Energy Savings By Plastics - Small Industries … of Pipe (Kg/m) 56 76 73 83 10 25 Material Energy (MJ/Kg) Ductile PP PET Clay Iron HDP PVC E Embodied Energy-Energy For Making The

Energy Savings By Plastics

Energy Consumption : Steel Vs Plastics

Source: Energy Analysis dept. University of California April 2000 &Annual report of Tata Steel

Foot Note:

8” Ductile Iron Pipe weight:33.5 :MT/KM

200mm(8”) Polyethylene PN 10 Pipe weight :8.74 MT/KM

.....Plastics reliable solution for Health, Hygiene & energy savings

4:01

REPLACEMENT RATIO BETWEEN STEEL AND

PLASTIC PIPE ( see Foot Note)

22890

Energy Saving with use of every MT of Plastic Pipe

(KWH)

1666Difference

1456010132Naptha to Plastic resin

2836118466Ore to Steel

KWH/KMKWH/MT

ENERGY REQUIRED

Energy Savings

PVC Pipes during Manufacturing

PVC Pipes GI Pipes CI Pipes

Wt/mtr (kg) Product Energy (M

Kcal)

Product Energy (M

Kcal)

Product Energy (M

Kcal)

1.441 98.91 1801.95 1132.05

Year KT Length (Km)

92-93 143 99363 9827976 179046827 112483676

93-94 171 118605 11731172 213719387 134266229

94-95 189 131222 12979169 236455492 148549871

95-96 217 150464 14882364 271128052 170332424

96-97 232 160873 15911961 289885338 182116428

97-98 305 211343 20903949 380829758 239250994

98-99 353 244780 24211141 441080437 277102643

99-00 332 230269 22775945 414933916 260676456

00-01 365 252981 25022339 455858905 286387010

01-02 566 392783 38850146 707774948 44464975702-03 507 351839 34800396 633996287 398299341

03-04 615 426787 42213498 769048751 483144171

04-05 610 423317 41870298 762796322 479216169

05-06 816 566273 56010104 1020396391 641049827

06-07 836 580153 57382901 1045406107 656761832

Total 6255 4341051 429373358 7822356918 4914286827

Total Energy Consumption (1992 to 2007)

PVC GI CI

Pipes M Kcal 429373358 7822356918 4914286827

Energy Saving

PVC V/s GI M Kcal 7392983559

Bn Kcal 7392984 8625 Million MWH

PVC V/s CI M Kcal 4484913469


Source: study conducted by IPCL

Energy SavingsPE Pipes during Manufacturing

Year KT Length (Km)

00-01 43 29054 1015439 1015439 1015439

01-02 68 45946 1605811 27597432 10402622

02-03 63 42568 1487736 25568209 9637723

03-04 66 44595 1558581 26785743 10096662

04-05 82 55405 1936419 33279257 12544338

05-06 110 74324 2597635 44642905 16827770

06-07 134 90541 3164392 54383176 20499284

Total 566 382432 13366014 213272162 81023838

All Figs in M Kcal

Total Energy Consumption (2000 to 2007)

PE GI CI

Pipes M Kcal 13366014 213272162 81023838

Energy Saving

PE V/s GI M Kcal 199906149


PE V/s CI M Kcal 67657824


Energy Saving Plastic Pipes in Production

2838212342009-10

221729642008-09

175497632007-08

164687162006-07

Power saved (GW)

Plastic Pipes in Agriculture andWater Supply

(KT)

Year

Every MT of Plastic Pipe that replaces equivalent Steel pipe saves

~23MW of power


Energy savings with Plastic Pipes: use in Submersible Pumps ( Riser Pipes)

4.45.610LakhsTOTAL

415Lakhs4" - V4No of Submersible Pumps

0.43.64Lakhs6" - V6No of Submersible Pumps

11Lakhs8" -V8No of Submersible Pumps

PEGITOTALUnit

Pumps with

following RiserPipes

No of Submersible pumps consumed 2006-07

1700Energy Saved

Karnataka Electricity Board StudySource:

3880KWH per annum

Saving

6120KWH per annum

Average Power Consumption with PE Riser Pipe

10000KWH per annum

Average Power Consumption with GI Riser Pipe

Power Consumption per Pump on average

Total energy saving eqv. to 2 plants of 100 MW by using submersible pumps


Energy saving in pump delivery

94450KWHEnergy Saving per annum per MT of UPVC

131300KWHEnergy Saving per annum

16.412KwEnergy Saving

540Cu. Mtrs/HrFlow measured in uPVC

370Cu. Mtrs/HrFlow measured in Steel

130mtrsLength Pipe Used

10.693Kg/mtr250mm PVC Pipe

26.4Kg/mtr8" MS Pipe

UnitsPipe

Source: Study by Ahmedabad Municipal corporation214512275692009-10

169151794482008-09

137021453642007-08

116231233082006-07

GWHKTKT

Energy Saved PIPE CONUSMPTION IN AGRCULURE PUMPSETS

uPVC PIPE CONSUMPTION IN AGRICULTUREYear


Power saving - Summary

Giga Watt

52096

41144

33031

29791

Total Saving

23714

19008

15572

13323

Savings due to pump

226321451283822009-10

205716915221722008-09

187013702175492007-08

170011623164682006-07

PE Pipe Submersible Pump

PVC Pipe

Suction &

Delivery

Production

Year

Power saved is eqv. to 7 plants of 500 MW in 2006-07


Energy saving – because of lack of incrustation

31057.037013.915050

15835.819013.915020

11229.4610013.915015

7824.6911013.915010

7524.2811113.91509

7223.8811213.91508

6923.4911313.91507

6623.1111413.91506

6422.7411513.91505

6122.3811613.91504

5822.0311713.91503

5621.6811813.91502

5421.3511913.91501

5121.0212013.91500

%Power HPC factorHPC factor

byPump W.HazenPump W.Haze

n

MoreSteelPlasticYEAR

POLYMER Vs STEEL

HP REQUIRED Vs PERIOD

YEARS

0

10

20

30

40

50

60

0 2 4 6 8 10 20

PERIO D - YEARS

HO RSE

POWE

R

Steel – Pumping cost increases

with age

� AMC has 5 French Wells having pumps which draw on an average

800,000 gallons of water per hour.

� MS pipes which were used in these wells, were causing frictional loss

as well as less draw of water.

� AMC replaced 8” MS pipes in one of the wells with 10” PVC pipes.

� Flow rate increased from 370 cu mtr / hr to 540 cu mtr / hr.

� AMC decided to replace 8” MS pipes in balance 4 wells with 10” PVC

pipes.

� Result = Saving of 1.7 million kwh of electricity per year, reducing

electricity charges by about Rs. 4.5 million.

Source : AMC Report

Ahmedabad Municipal Corporation : Case Study

……..plastic pipes save pumping energy..plastic pipes save pumping energy

Energy savings (uPVC) Windows vs. Aluminum Windows)

PVC window

Al window

Leads to energy saving in Air Conditioned/Cooled

spaces- recommended for usage in ECBC 2007

IIT Delhi (PVC Windows)

Floor area – 1000 Sq.ft. & window area – 300 Sq.ft.

Initial Cost : Conventional Window- 175/Sq.ft.

PVC double glazed Rs 235/ Sq.ft.

Increase in initial cost Rs.18,000/-

Power saving / annum by using PVC windows in place of Al – 4,369 units

Total power savings - Rs 15,292 / annum

……PVC profiles & Windows cut AirPVC profiles & Windows cut Air--conditioning costconditioning cost

Case Study-Energy saving by using uPVC window

India- Potential to Reduce GHG emission by using PVC Windows

……A potential CDM program for India!A potential CDM program for India!

1.12 billion

0.336 billion

0.1344 billion

0.01344 billion

0.00224 billion

6048000 MWh/annum

241920 MWh/annum

0.484 MMT/annum Carbon Dioxide(Green House Gas) reduction

No. of families(assumption 6 persons/family)

Electricity consumed ( assumtion 225 unit every

month/family)

Savings of energy 10% of 40%* by using uPVC

Windows

10% people of C would be using Air Condition/Cooling

Total Population (A)

30% of A is Urban Population(B)

Less 60% of B(rural & small towns) (C)

* Assuming 40 % for Air Conditioning

Sustainability of Plastics – Comparison with other Materials

Assumptions : All energy from Petrol ; Petrol Energy : 46MJ/Kg ; Not counting Installation Energy

65.221.531.420.726.820.8CO

2emitted

(Kg)

21.77.210.56.98.96.9

Oil Consumption (Kg)

1000330481.4318410319Energy (MJ/m)

40335.84.45.45.7Weight of Pipe (Kg/m)

251083737656

Material Energy (MJ/Kg)

Ductile IronClayPETPP

HDPEPVC

Embodied Energy- Energy For Making The Raw Material

0 2 4 6 8 10 12 14 16

Kilograms oil-equivalent / liter of raw material

Plastics

Steel

Zinc

Copper

Aluminium

Demand of energy for production of raw materials

Very Low for Plastics……

Energy Requirement In Product Manufacturing Phase eg. Pipe

19.7

10

6

3.5

0

5

10

15

20

CI GI RCC PVC

Energy requirement to make 1 km of 110 mm dia. Pipe ( MT of oil equivalent)

Very Low for Products Made from Plastics……

Energy Consumed During Transportation eg. Pipe

Plastic PIPE GI PIPE CI PIPE RCC PIPE0

5

10

15

20

25

3027

15

10

1.7

The use of PVC in transportation market saves an estimated

• 10 trillion BTUs per year, equivalent to

• 1.7 Million barrels of oil

• 10 billion cubic feet of natural gas (Source : Vinyl Institute, USA)

Approx. Weight

in Kg of 1 mtr

pipe of 110 mm

dia.

Plastics are Light Weight - Savings in Transportation cost, Installation costs,

Manpower costs

Energy Saved During Usage Phase eg. Pipe

120

100

130

140

80

60

115

150

0

50

100

150

Plastic Steel Cast Iron Asbestos Cement

Ha

ze

n-W

illi

am

s c

oe

ffic

ien

t -

'C'

New 20 years old

Lower Pumping power requirement with Plastics Pipes …..

Energy Required To Transport 350Mt Of Commodities in Jute – Paper – Plastic Sacks

Additional Trips Required To Transport 350Mt Of Commodities

Excess Fuel Required To Transport 350Mt Of Commodities

Energy Required For Pumping Of Water Through Plastic And Metal Pipes

4” DI Vs PVC pipe for domestic water conveyance

� Energy consumed in KW for discharge of same volume of water/day

� DI pipe : 6.5 KW

� PVC pipe : 4.5 KW

� Saving - over 30%

Case 1

Case 2

Energy Savings By Plastics - Small Industries … of Pipe (Kg/m) 56 76 73 83 10 25 Material Energy (MJ/Kg) Ductile PP PET Clay Iron HDP PVC E Embodied Energy-Energy For Making The

Documents