMS (D,I,C), CT, ET, WWTPdesign, CSR, Performance Evaluation Survey, Trainings

Cleaner Technology Installation of Caustic Recovery Plant (CRP)

Before2.3% (Approximately 3,800kg/day) of Caustic Soda wasbeing wasted from Mercerization wash boxes at a flow rateof about 7m 3/hr.

Technology Implemented

Caustic Recovery Plant with two stage multiple effectevaporator.

After No wastage of Caustic Soda from Mercerization wash boxes.Reduction in the daily chemical and fresh waterconsumption.

Cost Capital

O&M

Rs. 3.6million

Rs. 5.0million/yrSavings Caustic Soda

Fresh water 483ton/yr ( 35%) 18,000m 3/yr

Payback 4months

TextileTextile


6/13

Industry Name Sarena Industries & Embroidery Mills (Pvt.) Ltd. Lahore

Energy EfficientTechnology

Steam Traps Management

Before

Many faulty steam traps were found during audit. Regularinspection, repair and maintenance of these steam traps wasnot in place. Maintenance crew does not have schedulemaintenance record of these traps. A lot of steam wastageoccur unintentionally.


Steam Trap Management system was implemented. It

includes regular surveys of the installed steam traps withchecking and data collection. It followed by therecommendations for the replacement or repair of the faultytraps. Actions taken on the recommendations.

After Many steam traps have been repaired and/or replaced.Steam wastage is controlled.

Cost Capital Rs. 60,000.Savings Natural Gas

SteamFresh WaterCO2 reduction

288,000m 3/yr 2,700ton/yr 3,840m 3/yr 518ton/yr

Payback < 1months

TextileTextile


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SugarSugar

Industry Name Husein Sugar Mills Ltd. Faisalabad

PISD Partner since February 09

PISD Services Availed Integrated Audit, Action Plan, CT, ET, EMS (D,I), CSR, Trainings

Cleaner Technology Reuse of Caustic Soda Solution

Before20% Caustic Soda solution is used to wash the evaporatorsurface. This solution is drained after boiling, havingconcentration of about 5%.


It was recommended that this drained solution should becollected and reused. Concentration of chemical solutionshould be checked after each cleaning and fresh chemicalsmay be added to maintain the required concentration.

After All the drained Caustic Soda solution is collected and reused.Reduced chemical consumption.

Cost Incurred Rs. 0.5million

Savings Caustic Soda 20,040kg/4months season

Payback 3months


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Industry Name Huda Sugar Mills Ltd. Nankana Sahib

PISD Partner since February 09

PISD Services Availed Integrated Audit, Action Plan, CT, ET, EMS (D,I), CSR, Trainings

Energy EfficientTechnology Insulation of Bare Hot Surfaces

Before

Bare hot surfaces like valves, flanges, lines and vessels wastea lot of thermal energy through radiation and convection.Many bare hot surfaces were observed during the auditactivity.


Insulation of 2" thick rock wool, covered with GI (GalvanizedIron) sheet of 26 gauge.

After Reduction in thermal energy losses and fuel saving.

Cost Capital Rs. 2.0million

Savings BagasseCO2 gas

800tons/4months season 640tons/4 months season

Payback 3months

SugarSugar


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Industry Name Century Paper and Board Mills Ltd.

PISD Partner since July 2007

PISD Services Availed Integrated Audit, Action Plan, CT, ET, CSR, Trainings

Cleaner Technology Recycling of SO 2 Water

BeforeHot SO 2 water ( 1.5g/lit) was released during thepreparation of Sodium Sulfide. All this release was drainedout with wastewater.

Technology

Implemented

SO2 water recycling station was installed. It is a combinationof a Plate Heat Exchanger, a collection pit and a recirculationpump.

After

No hot SO 2 water drainage from the industry. Reduction inthe consumption of Sulfur (4% 250kg/day) and of freshwater ( 340m 3/day). Availability of hot water ( 1440m 3/day)to be utilized in other processes.

Cost Incurred Rs. 2.65millionSavings Sulfur

Fresh waterSteam

250kg/day ( 4%) 340m 3/day 86kg/ton of hot water

Payback 12 months

PaperPaper


10/13

Industry Name Century Paper and Board Mills Ltd.


Power Factor Improvement

Before

Power factor maintenance was not appropriate. Capacitorbanks with auxiliary equipment was not in good condition.Some of the control relays were not working. Low powerfactor penalty was also imposed by the authorities.


Automatic power factor correction was installed with thereplacement of damaged capacitor banks and control relays.

After Power factor penalty was saved and distribution losses werereduced.

Cost CapitalRunning

Rs. 2.0 million Rs. 0.4 million/yr

Savings Power factor penalty 1% of overall electricity bill

Payback 11 months

PaperPaper


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Industry Name H.Sadar Ali Akhtar Ali (Pvt.) Ltd.

PISD Partner since July 2007 (also since 2001)

PISD Services Availed Integrated Audit, Action Plan, CT, ET, EMS (D,I,C), WWTP (D,I)CSR, Trainings

Cleaner Technology Chrome Recovery Plant (CRP)

BeforeAll the tanning effluent having Chrome ( 146mg/l) wasdrained.

Technology

Implemented

A CRP consists of an underground effluent collection tank, areactor, chemical (acid and alkali) dosing tank, and aregeneration tank.

After Chemical (Chrome) conservation, reduction in the chromecontents (from 146mg/l to 0.03mg/l) in effluent drain.

Cost Incurred CapitalRunning

Rs. 1.2million Rs. 1.2million

Savings Chrome 145.97mg/l ( 99.98%)Payback 15 months

LeatherLeather


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Industry Name H.Sadar Ali Akhtar Ali (Pvt.) Ltd.


Insulation of Bare Hot Surfaces

Before

It was observed during audit that hot pipes of steam andcondensate and the hot water storage tanks were notinsulated. It resulted into lot of heat loss resulting in highernatural gas bills.


Insulation of 2" thick rock wool, covered with GI (GalvanizedIron) sheet of 26 gauge.

After Reduction in thermal energy losses and fuel saving.Cost Capital Rs. 3.5million

Savings Natural GasCO2 gas

105,875m3/yr 233tons/yr

Payback 5months

LeatherLeather


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