DM make up water reduction in thermal power plants using Six Sigma DMAIC methodology

Abstract

Six Sigma DMAIC (define, measure, analysis, improve, control) methodology has been applied to a process industry seeking energy conservation, taking a specific case of a thermal power plant. DM (De-mineralize) water in these plants is an expensive input material. It has been found that 0.1% increase in DM make up water consumption increases generation cost by Rs 82.82 lakhs per annum. In present study, implementation of Six Sigma project recommendations brought down mean make up water from 0.90% to 0.54% of MCR (Maximum Continuous Rating), accruing with it a comprehensive energy savings of nearly Rs 304.77 lakhs per annum.