Utility Optimization

ARMACO provide Energy Audit Services – Thermal & Electrical in various industrial sectors.


Thermal Audits:

Thermal Audits include audit of:

  • Steam systems – boilers, steam distribution, steam utilization, steam trapping & condensate recovery
  • Study of fuel fired equipment – thermic fluid heaters, hot air generators – covering areas like improvement in combustion efficiency, optimization of waste heat recovery etc.
  • Energy accounting – The first step towards thermal energy conservation is the Estimation of overall steam/heat balance in the plant – quantifying areas of steam usage, hot water/air usage in the plant, etc.


Energy conservations schemes are identified with techno-economic benefits as below:

  • Encon measures requiring little or low investment
  • Measures requiring medium scale investment
  • Long term measures which require high investment 


Some typical encon schemes are as below:

·         Optimization of condensate recovery network

·         Energy savings by generating hot water/hot air  generation through heat pumps

·         Simultaneous heating & cooling in the plant

·         Waste heat recovery from process streams

·         Boiler efficiency optimization


Electrical audits:

Electrical audits includes audit of:

  • Power factor/load factor /maximum demand management in the plant
  • Study of refrigeration systems – determination of kW/Tr, analysis of approach temperatures for evaporators & condensers
  • Study of HVAC systems
  • Study of compressed air systems – determination of kW/m3, optimization of compressor operational practices
  • Study of pumping systems in the plant – Analysis of pumping system, pump operating efficiency, pressure required vs. pressure delivered in the system
  • Study of cooling towers in the plant
  • Study of blowers in the plant
  • Study of plant & office lighting


Energy accounting

Energy accounting in electrical energy is very critical; it allows us to focus on the areas where maximum electricity is used. Accounting also surprises, as it is almost always against conventional wisdom. A graph is attached below for your reference:

It was an assumption at this company that the HVAC system for the clean rooms consumed the maximum electricity – more than 50%. However careful analysis showed that electricity in fluidized bed dryers in fact consumed the maximum electricity.

Similar approach is taken for refrigeration, compressed air, pumping systems etc. where the actual energy end use is analyzed & quantified. This gives us an in-depth understanding of the process operations in the plant – leading to optimized solutions in energy conservation.


Some typical encon schemes are:

  • Improvement in power factor in the plant
  • Optimization of pumping systems – Pumping systems account for 203-% of the electricity consumed in the industry & also offers the most scope for energy conservation. installation of correct-sized pumps, impeller trimming, installation of VFD drives are some of the measures that are suggested.
  • Optimization of refrigeration systems – minimization of refrigeration loads, decrease in approach temperature, improving condenser performance are some of the measures we suggest.
  • Reducing compressed air usage/pressure, Improving kW/m3 of compressed air systems, quantifying & minimizing compressed air leaks
  • Installation of heat pump for hot water generation- ( to replace electric heating)


Action Plan

The energy audit report also includes the action plan – A step by step approach about which measures can be implemented parallel & which need to be taken up sequentially.


Benefits of Utility Optimisation

Strong Economic Reasons

  • Fuel oil prices have galloped in the past decade from the lows of Rs.10000 per MT to Rs. 50000 per MT.
  • Natural gas prices have shot up through the roof from Rs.8-10 per scm to Rs.35-40 per scm in the last 4-5 years
  • Shortages in Indian coal output & rise in international coal prices has increased the cost of industrial electricity from Rs.4.00 per unit to Rs.6-7 per unit for grid supply.
  • HSD prices have been on the march forward for the last couple of years rising from Rs. 35 per ltr to Rs.50 per ltr. With pricing decontrol it is set to increase by a further Rs.10 per ltr depending on the international oil prices & the Rupee exchange rate. Increase in HSD prices has meant that cost of own electricity generation through HSD fired DG sets has shot upto Rs.13.5 per unit generated.


Minimization of Environmental pollution

There is a compelling CSR case for companies to pursue energy conservation due to the direct benefit of reduction in environmental pollution following implementation of encon measures.



Armaco's engineers will Plan, Design, Implement and Commission to the get the Desired Energy Conservation results.