Ecological Footprint Assessment …
69
d. Mode 2 (Replacement of Electric heater for corrugation with LPG burner)
Corrugation heaters are used to heat the corrugation roll to make plastic deformation of the fluted paper so that the paper must retain the shape of corrugation.
Three electric heaters of 12 kW each are used to carry out the corrugation process.
These electric heaters contribute to about 60% of the total energy requirements of the
industry. As the main source of electricity generation in India is coal [6], the overall
efficiency of energy utilization is approximately one-third. Therefore to reduce the
emissions for heating, use of LPG fuel is suggested which will be cost-effective as
well as it will reduce emissions. By replacing the grid-based electric heaters with
LPG burners, the total GHG savings are expected to be 30.70tCO 2 /year, as shown in
Table 12.
While calculating the cost savings, it is essential to consider that the carbon layer
will deposit on the burner during burning, this will have to be removed from time
to time. This, therefore, requires maintenance periodically whose cost needs to be
incorporated. The total cost savings due to the use of LPG may stand up to Rs.
52,153.2 as depicted in Table 13.
e. Mode 3 (Replacing electric heater with LPG gas burner and grid electricity
with grid-connected solar PV electricity to meet other energy needs)
As the investment cost of replacing all energy needs of the industry by solar PV
is quite high, the cost-effective mode which replaces the heating requirements with
LPG gas and other electrical needs by grid-connected solar PV is suggested. This
analysis is done using RETScreen for solar PV analysis, and the LPG analysis is done
Table 12 Total GHG savings of Mode 2
Electricity
Unit
LPG
Unit
GHG emissions
0.001186
tCO 2 /kWh
0.0000718
tCO2/MJ
Energy requirements
33,100
kWh/year
119,160
MJ/year
Total GHG emissions
39.26
tCO2/year
8.56
tCO2/year
Total GHG savings
30.70
tCO2/year
Table 13 Net savings of Mode 2
Electricity
Unit
LPG
Unit
Energy required for heating
33,100
kWh/year
119,160
MJ/year
The unit cost of energy
7.39
Rs/kWh
1.48
Rs/MJ
Cost of energy
244,609
Rs/year
176,855.8
Rs/year
Cost savings
67,753.20
Rs/year
Maintenance
300
Rs/week
Total maintenance cost
15,600
Rs/year
Net savings
52,153.0
Rs/year
69
d. Mode 2 (Replacement of Electric heater for corrugation with LPG burner)
Corrugation heaters are used to heat the corrugation roll to make plastic deformation of the fluted paper so that the paper must retain the shape of corrugation.
Three electric heaters of 12 kW each are used to carry out the corrugation process.
These electric heaters contribute to about 60% of the total energy requirements of the
industry. As the main source of electricity generation in India is coal [6], the overall
efficiency of energy utilization is approximately one-third. Therefore to reduce the
emissions for heating, use of LPG fuel is suggested which will be cost-effective as
well as it will reduce emissions. By replacing the grid-based electric heaters with
LPG burners, the total GHG savings are expected to be 30.70tCO 2 /year, as shown in
Table 12.
While calculating the cost savings, it is essential to consider that the carbon layer
will deposit on the burner during burning, this will have to be removed from time
to time. This, therefore, requires maintenance periodically whose cost needs to be
incorporated. The total cost savings due to the use of LPG may stand up to Rs.
52,153.2 as depicted in Table 13.
e. Mode 3 (Replacing electric heater with LPG gas burner and grid electricity
with grid-connected solar PV electricity to meet other energy needs)
As the investment cost of replacing all energy needs of the industry by solar PV
is quite high, the cost-effective mode which replaces the heating requirements with
LPG gas and other electrical needs by grid-connected solar PV is suggested. This
analysis is done using RETScreen for solar PV analysis, and the LPG analysis is done
Table 12 Total GHG savings of Mode 2
Electricity
Unit
LPG
Unit
GHG emissions
0.001186
tCO 2 /kWh
0.0000718
tCO2/MJ
Energy requirements
33,100
kWh/year
119,160
MJ/year
Total GHG emissions
39.26
tCO2/year
8.56
tCO2/year
Total GHG savings
30.70
tCO2/year
Table 13 Net savings of Mode 2
Electricity
Unit
LPG
Unit
Energy required for heating
33,100
kWh/year
119,160
MJ/year
The unit cost of energy
7.39
Rs/kWh
1.48
Rs/MJ
Cost of energy
244,609
Rs/year
176,855.8
Rs/year
Cost savings
67,753.20
Rs/year
Maintenance
300
Rs/week
Total maintenance cost
15,600
Rs/year
Net savings
52,153.0
Rs/year