Waste Heat Utilisation Potential in India

The 14th Regulators & Policymakers Retreat
1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa
Title: Waste Heat Utilisation
Speaker: G C Datta Roy
1

DESL-Contributing EE & RE
Development Globally
Enabled energy
saving of approx
200 MW in
commercial
buildings, industr
ies and municipal
facilities
Designed and
Engineered
over 500 MW
of biomass
based power
plants and
cogeneration
Designed and
engineered 22
MW solid
waste to
energy plant
Due Diligence
& Project
development
for 250 MW of
hydropower
400,000 LPD
solar water
heating in
industrial
processes
2

Talking Points in Brief
• Context
• Glimpses-global policy development
• Few DESL case illustration
• Drivers & barriers
• Innovative barrier strategy
3

The Context Furnace video.mp4
“Although it can be tricky and expensive to harness, waste heat is getting
increased focus as a source of power in both the U.S. and China, mostly because
of the quantities of heat out there. A study conducted by Lawrence Berkeley
National Labs estimated in 2005 that the U.S. alone has 100 gigawatts of
untapped electrical capacity in the form of waste heat that annually could
produce 742 terawatt hours of power. That's bigger than the solar fleet, which
gets measured in megawatts.”
Will waste heat be bigger than solar-Michael Kanellos-Greentechsolar; Jan 24, 2009
4

Japan
“The Japanese Ministry of Economy, Trade, and Infrastructure (METI) has
released its budget plan for the 2013 fiscal year. In it, METI outlines a
10.5 trillion yen, or over $124 million budget proposal to partially subsidize
the purchase and installation of low-temperature waste heat recovery
systems at various industrial plants around the country. Affected plants
will be those that can reduce their energy consumption by at least 15
kiloliters of oil-equivalent. The amount of subsidy received will be
dependent on the temperature of the waste heat recovered and be
entirely dependent on interested plants and businesses completing the
installations of such systems by the end of September 2013”.
Industrial Info Resources, Dec 27, 2012
5

USA
6

Policy Interventions-Illustrative
Examples
Country Policies*
Canada
Depreciation of WHRPG accelerated by 50%
Program ERSOP in Ontario: feed-in tariff of 70 €/MWh for the electricity
produced from waste heat, for projects selected through calls for tenders
USA
Project to amend the federal law in order to allow 30% tax credit on WHRPG
projects
A dozen States have acknowledged that waste heat is a renewable energy
source
California (2011): investment aid of 0,8€/W, up to 3 MW (DSM)
Japan Accelerated depreciation and soft loans
Investment aid up to 50%
Italy
Extension of the scope of White certificates to include WHRPG, with a new
scale in 2011:
one certificate is now worth 60 €/MWhe )
Norway Investment aid up to 20% and tax exemption on the electricity produced and
self used.
*Panorama of public policies supporting power generation from industrial waste heat-ADEME, Oct, 2012
7

India Scenario-DESL Case Studies
8

Kiln-Sponge Iron
Key financial ratios (Feasibility study)
Investment-Rs 20 Crs
Project tenure-10 years
Power sale rate-Rs 3.34 to 3.51/kWh
Project IRR -26.12%
Equity IRR -37.79%
Average Debt Service Coverage Ratio-2.09
9

Forging Furnace-MSME
SME Steel Furnace (under implementation)
Savings of PNG-24800 SCM/Year
Financial savings-Rs 9.6 Lacs/Year
Investment-Rs 2.0 lacs
Simple payback-2.5 months
10

Industrial Boilers
Boiler FG WHU recovery
Brief summary of the project is as follows.
Boiler capacity-5.6 TPH
Steam pressure-16 Kg/cm2 g
Exit flue gas temperature-210oC
Various design modifications such as replacement with a higher sized
economiser, installation of APH, installation of low pressure water heater were studied. As
per recommendation, the unit implemented the economiser solution and derived the
following benefits established by carrying out a performance test.
Exit flue gas temperature reduced from 210oC to 132oC
Gain in overall boiler thermal efficiency-8%
Coal saving-1270 TPY
Financial saving-Rs 45.7 lacks per year
Cost of additional economiser-Rs 25 lacs
Payback-< 6 months
11

India Scenario-High Potential-Very Low
Penetration (DESL database-2012)
Sector Application Penetration
Cement Preheating High
WHR STG system Low
Integrated steel GTG One demo project
Hot gas recuperators High
Sponge iron Preheating Low
WHR STG system Low
Steel furnaces Recuperation Low
Other metal furnaces Low
Glass furnaces Recuperator Low
WHR STG system One CDM project
VAM Low
Paper Hood PV system Medium
Sugar/Biomass power Bagasse/Fuel drying Low
Refineries FCCU recuperator High
WHR STG system Not known
Boilers Economisers/APH High (Partial gain)
Low Temperature Low
12

India Scenario-WHRPG System
About 70 projects overall against 900
in China*
India yet to promote specific policy
for WHU-PAT is likely to be a
potential driver
*ADEME report
13

Drivers & Barriers-(Recent Analysis)
Drivers
• Economics (Energy
prices, Energy cost
indices, Energy availability &
quality)
• OE (for MSME)/Peer (Large
scale) pressure
• Compliance
Barriers
• Low awareness-quantification
of opportunities (market
overall & individual units)
• Technology-real & perceived
risks
• Lack of warranty services-
Sustaining initial gain
• Market uncertainty-impact on
return
• Regulatory
Unlike in such
cases, successful
demos/pilots do not
seem to have made
desired impact
14

Barrier Strategy
• Assessment of the market opportunities
– Grades (High, medium & low temperatures)
– Sectors
– Technologies (Process, Power, VAM, ORC)
• Common strategy
– Awareness & promotion
– Policy development & deployment
– Demo projects
• Need for strategy innovation
15

Proposed Strategy Innovation
• WHR Alliance (Cluster, Sectoral, National)
Units
/Clusters/
Sectors
Vendors
BEE/SDAs
Banks/FIs
Service
providers
Technical
Institutes
OEM
(MSME)
16

Conclusion
• WHU-Next big thing in the EE domain
• Overall market potential high but not yet quantified-need for
market assessment study
• Penetration very low even in the relatively better identified
markets
• Need for innovative strategy-WHRA proposed under the
USAID sponsored PACE-D project (Capturing the learning from
the successful development of ‘Appliance Standard’ &‘Green
Building’ markets in India)
• Process initiated in one of the MSME Furnace cluster
• Successful implementation can catalyse faster development of
the WHU market
17

Thank You
Dr. G. C. Datta Roy
Chief Executive Officer
Development Environergy Services Ltd.
(Formerly Dalkia Energy Services Ltd)
# 819, 8th Floor, Antriksh Bhawan
22, Kasturba Gandhi Marg, New Delhi - 110001
Tel-+91 11 4079 1107 Fax-+91 11 4079 1101
Mob-+91 95829 40363 gdr@deslenergy.com
www.deslenergy.com
18

Waste Heat Utilisation Potential in India

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