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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
Bn Kcal 4484913 5232 Million MWH
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
Bn Kcal 199906 233 Million MWH
PE V/s CI M Kcal 67657824
Bn Kcal 67658 79 Million MWH
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
.....Plastics reliable solution for Health, Hygiene & energy savings
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
.....Plastics reliable solution for Health, Hygiene & energy savings
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
.....Plastics reliable solution for Health, Hygiene & energy savings
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
.....Plastics reliable solution for Health, Hygiene & energy savings
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 …..
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