ENERGY is the epic challenge of the 21st century. To meet gap between energy supply and demand as well as preserve natural reserves for future generation is blazing concern for all nations. The industrial sector of any country is major consumer of the Energy resources. Moreover energy consumption means more cost, more carbon emissions and more risk involved. Therefore it is need of the ERA to focus on the following:

• Reduce costs- this is becoming increasingly important as energy costs rise.
• Reduce carbon emissionsand the environmental damages, legal obligations to reduce carbon footprint and promote green world.
• Reduce risk- the more energy the greater the risk, that energy price increases or supply shortages could seriously affect sustainability of the business.

Keeping in view above Challenges, AGRITECH Limited managed Energy audit of its system with the coordination of AVANCEON and come-up with a proposal, which later on matured as "Energy Management Solution Project"

Energy Management Solution Project mainly focused on energy saving using i-water technology.

In AGRITECH Fertilizer, i-water Energy Management System Project was conceded to impart uniformity in the process and guaranteed energy and cost savings without process adversity, financial risk, product quality and production loss. I-Water EMS technology includes monitoring of process condition and Supply - Demand Management which in result saves energy, reduces maintenance cost and reduces water wastage.

At AGL, for the working of EMS project, initially Energy audit and PHA (Process Hazard Analysis) for selected applications was carried out. Following applications were finalized based on appreciable energy saving cushion:

• Raw Water System.
• Cooling Water System.
• Condensate Return System.

Main Philosophy of Energy Management Solution Project:

Energy Management Solution Project mainly focused on energy saving using i-water technology based on master controller which intelligently monitor and control selected plant process conditions and ultimately save energy whenever finds any cushion across these applications.

I-water use VFD technology based on Affinity law, gave Huge energy saving potential by

• 10 % speed reduction resulted into 28-30 % of power savings,
• 20 % speed reduction resulted into 55-60 % of power savings.

 Also, it played part in flow reduction by following Affinity Law,

• 10% speed reduction results in 10% flow reduction.

Before this project, desired process conditions were being controlled either by valve throttling or auto or manual on/off method. Energy Saving Solution based on i-water conceded on cooling water system for cooling towers provide the temperature control by continuously sensing the cold well temperature. Based on the cushion from the sensor, the controller increases / decreases the speed of the cooling tower fans. The control philosophy was implemented to control cooling water supply and header temperature with fan speed. Effect of the speed regulation on load side has been investigated in detail to figure out any process disturbance or saving loss as a result of EMS strategy. However for process safety, some critical parameters of urea & ammonia were taken into safety loop of EMS Logic.

EMS strategy based on i-water was also conceded on Raw Water and Condensate return system by continuously sensing the process conditions. Previously, desired process conditions were being met by valve throttling. According to EMS strategy, Pumps speed would be reduced to maximum of 15~20% depending on process conditions and plant load.

I-Water Energy Management System (i-water EMS) is flexible enough, that in case of any exception, with a single twist of a key at any time we can go back to previous scenario. In that case, EMS logic will be by-passed.

Out-Come from EMS Project:

Using i-water management system, AGRITECH saved total cost of Rs.11.30 Million/annum in term of Rs. 7.13 Million from cooling water system, Rs. 2.42 Million from raw water system, Rs 0.75 Million from condensate return system. The average speed reduction noted on Cooling water fans during whole year was 5% (summer), 10-12% (moderate season) and 16-18% (Winter). The increased in cooling water temperature due to reduction in fan speed was continuously analyzed .The average decrease in cooling water temperature was noted only 0.4 ^oC on behalf of average speed reduction by 20 %.