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    Energy Energy Energy

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    Mohankumar Raja
    This document discusses various ways to improve energy efficiency in industrial processes. It describes how energy is a key variable cost and outlines common reasons for accepting energy waste like lack of awareness and accountability. It then provides recommendations for improving efficiency in motors, boilers, furnaces, steam systems, air compressors, cooling towers, chillers and through other miscellaneous measures like variable frequency drives and reducing excess lighting. The overall goal is to reduce costs by minimizing energy usage through optimization and waste reduction.

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    © All Rights Reserved
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    Energy Energy Energy

    Uploaded by

    Mohankumar Raja
    49 views17 pages
    This document discusses various ways to improve energy efficiency in industrial processes. It describes how energy is a key variable cost and outlines common reasons for accepting energy waste like lack of awareness and accountability. It then provides recommendations for improving efficiency in motors, boilers, furnaces, steam systems, air compressors, cooling towers, chillers and through other miscellaneous measures like variable frequency drives and reducing excess lighting. The overall goal is to reduce costs by minimizing energy usage through optimization and waste reduction.

    Original Description:

    Energy saving tips for manufacturing Industries

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    This document discusses various ways to improve energy efficiency in industrial processes. It describes how energy is a key variable cost and outlines common reasons for accepting energy waste like lack of awareness and accountability. It then provides recommendations for improving efficiency in motors, boilers, furnaces, steam systems, air compressors, cooling towers, chillers and through other miscellaneous measures like variable frequency drives and reducing excess lighting. The overall goal is to reduce costs by minimizing energy usage through optimization and waste reduction.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    49 views17 pages

    Energy Energy Energy

    Uploaded by

    Mohankumar Raja
    This document discusses various ways to improve energy efficiency in industrial processes. It describes how energy is a key variable cost and outlines common reasons for accepting energy waste like lack of awareness and accountability. It then provides recommendations for improving efficiency in motors, boilers, furnaces, steam systems, air compressors, cooling towers, chillers and through other miscellaneous measures like variable frequency drives and reducing excess lighting. The overall goal is to reduce costs by minimizing energy usage through optimization and waste reduction.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 17

    ENERGY, ENERGY &

    ENERGY
    27-JUL-14

    Why Energy is Important ?


    Profit = Net Selling Price ( RM Cost+VC+FC)
    Elements of Variable Cost :
    Energy

    Power
    Steam
    Air
    Nitrogen
    Water
    Others

    Packing
    Stores & Spare
    Consumables & other chemicals

    Note : Effect of Waste/OG will be loaded


    in VC

    Why Do We Accept Energy


    Waste?

    Lack of awareness.

    Energy users never see the utility bills


    Dont realize the range of solutions

    Lack of accountability.
    Cost accrue to Dept A, savings to Dept B
    Management turnover, short tenure
    Not part of traditional job descriptions

    Fear.
    Were already as efficient as we can be
    Thats the way weve always done it.

    Sequence

    Energy Efficiency in :
    1.
    2.
    3.
    4.
    5.
    6.
    7.
    8.

    Motors
    Boiler
    Furnace
    Steam
    Air Compressors
    Cooling Towers
    Chillers
    Miscellaneous

    Specific Consumption

    Need of the Hour

    Energy Efficiency in Motors

    Energy Efficient Motors:


    Scope to improve 4 to 5 %

    Reduce Under loading


    60 to 70% optimum
    Otherwise loss will be higher; PF and efficiency will be lower

    Size to Variable Load


    To be slightly lower than the Highest Load

    Rewinding

    Use Qualified Vendor


    Maintain Original motor design
    Replace 40 HP > 15 Yrs Service
    Not worth rewinding more than twice.
    Coil to coil resistance shall not vary > 0.3 Ohms
    If rewinding is not OK, efficiency can be less by 3 to 5 %

    Energy Efficiency in Motors

    Improve Power Quality


    Voltage shall not vary
    Effect of Unbalance voltage :l
    Example 1

    Example 2

    Example 3

    Voltage unbalance (%)

    0.30

    2.30

    5.40

    Unbalance in current (%)

    0.4

    17.7

    40.0

    30

    40

    Temperature increase (oC)

    Power Factor Correction :


    Maintain Power Factor 0.9 or above
    Introduce Capacitors

    Improve Maintenance :
    Lubrication / Alignment / Dust
    Fan Cooling, Terminals

    Energy Efficiency in Boilers

    Stack Temp. Control


    Keep as low as possible.
    If > 200 Deg C, go for Heat Recovery

    Feed Water Preheating Economizers


    Recover heat from Flue Gas of 200 300 Deg C

    Combustion Air Preheating


    1% improvement in thermal efficiency for every 20 Deg C rise in
    Combustion Air.

    Minimise incomplete Combustion :


    Causes :Air shortage, Fuel Surplus, poor fuel distribution, poor Mixing

    Avoid Excess Air:


    1% Excess air decreases 0.6% Efficiency

    Energy Efficiency in Boilers


    Radiation/Convection Heat Loss Minimisation
    Improve Insulation in Exhaust

    Variable Speed Drives


    Introduce VFD for Fans, Blowers & Pumps, if loads are variable

    Scaling & Soot Loss Reduction


    1% efficiency reduction per 22Deg C increase in Stack temp.
    2.5% fuel increase per 3 mm soot

    Control Boiler Loading


    Max Efficiency of Boiler at 65 85% loading
    Poor efficiency at loads < 25%

    Energy Efficiency of Furnaces


    1. Complete combustion with minimum excess air
    2. Proper heat distribution
    3. Operation at the optimum furnace temperature
    4. Reducing heat losses from furnace openings
    5. Maintaining correct amount of furnace draft
    6. Optimum capacity utilization
    7. Waste heat recovery from the flue gases
    8. Minimize furnace skin losses
    9. Use of ceramic coatings
    10.Selecting the right refractories

    Energy Efficiency of Steam System


    Manage Steam Traps
    Visual, Sound, Temp,. Of discharge line
    Routine Maintenance
    Replacement of Internal Parts

    Eliminate Steam Leaks


    Repair/ Regular leak detection
    To the extent possible go for Welded Joints

    Dry Steam for Process


    Wet steam reduces total heat content and prevents heat transfer
    Improve Insulation
    Provide Steam Separators

    Energy Efficiency of Steam System

    Minimise/Avoid Water hammer


    Banging Noise by colliding condensate
    Sources: low points in the Pipe Work
    Solutions:
    Steam lines with gradual fall in flow direction
    Drain points at regular intervals
    Avoid sudden openings of Condensates

    Insulation
    Improve Condensate Recovery
    Saving Treated Water Cost
    Saving Energy
    1% fuel saving per 6 Deg C increase in the feed water

    Recover Flash steam


    Reuse Low Pressure Steam

    Energy Efficiency in Air Compressors

    Location of the Compressor


    Higher the altitude lower the volumetric efficiency

    Intake air to be free from Contaminants, Dust or Moist

    Keep intake temp. lower


    1% higher energy for every 5 Deg C rise in Tinlet

    Keep DP across inlet Pressure Minimum


    2% higher energy for every 250 mm WC DP

    Use Inter/After Coolers

    Eliminate Leakages
    Leak thro 1 mm hole @ 7 Bar pressure is equivalent to 0.5 kW loss

    Energy Efficiency in Air Compressors

    Pressure Settings
    High Pr : More Power , Lower Vol. Efficiency & Excessive Wear
    Reduce Delivery Pressure, Reduction by 1 Bar wil reduce Power by 9%
    Design for minimum DP in distributing lines
    Optimum Pipe Size and bends
    Ensure no corrosion
    Keep Filters Clean

    Condensate Removal
    Good Maintenance
    Regular Lubrication
    Clean/Replace Air filters
    Check Condensate traps
    Clean After Coolers periodically

    Energy Efficiency in Cooling Towers


    Proper Selection of Fills
    Proper Material, Surface Area, Contact time

    CT Fans
    Replacing metallic fans by FRP fans save 20 30% power
    Blades with aerodynamic profile with optimum twist, taper..

    Pumps and Water Distribution


    Using drift eliminators brings down the loss from 0.02% to only
    0.003 0.001%
    Optimise Cooling water treatment
    Clean the Spray Nozzles periodically

    Energy Efficiency in Chillers


    Let Condenser water inlet temp be as minimum as
    designed
    5.5 Deg C reduction will result in 20% Compressor power saving

    Proper Insulation of Chilled water storage tank


    Clean the Condenser periodically
    1 mm scaling will increase energy by 40%

    Miscellaneous

    Variable Frequency Drives


    Soft Starters to reduce high starting current
    Avoid Excessive lighting
    Upgrade obsolete fluorescent systems to compact fluorescents
    and electronic ballasts
    Consider daylighting, skylights, etc.
    Consider painting the walls a lighter color and using less
    lighting fixtures or lower wattages
    Make sure that all of the utilities to redundant areas are turned
    off-including utilities like compressed air and cooling water
    Provide restriction orifices in purges (nitrogen, steam, etc.)

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