01 Technical Session One

FIRST INDIA INTERNATIONAL ENERGY SUMMIT-2011

1 Energy Conservation & Management




ENERGY CONSERVATION & MANAGEMENT

TECHNICAL SESSION I



• • • CONTENT • • • TECHNICAL SESSION I

1. Energy Conservation, Universities and Carbon Footprint 5

Mr. Biswas, Mr. Gautam, Mr. Maheshwar, Ms. Shabana

2. Energy conservation opportunities in pasteurization process of milk in Dairies 13

Mr. Amit Kumar Mandal.

3. Energy Conservation, Conversion and Management 16

Ms. Amrit Pal Kaur

4. Energy Audit And Waste Heat Recovery Opportunities In Shree Cements Ltd, Beawar 27

Mr. P.C. Tiwari

5. Energy Efficient Approach for Alkyd Resin Manufacturing 35

Mr. Ranjeet Neve, Mr. Aniket Bodale, Mr. B.B. Gogte, A. Sachin

6. Energy Conservation Opportunities In Pharmaceutical Plant Air Conditionign 41

Prof. D.K. Joshi

7. Free Cooling As Energy Conservation Measure 46

Er. Balbir Singh, Er. V.K. Sethi

8. Feasibility Study Of Installation of VFD For Id Fans In Thermal Power Plant 53

Mr. Santosh Mahadeo Mestry

9. Industrial Economics 61

Mr. L. Manickavasagam

10. Domestic (Human factors) 64

Mr. Arunachalam Pillai. A

11. Design and Development of 100 kWp Stand Alone Photo Voltaic Power Plant 66

Ms. Madhu Sharma, Dr. S.J. Chopra, Dr. S.P. Singh, Dr. R.N. Singh

12. Eco At Gail , Vijaipur Township, Guna 84

Amita Tripathy



13. Power Optimization In Refrigeration Air Conditioning 109

Mrs. Snehlata Soni, Dr. G.S. Sharma, Brijesh Sharma

14. R&D Innovations towards Energy Efficiency in SAIL 118

Suresh Prasad, P. Kumar, M Sen, T S Reddy and D Mukerjee



Energy Conservation, Universities and Carbon Footprint Biswas, Gautam, Maheshwar, Shabana

Amrita School of Business, Amritapuri, Kerala

Introduction

As of 2009, India has 20 central universities, 215 state universities, 100 deemed universities, 5 institutions

established and functioning under the State Act, and 13 institutes which are of national importance.1 There are

16885 colleges with 99.54 lakh students and 4.57 lakh teachers.2 In a country like India where there are so many

students, and teachers, it is essential that the future citizens of this planet receive adequate information and

resources to ensure that they live with the limited resources and explore for better means of utilization to meet

the needs. The practices have to be planted into this generation, so that they carry it over to the work places and

eventually across the whole planet.In view of the deteriorating status of the environment, the Supreme Court has

recognized the need for basic knowledge about the environment among the youth population. Under the

direction of the Honorable Supreme court, UGC has made it mandatory that all University/colleges in India

should have a core course in Environmental studies3. This is a welcome move, as knowledge about the

deteriorating environment will induce a need for its protection among the youth. Broad and deep understandings

of the ways and means to deal with environmental issues have to be addressed and practiced from the

universities, where they can learn the best. Resources are limited and the needs are growing, a fact to be

admitted. The future generation has to deal with the limited energy resources unless a suitable substitute is

found. It has to be understood and accepted that reducing the needs or smarter utilization of resources will help

in reducing the demand for growing energy needs. Implementation and propagating the practices of smart

utilization in universities result in a better environment and also help the future citizens to live better.

Carbon footprint- A brief insight

This paper gives a brief idea for the smart utilization of energy, emphasizing on the carbon footprint produced

by each university. A carbon footprint is "the total set of greenhouse gases (GHG) emissions caused by an

organization, event, product or person".4 The carbon footprint is not only a direct indicator to the amount of

pollution that is being spewed into the planet, but also and indirect indicator of the amount of energy that is

being consumed. This can serve as an effective yard stick for universities to gauge their consumption of energy

and accordingly reduce it. There are two ways to measure the carbon footprint. One is the bottom-up approach

1http://en.wikipedia.org/wiki/Education_in_India#cite_ref-I09RA-237_43-1 2http://www.education.nic.in/higedu.asp 3http://www.nlsenlaw.org/resources/ugc-formulates-new-course-on-environmental-studies 4,4Wiedmann, T. and Minx, J. (2008). A Definition of 'Carbon Footprint': In: C. C. Pertsova, Ecological Economics Research Trends: Chapter 1, pp. 1-11, Nova Science Publishers, Hauppauge NY, USA. https://www.novapublishers.com/catalog/product_info.php?products_id=5999.



or Process Analysis (PA); the other is the top-down approach or Environmental Input-Output analysis (EIO).5

The detailed methodology to calculate the carbon footprint is beyond the scope of this paper. There are many

online tools that help in this calculation. But, it is essential for universities to know their carbon footprint for

them to set targets that can be achieved by significantly reducing them, thereby reducing the energy

requirements.

Buildings and Carbon footprint:

With an average area ranging from 4000sqm to 29212120sqm, every university has separate departments,

different buildings that come up to almost an average30% of the area.6 Though carbon emission and buildings

might seem unrelated in the first look, a detailed insight will show us that they are actually very closely related.

American Institute of Architects (AIA) National Government Advocacy Team has pointed out: “the largest

source of greenhouse gas emissions and energy consumption in America, as well as around the world, is

buildings. Buildings account for an estimated 48% of all greenhouse emissions (in fact buildings consume more

than 40% of all the energy produced in the world!)7

The term “CO2 emissions from buildings” is a misnomer as it is not directly like CO2 from vehicles. But they

are responsible as the power plants that provide the electricity to run these buildings produce for tonesof CO2.

That’s where most of the CO2 emissions attributed to buildings are coming from.

6www.amrita.edu/about/infrastructure.php .The percentage is calculated on the basis of area of campus to buildings ratio of Amrita Vishwa Vidyapeetham. 7http://www.treehugger.com/files/2006/05/buildings_accou_1.php



The main difference between CFC’s and CO2 is that the people would not feel that they are contributing

something to CO2 emission while using electricity. But at the same time while using a refrigerator they know

that this would produce CFC’s.

In the life time of an average building most energy is consumed, not for construction, but during the period

when the building is in use. Typically more than 80% of the total energy consumption takes place during the use

of buildings and less than 20% during construction of the same. A building needs a lot of energy to keep its

occupants safe, comfortable and productive. It has to keep warm in the winter and cool in the summer, provide

lighting, power security systems and heat water, among many other things That is, the energy used for heating,

cooling, lighting, cooking, ventilation and so on.

Significant gains can be made in efforts to combat global warming by reducing energy use and improving

energy efficiency in buildings. The right mix of appropriate government regulation, greater use of energy saving

technologies and behavioral change cansubstantially reduce carbon dioxide (CO2) emissions from the building

sector, says the report from the United Nations Environment Program (UNEP) Sustainable Construction and

Building Initiative (SBCI)8.

Government regulations

Many countries have developed their own standards for green building or energy efficiency for buildings. In

India we have Indian Green Building council (IGBC) or GRIHA(Green Rating for Integrated Habitat

Assessment)9.

GRIHA attempts to minimize a building’s resource

consumption, waste generation, and overall ecological

impact to within certain nationally acceptable limits /

benchmarks. Along with that they quantify the aspects

like energy consumption, waste generation, renewable

energy adoption, etc.

GRIHA has also a rating tool that helps people assess the

performance of their building. It will evaluate the

environmental performance of a building holistically over

its entire life cycle to provide definitive standards for a

‘green building’. The rating system, based on accepted energy and environmental principles, will seek to strike a

balance between the established practices and emerging concepts, both national and international.

For a free and democratic country like India we cannot impose regulations forcefully as it may put a large part

of the population in difficulty, especially those who are financially backward. But for universities it would not 8http://www.unep.org/Documents.Multilingual/Default.asp?DocumentID=502&ArticleID=5545&l=en 9 http://www.sustainable-buildings.org/index.php?option=com_cstudy#featured

‘Suzlon One Earth’- Suzlon group global headquarter based at Pune. It received provisional Five Star Rating under GRIHA green building rating system



be a problem if it is made mandatory. So governments can lead the way by providing a ratings and recognitions

for green buildings and make green buildings for all government related buildings. Government can also go for

a tax exemption to promote green buildings.

Greater use of energy saving technologies

Thermal insulation, solar shading and more efficient lighting and electrical appliances, as well as the educational

and awareness campaigns should be welcomed for this. Simple solutions can include sun shading and natural

ventilation, improved insulation of the building envelope, use of recycled building materials, adoption of the

size and form of the building to its intended use etc. Of course we can achieve even better result ifwe go for

more sustainable construction system solutions, like intelligent lighting and ventilation systems, energy pricing

and financial incentives that encourage reduction in energy consumption. It also emphasizes that the building

sector stakeholders themselves, including investors, architects, property developers, construction companies,

tenants, etc. need to understand and support, such policies in order for them to function effectively.

Carbon Neutral Buildings

In 2006 the US Conference of Mayors proposed a Resolution which sets a goal for carbon neutral buildings by

203010. Opportunities exist for governments, industry and consumers to take appropriate actions during the life

span of buildings that will help mitigate the impacts of global warming.

How does a building becomes carbon neutral?

New green building products and procedures enable us to utilize natural resources and provide power and

heating to buildings. By using green building technologies we can reduce your carbon footprint and along with

energy-efficient products we can make our scheme or building Carbon Neutral.

Green Building Design ranges from the siting and orientation for passive solar gain to the building form and

external environment. Important considerations for any build are crucial when determining green building

design. The concept of living in a low carbon or carbon neutral house was once thought to be costly and

impractical, especially in the colder climates of the world. However with new green building design and

breakthroughs in sustainable living this conception can now be realized through Carbon Neutral Building.

This is the green Lighthouse which is the first CO2 neutral public

building in Denmark. It demonstrates that sustainable design is not a

question of stuffing the building with brazen, expensive high-tech

gadgets, but that it starts with good old fashioned common sense. In



fact, 75% of the reduction of the energy consumption is the direct consequence of architectural design11

Only form Europe, more than one-fifth of present energy consumption and up to 45 million tons of CO2 per

year could be saved by 2010 by applying more green standards to new and existing buildings. (According to

UNEP’s buildings and climate change, Status, Challenges and Opportunities report, 2007)Along with cleaner

and renewable forms of energy generation, the energy efficiency is one of the key factors that determine the

emission of the CO2. The savings that can be made right now are potentially huge and the costs to implement

them relatively low if sufficient numbers of governments, industries, businesses and consumers act.

By investing in energy efficiency in buildings, it not only reducing CO2 emission, but better life, wealth and in

fact more jobs!! The WWF estimates that 280,000-450,000 jobs can be created in the building sector alone by

2020, just by making our existing building stock more energy efficient and by constructing new buildings

according to the best available technologies12.

According to architecture2030.org, by 2035 approximately 75% of the Built Environment Will be Either New or

Renovated.

11 http://karmatrendz.wordpress.com/2010/01/03/green-lighthouse-carbon-neutral-faculty-building-by-christensen-co-arkitekter/

12http://wwf.panda.org/wwf_news/?167022/Going-green-is-where-the-jobs-are-new-study



Green buildings in India

In India the Energy and Resource Institute plays a very important role in developing green building capacities in

the country. The government has recently adopted the rating system of TERI called GRIHA as the National

Green Building Rating System for the country. It aims at ensuring that all kinds of buildings become green

buildings.

THE CESE building in IIT Kanpur became the first GRIHA rated building in the country and it scored 5 stars,

highest in GRIHA under the system13.

It has become a model for green buildings in the country. It has proved that with little extra investment,

tremendous energy and water savings are possible. There are various projects which are the first of their kinds to

attempt for green building ratings like apartment residential buildings and non-air conditioned buildings.

We can say that though the numbers of Green buildings are less in India the awareness is increasing. People are

slowly recognizing the need and necessity of green buildings. According to Biodiversity Conservation [India]

Limited (BCIL), a green home can reduce the energy demand load by 45 per cent, water consumption by 75 per

cent and CO2 emissions by 22,000 tons annually — as compared with a conventional home. The partial lists of

green buildings are listed in Wikipedia (http://en.wikipedia.org/wiki/List_of _energy _efficient _buildings_ in_

India)

More on reducing Carbon footprint

Apart from the buildings, other measures can also be adopted to reduce the carbon footprint.

Recycling:

There are many items used at a university that can be recycled. Papers, plastics and cardboard boxes are items

that are most frequently used at a university and are then thrown out. Collecting these items and reusing or

recycling them will help reduce so much of wastage and can bring down the carbon footprint of the university to

a very low level. Cardboard boxes can be reused for storage, one-sided assignment papers can be used as

scrapbooks or for rough work. Most common plastics seen around college campuses are the soft drink bottles,

plastic covers and other packing material. Aluminum cans also contribute to the waste heap. All this can be

collected to be given away to recycling units. Conducting a recycling drive inside the campus will increase the

sense of awareness and also gives an opportunity to students to perform their bit of service to Mother Earth.

Amrita Vishwa Vidyapeetham has set up a system of recycling where every student separates their own waste in

to organic and non-organic. The recyclable materials are dealt with separately. At the Ecological department of

the Mata Amritanandamayi Math, recyclables like soft plastic bags, potato chip covers etc. are converted into

13 http://en.wikipedia.org/wiki/Green_building_in_India



useful items like Shopping bags, purses and pouches. Bio degradable substances are converted into compost

which is used to manure vegetable gardens. Efforts are made to create a closed loop system in the campus

Transportation:

For large campuses, commuting between locations inside the campuses becomes a major source of carbon

emission. Using energy saving vehicles like bicycles will help reduce the pollution inside the campus.

Encourage walking for better health and better environment. Other vehicles should be strictly banned inside the

campus.

Lighting:

Students and staff need to be encouraged to use lesser lights when there’s ample daylight available. It is the

easiest way to save electricity. Classrooms need to be designed in a way that they let in enough daylight and

wind in to save costs on lighting, fans or air-conditioning. Students need to be encouraged to switch off lights

that are not needed in their hostel rooms Timers could be built into the switchboards to ensure that there is no

light left on after class hours. Also CFLs are a good way of reducing electricity wastage as they use less energy.

Alternate Sources of Energy:

Universities like the Arizona State University, USA, have started using this alternate source of energy which is

easy to procure14. Entire college roofs can be converted into a power station by installing solar panels on every

available space. This will give energy enough for many computers and devices to function, helping in reducing

the carbon footprint and consumption of energy by significant levels. Also campuses can also exploit the wind

energy to generate energy if applicable.

Energy saving devices:

Use energy saving devices in office and hostel. When purchasing electronic devices (like checkingtheir

Renewable Energy certificates15) certifications help in conserving energy.

Save water:

Reduce wastage of water. People need to be encouraged to develop water and energy saving habits like reducing

use of hot water for washing and bathing, not letting the water run free when you are brushing, shaving etc.

Some major universities have waste water treatment plants. The water treated from these plants is used for

watering gardens.

14http://www.upi.com/Science_News/2008/06/10/ASU-boosts-solar-power-on-campus/UPI-82991213153860/ 15http://www.epa.gov/greenpower/gpmarket/rec.htm



Avoid ornamental gardening:

Many universities are of the habit of making huge ornamental gardens and lawns with exotic plants that

consume so much water and need constant care. Using native plants in gardening can significantly reduce the

usage of large amounts of water and other gardening chemicals like fertilizers. Turf grass, the most commonly

used groundcover requires much effort and energy constantly to be grown well. While native plants require only

the initial costs of establishment. Most native plants use less water because they are adapted to the rainfall in the

area. Growing herbal gardens in the campus increases the air quality of the area and helps absorb carbon

emissions.

Paperless campus:

The greatest source of paper wastage in campuses comes from assignments, exams and records made in paper.

The energy wastage that happens when all this paper is thrown away after use is enormous. One way to prevent

this wastage is to recycle the paper. Or better even, reduce the use of paper. Many universities, like

AmritaVishwa Vidyapeetham’s Amrita University Management System (AUMS)16, now have their own intranet

or other licensed software that helps in keepingrecords from the office or library and helps in faculty to student

online communication. This can be taken into advantage and the whole system can be converted into an online

mode. Exams, assignments can be conducted online. Also, all records can be kept electronically, preventing so

much of wastage and thereby reducing carbon footprint.

Organic Food:

A large amount of energy goes into the preparation of food and the same is wasted when food is wasted in large

amounts as is common in some universities. This wastage must be curbed. Educating the need for conservation

of energy by reducing the wastage of food and using the waste materials for making compost, which can be

recycled as manure, will help in energy conservation and reducing carbon footprint. Universities can grow the

vegetables that they need in the campuses with the help of students. This is a great opportunity for students and

staff to come together and interact. This also gives them a sense of being part of the greater energy conservation

movement. Student organic farms can be developed. The experience will stay with the students even when they

move out of campus. Amrita Sanjeevani, the seva association, at the Amrita Vishwa Vidyapeetham thrusts on

students’ responsibility to the nature.17

Planting trees:

Planting trees in the campus is always a fun way of being part of the energy conservation movement. Trees are

an amazing way to purify air and refresh the ambience. Tree planting drives bring together students. Campuses

such as the IIMs and the IISC are known for their greenery.

16http://www.amritatech.com/amritavidya.htm 17http://www.amrita.ac.in/amritasanjeevani/



Energy conservation opportunities in pasteurization process of milk in

Dairies

Amit Kumar Mandal [email protected]

Abstract

In dairy industries , milk is to be pasteurized by heating it to a temperature around 78ºC and than keeping the

milk for 15ºC and than sudden cooling it to a temperature of 6ºC. Thus , this process ensure killing of the

microorganisms which are harmful for human health and the milk can be kept for a long time by refrigeration .

The actual killing of the microorganisms takes place in the heating process of the milk . The time taken for

cooling of milk in case milk is not exposed to surroundings after heating , do not have so much impact on the

quality of the pasteurization .Generally , for pasteurization , milk is first heated through an heat exchanger ,

passed through a milk holder so that it can take 15 seconds to pass and to retain the hot temperature for 15

seconds . After milk holder , the hot milk is directly cooled to 6ºC by an another heat exchanger . There is a

potential saving of heat by regeneration of the hot milk coming out of the heat exchanger and the cold milk

entering inside the hot heat exchanger .

Keywords – Pasteurization of milk , hot heat exchanger , cold heat exchanger, regeneration of heat .

Pasteurization process in milk industry

Milk coming from the milk silos or the day tanks is sent to a hot plate type heat exchanger. The temperature of

entrance of the milk is 5-6 ºC. The milk is brought to temperature of around 80 ºC( for example 78 ºC in a

typical industry in Jaipur dairy, Rajasthan , India). The milk as soon as been reached to desired hot temperature

is been sent to a milk holder . The milk holder is a long duct coiled in shape , makes the milk to pass through it

in 15 -16 seconds . In this period almost all harmful bacteria’s are been killed . After passing through milk

holder the milk is directly cooled in an another plate type heat exchanger in which the heat conveying fluid is

chilled water . Thus there is potential saving of heat and refrigeration load by refrigeration of heat by the

incoming fluid at 6 ºC and the milk coming out from the milk holder . For heat transfer , a plate type heat

exchanger can be used .

Method

The circuit diagram of the existing method of pasteurization in most of dairy industry is given in fig 1 , similarly

the improved method of pasteurization for energy conservation is given in fig 2 . We can observe



in fig 1 that milk is coming at 6 ºC and heating to temperature of 80 ºC in hot heat exchanger . After passing

through hot heat exchanger , the milk is passed through a milk holder where it takes the milk to pass out in 15

seconds at 80ºC . The milk is than passed through a cold heat exchanger where it is again brought to 6ºC.In fig 2

, the hot milk coming out from the milk holder is been sent to a heat exchanger for regeneration . The incoming

milk at 6 ºC is been passed through regenerative heat exchanger as a cold fluid in . Similarly the hot milk

coming out from the milk holder is going inside the regenerative heat exchanger as a hot fluid in . The cold fluid

comes out by recovering the heat of hot milk coming out from the milk holder . The hot milk of the milk holder

also becomes cool by this process .The base of doing such arrangement is pasteurization is process of heating

the milk above 80ºC and keeping it for sufficient time so that the cell wall of the bacteria rupture and been

killed . Once the bacteria’s are been killed ,the milk can be kept refrigerated for long time without any harm . In

dairy processes , the milk is heated in heat exchanger and it is not exposed to atmosphere anywhere after heating

it . Thus the regenerative process can work out and an huge amount of energy can be saved .

fig (1)

Fig (2) Observation and measurement



In a typical dairy in India, it is found that milk flow rate of 8.2 ltr/sec is to be pasteurized .The processing is

done almost 24 hrs/day . Since the milk coming from the inner silo is at 6ºC to hot heat exchanger . So after

coming out from the hot heat exchanger , the milk at 80 ºC can be passed through an regenerator which heats up

the cold milk of silo reducing the hot heat exchanger duty , similarly the milk of 80 ºC will becomes cooler

after coming out from the regenerator reducing the cold heat exchanger duty .In case the milk is brought to

temperature of 40ºC in regenerator and the cold milk of silo is also brought to 40 ºC in regenerator than :-

Heat saving = 8.2×4.2 ×(40-6)=1170KW

=879223Kg FO/yr=21980575rs/yr

Similarly refrigeration saving

= 8.2×4.2 ×(40-6)=1377.6KW

Taking COP= 2.5

Electrical power consumption = 550KW (Electricity cost – INR 4.51/KWH)

Thus saving of 21729180 INR /yr is there .In case we save the half of the above calculated amount , still a

significant energy and monitory saving is there .

Results

There is a potential saving of heat and refrigeration load . As calculated above for 8.2kg/sec mass flow the

saving in a typical dairy industry may be 21729180 INR /yr running 24 hrs/day .

Conclusions

The process of regeneration can prove a great saving of energy as well as carbon emission to the environment

.The investment as compared to the benefits is quite less comparatively .

References

• www.foodscience.uoguelph.ca/dairyedu/pasteurization.html,

• http://books.google.co.in/books?id=6ROLbW8klRsC&pg=PA196&lpg=PA196&dq=regeneration+in+pasteurizati

on&source=bl&ots=17aaGQrPv&sig=yKf4sUJsmVnNkGEmIk8xT3l4BYs&hl=en&ei=H6gITbnPDJDNrQeeqsn

VDg&sa=X&oi=book_result&ct=result&resnum=9&ved=0CE0Q6AEwCA#v=onepage&q=regeneration%20in%

20pasteurization&f=false,

• http://www.medindia.net/patients/patientinfo/pasteurizationofmilk_htst.htm,

• http://www.wikipatents.com/US-Patent-5266343/pasteurization-process-for-dairy-products



Energy Conservation, Conversion and Management

The future 5: savior of energies

Ms. Amrit Pal Kaur [email protected]

Abstract

Energy is one of the major inputs for the economic development of any country. In case of the developing

countries the energy sector assumes a critical importance in view of the ever increasing energy needs requiring

huge investments to meet them. also another major concern of the time is the ever increasing global warming

and its effects. Now is the time to raise alarms and work towards a better future.

This can be achieved by the following five energy technologies.

HVAC:

The goal for a Heating, Ventilation and Air Conditioning (HVAC) system is to provide proper air flow, heating,

and cooling .The HVAC considers all the interrelated building systems while addressing indoor air quality,

energy consumption, and environmental benefit.

Cogeneration:

Cogeneration (also combined heat and power, CHP) is the use of a heat engine or a power station to

simultaneously generate both electricity and useful heat.

Cogeneration is a thermodynamically efficient use of fuel.

Fusion Energy

Fusion produces no greenhouse gas emissions. Fusion is suitable for the large-scale electricity production

required for the increasing energy needs of large cities. A single fusion power station could generate electricity

for two million households.

Carbon Capture And Storage:

This technology is the best solution to the rising earth’s temperature.

CO2 storage is simply the process of taking captured CO2 and then placing in a location where it will not be in

contact with the atmosphere for thousands of years.



Plastic Solar Cell:

The plastic material uses nanotechnology and contains the first solar cells able to harness the sun's invisible, infrared rays.

A new type of plastic cell that can harness some 30 percent of the energy falling on it, up from an industry standard of 6 percent. The key is a thin layer of nanoparticles.

KEY WORDS: global warming, HVAC, Cogeneration, fusion, plastic solar cell

Introduction

The current energy scenario has forced us to think of alternatives for the present energy sources. Thus new

advanced energy technologies are the need of time.

Another serious issue engulfing our planet is global warming which is spreading like wild fire. Thus we must

propose to develop new technologies keeping in mind the present situation.

HVAC

An HVAC system provides adequate indoor air quality by: conditioning the air in the occupied space of a

building in order to provide for the comfort of its occupants; diluting and removing contaminants from indoor

air through ventilation; and providing proper building pressurization.

The goal for a Heating, Ventilation and Air Conditioning (HVAC) system is to provide proper air flow, heating,

and cooling to each room. HVAC is sometimes referred to as "climate control" and is particularly important in

the design of medium to large industrial and office buildings such as sky scrapers and in marine environments

such as aquariums, where humidity and temperature must all be closely regulated whilst maintaining safe and

healthy conditions within. HVAC systems have a significant effect on the health, comfort, and productivity of

occupants. Issues like user discomfort, improper ventilation, and poor indoor air quality are linked to HVAC

system design and operation and can be improved by better mechanical and ventilation systems.



In general, outside (“supply”) air is drawn into a building’s HVAC system through the air intake by the air

handling unit (AHU). Once in the system, supply air is filtered to remove particulate matter (mold, allergens,

dust), heated or cooled, and then circulated throughout the building via the air distribution system, which is

typically a system of supply ducts and registers.

In many buildings, the air distribution system also includes a return air system so that conditioned supply air is

returned to the AHU (“return air”) where it is mixed with supply air, re-filtered, re-conditioned, and re-

circulated throughout the building. This is usually accomplished by drawing air from the occupied space and

returning it to the AHU by: (1) ducted returns, wherein air is collected from each room or zone using return air

devices in the ceiling or walls that are directly connected by ductwork to the air-handling unit; or (2) plenum

returns, wherein air is collected from several rooms or zones through return air devices that empty into the

negatively pressurized ceiling plenum (the space between the drop ceiling and the real ceiling); the air is then

returned to the air-handling unit by ductwork or structural conduits.

HVAC is one of the largest consumers of energy in the hospitality industry, Constituting approximately 30

percent or more of total costs. Because HVAC systems account for so much electric energy use, almost every

Facility has the potential to achieve significant savings by improving its control of HVAC Operations and

improving the efficiency of the system it uses through proper design, Installation and scheduled maintenance.

Advantages

1) Quieter, and therefore more likely to be turned on or left on by teachers and staff.

2) Less drafty due to multiple supplies and a return that is away from occupants.

3) Better at controlling humidity and condensed moisture drainage.

4) Easier to maintain due to reduced number of components and few units to access.

5) More space around units and can be accessed without interfering with class activities.

6) Space for higher efficiency air filters, and more surface area.



Cogeneration

Cogeneration (also combined heat and power, CHP) is the use of a heat engine or a power station to

simultaneously generate both electricity and useful heat.

Cogeneration is a thermodynamically efficient use of fuel. In separate production of electricity some energy

must be rejected as waste heat, but in cogeneration this thermal energy is put to good use.

Co-generation is the concept of producing two forms of energy from one fuel. One of the forms of energy must

always be heat and the other may be electricity or mechanical energy.

Need for cogeneration

The major source of loss in the conversion process is the heat rejected to the surrounding water or air due to

inherent constraints of different thermodynamic cycles employed in the power generation. In a cogeneration

plant, very high efficiency levels, in the range of 75%–90%, can be reached.

A number of environmentally positive consequences flow from this fact: Power tends to be generated close to

the power consumer, reducing transmission losses, stray current, and the need for distribution equipment

significantly. Cogeneration plants tend to be built smaller, and owned and operated by smaller and more

localized companies than simple cycle power plants. As a general rule, they are also built closer to populated

areas, which causes them to be held to higher environmental standards

Combined cycle system

1) The engine cooling circuit can be sent to a heat reservoir, from which hot water and space heating is

produced.

2) The amount of heat recovered is roughly equal to the amount of electric power produced. , this is sufficient to

cover the hot water needs free of charge.



3) When the heat reservoir is full, excess heat is classically dissipated by the engine radiator.

An optional heat exchanger further recovers exhaust heat, doubling the amount of heat recovered and pushing

thermal efficiency to 90%.

4) This enables to cover free of charge the heating needs of a sufficiently insulated house.

Advantages of Cogeneration

1) In separate production of electricity some energy must be rejected as waste heat, but in cogeneration this

thermal energy is put to good use.

2) Since co-generation can meet both power and heat needs, it has other advantages as well in the form of

significant cost savings for the plant and reduction in emissions of pollutants due to reduced fuel consumption.

Even at conservative estimates, the potential of power generation from co-generation in India is more than

20,000 MW

Fusion Energy

In a fusion power plant most of the energy produced by the reactions in the plasma is carried by the neutrons.

These high energy neutrons (14 MeV) are captured and their energy used to generate electricity.



The energy of the neutrons is absorbed in the structures lining the plasma chamber walls. The remaining energy

in the helium (4He) particles maintains the high plasma temperature. In a fusion power plant the plasma would

be confined in a large vacuum vessel surrounded by a neutron absorbing breeding blanket.

The breeding blanket has a dual function: it converts the energy of the neutrons into thermal energy and it

‘breeds’ new tritium from lithium to provide more reaction elements.

How can fusion produce electricity in a future power plant?

The fusion reaction can be simply written as:

Tritium (3H) + deuterium (2H) >> Helium (4He) + a high-energy neutron (n)

The main challenge in fusion is to maintain the high temperature of the plasma for long periods of time. In

burning plasma the energy of the Helium nuclei are the main contributors to heating the plasma. However, the

plasma is constantly being cooled by impurities picked up from the vessel wall.

The deuterium-tritium or D-T reaction is the most promising because of the forces between nuclear particles. At

very short distances, nuclear particles attract each other through the strong force, and the neutron in tritium adds

to this attractive force, thereby promoting the fusion reaction.

In the D-T reaction, each neutron carries off about 14 million electron volts of energy, roughly 80% of the

released energy (an electron volt is the energy acquired by an electron in moving through a potential difference

of one volt).



These energetic neutrons constitute a considerable radiation hazard, so a fusion reactor will need a one-meter

thick lithium blanket to absorb neutrons and breed more tritium.

To some degree, quantum mechanics provides a way around the electrostatic repulsion of the protons, because it

is possible for the two nuclei to “tunnel” through this barrier and thereby considerably reduce the necessary

collision energy.

To keep the fusion reaction going, the deuterium and tritium must be heated sufficiently that the ions’ thermal

motion will produce sufficiently energetic collisions. In this case the ions must be hot enough that they will form

plasma. As plasma moves, its electric currents produce electromagnetic forces that act back on the plasma, so

controlling and confining the plasma is a daunting challenge.

Cost of fusion energy

An obvious concern with fusion energy is the cost of electric power. A fusion plant must be competitive with

both conventional and fission plants in order to be economically viable. As the shown in the above figure which

was assembled from several cost comparison studies, IFE plants driven by heavy ion accelerators may produce

electricity at a 20-30% cost advantage and may also be competitive with fossil-fuel plants and advanced-

designed fission plants.

Advantages of fusion energy

1) Fusion is an almost limitless fuel supply. Deuterium is abundant and can be extracted easily from sea water.

Lithium, from which tritium can be produced, is a readily available light metal in the Earth’s crust.

2) Fusion produces no greenhouse gas emissions. Fusion power plants will not generate gases such as carbon

dioxide that cause global warming and climate change, nor other gases that have damaging effects on the

environment.

3) Fusion is suitable for the large-scale electricity production required for the increasing energy needs of large

Zities.

4) Waste from fusion will not be a long-term burden on future generations. Any radioactive waste generated will

be small in volume and the radioactivity will decay over several decades with the possibility of reuse after about

100 years

5) No transport of radioactive materials is required in the day-to-day operation of a fusion power station, as the

intermediate fuel tritium is produced and consumed within the power plant.

6) The abundance of raw materials, their wide distribution, and the environmental acceptability of fusion are

augmented by the expectation that fusion energy will be an economical source of electricity generation.



A single fusion power station could generate electricity for two million households.

Carbon Capture And Storage

To prevent the carbon dioxide building up in the atmosphere (possibly causing global warming and definitely

causing ocean acidification), we can catch the CO2, and store it. As we would need to store thousands of

millions of tons of CO2, we cannot just build containers, but must use natural storage facilities

CO2 storage is simply the process of taking captured CO2 and then placing in a location where it will not be in

contact with the atmosphere for thousands of years. Storage of the CO2 in underground sites beneath a layer of

impermeable rock (cap rock) which acts as a seal to prevent the CO2 from leaking out is the most popular

option at present.

Carbon capture and storage (CCS) encompasses the processes of capture and storage of CO2 that would

otherwise reside in the atmosphere for long periods of time. CCS involves the separation and capture of CO2 at

the point of emissions followed by storage in deep underground geologic formations.

There are three main types of proposed underground storage sites:

1) Depleted Oil and Gas Reservoirs CO2 can be pumped into the reservoirs to fill the empty spaces left by

removal Of hydrocarbons.

2) Deep Saline Aquifers CO2 can also be stored in deep salt water-saturated rock formations.



3) Deep Unminable Coal Seams

CO2 can be stored in deep coal seams where it will be held in the pores on the surface of the coal and in

fractures.

Saline Aquifer

Four steps are required for CCS:

1. Capture of CO2 from a power plant.

2. Transport of the CO2 gas to a suitable storage facility.

3. Injection of CO2 gas into an underground reservoir.

4. Monitor the reservoir.

While a lot of research on CCS technology has already been done, an overall regulatory framework is still being

developed.

Nanotechnology To Generate Electricity

A new type of solar cell uses layers of two different types of conducting polymers to increase the device’s

efficiency. The design has achieved a record high efficiency for photovoltaics that use conductive polymers to

generate electricity. A new process for printing

Plastic solar cells boost the power generated by the flexible and cheap form of photovoltaics.



How Plastic Solar Cells Turn Sunlight Into Electricity?

When the film is exposed to light, each photon excites an electron in the polymer.

If an interface between the polymer molecule and the functionalized buckminsterfullerene exists, a current can

be produced.

The film is exposed to light using ultra short laser pulses.

Not only does this technology make sense from a financial standpoint but it can also be the catalyst, which will

make solar power attractive and affordable for the masses.

High- performance and low-cost plastic solar cells:

A solar cell that includes a high efficiency thin film plastic (polymer) as the active material. The active material

includes a mixture of a semi-conducting polymer and an ionic electrolyte. The semi-conducting polymer is

made up of a p-type polymer and an n-type electron acceptor. The ionic electrolyte is present in said mixture in

an amount ranging from 0.01 to 5 weight percent.

Konarka technology solar cells

Solar company Konarka has developed technology to create rolls of plastic that can convert light to electricity.

Inkjet printing is a commonly used technique for controlled deposition of solutions of functional materials in

specific locations on a substrate. It can provide easy and fast deposition of polymer films over a large area.



Advantages

1) Reduced Cost

2) Flexibility

3) Lesser Weight

4) Working in cloudy days

5) Utilizing Infrared light

6) Easy to manufacture

Conclusion:

The paper discusses that the above five energy technologies are the foremost means to help survive through the

energy crisis in the present and the future.

Also global warming, environmental degradation is sure to be curbed.

Bibliography:

www.nottingham.ac.uk

Modern Refrigeration and Air Conditioning (August 2003) by Althouse, Turnquist, and Bracciano, Goodheart-

Wilcox Publisher.

Fusion as an energy source-a guide from institute of physics.

Fusion science and technology

www.geos.ed..ac.uk

Cogeneration- Wikipedia. The free encyclopedia

www.solarmer.com, www.universityofcalifornia.com



Energy Audit And Waste Heat Recovery Opportunities In Shree Cements

Ltd, Beawar

Mr. P.C.Tiwari

Cement Manufacturing Process Details :-

The history of Portland Cement may be said to date back to the time when it was found that by burning

limestones containing clay and silica, a cementing agent was produced which hardened under water and after

hardening was not soluble in water. As this end product somewhat resembled Portland stone in colour and

character, it was named Portland Cement. Earlier cements were incompletely burnt as the material was not

heated to a temperature sufficiently high for sintering to occur. It was soon found that higher strengths could be

obtained by burning the material more completely i.e. beyond decarbonising and upto sintering which is a stage

immediately preceding the melting of the mix. Basically, the ground raw mix containing suitable mixture of

calcium oxides, silicon oxides, aluminium oxides and iron oxides respectively occurring as limestone, sand,

clay, bauxite, laterite etc. is after fine grinding and blending subjected to burning process inside the kiln. As the

temperature rises, carbon dioxide is first evolved at temperatures between 700 deg and 900 deg C transforming

the calcium carbonate into lime. Lime being strongly basic reacts with other materials in the raw mix when the

temperature further rises and calcium carbonate into lime. Lime being strongly basic reacts with other materials

in the raw mix when the temperature further rises and in this way silicates of calcium, aluminium and iron,

which are basic constituents of Portland Cement, are formed. At a temperature of 1350 deg C the process of

sintering begins inside the kiln and is normally completed between 1400 deg and 1450 deg C. At this stage the

material which by now has acquired a greenish black colour is converted into what is known as clinker. This

clinker after cooling is ground in finish mills along about 5% gypsum to give the finished product known as

Ordinary Portland Cement (OPC).

Raw Material Preparation

Limestone of differing chemical composition is freely available in the quarries owned by Shree Cement

Limited. This limestone is carefully blended before being crushed. Crusher installed is single rotor impactor of

800TPH capacity and motor 950kW, 1000 rpm, 6600VRed mineral is added to the limestone at the crushing

stage to provide consistent chemical composition of the raw materials. Once these materials have been crushed

and subjected to online chemical analysis they are blended in a homogenized stockpile. The Stacker used having

luffing, slewing and travelling and can pile upto 125m length and storing capacity of 2x30,000MT. A Bridge

Scrapper reclaimer 700TPH capacity is used to recover and further blend this raw material mix before transfer to

the raw material grinding mills.



Raw Mill

Transport belt conveyor transfers the blended raw materials to ball mills where it is ground. The chemical

analysis is again checked to ensure excellent quality control of the product. The resulting ground and dried raw

meal is sent to a homogenizing and storage silo for further blending before being burnt in the kilns. The Raw

Mill is vertical roller mill with 300TPH capacity, 4.75m dia grinding table, 13 Nos. larger segment, 26 Nos.

smaller segment, grinding track dia is 3.75m. there are 3 Nos. grinding rollers with 2.65m diameter 12 Nos.

segmented, the roller material is MU18 Chromium Cast Steel. The power requirement is 2400kW and mill

speed is 23-37 RPM. Drive Main Gear box is having ration of 64.5:1. motor is 2710kW, BHEL make, 1000

RPM, 6600V HT motor. The Raw Mill fan has a 2400kW, 1000 RPM motor. Silo has a capacity of 20,000 ton

and 50.7m height with effective dia of 20m.



Fuels

The heat required to produce temperatures of 1,800°C at the flame is supplied by ground and dried petroleum

coke and/or fuel oil. The Petcoke is imported via the companies' internal wharf, stored and then ground in

dedicated mills. Careful control of the mills ensures optimum fineness of the Petcoke and excellent combustion

conditions within the kilns system. Coal Mill is having capacity of 38TPH.

Burning

The raw meal is fed into the top of a preheater tower equipped with 6 cyclone stages. The Preheater contains

Pyro string and kiln string cyclones. The Pyro string preheater is type PR7044, 6-stage, cyclone dia stage 2-6 is

7300mm, twin cyclone dia 4600mm, the kiln string preheater type PR6742, 6-stage, ccyclone dia stage 2-6 is

6700mm, twin cyclone dia 4200mm. The pyro-clone precalciner is 3.7m dia and 60m long. As it falls, the meal

is heated up by the rising hot gases and reaches 800°C. At this temperature, the meal dehydrates and partially

decarbonizes. The meal then enters a sloping rotary kiln, which is heated by a 1,800°C flame, which completes

the burning process of the meal. The kiln has a dimension of 4.4m dia, 60m length, 3.5% inclination in length

and speed 0.35 to 3.5 RPM. The motor used is 550kW, 1000 RPM, VFC drive with auxiliary drive of 30kW,

1500 RPM motor.The pyrojet burner is having overall thermal capacity 262GJ/hr, burner pipe dia 457.2 x

14.2mm length of total burner 13.602m. The meal is heated to a temperature of at least 1,450°C. At this

temperature the chemical changes required to produce cement clinker are achieved. The dry process kiln is

shorter than the wet process kiln and is the most fuel-efficient method of cement production available.



Air Quenched Cooler

The clinker discharging from the kiln is cooled by air to a temperature of 70°C above ambient temperature and

heat is recovered for the process to improve fuel efficiency. Some of the air from the cooler is dedusted and

supplied to the coal grinding Plant. The remaining air is used as preheated secondary air for the main

combustion burner in the kiln. Clinker is analyzed to ensure consistent product quality as it leaves the cooler.

Metal conveyors transport the clinker to closed storage areas. The AQC is a grate cooler capacity 3500 TPD,

cooling area 92m2 with 12 Nos. grate plates, and it is a stepped grate single stage type. The Reciprocating grate

is having 11 nos. of hopper and one drag chain with double pendulum flap 300/22. There are 3 Nos. of grate

drives of 40kW capacity each with speed 150-1500 RPM and 2.38-23.81 strokes per minute, and stroke length

140mm.

Filters : Air Pollution Control Devices

Dedicated electrostatic precipitators dedust the air and gases used in the Clinker Production Line Process. In this

way, 99.9% of the dust is collected before venting to the atmosphere. All dust collected is returned to the

process. The ESP’s are rated for 280 degree Celcius temperature, 525000m3/h gas quantity, static pressure

150mmWC, raw dust content 37.1g/Nm3, clean gas dust content 75mg/Nm3, 9787.5m2 collecting area, single

chamber 3 Nos. field, operating pressure -200mmWC, pressure drop across ESP is 2.5mbar, 0.37kW geared

motor for collecting/emitting rapping.



Cement Mill (clinker grinding):

The ball mill is designed for clinker grinding, inner dia 4.6m, 14.7 RPM, 4200kW power requirement, grinding

path 13m, grinding media size 25mm motors of 2x2400kW, 993RPM with 216 teeth girth gear & 29 teeth

pinion gear of 30mm module.

Constituents

Different types of cement are produced by mixing and weighing proportionally the following constituents:

Clinker

Gypsum

Limestone addition

Fly ash for PPC

Grades

The grade 43 and 53 in cement mainly corresponds to the average compressive strength attained after 28 days (

672 hours) in mega pascals (Mpa) of at least three mortar cubes ( area of face 50 cm squared) composed of one

part cement, 3 parts of standards and ( conforming to IS 650:1966) by mass and P/4 ( P is the percentage of

water required to produce a paste of standard consistency as per IS standard) + 3 percentage ( of combined mass

of cement plus sand) of water , prepared, stored and tested in the manner described in methods of physical test

for hydraulic cement.

Case Study # 1

Replace the existing HT Motor of Raw Mill ESP fan with HT motor 450kW 450 RPM with HT VFD in plant-2

(4500TPD)

Raw Mill ESP Fan was observed for its performance and it was found that the fan is operating at 355 rpm

against rated 468 rpm and generating a pressure rise of 80mmWG at flow rate 172.66 m3/sec. The HT Slip Ring

Induction motor rated for Output power of 710kW and a speed of 740 rpm is driving the fan at 355 rpm which is

normal speed required for process requirement. The speed of the fan is being controlled by inserting delta

connected external Grid Rotor Resistance where the significant power is lost. The fan installed is Energy

Efficient Fan with estimated efficiency of 79% at the operating pressure rise and flow but the motor is operating

at only 43% efficiency. The Power loss in GRR is estimated and measured to be 193kW. Air kW generated by

the Fan is only 135kW and fan shaft Power required by the fan is 135kW/(0.79 x 0.9 ) which is equal to 190kW.

Keeping the other plant operations in view for extreme conditions, an energy efficient HT motor of 450kW, 450

RPM with HT Variable Frequency Drive (VFD) is proposed for driving the fan.



Also the CGR & GRR requires 5 Nos.X 2.2kW blowers for cooling and 11kW power can be saved in new

scheme.

Operating Parameters:

Motor Input power = 392kW,

Motor Speed = 355 rpm,

Slip = 52.19%

Air Gap Power = 373kW,

Total Cu Loss in Rotor = 373kW X 52.19% = 195kW

Motor efficiency at operating load = 43%

Power Saving potential

= Total Rotor Cu Loss – Cu loss in rotor winding + Power wasted in Cooling Blowers = (195kW-

3X2002X0.016/1000 + 11kW) = 204kW

Energy Saved=204kWX24Hrs./dayx330 days/ annum=16,15,680 kWh

Amount Saved = 16,15,680 kWh X Rs.6/kWh = Rs.96.94 Lacs

Investment required = 70 Lacs, Simple Payback period = 9 Months

Reduction in CO2 emission=2x0.204MWx24 hrs.x330days/annum

=3231 tCO2/annum

Saving in cost of Generation=2x0.204MWxRs.600Lacs/MW=Rs.244Lacs

Case Study # 2

Remove damper from the Raw Mill ESP fan suction Unit-2 (4500TPD)

Raw Mill ESP Fan was observed for its performance and it was found that a damper is provided for flow

control. It was found that the pressure drop across the damper is 11mmWC for the 100% open position and flow

is 172.66m3/s. It is proposed to remove damper from the duct as it is wasting an air power of 19kW.


Draft before damper = -101mmWC

Draft after damper = -90mmWC

Draft at fan outlet = -10mmWC

Pressure drop across damper = -90 – (-101) = 11mmWC

Power loss due to damper = 172.66m3/s X 11mmWC/102 = 19kW

Energy Saved = 19kW X 24 Hrs./day x 330 Operating days/ annum

= 1,50,480 kWh

Amount Saved = 1,50,480 kWh X Rs.6/kWh = Rs.9.02 Lacs



Investment required against Labour cost = 0.2 Lacs

Simple Payback period = 8 days

Reduction in CO2 emission = 2 x 0.019MW x 24hr. x 330days/ annum =301tCO2/Yr.

Saving in Cost of power generation = 2 x 0.019MW x Rs.600Lacs/ MW

= Rs.22.8Lacs

Case Study # 3

Replace the existing HT Motor of Sepax ESP fan wih HT motor 500kW 988RPM with HT VFD in plant-2 (4500TPD)

Sepax Fan was observed for its performance and it was found that the fan is operating at 650 rpm and generating

a pressure rise of 424mmWG at flow rate 63.06 m3/sec. The HT Slip Ring Induction motor rated for Output

power of 1110kW and a speed of 988 rpm is driving the fan at 650 rpm which is normal speed required for

process requirement. The speed of the fan is being controlled by inserting delta connected external Grid Rotor

Resistance where the significant power is lost. The fan installed is Energy Efficient Fan with estimated

efficiency of 81.35% at the operating pressure rise and flow but the motor is operating at only 59.78%

efficiency. The Power loss in GRR is estimated and measured to be 193kW. Air kW generated by the Fan is

only 135kW and fan shaft Power required by the fan is 262kW/(0.81 x 0.94 ) which is equal to 343kW. Keeping

the other plant operations in view for extreme conditions, an energy efficient HT motor of 500kW, 988 RPM

with HT Variable Frequency Drive (VFD) is proposed for driving the fan.


Motor Input power = 539 kW, Motor Speed = 650 rpm, Slip = 34.34%

Air Gap Power=508 kW, Total Cu Loss in Rotor = 508kW X 0.3434%=174.3kW

Motor efficiency at operating load = 59.78%

Power Saving potential = Total Rotor Cu Loss – Cu loss in rotor winding

= (174.3kW-3X1702X0.02/1000) = 174.3-1.734= 172.61kW

Energy Saving potential= 172.61kW X 24Hrs./ day x 330 days/ annum =13,67,071 kWh

Amount Saved = 16,15,680 kWh X Rs.6/kWh = Rs.82 Lacs

Investment required=70 Lacs, Simple Payback period = 11 Months

CO2 emission Reduction=2 x 0.1726MW x 24hr. x 330days/ annum

= 2734 tCO2/Yr.

Saving in cost of Generation=2x0.1726MWxRs.600Lacs/MW=Rs.207Lacs



Case Study #4

Remove damper from the Sepax fan suction Unit-2 (4500TPD)

Sepax Fan was observed for its performance and it was found that a damper is provided for flow control. It was

found that the pressure drop across the damper is 12mmWC for the 100% open position and flow is 63.06m3/s.

It is proposed to remove damper from the duct as it is wasting an air power of 7.4kW.

Operating Parameters :

Draft before damper = -548mmWC

Draft after damper = -560mmWC

Draft at fan outlet = -12mmWC

Pressure drop across damper = -560 – (-548) = 12mmWC

Power loss due to damper = 63.06m3/s X 12mmWC/102 = 7.4kW

Energy Saved = 7.4kW X 24 Hrs./day x 330 Operating days/ annum

= 58,608 kWh

Amount Saved = 58,608 kWh X Rs.6/kWh = Rs.3.5 Lacs

Investment required against Labour cost = 0.2 Lacs

Simple Payback period = 21 days

CO2 emission Reduction = 2 x 0.074MW x 24hr. x 330days/ annum =117tCO2/Yr.

Saving in Cost of power generation=2 x 0.0074MW x Rs.600Lacs/ MW =Rs.4.4Lacs

Investment Risk Barrier

In Indian cement industry, this technology has not been implemented so far owing to the following reasons:

Non-availability of proven technology indigenously.

Non-availability of installation or their operating experience in India resulting in lack of confidence.

Special design requirements of waste heat recovery boiler suiting to high dust load.

Large capital requirement and financial constraints owing to depressed cement marketing scenario

Dust content of the exit gases from the cement manufacturing process, is as high as 100 g/Nm3. Most of the dust

particles are sticky at high temperatures. This makes waste heat recovery very difficult as large amount of dust

collects at heat transfer surfaces and leads to complete choking of the heat exchanger. In the project scenario the

dust content in the preheater exit gases are expected to be as high as 80-100 g/Nm3 which pose

a real threat to the success of the project activity which entails high up front-cost.

The feature of the dust in exit gases from AQC is the strong hardness which shall make the heat

exchanger surfaces of AQC boilers abraded quickly. If anti-wear measure of the AQC boiler is in appropriate,

the normal running of AQC boilers shall be influenced. The anti-wear measure of domestic equipment is less

efficient than that of advanced foreign equipment, thereby also forming a barrier to the project activity.



Energy Efficient Approach for Alkyd Resin Manufacturing

Ranjeet Neve1, Aniket Bodale1, B B Gogte2 and Sachin A Mandavgane1

1Department of Chemical Engineering, Visvesvaraya National Institute of Technology, Nagpur, 440010, India.

2 Retd Professor, Department of Oil Technology, Laxminarayan Institute of Technology, Nagpur,440010, India. [email protected]

Abstract

Alkyd resin is a key ingredient of all surface-coating products like paints, primers, adhesives, printing ink etc.

Conventional alkyd resin uses petroleum-based products (50-70%) like phthalic anhydride (35-50%) and

organic solvents (30%). In the present work, a novel alkyd resin was developed containing renewable vegetable

product (50-70%) petroleum based products (25%). Volatile organic compounds (VOC) content of conventional

alkyd resin is 40% while the new alkyd resin was 14%. The novel alkyd resin manufacturing temperature was

around 200 oC for 7-8 hours as compared to conventional resin (225-240oC for 12 hours) thus saving energy and

time. The physicochemical and film properties of resin have been studied and compared with commercial

sample. The cost of the present product is less than the conventional product.

Keywords

Alkyd resin, Agro base, Energy efficient, short oil, surface coating products.

Introduction

Worldwide the paint and coating industry represents some $50+ billion market with predicted yearly growth rate

of 2-5% over the next 10 years. Surface coating materials (paints, primer, printing inks) contain three major

ingredients: pigments (including extenders), binder/ film former (alkyd resin) and solvent (or thinner). Alkyd

resins are polyester polymers of fatty acids and responsible for the mechanical properties, drying speed and

durability of surface coating materials.

Alkyd resins (Lambourne 1987) are essentially polyesters of polyhydroxyl alcohols and polycarboxyl acids

chemically combined with the acids of various drying, semidrying, non drying oils in different proportions. The

basic reaction involved in the preparation of alkyd resin is esterification. The reversible reaction can be shown

as;

R-COOH + ROH → RCOOR + H2O

Two general processes can make alkyd resin are: a) fatty acid process and b) monoglyceride process (two-stage

process). In fatty acid process, the ingredients are placed in the reaction kettle and heated at temperature ranging

from 410°c to 450°c or higher. The batch is held at reaction temperature until the desire acid value and viscosity

have been reached. In monoglyceride process, drying oil is first made to react with glycerol, and an intermediate



product called a monoglyceride is obtained, which can then react with phthalic anhydride at 250-280°C, to form

a homogenous alkyd resin.

Kharkate et. al. (2005) synthesized alkyd resin binder based on renewable vegetable resources like soyabean oil

and rosin by heating at 210-245oC for 8-9 hrs. Sathe et. al. (1999) developed a new type of alkyds using

substantial proportion of

styrene ( 30-50%) , a low percentage of polyols and anhydride by heating at 230-240oC for 8-9 hrs. Kulkarni et.

al. (1994) reported preparation of sorbitol based alkyd by heating at 230-240oC for 8-9 hrs. Vaidyabthan et.

al.(1988) prepared ‘CASTRO’ alkyds by cooking mainly castor oil and rosin at 275°C. Gogte et. al. (1981)

reported preparations alkyd resin by using epoxidised karanja oil by selecting appropriate temperature (200°C).

In the present work a novel alkyd resin is prepared at very low temperature (200-220 oC for 7-8 hrs) as compare

to convention process (225-240oC for 12 hours) thus saving energy.

2. Materials and Methods

Materials used in the present experimental work; linseed oil, glycerol, maleic anhydride, benzoic acid, rosin,

sodium bisulphate, sodium bisulphate, red oxide, talc, whitting and tween 20.

2.1 Experimental setup

The preparation of alkyd resin was carried out in a glass reactor. The reactor consists of two parts. Lower part of

the reactor is round bottom vessel with very wide mouth. The capacity of the flask is about two liters. The upper

part of the reactor is its lid, having four necks with standard joints. Figure 1 shows the experimental setup.

Out of these four necks, a motor driven stirrer was inserted in the rector through the central neck while another

neck was used for the thermometer. A condenser was fitted with the reactor through the third neck. And the

fourth neck was use for introducing the chemicals into the reactor. The reaction vessel and its lid were tied

together with the help of clamps. The reactor was heated by an electric heating mantle having automatic

thermostat for smooth control of the temperature of the reactor within +2°C. The speed of the stirrer was

controlled by a regulator.

Figure 1. Experimental setup



2.2 Synthesis of alkyd resin

For synthesis of alkyd resin (Payne 1961), mixture as given in Table 1 was charged and reacted in a standard

glass reactor (2l). Xylene, butanol and toluene (1:1:1) were used as solvent. The order of addition of raw

material and heating schedule for making eco-friendly resin was standardized (Table 2). After completion of

reaction, solvent was removed from product by vacuum evaporation at 200 mm Hg. Physiochemical properties

of pale yellow alkyd resin are reported in Table 3.

Table 1. Composition Alkyd Resin

Ingredients Composition (by

wt%)

Linseed Oil 20

Glycerol 15

Maleic anhydride 10

Benzoic acid 1

Rosin 53

Sodium bisulphite 0.5

Sodium bisulphate 1.5

Table 2. Heating schedule of alkyd resin

Order of addition of reactants Time

H:min



Linseed oil, glycerol, maleic

anhydride, benzoic acid, rosin, sodium

bisulphate, sodium bisulphite

03:00

Heat at 220 0C 00:30

Heat at 210 0C 00:30

Heat at 205 0C 00:30

Heat at 200 0C 02:00

Total heating time 06:30

Cool to 80 0C,added solvent &

removed the product

02:00

Table 3. Physiochemical properties of alkyd resin

Properties RI

Acid Value 37.38

% Solid 86.33

Color Pale yellow

Stability Six moths



2.3 Applications of alkyd resin

The alkyd resin thus prepared was used in surface coating product formulations like screen ink (Mandavgane et.

al. 2007a), primer (Mandavgane et. al. 2007b,c), paint (Mandavgane et. al. 2007d), detergents (Mandavgane et

al 2006e) and floor cleanser (Mandavgane et al 2006f). The products were found to exhibit properties at par with

commercial samples.

3. Results and Discussion

Alkyd resin polymeric composition with short oil length (20%) was prepared with the use of chain stoppers and

catalysts. Due to gelation, it becomes very difficult to synthesis alkyd resin with oil content less than 30%.

Conventional alkyd resin is long oil resin (40-50%).

The novel alkyd resin manufacturing temperature was around 200 oC for 7-8 hours as compared to conventional

resin ( 225-240oC for 12 hours) thus saving energy and time.

Novel alkyd resin contains agro (50-70%) and petroleum (25%) base raw materials as compared to conventional

resin containing 50-70% petroleum based products, which is to be imported. The agro products used are non

edible oil and rosin. Rosin imparts the mechanical strength, helps in smooth propogation of polymerization and

gives high molecular weight polymer (higher the molecular stronger the polymer). Volatile organic compounds

(VOC) content of conventional alkyd resin is 40% while the new alkyd resin was 14%. The gram of VOC per

liter in the developed surface coating formulations is 370 well within the limits (Gloss and semi gloss

architectural coatings: 380)

4. Conclusion

Alkyd resin manufacturing is highly energy intensive. The conventional process involves 10-12 hrs heating at

225-250oC. The success rate of each batch is also low because of over polymerization and gelation resulting in

loss of energy and material. Here a formulation and method is developed which has brought down the heating

schedule to just 8 hrs at around 210 oC and risk of over polymerization has been avoided using chain stopper.

Very short oil alkyd resin thus developed is highly hydrophilic and can be used in Emulsion Polymers.

Emulsion Polymers since uses water as a solvent; instead of organic solvents the Volatile Organic Compounds

(VOC) of surface coating products prepared using such polymers is very low. The cost of novel alkyd resin is

less than the commercial it uses more agro base products and less energy. The alkyd resin thus developed is

novel, energy efficient, ecofriendly and agro based. ANN Modeling (Mandavgane et al 2006g) of parameters

like composition, heating schedule and physical properties can make the results generalized.

5. References

• Gogte B. B. and Dabhade S. B. 1981, Alkyds based on non-edible oils Karanja oil (Pongamia glabra),

Paint India, 3-5.



• Kharkate S. K. and Gogte B. B. 2005, A novel eco-friendly short oil rosinated alkyd binder, Paint

India, 129-138.

• Kulkarni R. D. and Gogte B. B. 1994, ‘SORBO’ alkyd emulsion paste for primers and synthetic

enamels, Paint India, 41-44.

• Lambourne R. L. 1987, Paint and Surface Coatings: Theory and Prctice, Ellis Horwood Publisher,

Chichester,75-79.

• Mandavgane S. A., Gogte B. B. and Subramanian D. 2007, Sulphonated lignin based screen ink

formulations, Indian Jr of Chemical Technology, 14, 321-324

• Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2007, Development of steel primer

from spent black liquor and short oil alkyd resin, Jr Sci Indus Res, 66,407-410.

• Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2006, Development of eco-friendly

primer from spent black liquor and linseed oil based novel alkyd resin, Proc of CHEMCON 2006,

Bharuch, India, Dec 26-31, 2006.

• Mandavgane S. A., Rokde S. N., Gogte B. B. and Subramanian D. 2007, Synthesis of eco-friendly

paint from kraft lignin and rice bran oil based novel alkyd resin, Indian Jr. of Chemical Technology,

(communicated)

• Mandavgane S. A., Gogte B. B. and Subramanian D. 2006, Some spent black liquor based powder

detergents cum stain removers, Jr Sci Indus Res, 65,760-764.

• Mandavgane S. A., Vivek, Pawar S., Gogte B. B. and Subramanian D. 2006, Development and study of

floor cleanser from modified black liquor, Chem Engg. World, 41,66-68.

• Mandavgane S. A. and Venkateshwarlu K., Modeling of Biomass Briquetting Using Artifial Neural

Networks, Proc of Advances in Energy Research 2006, IIT Bombay, 2006.

• Payne H. F.1961, Organic Coating Technology, vol 1,John Wiley & Sons, New York, 87-106,

• Sathe P. D. and Gogte B. B. 1999, Primer and synthetic enamel compositions based on new type of

styrenated alkyds, Paint India, 129-138.

• Vaidyabthan K. S. and Gogte B. B. 1988, High gloss enamel paints based on ‘CASTRO’ alkyds, Paint

India, 25-28.

Acknowledgements

SAM is greatful to Department of Science and Technology (SSD/TISN/020/2009), New Delhi, India for

Financial support and encouragement for the research project.



Case Study

Energy Conservation Opportunities In Pharmaceutical Plant Air

Conditioning

D.K.Joshi

[email protected]

Abstract

Evaluation of energy saving opportunities in a typical pharmaceutical unit using VAM (Vapor Absorption

Machine). Capacity of vam depends upon efficient working of cooling Tower( Temperature of the sumpwater).

Key words : Vapor absorption, Coefficient of performance

I.Introduction

Basically Air conditioning is used in Pharmaceutical plant to control followings The major areas of consumption in air conditioning pharmaceutical plants are:

Refrigeration chillers (High side).

Primary &Secondary Pumps.

Air handling units (AHU) (Low side).

Cooling tower

(a). Temperature

As per USFDA (United States Federal drug Agency) the temperature requirement is NMT 250C. Which is

needed for some product stability.Certain products are more stable in the above said temperature range.

Temperature is maintained by circulating chilled water in. AHU(Air HandlingUnit)

(b). Humidity

Humidity is also an important factor for product and human comfort. It should be in the range of 55% but it also

varies from product to product. As per USFDA it should be NMT 55 %

(c) Contamination.(in term of Particulate Matter)

Temperature and humidity for human comfort and product requirement and to Avoid Contamination for product

purity.



To get space conditioned, Centralized chilled water system with a combination of Air handling unit fitted with

different types of filters is achieved

2. Methodology and Model description.

Vapor absorption technology is based on using Heat Energy, instead of Electrical/Mechanical Energy as in

vapor compression system, in order to change the conditions of the Refrigerant, external source of heat (Steam)

is required. Steam required for generating

1 TR (Tone of Refrigeration) = 4.5 Kgs (steam).[1]

Vapor absorption system is most Economical where Steam is available as by- Product or waste heat is available

as in case of Exothermic Reactions.

Figure -1 Vapor Absorption Machine having a Capacity of 250 TR

(Steam Operated)

3. Observations and Measurements 3.1 Details of Chillers.

Table 1

S.NO Type Make Refrigerant Cws Cwr Chws Chwr

1 VapourAbsortion Thermax Cr +Li Br 320C 320C 320C 320C

2 VapourAbsortion Thermax Cr +LiBr 320C 320C 320C 320C

3 VapourAbsortion Thermax Moly+LiBr 320C 320C 320C 320C

4 VapourAbsortion Thermax Moly+LiBr 320C 320C 320C 320C



3.2 Readings on Chillers.

Table 2

S.NO Description Chiller 1 Chiller 2 Chiller -3 Chiller -4

1 CHW-R Not Not 120C 120C

2 CHW-S - 7.20C 7.50C

3 CHW-S. Prs. - 1.5 kg/ cm2 1.5 kg/ cm2

4 CHW-R Prs 0.5 kg/ cm2 0.5 kg/ cm2

5 C.Water-S 320C 330C

6 C.Water-R 370C 370C

7 C.Water-S Prs 1.5 kg/ cm2 1.5 kg/ cm2

8 C.Water-R Prs 0.5 kg/ cm2 0.5 kg/ cm2

9 Steam pressure 4.0 kg/ cm2 6 kg/ cm2

10 Valve Opening 98 97

3.3 Capacity loss due to high temperature of cooling water

Design temperature for chiller operation at optimal capacity is under

Cooling water supply temperature = 290 C

Cooling water return temperature = 340 C

But we are getting

Cooling water supply temperature = 320 C i.e. 30 C higher

From OEM[1] data 10 C rise will loose 9% of it’s capacity

Present cooling tower is of 250 TR capacity which is equals to Chiller Capacity.



4. Calculations

(1) For losses

First 10 C rise = 250 TR x 9 % = 22.5 TR loss, 227.5 TR available

Second 10 C rise = 227.5 x 9% = 20.47 TR loss, 207.03 TR available

Third 10 C rise = 207.03 x9% = 18.63 TR loss , 188.4 TR available

Total loss = 61.6 TR

To produce 61.6 TR Cost will be = 61.6 x 4.2 x Rs 1.60

= Rs 414 / hr on single chiller

On four chiller annual loss will be = 4 No x Rs 414 x20 hrs x300days

= Rs99, 36,000 per annum.

(2) For savings

If we install four Energy efficient cooling tower of having capacity 350TR[2]

This will cost Rs 5, 20,000/-each i.e. Rs 20,80,000/-

That will save loss in capacity of chillers

(3) Pay back

Pay back = Investment / savings

= 20,80,000 / 99,36,000

= 3 Months

5. Results and Discussions

Cooling tower sump temperature play a vital role in operation of VAM, as we have seen that every 10 C rise of

sump temperature water will loose9% of its capacity and the cooling capacity of the cooling tower was just

equal to the capacity of chiller.

We must have capacity of cooling tower to be slightly higher that that of chiller and at the same time a proper

maintenance of cooling tower should be done to avoid it’s detoriate its rated capacity.

6. Conclusions

The above case study is done in a leading pharmaceutical unit near Indore, It was also pointed out to the

management that cooling tower is in very shape it requires immediate attention, for getting full advantage of

rated capacity of VAM.



To operate VAM on fossil fuel is now a days very costly, if we use any Renewable source of energy to run

VAM will be a financial and technically sound gooddecision.

7. References

1 Thermax [1] operation& maintenance of vpour absorption machine

2 Mihir cooling tower[2] specification of cooling towers



Free Cooling As Energy Conservation Measure

Er. BALBIR SINGH, IES Er. V.K.SETHI

Chief Engineer (E), Sub Divisional Engineer (E),

BSNL, Haryana. BSNL, Yamuna Nagar.

Majority of the air conditioning systems are based on re-circulated air system, in which irrespective of the

outside ambient conditions, the conditioned space/equipment area is to be air conditioned by maintaining the

temperature at desired level. The required fresh air and return air are cooled by refrigeration compressors. All

the telephone exchanges, major & small, function under controlled conditions and are air conditioned. The

temperature is required to be maintained at certain level throughout the year. The major exchanges are

temperature sensitive and temperature is required to be maintained in the range of 23 +3˚C, There are around

100 air conditioning plants in BSNL in the State of Haryana and the capacity of Air Conditioned plants

normally ranges between 21 TR to 50 TR. The majority of Air Conditioned plants are of 21 TR capacity. The

Air Conditioned plants consume energy in bulk and there is a great potential of ENERGY CONSERVATION in

air conditioning. This is to be noted that even decrease of indoor temperature by 1˚C result in increase of 4%

energy consumption.

CONCEPT:

In Northern India the outside temperature during winter (November to February) is quite low. These favorable

outside conditions can be used for maintaining the Switch Room/ equipment room temperature by pumping

outside cold air into the equipment room through plant room by running the blowers of package AC units. This

concept is known as FREE COOLING. The normal temperature of cool air at canvas connection of Package

AC unit is 13 to 14˚C. So when the outside temp is < 14˚C than no package AC unit is required to be run.

When out side temperature is upto 20˚C, the temperature in switch room/ equipment room can be maintained by

pumping more air.

Design And Metholody:

CFM [Cubic feet per minute] requirement for free cooling for a particular AC plant is calculated on the basis of

average running of number of AC package units during the winter season for e.g. one package unit means 5000

CFM.

Free air from outside is pumped in the package room and further supplied in the switch room through blowers of

AC package units.

The hot air from the switch room is thrown out using exhaust fan/ damper or by door opening as feasible.

The system can be Manual or Automatic.



Manual:

The system is operated by the operative staff. The free cooling system is started manually and the

dampers are adjusted accordingly. The system is operated when outside temperature is < 20˚ C. The

components used are as follows:

24 SWG GI duct with mechanical filter, 600 mm Axial fan, damper, contactor and cables etc.

(b) AUTOMATIC:

Free cooling will be working as and when outside temperature goes < 20˚C and will be OFF when

temp inside switch room is below 25.5˚C, also the compressors will be ON only when free cooling is not

working due to fault or outside conditions are not favorable.

In this system, the louvers of the inlet and outlet fans shall work automatically with the thrust of the air.

The components used are as follows:

24 SWG GI sheet duct with mechanical filter, 600 mm dia Axial fan, 450 mm exhaust fan, dampers, louver,

Digital temperature controllers, contactors, relays, control wiring and cable etc.

Implementation:

PILOT AUTOMATED PROJECT UNDERTAKEN:

The project has been undertaken with automated system at Telephone Exchange Building, Yamuna

Nagar (Haryana)

Desired inside temperature: 25˚C

In this project, 10,000 CFM is required to cool the conditioned space i.e. Switch Room/ equipment room

containing C-DoT and OCB exchange equipment. 2 No: 5000 CFM fans with mechanical filters with suitable

duct work have been provided to push the air into the existing AC plant room and 4 Nos 18” exhaust fans with

shutters in the return air path to exhaust the air into the atmosphere have been provided. Whenever the outside

temp is below 20˚C, The fresh air and exhaust air fans start working through temp sensor, sensing the outside

ambient temp. This forced air is sucked by the package units and supplied into the conditioned space, where

after taking the heat of the equipment; it is exhausted by the exhaust fans. Temperature sensor has also been

provided in the switch room so that the when the temp is about to go below 25˚C the system stops to work and is

only ON when the desired temperature is about to increase from 25˚C. This also adds to further savings by

switching off the inlet and outlet air fans.

The general layout of the system with and without free cooling is as shown as per annexure attached at ‘A’ and

‘B’. The Control circuit is at Annexure ‘C’



The free cooling concept has been concept has been successfully implemented in around 90 AC plants in BSNL,

Haryana. Thereby resulting in reduction of energy consumption, as detailed below:

Sr. No. Description Result

(i) No. of AC plants in which free cooling concept

implemented

90

(ii) Reduction in running of package AC units [at least one

package of 7 TR in each plant]

7 TR x 90 = 630 TR

(iii) No of working hours [round the clock] 24 Hours

(iv) Power consumption 1.8 KW / TR

(v) Period of operation of free cooling [ Oct. to March] –

restricted to 3 months for calculations purpose

90 days x 24 Hrs

= 2160 Hrs

(vi) Reduction in energy consumption in units 630 x 1.8 x 2160

= 24,49,440 KWH

(vii) Units consumed for running free cooling system @ 1.50

KW per free cooling system [in units]

1.50 x 90 x 24

= 3,240 KWH

[which is negligible]

From the above, it is observed there is huge potential of energy conservation by using Free cooling concept as

an ‘Energy Conservation Measure’. As per our practical experience, it has been observed that actual running of

the free cooling concept is around 4½ months.



Benefits:

Reduction in compressor run hours.

Increased compressor life

Less energy cost.

Less CO-2 emission.

Lot of energy conservation measures have been initiated &

implemented.

In appreciation of the achievement in ENERGY CONSERVATION in the Office buildings sector, BSNL

Haryana has won three National Energy Conservation Awards - 2010. The awards have been presented by

Honorable Minister of Power, Sh. Shushil Kumar Shinde on 14th December, 2010.


ANNEXURE ‘A’

Switch room

X-MISSION

BTS

OFFICE

AC PLANTCONDENSORS

OMC

OFFICE

LAYOUT PLAN OF AC PLANT AT T.E. YAMUNANAGAR (AIR CIRCUIT NORMAL)

GREEN (SUPPLY AIR)

RED (RETURN AIR)

BLACK ( CONDENSOR AIR CIRCUIT)

CONDENSOR


ANNEXURE ‘B’

Switch room

X-MISSION

BTS

OFFICE

AC PLANTCONDENSORS

OMC

OFFICE

LAYOUT PLAN OF AC PLANT AT T.E. YAMUNANAGAR (FREE COOLING)

GREEN (FREE OUTER COLD AIR)

RED (HEATED EXHAUST AIR)

RETURN AIR PATH

CONDENSOR

AC PACKAGE

5000CFM AIR INLET FAN

OUTER COLD AIR


ANNEXURE ‘C’

----• TEMPERATURE CONTROLLER FOR FREE AIR COOLING

IN WINTER (SCHEMATIC DAIGRAM)

TC-1

NEUTRAL

TC-2

FREE AIREXHAUST

OUTSIDE TEMP. SENSOR

INDOOR TEMP SENSOR


53Energy Conservation & Management

Technical Paper on

Feasibility Study Of Installation Of VFD For Id Fans In Thermal Power

Plant

Santosh Mahadeo Mestry

[email protected], [email protected]

1. Introduction:-

The function of Induced Draft fan is to suck the gases out of furnaces and throw them into the stack. Boiler is

provided with two nos. of Induced Draft Fans. Each ID fan is provided with regulating damper control and

scoop control for controlling the loading on fans.



3. Principle of Hydraulic Coupling:-

The ID fans are controlled with VFC control. The variable fluid coupling works on the principle of

hydrodynamics. It consists of an impeller and rotor(runner) enclosed in a Casing. The impeller is connected to

the prime mover, while the rotor is connected to the driven machine. The coupling is filled with fluid, usually

mineral oil. The speed of the driven equipment is varied by varying the quantity of fluid Supplied between the

impeller and the runner.

3.1 Slip:-

A difference between input & output speed is essential in a fluid coupling in order to enable it to transmit

torque. Difference between input & output speed is normally expressed as percentage of the input speed &

refereed to as slip.

(I/P speed- O/P speed)

Slip % = - ------------------------------ *100

I/P speed

4. Hydraulic Coupling Losses:-

There are two Types of Losses of power in VFC.



4.1 Hydraulic Losses :-

Since the regulation is based on slip regulation, evidently there is slip loss occurred which heat up the working

oil & must therefore be removed by a heat exchanger. The amount of loss depend upon the run- of Char. & slip

required to attain the desire O/P speed.

4.2 Mechanical Losses :-

Mechanical losses occurred due to friction in the bearings, ventilation losses & losses in the oil circulating

system which usually do not exceed 1% and are therefore of little significance.

Loss in a typical VFC can be shown graphically as below.

5.0 Hydraulic Losses Calculation:-

5.1 Heat Loss Method:-

The heat gained by the cooling water supplied to the VFC is an indication of the Power loss. The energy loss in

VFC is estimated by measuring the cooling water flow and the temperature difference between the inlet and

outlet cooling water. Cooling water flow rate is measured by ultrasonic flow meter & ECW temp. gain is

obtained from infrared thermometer.

Mechanical Losses

(W. R. T. Speed)

Hydraulic Losses

(W.R.T. Slip)

Losses (KW)

Speed (RPM)

Slip (%)



The calculations related to VFC loss are given below

Total heat loss (KW) = ECW flow in m3/h x ECW Temp. Gain in 0C x 1000

---------------------------------------------------------

860 Kcal/hr

Hydraulic loss :-

SR. NO. PARAMETER UNIT

UNIT-1 UNIT-2

AVERAGE ID FAN-1A ID FAN-1B ID FAN-2A ID FAN-2B

A

Cooling Water

Flow of Working

Oil Cooler M3/Hr, 104 78 89 105 94

B

Temp. Rise of

CW Across WO

Cooler

Deg.

Celsius 2.2 2.6 3 2.8 2.65

C Scoop Position % 55 54 53 54 54

D=(A*B*1000)/860

Total Heat Loss

in VFC KW 266.04 235.81 310.46 341.861 288.54

The above calculation of Hydraulic Loss by heat loss method is validated by Slip Loss calculation. It is given

below.

5.2 SLIP Loss Method:-

Some technologist regarded Fluid coupling as the hydraulic analog of the AC squirrel cage induction motor as

the motor torque is developed by interaction between the magnetic field at synchronous speed created by the

stator current, and the field created by the current it generates in the rotor cage, which in turn is slightly lower

speed equivalent to the slip.

Speed measurement is done by Stroboscope. Current & Voltage values are from PMS.

O/P Power

I/P Power = ----------------

(1- Slip)

Hydraulic Loss by Slip Loss method is shown in following table.



5.3 Validation of Hydraulic loss by slip loss calculation:-

SR. No. PARAMETER UNIT

UNIT-1 UNIT-2

AVERAGE

ID FAN-

1A

ID FAN-

1B

ID FAN-

2A

ID FAN-

2B

A Motor I/P Power KW 1224.00 1243.00 1257.00 1289.00 1253.25

B

ID fan Motor

Efficiency % 96.00 96.00 96.00 96.00 96.00

C Scoop Position % 55.00 54.00 53.00 54.00 54.00

D Motor Speed RPM 733.00 734.00 731.80 733.50 733.08

E Fan Speed RPM 574.00 576.10 568.20 573.00 572.83

F=100*(F-G)/F Slip % 21.69 21.51 22.36 21.88 21.86

G=A*B/100 VFC, I/L Power KW 1175.04 1193.28 1206.72 1237.44 1203.12

H=G*(1-F/100)

Fan Shaft I/L

Power KW 920.15 936.58 936.95 966.67 940.09

I=G-H VFC Loss KW 254.89 256.70 269.77 270.77 263.03

6.0 Efficiency Aspect:-

Efficiency of variable fluid coupling is= 1- slip. Fan driving system efficiency can be improved by regulating

fan speed by digital Variable Frequency Drive(VFD) instead of VFC.

Fan driving system efficiency ηdriving= ηmotor* ηVFC = ηmotor*(1-slip)

MOTOR VFC FAN

I/P Power

P

ηmotor= 96% ηVFC= 1-slip I/P Power at Fan Shaft

P* ηmotor%* ηVFC%



6.1 Present Efficiency Calculation:-

Average Slip of VFC =21.86%.

PRESENT EFFICIENCY ( ηold)

SR. NO. PARAMTER UNIT ηold

A ηmotor % 96

B slip % 21.86

C=(1-B/100)100 ηvfc % 78.14

D=A*C/100 ηdriving % 75.0144

7.0 Recommendation:-

Installing a Variable Frequency Drive for this variation in flow requirements will result in substantial energy

savings. The speed of the fan can be varied to attain the desired flow.

There are two options.

1. To install variable frequency drives for the ID fans with VFC in place.

2. In this case, fan speed is varied by VFD keeping VFC scoop 100% open.

Design VFC slip at scoop 100%: - 3.4%

NEW EFFICIENCY (ηnew)

SR.NO. PARAMTER UNIT ηnew

A ηmotor % 96

B slip % 3.4

C=(1B/100)100 ηvfc % 96.6

D=A*C/100 ηdriving % 92.736



1. To install variable frequency drives for the ID fans & remove VFC .

In this case VFC slip loss is nil since slip =0

NEW EFFICIENCY

SR.NO. PARAMTER UNIT ηnew

A ηmotor % 96

B ηdriving % 96

HT VFD of this capacity is running in several plants

8.0 Cost-Benefits:- (New Efficiency-Old efficiency)

% Energy Saving = ---------------------------------- *100

New efficiency

SR. NO. PARAMETER UNIT Value

A

AVERAGE

MOTOR I/P

POWER A 1253.25

B ηold % 75.01

VFD

WITH VFC

OPERATING

AT FULL SPEED

(SCOOP=100%)

VFD

WITHOUT

VFC

C ηnew % 92.73 96

D=100*((C-B)/C)

ENERGY

SAVING % 19.10 21.86

E=A*C/100 KW SAVING KW 239.48 274.02

In DTPS, there are 4no. ID fans. Above energy saving calculation is for one fan.



If cost of unit- 3.50 Rs/KWH & annual Operating Hrs. =8200 Hr, benefit & simple payback period is shown in

the following table.

SR. NO. PARAMETER UNIT

VALUE

VFD WITH VFC

OPERATING AT FULL

SPEED(SCOOP=100%)

VFD

WITHOUT

VFC

A

ENERGY

SAVING/FAN KW 239.48 274.01

B NO.OF FAN No 4

C=A*B

TOTAL ENERGY

SAVING KW 957.92 1096.04

D COST/UNIT Rs. 3.5 3.5

E TOTALINVESTMENT Rs.CR. 5.6 5.6

F

ANNUAL

OPERATING HRS Hrs. 8200 8200

G=C*D*F ANNUAL SAVING Rs CR 2.74 3.14

F=12*(E/G)

SIMPLE PAYBACK

PERIOD Month 24.44 21.36



Industrial Economics

Mr. L.Manickavasagam.

Managing Director & Energy Auditor.

Introduction:-

Most of the industries especially textile industries are located in the rural areas and the up to date technology is

not reaching at the level of electrical engineers in all industries about various factor like energy saving, energy

auditing etc.

Case study 1 (Example):

In leading industries like heavy Automobile industries maximum demand is 8000 KVA. But Maximum units per

hour consumption are 4000 KWA only. The PF in the metering pointer is 0.995. The Power factor at load point

is varying from 0.45 to 0.85. This result of load factor is 50 %.

Case study 2 (Example):

In another light vehicle automobile industries located in north is having a maximum demand of 12MVA. But the

consumption is 6 MWH Units/ Hour. The electrical engineer is having a problem of locating a fault if it is in tail

end due to shortage of labor. This result 6MVA is not pumped in to the cables and 1000 Unites / hour is waste.

Case Study 3 :-

2.1 Methodology:-

A textile industries a compressor motor 200 HP/ 150 KWh having a PF of 0.82 after 6 months of time duration

the PF come down to 0.75. The capacitors are not helping to improve beyond 0.85. The reason found is that the

inductance in 3 phases varies. This could happen in rewind motors. A remedial measure that Compressor motor

is fed by VFT with a result of energy saving 20% , PF UPF and KVA reduction of 440 KVA.

1.2 In Text tile industries is having a MD of 2600KVA in Tamilnadu .The unit consumption is 1600 KW

/hour. Due to power cut in Tamilnadu the TNEB permitted only 1200KVA. The balance load is

balanced by DG sets 2*750 KVA . The monthly energy charges including Diesel cost around 75

Lakes. The PF at the meter point is 0.995.

1.3 Executive summary and methodology:



All machine tail end PF measured and corrected unity PF due to this 700 KVA reduces. One generator

put off with a saving of Diesel charges 10 LAKS per month secondly one of the DG set running was

operated at 440 Volt 50 cycle with PF 0.8 .The corrective measure taken to operate 400 Volt 48.5

Cycle and unity PF . This result reduces 200 KVA and a saving of 20 % diesel

2.4.

An additional load of 500 KVA received from EB.DG set get off. The electric city bill rise in to 50 lakes only

with a saving of 25 lacks per month and 3 cores per annum. The industries is getting loss of 5 cores in book

value and 3 cores recovered from energy charges leaving 2 cores. Action is being taken to avoid failure of

equipment and labor problem to improve production.

2.5

The harmonics is taking major role in poor PF and failure of Motors. One of the association raised voice to ban

in condition bulb and available bulb to be replaced by CFL. In the same way we need to raise a voice 3 phase

convector in VFT extra. To be ban which has used mainly in chloride industries textile industries, cement

industries, etc. the harmonics produced in the convector result low PF and remise the PF. The Total KVA

increases continuous power loss in capacitors and degrading of capacitor. In leading manufacturer of VFT is

giving only 0.9 PF. An additional harmonics filter is to be installed to get the unity PF. BEE should take steps to

provide 5 star rating for VFT even though in ported one , eddy current control motors and voltage vector

control motors.

3.1 Conclusion:

Capacitors are used in industries mostly in control room where ever MD Is exceeded average units by more than

one times should be penalized even 5 to 10 times. So the industries come forward to provide the quality

capacitor in the motor end with help of energy consultant. Our national maximum demand can be utilized in

beneficially the loss in generation transmission and distribution, utilization is now 50 % to 100%. This will be

reducing considerably 220%.

3.3.2

In Tamilnadu agriculture service connection serviced with free energy efficiency Motor by replacing the

exciting motor. This will considerably reduce the maximum demand by 800 MA in Tamilnadu grid. This can be

extended to all India level not only agriculture but also in industrial services.



3.3.3

A quality capacitor cost about rupees 450 to 500. Govt of India and state government should get the technology

high quality capacitor( This is per /KVA watt consumption , Durability not to be degrade cost) should be

manufacture and supplies and not to be imported. The subsidy can be given to capacitors this will make

reduction of KVA in national level MD and this MD can be utilized beneficially without incurring a huge

amount on generation as a short term measure.

3.3.4

A cement industries is consuming 67 unites /ton where international standard is 91 units / ton.

The reduction of units is due to very simple technology. The horizontal rotary kiln converted in to vertical rotary

. Energy consumption reduces by 26 % this would be implemented in all cement industries by giving all

assistant.

3.3.5

The board should supply the quality of voltage and without harmonics current, Over voltage, under voltage,

transcend voltage, surge voltage and Un intersectional supply. This will ensure the increase in production.

Request:

This message should reach the people consent people. The summit will help expertise.



Domestic (Human factors)

Mr.Arunachalam Pillai

Introduction :

In all India domestic consumers are meeting high energy charges . This is due to the electrical engineer is not at

all involving the design. An electrician is the taking a major role in deciding wiring and equipment etc. he didn’t

know energy saving or energy conservation in domestic services. This submit will help to educate the domestic

consumer on energy saving.

Capital out lay :

Methodology:-

Most of the houses are constructed in apartment or flats in metro, state capital etc, where the land value is very

high. In multi story building natural lighting near hall rooms are big question? It should be design and

implemented by MMDA .In AC rooms the height of the room should maintain at 2.5 Meter only. Normally

rooms are designed 3.5 meter height. The fall selling should be provided at a height of 2.o meter to 2.5 meter.

This will save the 30 % energy.

In normal house having a ground floor only 75 square meter or provided with refrigerator , water pump with

motor , electrical oven , heater, Cooker , vacuum motors and lightings.

Executive summary:-

A tube light to be used with energy efficiency lamp .This energy consumption will be 30 watts with servo

stabilizer of 195 Volt. This will save 15 watts lower than 45 watts CFL with same light energy.

This will save 30% of energy. The power circuit should be provided with 225 V to 230 V output always. This

will save the equipment, life, energy saving.

2.2.3

A water pump should be used with level limiting switches.

2.2.4

A water tank should be providing with each floor level.



2.2.5

For gardening GLR should be used.

2.2.6

A five star refrigerator and Air conditioner should be used. Thermal switch checked for it is sound for 6 months

once. The refrigerator should used of it is full accommodation this will increase the efficiency in the refrigerator.

When the refrigerator is empty the thermo material should be provided inside. This will avoid cooling of the air

in side.

2.2.7

Fan should be used capacitor type regulator only. The consumer should be educated to use the regulator only in

off condition while reducing the speed. This will avoid failure of regulator.

2.2.8

The wiring to be checked in a year for good insulation. When the earth to natural voltage increase more than 1.5

V . The electronic devices light, computer, printer, scanner will be get damaged.

2.2.9

When the inventor or UPS used the harmonic should be used below than 5 %. This should be checked at the

level of UPS and Inventor by the license authority.

2.2.10

The consumer have to be educated to penalize supplier in the consumer court ,when the voltage fluctuate more

than 5%.

Conclusion:

To achieve this with the consumer the awareness to be made. In syllabus of 10th and12th subject of Physics,

energy efficient should be including. In ITI, Polytechnic , Engineer colleges the energy saving, energy

conservation , energy efficiency to have a one subject as a mandatory . In TV wide publicity should give about

energy saving and energy conservation. I hope this submit will open the eye of the customers and Government

to implement all recommitting.



“Design and Development of 100 kWp Stand Alone Photo Voltaic Power

Plant at University of Petroleum and Energy Studies, Dehradun”

Ms. Madhu Sharmaa, Dr. S.J.Chopraa, Dr. S.P. Singhb, Dr. R.N.Singhb aUniversity of Pertroleum and Energy Studies, Dehradun ([email protected])

bSchool of Energy and Environment Studies, DAVV, Indore

Need & Justification of the Project

India is the sixth largest and one of the fastest growing energy consumers in the world. Economic growth at

80/o to l0% % over the next few decades, will lead to a substantial increase in demand for Energy in general

and petroleum products in particular. India is relatively poor in oil and gas resources. It meets nearly 72% of

its petroleum products demand through imports. With depleting crude oil reserves globally, we have to look

at ways other than hydrocarbon resources to satiate our energy appetite. Solar energy is a good option &

has a great potential.

The University consumes about 40,000 Lts of diesel annually for our DG set for the emergency supply of

electricity. By replace emergency generation of electricity from diesel based to solar will help to save a huge

amount of petro energy and also money.

Objective of this project

Keeping above things in mind the following are the objectives of the project

1. To use the most effective and environmental friendly power saving methods in the UPES campus at

Dehradun.

2. Shift entire day time lighting load to Solar Power

3. Replacing the DG set with solar system.

4. Develop solar PV based demo system..

Introduction

In the coming centuries of the decline of the World’s fossil Energy Stocks, a electricity production mix will

established which will be inevitably dominated increasingly by the direct & Indirect use of Solar Energy. Except

Nuclear, all common energy carriers like coal & Oil are indirectly solar energy carriers, for their genius is

basically due to prehistoric solar irradiation on earth. Over the last few decades a strong public desire to

introduce rapidly sustainable energy conversion technologies with a minimum of harmful impacts on society &



Environment developed & proved its realization in various projects worldwide. The design of a Sun power

station depends mainly on the basic technology of its energy conversion system.

Solar PV is a renewable energy system which uses Photovoltaic modules on the roof or façade area of a building

to convert light into electricity. Voltaic cells are made up of thin layers of Semi Conducting material (Usually

Crystalline Silicon) which generate an electrical charge when exposed to direct light.

SAPV system design is very dependent on the geographical location of the system since the amount of

electricity generated varies with the irradiance and temperature but also with the consumed energy in general.

Balance-Of-Systems (BOS) : The PV system includes not only the source circuits or subarrays, but also the

associated power conditioning, protection & safety equipment, and support structures. All these components

come under the one category named ‘Balance of Systems’. The BOS is defined as everything except the PV

modules and the load. The BOS includes module support structures, external wiring & connection boxes, Power

Conditioning equipment, inverter, charge controllers, transformers, Safety & Protective equipment- diodes,

switches, lighting protection, circuit breakers, ground rods and cables , Energy Storage batteries, Utility Grid

Interface and Connective devices, Wretches monitoring instruments and associated sensors (pyranometers,

thermometers, anemometer etc), Data acquisition equipment for monitoring & evaluating the PV system

performance.

Materials and methods

UPES has a campus of 25 acres (approximately 2 Lakh sq Feet) of space and has an electrical load connected

250 KW by the state electricity department. Beside this 4*125 KVA & two sets 65 KVA DG sets are running

for emergency power supply to our Class rooms, Hostels, Mess hall. Faculty seating which include Computers,

LCDs, Exhaust Fans, Lighting fixtures etc

4.1 Arrangement of Finances

As per document No. 32/01/2009-10/PVSE, Government of India of MNRE, Solar Photovoltaic Group,

University is eligible for applying the financial assistance as per article 7 of the document i.e. Rs.100 / watt .

4.2 Solar Energy Potential in Dehradun

Solar Energy resource assessment is the primary & essential exercise for solar energy projects because of its

intermittent nature. The maximum possible values of solar radiation on earth are solar Constant (1367 W/m2).

To know the Solar Energy Potential in Dehradun average of sunshine hours, wind speed, rainfall, ambient air

temperature, maximum solar radiation, ,minimum solar radiation, solar radiation on Horizontal Surface, rage

solar radiation on tilted surface as resources have been used.



Collection of meteorological data ( Source : NASA)

Parameters for Tilted Solar Panels:



Minimum Radiation Incident on an Equator-pointed Tilted Surface (kWh/m2/day)

Lat 30.5

Lon 78.5

Direct Tilt 0 Tilt 15 Tilt 30 Tilt 45

January 6.13 3.35 4.18 4.77 5.10

February 5.50 3.46 3.96 4.26 4.34

March 7.07 4.88 5.32 5.49 5.37

April 7.62 5.98 6.17 6.04 5.60

May 7.40 6.46 6.36 5.94 5.23

June 5.56 5.67 5.50 5.09 4.44

July 3.43 4.51 4.42 4.15 3.70

August 2.62 3.87 3.88 3.72 3.42

September 4.65 4.24 4.45 4.46 4.25

October 6.93 4.40 5.04 5.40 5.48

November 7.28 3.73 4.60 5.22 5.54

December 6.64 3.17 4.05 4.70 5.08

Annual Average 5.90 4.48 4.83 4.94 4.80



4.3 Project Site Details

Location/Address - University of Petroleum & Energy Studies, Bidholi, Dehradun

Altitude - 2237 feet (682 m), Latitude - 30 o 19’ N, Longitude - 78 o 20” E, Av rainfall -

2073.3 mm, Temperature - Summer - Max 36 oC and Min 16.7 oC, Winter - Max 23.4 oC and Min 5.2 oC.

4.4 Determining electrical load and identify the location

The very first step in designing a PV system must be a careful examination of electrical loads because sizing of

the system components is dependent on the electricity and power demand.

Based on the lighting load calculations in different buildings at University campus and available roof top /

façade area to install arrays and battery banks , 4 independent sites were selected to install the 25 KW Solar

Photovoltaic System each.

Location to install PV Generator

S.No. Location Location for PV generator Lighting

Load(kW)

1. Parijat -building Rooftop

35.5*

2. New Building Rooftop

3. Chitrakoot Flat facade area 22.55

4. Hostel block – A Slightly sloped facade area 14.2



*For the first two buildings the inverter room and battery room is common and load can be distributed either

way.

4.5 Designing of PV Generator

A PV generator comprises modules, fixation material, mounting structure, bypass diodes, blocking diodes,

fuses, cables, terminals, overvoltage/lightning protection devices, circuit breakers and Junction boxes.

Module selection - After collection of Meteorological data different PV modules were compared according to

their type, rated power, efficiency, Fill factor, protection level, life and anufacturing standards (IEC) for

selection. PV modules based on thin film technology are not considered as their efficiency is less and there is

probability of breakage. Around 5 % of breakage has been reported as per different case studies.

CEL has been selected to supply and commission proposed solar pack and modules of 156 Wp have been

considered.

PV Array size

The key factors affecting system sizing are Load Size, Operation Time, Location of the system (solar radiation),

Possible sizing safety margin, Available roof or façade area can restrict the PV array size.

PV modules are combined by series and parallel connection to form an electrically and mechanically larger unit,

the PV Generator. The number of series connected modules i. e. string determines the system voltage, which

corresponds to the input voltage of the connected inverter. The number of strings connected in parallel

determines the system power.

Module voltage decreases with increasing temperature. The maximum power point of the string must be

calculated to be in the range of the designed system voltage for all operating temperature.

Calculation of Maximum no. of modules in string In our case as per module characteristics

Temperature dependence

Voltage coefficient - 0.34 % / oC Current coefficient + 0.04 % / oC

As per inverter specification

Minimum input voltage 120 V Maximum input voltage 220 V

Minimum site temperature 5oC Maximum site temperature 37oC

Nmax = = = 5 Nmin = = = 4



Total 5 numbers of modules in a string is considered.

Specification of string

S.No. Parameters Specifications Units

1 Total modules in series 5 Nos.

2 Voc 214 V

3 Vmp 170 V

4 Imp 4.4 A

Calculation of number of string to be paralleled to the inverter Inverter maximum input current = 146 A

String current = 4.4 A

Nstring = 33

Number of strings considered to be paralleled = 32

Five Modules connected in series to make a string

4.6 Orientation of PV array and shadow analysis

Orientation of the PV array is south facing at a tilt angle of 25o to have the optimum output throughout the year

at 30.33o latitude and 78o longitude

Shadow Analysis

Latitude, = 30.33o Tilt angle, β = 25o Day no., N = 355

(on 21st December sun - at lowest height & shadow of string – largest)

Declination angle, δ = -23.45o

Panel Width, b = 4 m Panel length, L = 1.58m

Hour angle,

Solar altitude angle,



Module row distance, d

Tilt height, h h = b Sin β = 1.6

Frame distance, d2 d2 = (i.e. distance between two rows)

Time

8:00

AM

8:30

AM

9:00

AM

10:00

AM 2:00 PM 3:00 PM 4:00 PM 4:30 PM 5:00 PM

Hour

angle,

-60 -52.5 -45 -30 30 45 60 67.5 75

Solar

Altitude,

24.82 31.26 37.51 48.94 48.94 37.51 24.82 18.21 11.5

d2 (m) 3.28 2.63 2.08 1.39 1.39 2.08 3.28 4.86 7.86

Panel



4.7 Area required

As already discussed above the selected locations to install PV Generators are

S.No. Location Location for PV generator

1. Parijat -building Rooftop

2. New Building Rooftop

3. Chitrakoot Flat facade area

4. Hostel block – A Slightly sloped facade area

1 & 2. Parijat Building & New building

For the first two above location available roof area is sufficient.

3. Chitrakoot

Array matrix has been designed as

1st row - 6 structures, 2nd row - 5 structures, 3rd row - 5 structures

Each structure is of two strings.

Total no. of strings = 32

Structure size = 3.2 x 4 m2

Space between structures = 0.5 m

Distance between rows = 2.25 m (Calculated by shadow analysis)

Length of the row = 3.2 x 6 + 0.5 x 5 = 21.7 m

Width of the structure = 4 x cos 30 = 3.464 m

Total width required = 3.464 x 3 + 2.25 x 2 = 15 m

Area required = 21.7 x 15 = 326m2 = 3510 square feet

4. Hostel block – A



All the structures installed in one row.

Required length = 3.2 x 16 + 0.5 x 15 = 58.7 m, Required width = 4 x cos 30 = 3.5 m

Area required = 58.7 x 3.5 = 206 m2 = 2217 square feet

4.8 Bypass diodes - A bypass diode provides a current path around a module or a part of a module. It

protects the bypassed cells in the module, e.g. under partial shading conditions, from operation in a load mode

and possible destruction. The need for bypass diodes depends on the system configuration and module

specifications.

4.9 Blocking diodes - Blocking diodes prevent current flow backwards into a string. However, using

modern "protection class II" modules and "ground fault proof and short circuit proof' wiring virtually eliminates

the occurrence of such a failure. Blocking diodes of 10 A has been selected.

4.10 Fuses - Fuses protect cables from over current. In PV generators they should be used only if a large

number of strings is connected in parallel and the generator's short circuit current could exceed the cable's rated

current in one string. Fuse of 10 A with HRC base has been selected.

4.11 Cables - The cable cross section is sized in accordance with the maximum current. The maximum

current that may flow through the module or string cable is the generator short circuit current minus the short

circuit current of one string.

1. Sizing of the cable has been done as per IS

2. Interconnection of modules in series-parallel combination as per following

3. Each source circuit to have 5 modules in series to make one string

4. Output of the string to be taken to PJB’s using 1 x 4 mm2 single core wires

5. From 32 PJBs to 6 FJBs using 2 x 4 mm2

6. 32 sets of strings to be paralleled in 6 FJBs using 2 x 10 mm2 cables

7. Output from 6 FJB’s to be taken to one MJB

8. Output from MJB to be connected to charge controller terminal of the 25 kW PCU, using 2 x 16 mm2

cable.



Wiring Diagram

From To Cable (mm2)

Module Module 1 x 6

Module PJB 1 x 4

PJB FJB 2 x 4

FJB MJB 2 x 10

MJB PCU 2 x 16

PCU B/B 2 x 25



4.12 Overvoltage/lightning protection devices - Over Voltage Protection against atmospheric lightning

discharge to the PV array is provided.

4.13 Circuit breakers - Circuit breakers between the PV generator and the inverter or charge controller are

needed to remove the PV generator's voltage from the main DC line. They must be rated for the generator's

nominal short circuit current and open circuit voltage and for DC. The above-mentioned components are located

and electrically connected in one or more junction boxes. This box must be suited for the mounting location in

terms of IP-protection, temperature rating, UV-resistance etc. It should be easily accessible to regularly check

the fuses and the overvoltage protection devices and to open the DC circuit breaker(s).

4.14 Junction boxes

Series boxes - To connect modules in series box is used. Total no. of series boxes required = 5 x 32 = 160 for

each unit

Panel Junction Box (PJB) - Panel JB is used to run the electrical supply cables for the cell strings from the

embedding material to the outside. Selected panel junction box Hensel make having two nos. of terminals 4

mm2 and ½ “gland (one for entry and another for exit) With IP 65 protection

Quantity required 32 x 4 = 128 sets one for each string

Field junction box - Field junction box is a device which is used to parallel the different module strings.

Terminal blocks are provided for paralleling +ive & -ive electrical output from series junction boxes.

Sizing of junction box depends on the voltage and current rating and also on the number of strings which it can

parallel.

The module junction boxes must have minimum protection to IP 54 and protection class II when mounting; care

should be taken to avoid any water penetration.

Selected Field junction Box

FJB-I FJB-II

Type Hensel make Hensel make

Parallel connection 6 nos. 5nos.

Blocking diode 10 A 12 6 nos. 5 nos.

HRC fuse with fuse base 10 A each 6 nos. 5 nos.

MOVs 500 volts rating each 3 nos. 3 nos.

Protection IP 65 IP 65

Quantity 2 x 4 = 8 sets+ 4 sets spare 4 x 4 = 16

sets = 12 sets



Main junction box ( Array junction box) - This is for paralleling all +ve and all –ve points from the individual

field junction boxes. A bus bar is provided with suitable studs and lugs for paralleling electrical outputs from

field junction boxes. Selected MJB is of Hensel make.

Copper bus bar capacity – 200 A one pair

Protection IP 65

Quantity 4 sets

4.15 Mounting structure - The mounting structure holds the modules in place. It must take all mechanical

loads, potential wind loads and thermal expansion/ contraction with an expected lifetime of at least 20 years. In

building applications water tightness is often needed as well. Module mounting and wiring should be simple.

The replacement of individual modules should be possible without dismantling the whole PV generator.

Each structure fabricated from drawn steel and hot dip galvanized should capable of supporting 10 numbers of

PV modules and capable of withstanding a horizontal wind speed of 150 km/hr after grouting and installation.

The mounting structure design should be such that the frame, on which PV modules are mounted, can be kept

inclined at 25o to the horizontal.

4.16 Power Conditioning Unit - Power conditioning unit (PCU) provides uninterrupted AC power using

battery power. DCDB output will be fed to the PCU which mainly consists of MPPT (Max. Power point

tracker), Charge Controller & Inverter.

The Power Conditioner Units shall convert DC power produced by SPV modules and stored in battery bank, in

to AC power.

Common Technical Specifications:

Type: Self commuted, current regulated, high frequency, IGBT based

Output Voltage : 3Φ, 440 VAC (±10%)

Waveform : Pure Sinewave

Output Frequency : 50 Hz ± 3 Hz

Continuous Rating : 25KVA

Nominal DC Input : 120 VDC

Total harmonic Distortion : < 3%

Operating temp. range : 5° to 50° C

Housing Cabinet : IP 20

Inverter Efficiency : >90%

4.17 Determining Battery bank Size

The battery’s task is to compensate for the mismatch between energy supply and energy consumption. The

battery capacity is stated in Ah.



The nominal cell voltage is 2 V, but the actual open circuit voltage of a fully charged cell is in the range of 2.1

V—2.4 V depending on acid density and temperature.

Depth of discharge (DOD)

During discharge, the operating cell voltages decrease from the above average to cut-off between 1.75 V and 1.9

V. This cut-off voltage is very important for the battery lifetime as it defines the depth of discharge (DOD). The

DOD is both rate and temperature dependent. This maximum allowable DOD depends on battery type and load

profile. For typical lead acid battery DOD is between 0.5-0.8.

Autonomy time Autonomy time varies from case to case and depends on latitude, operation season, required percentage of

availability.

Reserve days (Autonomy days) = 2

Required energy for 6 hours daily = 25 kW x (2 x 6 hours) = 300 kWh

Battery capacity = = = 2500 Ah

Selection of battery bank

Exide made

Maintenance free Tubular lead-acid batteries

Conform to : IS 1615 standard

Nominal capacity : 2500 Ah @ 27oC

Total number of cell per battery bank : 60

Float voltage : 2.25 + 0.01 Vpc @ 27oC

Boost voltage : 2.30 + 0.01 Vpc @ 27oC

Guaranty : 5 years

4.18 Sizing of Inverter

The requirements for a stand- alone inverter are best fulfilled by sine wave inverters. These devices work on the

principle of pulse width modulation.

They are suitable even for operating sensitive electronic equipment. Compared with trapezoidal inverters, sine

wave inverters are higher in price on account of the greater complexity of their circuitry.

In stand-alone application sizing of the inverter is very critical.

Care must be taken to avoid over sizing the unit because it will not deliver as peak efficiency when operated at

only fraction of its rated power.



High Conversion efficiency is essential for the use in autonomous system with battery storage. The slope of the

output wave form is an indication of the quality & cost of the inverter.

System Concept

The inverter power is approximately equal to the PV generator.

The following power range has been used for design

0.8 * Ppv < Pinv < 1.2 Ppv

For this system we have chosen inverter of 25 KW rating for each system.

Selected Inverter

The models should have qualification as per IEC 61683, IEC 62109-2 & IEC 62093

The Power Conditioner Units (25KVA) shall convert DC power produced by SPV modules and stored in battery

bank, in to AC power.

Common Technical Specifications:

Rating 120 V ,25 KW Pure Sine-wave

Mounting Inside Control Room, Floor/Wall Mounted

No. of Inverters 1 (for each system)

Enclosures Indoor

4.19 Charge Controller & MPPT

The power available from the solar array varies with module temperature and solar insolation.

The inverter has to extract the maximum power out of the solar array. Therefore it is equipped with a device

called ‘Maximum Power Point Tracer (MPPT-Unit).

With the help of the MPPT unit the inverter input stage varies the input voltage until the maximum power point

on the arrays IV Current is found. In the stand-alone systems, the system voltage of the PV generator must be

matched to accumulators. The charge voltage must be higher than the battery voltage.



Advantages of using MPPT charge controller:

There is greater flexibility in selecting modules and batteries

In case of very long wires from PV generator to battery, much higher generator operating voltage can be chosen

than the battery voltage, resulting lower currents and wiring losses.

Selection of MPPT charge Controller

The safe charging of the battery is ensured by using pulse width modulation (PWM) for the charge current.

Operational Voltage range - 150 V to 410 V, Rating - 120 V pulse width modulated

Mounting - Inside control room, The current will be fed to the charge controller and MPPT should preferably

confirm to IEC 62109-3, IEC 62093 and IEC 62509 standards.

5 SAPV system maintenance

The standard maintenance schedules is followed for the SAPV system mentioned by the Solar PV Training

Programme Field Technician Manual prepared by the Central Electronics Centre, IIT Madras in association

with SIEMENS in the year 2001 (SIEMENS and Central Electronics Centre IIT Madras, 2001).

6 Estimation of CDM Benefit

Unit generated = 1, 14,750 kWh

GEI for North Zone = 0.8 kg of CO2 / kWh

GEI = 1, 14,750 x 0.8 = 91,800 kg of CO2 / annum

1 CER = 1000 kg of CO2, No. of CERs = 91,800 / 1000 = 91.8

1 CER = 10 $

CDM benefits / year = 91.8 x 10 x 45 = Rs.41, 310

Approximate cost involved in availing (consultant, validator, registration) CDM benefits is much higher than

possible benefits. May be taken as extra benefit.

7. Calculation of IRR

The discount rate which achieves a net present value of zero is known as the Internal Rate of Return (IRR). The

higher the IRR, the more attractive the project.



8. Conclusions

Based upon the detailed studies following conclusion has been drawn:

1. 100 kWp SAPV power plant has been designed and developed

2. As per the load requirement and availability of land 4 different buildings are identified to install PV

system and occupied 4 x 300 sq meters area at selected location.

3. The capital cost for 1kWp SAPV power system is INR 2.75 lacs / kWp.

4. The total amount of CO2 emissions mitigated due to the SAPV supply in its life span (i.e. 20 years) is

estimated at 1836 tons.

5. It can be safely concluded that, the PV power systems can play a major role which has a potential to

convert sunlight energy directly to electrical energy at low operating and maintenance costs and would



help to save already degraded environment. Developed solar based power system would be eco-

friendly, reliable and a sustainable solution for the near future of the World.

9. Suggestions

1. The PV system is an efficient source of power and its system cost goes down with improvement in

material research and PV module efficiency through research and development of PV system design.

2. The PV system is most suitable for remote village locations where there are frequent power cuts or grid

extension is a costlier option.

10.References

• Photovoltaics In Buildings

A Design Handbook for Architects and Engineers

Published by – James & James, London

• Planning and Installing Photovoltaic Systems

Published by – James & James, London

• Solar Energy

Principals of Thermal Collection and Storage

–by S P Sukhatme & J K Nayak, 2008

• Sizing and Cost estimation methodology for stand-alone PV power System

–Chel A, Tiwari G.N., Chandra A

Int. J. Agile Systems and Management, Vol. 4, Nos. 1/2, 2009

• Optimal sizing of solar array and inverter in the grid connected photovoltaic systems

-Source springerlink



Title of the research paper/ Case study: Eco At Gail , Vijaipur Township,

Guna.

Amita Tripathy

[email protected]

Abstract Heading: Energy Conservation Opportunities

Lighting is an essential service in all the townships. The power consumption by the lighting varies between 2 to

10% of the total power depending on the type of township. Innovation and continuous improvement in the field

of lighting, has given rise to tremendous energy saving opportunities in this area. Lighting is an area, which

provides a major scope to achieve energy efficiency at the design stage, by incorporation of modern energy

efficient lamps, luminaries and gears apart from good operation.

The Township of GAIL, Vijaipur is spread over an area of 150 acres. The power requirement of this complex is

catered through it’s own CPP of 2X2.7 MW (GTG’) and power import from utility grid ( MPSEB.) having

contract demand of 3.5 MVA. The main power distribution is through 6.6 KV system and utility grid is hooked

up at 132 KV.

Key Words: Lighting, bill analysis, solar water heaters, leds

I.Introduction:

GAIL (India) Ltd (Erstwhile Gas Authority of India Ltd), India’s principal gas transmission and marketing

company, was set up by Government of India in August 1984 to create gas sector infrastructure for sustained

development of gas market in the country. Today GAIL has expanded into Gas Processing, Petrochemicals,

Liquefied Petroleum Gas Transmission and Telecommunications. The company has also extended its presence

in power, Liquefied Natural Gas Re-gasification, City Gas Distribution and Exploration & Production through

equity and joint ventures participations. GAIL (India) Ltd is having it’s one of the gas processing complex at

Vijaipur, Dist. Guna, M.P.

1.1 Township Of Vijaipur:

The Township of GAIL, Vijaipur is spread over an area of 150 acres with 170 A- Type , 230 B -Type, 120C -

Type, 68 D -Type residential quarters, 48 bedded guest house, two hostels with 45 rooms, hospital, club

building swimming pool, Administrative building and two shopping complexes.



2.Methods And Materials

2.1energy Scenario:

The power requirement of this complex is catered through it’s own CPP of 2X2.7 MW (GTG’) and power

import from utility grid ( MPSEB.) having contract demand of 3.5 MVA. The main power distribution is

through 6.6 KV system and utility grid is hooked up at 132 KV. Major loads include motors up to 665KW,

lighting system and heater. For emergency power back up there is DG Set of 1.35MW, 415V and 4nos UPS of

ratings from 50-75KVA and small size UPS of 5-10KVA.

2.1.1Electricity bill analysis

• POWER FROM GRID – 3.5 MVA at 132KV from MPSEB.

• CAPTIVE GENERATION- 2x2.7MW Gas Turbine Generator.

• EMERGENCY BACK UP SUPPLY- 1X1.35MW DEG

• SUB STATION- 6 NOs IN PLANT

• 3 NOs IN TOWNSHIP

In the electr ical b i l l analysis , a wide var ia t ion is in the kWh (Units) consumption on a

monthly basis . The ra t io of maximum to minimum consumption is about1.75.

Maximum Power Consumption: 196812.5kWh for the Month of May. Here demand

registered for the same month is 400 kVA.

Minimum Power Consumption: 112110kWh power consumption and. demand regis tered

was 457 kVA for the month of August .

2.1.2 Demand Analysis



0

1000000

2000000

3000000

4000000

5000000

6000000

Apr-08

May-08

J un-08

J ul-08

A ug-08

S ep-08

Oc t-08

Nov-08

Dec -08

J an-09

F eb-09

E NE R G Y C HA R G E S DE MA ND C HA R G E S

2.1.3POWER FACTOR ANALYSIS



T OT AL E NE R G Y C ONS UME D IN C OL ONY

100000

120000

140000

160000

180000

200000

220000

A pr-08

May-08

J un-08

J ul-08

A ug-08

S ep-08

Oc t-08

Nov-08

Dec -08

J an-09

F eb-09TOTA L E NE R G Y C ONS UME D IN C OL ONY


100000

120000

140000

160000

180000

200000

220000

A pr-08

May-08

J un-08

J ul-08

A ug-08

S ep-08

Oc t-08

Nov-08

Dec -08

J an-09


2.1.4 ELECTRICITY TARIFF

contract demand=3.5 MVA

Tariff charges =Rs.130/KVA

Kwh charges: Rs.2.90>50% load factor

: Rs.3.50<50% Load factor

Average Load Factor=56.3

Average cost of unit=Rs.4.15/-

Average Power Factor for township=0.95

2.1.5 MPSEB CONSUMPTION

2008-2009 ENERGY CHARGES Apr-08May-08Jun-08Jul-08Aug-08Sep-08Oct-08Nov-08Dec-08Jan-09Feb-09Mar-09

Total

2008-2009 ENERGY CHARGES Apr-08May-08Jun-08Jul-08Aug-08Sep-08Oct-08Nov-08Dec-08Jan-09Feb-09Mar-09

Total



2.1.6 Power Distribution In Township

Total power requirement of township is being fed from LPG plant main substation. .

There are 3 substations in Vijaipur Township.

Substation-1 in phase-1.

Substation-2&3 in phase-2 colony.

The power is received in the colony in 3 different voltage levels.

They are a).6.6KV b).440v c) 33KV.

The power is received at 132KV voltage level. This is stepped down to 6.6KV, which is further stepped down to

440V in the plant substations.

6.6KV in plant is stepped up to 33KV voltage and being transmitted to Colony Via transmission line.

440V, 6.6KV is transmitted via cables to township.

SUBSTATION-1:

There are 2 sources of power in substation-1; one is at 440V level, other at 33KV voltage level.

33KV is stepped down to 440V in substation-1 by 1000KVA, 33KV/440V transformer and fed to PCC as

incomer-2.

440V coming directly from plant is being fed as incomer-1 to PCC.

For the PCC present in substation-1 there are two incomers.

Incomer-1:440V directly from plant

Incomer-2:440V coming from 33KV/440V transformer which is being fed by 33KV from plant.

All incoming breakers are rated as 1800A including bus couplers.

From PCC power is being fed to quarters in phase-1, administrative building, hospital, shopping complex,

bachelors hostel.



SUBSTATION-2:

In substation-2 there are 2 incomers

Incomer-1:440V from 6.6KV/440V, 1000KVA transformer present in SS-3.

Incomer-2:440V coming from 33KV/440V, 750KVA transformer which is being fed by 33KV from plant.

Power from PCC is being fed to guest house, schools, pump house, shopping complex, some quarters.

SUBSTATION-3:

In substation-3, there are 2 incomers

Incomer-1:440V from 6.6KV/440V, 1000KVA transformer

Incomer-2:440V coming from 33KV/440V, 10000KVA transformer which is being fed by 33KV from plant.

Power from PCC is being fed to sewage treatment plant, boundary wall area, D-type quarters, some B-type

quarters, club building, and some A&B type quarters.

3.Observations And Measurements:

3.1eco In New Bachelor’s Hostel

In New Bachelor hostel, there are 45 rooms which are provided with geysers, where there is scope energy

conservation. Also mess facility is provided which requires hot water for cleaning utensils and for other

activities. These run for about 15 hrs continuously in the mess and 1 hr in the rooms.(For the months Nov, Dec,

Jan, Feb).



3.1.1Power Consumption in Geyser:

Particulars of

the Electrical

Devices

Capacity Power Rating Period of

Operation

Power

Consumption

Unit Rate

@ Rs.4.15.

Geyser 1lt.X45Nos 3kw,230VAC 1hr/day 20250kwh/ year 84037

Geyser 25lt 3kw,230VAC 15hours/ day 1800Kwh/ year 7470

Total Cost 22050Kwh/year 91507

Power Consumption Vs time of day

2.6

2.62

2.64

2.66

2.68

2.7

2.72

2.74

2.76

2.78

8:00 8:05 8:10 8:15 8:20 8:25 8:30 8:35 8:40 8:45 8:50 8:55 9:00

time of the day(AM)Room No.9,NBH, Date-12.10.2009

pow

er c

onsu

mtio

n(Kw

)

Power Consumption Vs time of day

2.6

2.62

2.64

2.66

2.68

2.7

2.72

2.74

2.76

2.78

8:00 8:05 8:10 8:15 8:20 8:25 8:30 8:35 8:40 8:45 8:50 8:55 9:00

time of the day(AM)Room No.9,NBH, Date-12.10.2009

pow

er c

onsu

mtio

n(Kw

)



3.1.2 Estimate for supply & installation of solar water heater at NBH in GAIL township,

Vijaipur

Description

Quantity

Unit

Rate

(in Rs.)

Amount

(in Rs.)

Remarks

Solar heater modules of capacity

500Ltr.

4 No.

88000

352,000

budgetary

offer

Pipe 1" dia (cold line main header)

90 Mtr. 205 18,450 budgetary

offer

Pipe 1" dia (hot line water dropping

header + interconnector) with PUF

insulation charges

275 Mtr.

508

139,700

budgetary

offer

Pipe 0.5" dia (hot water branch line)

with PUF insulation charges

90 Mtr.

305

27,450

budgetary

offer

MS Fabrication job

400 Kg.

47.50

19,000

Rate from

current ARC

T/S

Interlock switched socket box & plug

IP66 Legrand Cat. No. 601426

4 No.

2,304

9,216

Rate taken

from Legrand

price list

Description

Quantity

Unit

Rate

(in Rs.)

Amount

(in Rs.)

Remarks



Cable 4x16 (cu.)

50 Mtr.

200

0

From our

stock

Installation charges @5 per litre

2000 No. 5.00 10,000

Electricity back up

4 No. 1,250 5,000

Total estimate of the project

592192

Add-Vat @4% 23688

Grand Total 615880

Savings and payback period:

Energy consumption charges = 45*(3 kW)*(150 days/year)*(1Hr/day)*(4.15 Rs./unit) =Rs. 84,038/- per year.

Reduction in Fixed charges on account of reduced MD = 70%*(45*3 kW) @ 110/- =Rs. 124,740/- per year.

Savings in maintenance cost for 45 no. geysers @Rs. 200/- per year = Rs.9000/- per year.

Savings in spares for geysers @ (200+150) for 15 geysers, i.e. about 25% of total qty.=Rs.5250/- per year.

Total savings per year on installation of Solar water heating system at NBH in place of normal geyser

=Rs.223028/-.

Estimated cost of installation of solar water heater at NBH Rs.615880/-.

Payback period with Solar water geyser = 615880/223028 = 2.76 Years or 33 months (approx).



3.2 ENERGY SAVING IN HVAC IN ADMN. BUILDING

Description:

The Admin HVAC plant AHU motors run at full speed all the time irrespective of heat load from Off-peak

season to On-peak season ,It is observed that there is the potential for additional energy savings possible in

ADM HVAC Plant by using VFDs to reduce the speed of fans in air handling units, in line with the reduction in

heat load from morning to evening hours and from season to season as the outdoor temperature varies or as the

internal load of equipment and occupants is reduced. It is observed that energy saving depends on the variations

in cooling load, since on very warm days the air conditioning and AHU motors will have to run at full speed but

such situations occur on very few occasions in a year or may be a couple of hours in a day. The rest of the year

or during off-peak periods ,each day there is scope for energy saving.

The following table gives the possibility of energy saving in HVAC plant by installing VFD drives

Table showing Energy consumed normally under present conditions:

S.NO MOTOR

DESCRIPTION

MOTOR

RATING

ENERGY

CONSUMED PER

DAY(taking 12hrs a

day)

ENERGY CONSUMED

IN AN YR(312days)

1 AHU MOTOR-1 7.5KW 90KWH 28080KWH

2 AHU MOTOR-2 7.5KW 90KWH 28080KWH

3 AHU MOTOR-3 11KW 132KWH 41184KWH

4 AHU MOTOR-4 11KW 132KWH 41184KWH

TOPTAL ENERGY CONSUMED IN A YR = 138528KWH

Estimating Rs.4.15/- per unit Total amount payable per yr=138528x4.15

=Rs.574891



Table showing Energy consumed if VFD drives are installed:

Estimating Rs4.15/- per unit Total amount payable per yr=85113.6X4.15=Rs.3,53221

Total savings in 1 yr after using vfd drives=574891-353221=Rs.221670

3.3 ECO IN STREET LIGHTING

Lighting is a very significant aspect from utility as well as from aesthetic point of view for a township. The

efficiency, comfort factors and the quality of lighting should not be comprised at any cost. An energy efficient

lighting system is the one which provides illumination of sufficient quantity and quality for the task being

performed at the lowest cost .This depends on the elements constituting the lighting system i.e., lamps ,ballasts,

fixtures, etc. Total lighting load is650 KW.

Sl. No Motor Description Motor

Rating

Motor

Running at

rated speed

( Taking

4hrs / day)

Motor running at

75% of rated

speed ( 8hrs /

day)

Energy

consumed /

day

Energy consumed

in a year( i.e. 312

days)

1 AHU MOTOR-1 7.5KW 30KWH 25.3KWH 55.3KWH 17253.6KWH

2 AHU MOTOR-2 7.5KW 30KWH 25.3KWH 55.3KWH 17253.6KWH

3 AHU MOTOR-3 11KW 44KWH 37.125KWH 81.1KWH 25303.2KWH

4 AHU MOTOR-4 11KW 44KWH 37.125KWH 81.1KWH 25303KWH

TOTAL ENERGY CONSUMED IN A YR = 85113.6KWH



3.3.1 Average lux level in the township (on 5.11.2009, evening 6PM):

Sl. No Location Average lux level

1 Priyadarsini ground 24

2 Park 20

3 Near temple 22

4 D type street line 24

5 C type line 24

3.3.2 The quantification of different types of fixtures

Sl. No Fixtures HPSV Rating Number

1 High mast lights 400w 20

2 Short poles 70w 400

3 Street lights 150w 250

4 Street lights 70w 110

3.3.3 Replacement of 70W short poles with 23W CFL Short poles

Total nos. of short poles present in Phase-I & II colony=400

Power input to each short pole( including wattage in choke)=70W+12W=82W

Total connected load of the short poles (i.e. 400*82)=32.8KW

Assuming daily usage of 10hours (6PM to 4 AM)

Power consumption of all short poles per day ( i.e. 32.8*10KWH)=328KWH

Cost of energy consumed @ Rs.4.15/KWH (i.e. 328*4.15)=Rs.1361/-

Cost of energy consumed in a month (i.e. 1361*30)=Rs.40830/-

Replacement of 70W HPSV lamp with 23W CFL

Power input to each short pole=23W



Total connected load of the short pole (i.e. 400*23) =9.2KWH

Assuming daily usage of 10hours,

Power consumption of all short poles per day (9.2*10) =92KWH

Cost of energy consumed / day @Rs.4.15/KWH (92*4.15)=Rs.382/-

Cost of energy consumed in a month (382*30) =Rs.11460/-

Savings:

Net energy saving in a day (i.e. 328-92) =236KWH

Net energy saving in a month (i.e. 236*30) =7080KWH

Annual energy saving (i.e. 7080*12) =84960KWH

Total amount saved per day (236*Rs.4.15) =Rs.979/-=

Total amount saved per month (7080*Rs.4.15) =Rs.84960/-

Total amount saved in a year(84960*Rs.4.15) =Rs.352584/-

Pay Back period:

Cost of 23W CFL: Rs.180/- to Rs.200/-

Cost of 400 Nos. of 23W CFL (400*Rs.200) =Rs.80000/-

Pay Back Period (Rs.80000/352584) =2months (Approx)

3.3.4. Eco In Lighting:


100000

120000

140000

160000

180000

200000

220000

A pr-08

May-08

J un-08

J ul-08

A ug-08

S ep-08

Oc t-08

Nov-08

Dec -08

J an-09




3.3.5 Connected Lighting Load Details In Different Quarters

(I) TYPE-A QUARTER:

There are total 170 ‘A’ type quarters out of which 90 quarters are occupied.

(II) TYPE-B QUARTER:

There are total 230 ‘B’ type quarters in Phase-I & Phase-II Township, which are fully occupied.

(III) TYPE-C QUARTER:

There are total 120 ‘C’ type quarters which are fully occupied.

(IV) TYPE-D QUARTER:

There are total 68 ‘D’ type quarters which are fully occupied.

3.3.6. Replacement of all 60w GLS by CFL

Total No. of 60 w lamps in all the Quarters

A Type: 90*6=540

B Type: 230*6=1380

C Type: 120*6=720

D Type: 68*12=816

Total No. of lamps =3456

Total load =3456*60 w

=207.36kw

Assuming total usage of 5 Hrs of the lamps =1036.8kwh

Total power consumption in a month=31104kwh

3.3.7 Replacing with 11w CFL

Total load =3456*11 =38.016kw

Reduction in load =169.35kw

Assuming usage of 5 Hrs =169.35kw *5 h

=846.75kwh

Power saving in a month =25402 kWh

Total saving in cost @ Rs. 4.15/- =Rs.105420/-

Total cost of 3456 CFL @Rs. 180/- =Rs.622080/-

Payback Period =6 months



3.3.8 Saving by replacement by T5 type FTLs:

Replace all single FTLs by equivalent number of T5s.(28 Watts). Simultaneously, all the new T5s fittings

should be equipped with reflectors. It is a proven fact that lux level available at the place almost doubles with

the help of good quality reflectors.

3.3.9 Cost benefit calculations are as under:

Savings by replacement by T5 tube lights and installation of reflectors

Retrofitting present T-8 fittings by T-5 fittings having electronic ballast and installing reflectors

Tube Lights Unit

Quantity 2134

Present power consumption per unit W 48

Proposed power consumption per unit W 30

Savings W 18

Operating hours per annum Hour 3000

Units saving per annum kWh/annum 115236

Cost of power (assumed) Rs./kWh 4.15

Monetary Saving per annum by replacing with T-5 tube lights Rs./annum 478229

Total Savings Rs./annum 478229

Cost of tube light with electronic ballast and reflectors Rs./no. 1000

Total cost of replacement of 2134 tube lights Rs. 2134000

Simple Payback Period Months 4.46



3.3.10 Saving by voltage reduction:

VOLTA

GE

PREVI

OUSLY

POWER

CONSUM

PTION IN

KW(PREV

IOUSLY)

POWER

CONSUM

PTION IN

KW(PREV

IOUSLY)

POWER

CONSUMP

TION IN

KW(AFTE

R

CHANGIN

G

VOLTAGE

)

UNIT

S

SAVE

D

PER

HR

UNITS

SAVED

PER

DAY

UNIT

S

SAVE

D

PER

YR

COST SAVINGS PER

YR

233v

13

216

9

4

48 17520

72708

It is observed that the overall supply voltage is well above the standard 216 volts. Hence, as explained earlier,

the luminaries are being over-burned due to the high voltage. Hence it is advisable to operate discharge type

lights at a reduced voltage. This is possible by installing an energy saver which basically works on the principle

of voltage reduction.



3.3.11 Saving by installing string operated micro-switches fitted to every dedicated FTL / Fan

It is a general observation that fans and lights fitted for providing service to specific rooms are left ON even

when the occupant is away. This is mainly because of human lethargy towards reaching out to a centrally

located switch to put it OFF. However, if such switch is provided in a manner such that the occupant has to only

pull a string hanging, it is a general observation that the occupant will generally switch OFF the particular light /

fan when leaving his / her place.

While it is difficult to estimate the saving out of such provision, it is also safe to presume that a `Switching

OFF’ habit can be made to prevail over a period of time. Surprisingly, the savings could be anywhere in the

range of 5 – 15% and the pay-back short enough to justify the investment.

3.3.12 Use of electronic ballasts:

New high frequency (28–32 kHz) electronic ballasts have the following advantages over the traditional

magnetic ballasts:

Energy savings up to 35%

Less heat dissipation,

• Lights instantly

• Improved power factor

• Operates in low voltage load

• Less in weight

• Increases the life of lamp

The advantage of HF electronic ballasts, out weigh the initial investment (higher costs when compared with

conventional ballast)

3.3.13 Optimum usage of day lighting

Whenever the orientation of a building permits, day lighting can be used in combination with electric lighting.

This should not introduce glare or a severe imbalance of brightness in visual environment.

In many cases, a switching method, to enable reduction of electric light in the window zones during certain

hours, has to be designed.



3.3.14 Cost base comparative statement of led street light fittings wrt. sodium vapour light

fittins.

RATINGS- 30 Watts LED light with 70Watts SVP/Metal Allied Lamp.

LED Street light Use Benefit Analysis.

Sr. No Lamp Power

Consumption(A)

70 watt SVP Lamp.

30 watt LED

Lamp.

Remarks.

1 Self consumption Loss

(B)

21 watt 6 watt Internal choke /

ballast /SMPS.

Consumption

2 Comprehensive cable

loss(@ 5%)

(C)

3.5 watt 1.5 watt As per

international

standard 5%

3 Transformer Loss ( @

3%)

(D)

2.1 watt 0.9 watt Lowest % loss of

100 Kva

Transformer

4 Operating Power Factor

(E)

0.45 Lag 0.99 Lag

5 Total Power

(F) =(A+B+C+D)

96.6 watt

approx.=97watt

38.4 watt.

39 watt

6 Daily consumption

@12 hrs/day

1.164 Kwh 0.468 Kwh



(G)

7 Yearly consumption

(E)

424.86 Kwh 170.82 Kwh

8 Yearly electricity bill @

Rs. 5.25/Kwh

(F)

Rs-2230.52/- Rs-896.80 /-

9 10 Year’s electric bill

(G)

Rs-22305.15/- Rs-8968.0/-

10 Cost of KW saved in 10

year’s

(H)

Rs-13,337.15/-

Operating Power factor 0.45 Lag 0.99 Lag

KVA used for Total

Power

(I)= (F)/(E)

215 VA 39.50VA

Saved VA 175.50 VA

Possible Load Growth in

watts @ PF 0.99

173.85 watt

Load growth in Kwh for

10 years @12 working

hours Daily.

(173.5 W X 12 hrs X 365 X10)

1000

=7599.3 Kwh



Possible Revenue

Generation for additional

load growth (Kwatt) for

10 years.

7599.30X 5.25

= Rs-39896.35/-

Comparative study on the aspect of operating life.

1 Working Life <2 Year

10 Year

2 Replacement

frequency per 10

Year

5 More than 10

years.

3 Cost of material

replaced

Rs. 1000/- Not required.

4 Cost of material

replaced

For 10 Years

Rs. 5000/- Not required.

5 Total (G) Rs. 6000/- Not required.

6 Maintenance

manpower price

Rs. 1500/Time Rs.1500 /-

7 Maintenance

frequency per for 10

Year.

5 times. 1 times.

8 Total (H)

Rs. 7,500/- Rs. 1500/-



9 Sub Total =(H) +

(G)

Rs.13,500/- Rs. 1500/-

10 Savings in

maintenance.

Rs. 12,500/-

Calculations of Savings for 10 years.

1 Savings in Cost Of

Energy Consumed

for 10 Years

Rs.22305.15 - Rs.8968.0/-

=Rs.13,337.15/-

2 Savings in Cost of

maintains for 10

years

Rs. 13,500-Rs. 1500

=Rs. 12,000/-

3 Subtotal (J) Rs.25,500.15/-

Saving done due to

kva saved.

Rs. 39,896.35/-

4 Total Saving

=(J) +(K)

Rs.25,500.15 + 39,896.35/-

=Rs. 65,396.50 /-

Total Cost of Expenditure and savings

1 Cost of Unit

Installed

Rs. 2250/- Rs. 7500/-



2 Cost Of energy

Consumed for 10

Years

Rs.22,305.15/- Rs.8968.00/-

3 Cost of maintains for

10 years

Rs.13,500/- Rs. 1500/-

Saving done due to

kva saved.

Rs. 39,896.35/- Rs-0000/-

4 Total Rs.75,701.15/-

Rs.17,968/-

5 Saving (J) Rs. 75,701.15 – Rs-17,968/-

6 Total Saving

L=(J) +(K)

Rs.57,733.15/-



Calculation of Expected Payback Period.

Type 70 watt SV Lamp

30 watt LED Lamp

Unit basic Cost. Rs. 2250/-

Rs. 7500/-

Difference in cost Rs. 5250/-

Saving achieved in Rs. Per

month=(L /10Y/12M)

= Rs-57,733.15 /10/12

=Rs. 482/-

Payback period for extra Cost

paid for LED Lamp

= 5250/482/-

=10.89months

Eleven Months.

CONCULSION

Maximum payback period is 12

months.

Thus replacement of street lights with LED is a good saving opportunity. The details of LED as given by a

vendor is as follows:

LED DETAILS 1W *28 1W*36 1W*48 1W*60 1W*90



LED Ratings.

30 watts. 42 watts. 60 watts. 75 watts. 112.5 watts.

Input voltage. 110v-300volt. 110v-300volt. 110v-300volt. 110v-300volt. 110v-300volt.

Angle. 120 degree

wide spreading

angle

120 degree

wide spreading

angle

120 degree

wide spreading

angle

120 degree

wide spreading

angle

120 degree

wide spreading

angle

Luminous flux. 2160 3240 4320 5400 8100

Illumination at

centre.

>25 lux from 15

feet.

>25 lux from 15

feets.

>30 lux from 15

feets.

>30 lux from 15

feets.

>30 lux from 15

feets.

Recommended pole

Height.

15 feet. 15/30 feet. 15/30 feet. 15/40feet. 15/40 feet.

Area of Illumination 25 feet. 40 feet. 50 feet. 50 feet. 50 feet.

Life Span. 60,000 hrs.

16 years.

60,000hrs.

16 years.

50,000hrs.

14 years.

50,000hrs.

14 years.

50,000hrs.

14 years.

Light source point Multi source

Light point.

Multi source

Light point

Multi source

Light point

Multi source

Light point

Multi source

Light point

Led light generation. No carbon or

chemical

generation

No carbon or

chemical

generation

No carbon or

chemical

generation

No carbon or

chemical

generation

No carbon or

chemical

generation

Light Clearness . Clear, pleasant

milky light.

Clear,

pleasant

milky light.

Clear,

pleasant

milky light.

Clear,

pleasant

milky light.

Clear,

pleasant

milky light.

Replacement/

Equivalent to SV

70 watts 100 watts. 150 watts. 250 watts. 400 watts.



Lamp or

Metal Allied

Fittings.

Advantages of using LEDS: Environmental friendly.

Zero maintenance.

Long life.

Quick investment return.

Reduces power consumption by 70%. Despite their apparent initial high price, the use of LED lighting can offer significant savings in long term,

particularly in terms of reduced energy and maintenance costs

4. Results And Discussion:

4.1Recommendation:

Keeping the above facts in view it is proposed to replace the electric Geysers with Solar Water Geysers.

4.2Recommendation:

Replacement of street lights with LED is a good saving opportunity.

4.3Recommendation:

Saving by voltage reduction

5.Conclusion:

Electric Geysers have already been replaced with solar water heaters and replacement of street lights with LED

is to be implemented very soon by the company.



Power Optimization In Refrigeration Air Conditioning

(A Case Study Of Bharat Oman Refinary Limited Bina) 1

Mrs. Snehlata Soni Dr. G. S. Sharma Brijesh Sharma , [email protected] [email protected]

Abstract

Refrigeration is a technology which makes a major contribution to humanity in many ways including

food preservation, control of indoor air quality, gas liquefaction, and industrial process control, production of

food and drink and computer cooling. Without refrigeration, modern life would be impossible. About 15% of

the world’s electricity is used to drive refrigerating and air-conditioning systems. Inefficient use of energy is a

waste of valuable resource and contributes to global warming. Most of the global warming effect of refrigerating

systems comes from generating energy to drive them. Only a small proportion comes from the release of certain

refrigerants. This informatory note describes how the efficiency of refrigerating systems can be maximized

thereby minimizing their global warming impact.

Introduction

Long cross country crude pipeline from Vadinar Refrigeration is the science of making heat flow “uphill” from

low to high temperatures. A refrigeration system extracts heat from the substance being refrigerated (cold

reservoir) and rejects it to the ambient at a higher temperature (hot reservoir) as indicated in Figure 1. This is

analogous to the pumping of water to an elevated storage tank. The energy consumption of a refrigerator is

roughly proportional to rate of heat extraction (amount of water pumped) and to the temperature lift through

which the heat is raised (height water is pumped).

The energy efficiency of a refrigeration system is usually expressed as a Coefficient of Performance (COP)

which is the ratio of the heat extraction rate to the rate of energy use.

Whatever type of refrigerating system is being used, it is fundamental to minimize the required heat extraction

and to keep the difference between TC

(condensing temperature) and T0

(evaporating temperature) as small as

possible. Minimizing heat extraction is done by insulating the refrigerated room and low-temperature parts of

the refrigeration system, minimizing ambient air infiltration (e.g. door openings and leakage) and reducing

energy use in refrigerated applications (e.g. fans and forklifts). Reducing (TC

– T0) is done by maximizing

condenser and evaporator heat transfer performance and minimizing refrigerant pressure drops in suction and

discharge pipelines. The aim of an air conditioning system design is to achieve a highly quality system that

functions effectively and is energy efficient and cost effective.



*All design are fulfilled and the requirements of the owner and user are satisfied.

*The system is reliable and has adequate fire protection level.

*A good indoor air quality is provided

Renewable energy sector growth in India during the last four years has been significant even for electricity

generation from renewable sources. Renewable energy systems are also being looked systems are also being

looked upon as a major application for electrification of 20,000 remote and unclarified in such villages and

hamlets by 2012.

BORL Location: Bharat Oman Refinery Limited is located at Bina Dist Sager in Madhya Pradesh and it 135

km from Bhopal location represented by

Figure-1 Location of BORL Bina in MP

Overview: BORL is accompany promoted by Bharat Petroleum Corporation Limited with equity participation

from oman oil company limited to set up a 6MMTPA grass root refinery at Bina . The project also involves a

crude supply consisting of a terminal at Vadinar District Jamnagar Gujrat and 935 km

Figure-1 Description of a Vapor Compression Refrigeration System

The standard vapor compression refrigeration system consists of a refrigerant in a closed circuit comprising a

compressor, a condenser, an expansion device, an evaporator and interconnecting piping (Figure 2). In the

condenser, compressed refrigerant vapor at high pressure is condensed at high temperature by heat transfer to

the surroundings. The high-pressure refrigerant liquid is reduced to a low pressure at the expansion valve. At

low pressure, the refrigerant will evaporate at a low temperature enabling it to extract heat from the substance to



be cooled. To complete the cycle, the low pressure refrigerant vapor exiting the evaporator is compressed to

high pressure by the compressor. The total heat rejected in the condenser is the sum of the heat extracted plus

the compressor energy use Loss of refrigerant from the circuit would have a very detrimental effect on the

reliability of the system, so great care is taken to make years refrigerating systems as leak-tight as possible.

Individual domestic refrigerators, of which there are more than one billion, each contains a very small amount of

refrigerant. Such systems are expected to run for more than 20 years without addition of refrigerant. The global

warming effect of such refrigerators is significant but nearly all of it is caused by carbon dioxide produced when

the electricity to run the refrigerator is generated

Effect of System Components on Efficiency

Refrigerant

Very few substances have properties appropriate for a refrigerant and, of these; few have stood the test of time

and continue to be used as refrigerants. Figure 3 shows some of the substances that have been used as

refrigerants and how their use has varied over time. There is no ideal refrigerant. Selection of a refrigerant is a

compromise between many factors including ease of manufacture, cost, toxicity, flammability, environmental

impact, corrosiveness and thermodynamic properties as well as energy efficiency. A key characteristic is the

pressure/temperature relationship. In general, for energy efficiency it is desirable for the refrigerant critical point

(temperature above which the refrigerant cannot condense) to be high compared with the heat extraction and

rejection temperatures.

Good transport and heat transfer properties are also important for energy efficiency as they reduce running costs

and allow smaller temperature differences to be employed in evaporators and condensers and hence smaller

overall temperature lifts. In general, refrigerants of low molecular weight and low viscosity will have the best

properties.

Site name :BORLSite

Adress:Bina Dist Sager (MP)

Machine configuration: 260T

1. Air Conditioning System Selection:

2. Evaluate the following factor Building location, surrounding environment and external climate.

3. Use and functional requirements of the building

4. Client’s budget, investment policy and expected

5. Quality of service



6. Some of the selection criteria include

7. Performance requirements: On comfort, noise, control

8. Options flexibility and meeting requirements of local regulations.

9. Capacity requirements: Plants room space for ducting and

10. Piping (vertical shaft) space for terminal equipment.

11. Costs: initial cost ,operating cos and maintenance cost.

12. Energy Consumption: For both economic and environment reasons.

13. System qualities

14. A Selection Of Best Location:

15. Air conditioner should be selected as per the heat load of the area to be air conditioned

16. location of the indoor and outdoor unit.

17. Indoor unit should not be installed in front or above the door

18. Refrigerant piping length and bends should be minimum for better efficiency.

19. Ensure the proper clearance from all sides as shown.

20. Refrigerant piping and wiring should be provided in order to avoid vibration,

21. Noise and gas leakage from the flare connection

22. Outdoor unit should not be exposed to direct sunlight.

23. Air conditioner should be easily accessible for service and maintenance.



Compressor

Compressors will lose efficiency if the temperature lift is higher than necessary and they will also lose

efficiency if droplets of refrigerant liquid are present in the suction vapor or if the suction vapor becomes too

hot. Compressor maintenance, where possible, and the preservation of lubricant quality are important to retain

energy efficiency. For some compressor types (particularly screw and centrifugal), their part-load energy

efficiency performance is poor compared with at full load, so sustained part-loaded operation should be avoided.

Variable speed drive technology and improved control systems can minimize the energy penalty but increase

capital costs.

Condenser

To keep refrigerant heat rejection temperatures as low as possible, condenser heat transfer rates should be

maximized and the cooling medium temperature minimized. Evaporative condensers are often the most efficient

because they reject heat to the wet-bulb temperature of the ambient air. For instance, humid air at 25°C and

60% relative humidity has a wet-bulb temperature of 16°C. However, they require careful maintenance to avoid

Legionella contamination. Water-cooled condensers combined with cooling towers also approach ambient wet-

bulb temperature but there is an additional temperature difference to drive heat from the refrigerant into the

water, so refrigerant heat rejection temperature is generally higher. Water use can be excessive if a cooling

tower is not used. Air-cooled condensers are usually the least efficient method as they reject heat to the air dry-

bulb temperature, which is generally significantly higher than wet-bulb or water temperature. However, for

small systems they are commonly used because they are cheap, simple and require little maintenance.

It is important to keep all types of condenser clean and free from fouling. Condensers rejecting heat to

atmosphere must be allowed plenty of fresh air and protected against any tendency for the air to re-circulate

back to the condenser inlet. Systems that operate with refrigerant suction pressures less than atmospheric (e.g.

low temperature ammonia or air-conditioning with HCFC-123) should use pursers to remove non-condensable

from the refrigerant.



Figure-2 Outdoor unit location

Expansion devices

Many expansion devices require significant pressure difference to allow proper operation. Therefore condensing

pressure is often maintained at artificially high levels, even at low ambient temperatures. The biggest culprit in

this respect is the conventional thermostatic expansion valve which is often selected because of its very low

cost. One solution is to use electronically controlled expansion valves.

As for condensers, evaporators should be designed to operate at minimum economic temperature difference so

that the refrigerant heat extraction temperature can be as high as possible for a given substance temperature.

Increasing heat extraction temperature also reduces the size of the compressor required.

As well as evaporator size, aspects such as refrigerant distribution, circuiting and velocity, use of enhanced

surfaces, air speeds (for air coolers) can all significantly affect energy efficiency. Air coolers that operate at

temperatures below freezing must be defrosted regularly to restore performance. Electric defrost is simple but is

least efficient and therefore only suitable for small systems. Electric defrost has to be paid for at least twice, to

put the electric heat into the cooler and to take it out again. Water defrost, hot gas defrost, and defrost by the

circulation of warm fluid through the cooler, are all potentially more efficient. However, whatever the system, it

is important to optimize the frequency and duration of defrost to avoid unnecessary defrosting

Interconnecting piping

Efficiency can be reduced if interconnecting piping is of the wrong size or is arranged in ways that cause

unnecessary pressure drop or inhibit oil return (e.g. excessive bends and fitting).



Figure-3 Installation of indoor unit

Importance of controls

A refrigeration system with well-designed components will not operate efficiently unless the components are

correctly matched and controlled. Energy efficiency has not always been the prime consideration when selecting

effective controls. If possible, the following control options should be avoided to maximize energy efficiency:

i. Slide valve unloading of over-sized screw compressors;

ii. hot gas bypass of compressors;

iii. throttling valves between evaporators and compressors;

iv. evaporator control by starving refrigerant supply;

v. too frequent defrosts;

vi. condenser head pressure controls except when necessary.



Figure-4 Bharat Oman Refinery Limited Bina

Figure-5 Outdoor unit location

Conclusion

Improving the energy efficiency of refrigeration systems is not difficult and should be encouraged because of

the environmental benefits. It often involves a trade-off between initial costs and on-going operating costs.

There are many situations where economics motivate the equipment supplier to provide the cheapest solution,

especially if the supplier does not have to pay for the running costs of the system. Standards should be set for

energy efficiency for all types of refrigerating system. Governments should legislate ensure that suppliers are

penalized for supplying systems that do not reach acceptable standards of efficiency and to ensure that users of

efficient systems benefit by more than the resulting reduction in running costs. If this were done, it is reasonable

to suppose that the energy consumption of refrigerating systems could be reduced by at least 20% in the short

term. An objective of 30-50% reduction — depending on applications 2020- as



References

• MECh9751– Refrigeration and air conditioning course outline Dr. Amir Tadors

• ISESCO Science and Technology Vision Volume1 May 2005 (61-64)

• Renewable Energy in INDIA Programmes and case studies

• Pradeep Chaturvedi President of Indian Association for the Advancement of Science

• ASHRAE Hand book

• Carrier Hand book



R&D Innovations towards Energy Efficiency in SAIL

Suresh Prasad, P. Kumar, M Sen, T S Reddy and D Mukerjee

[email protected]

Abstract

The iron and steel industry is constantly striving to reduce its energy consumption and thereby minimize its

overall costs. In the present scenario of global cost competitiveness, the challenge could be met by finding

solutions to reduce energy consumption, which is one of the major cost factors. Research & Development

Centre for Iron & Steel (RDCIS) is a corporate research centre for Steel Authority of India Ltd (SAIL) and

nodal agency for working out measures for reduction of energy consumption in its steel plants. RDCIS has made

immense contribution towards reduction in energy consumption & GHG emission by implementing supervisory

computer control based on in-housed developed mathematical model for BF stoves operation, Blast Furnace Gas

burners in boilers, in-house developed energy efficient combustion system like curtain flame burners for ignition

hood of sinter machines, etc. RDCIS also plays a major role in suggesting measures for reducing energy

consumption by conducting energy audit.

1.0 Introduction

Present global energy consumption level is around 120 trillion Gcal (120 x 109 Gcal), which has increased in

last 30 years by 66 %. Major source of global energy is from fossil fuels constituting 86%. Global energy

demand mostly by developing countries is expected to rise by 40-50% by 2030, which will reduce sustainability

of fossil fuels further.

The iron & steel industry accounts 3 to 4% of world’s total energy consumption, which is mainly from fossil

fuels. The use of renewable sources of energy in steel industry is still to be explored. On an average 4.3 Gcal

energy is consumed for every tonne of steel produced in the world. Energy consumption in Indian steel industry

is considerably higher and consumes more than 6 Gcal/tcs. Energy consumption in Indian steel plant varies from

5.0 to 8.0 Gcal/tcs depending upon the level of technology and process route adopted. In the present scenario of

global cost competitiveness in steel industry, the challenge could be met by finding solutions to reduce energy

consumption, which is one of the major cost factors. RDCIS have made immense contribution towards energy

conservation and improvement in furnace productivity and product quality in SAIL plants by implementing

innovative ideas, introducing in-house developed energy efficient combustion systems and optimisation of

thermal regimes. RDCIS has been playing a lead role in identifying energy conservation schemes for

modernisation of SAIL plants. In SAIL, RDCIS has been in the forefront for development and

commercialisation of energy efficient burners using by-product fuels available in integrated steel plants. SAIL



plants have decreased energy consumption and GHG emission considerably over the years after successful

implementation of various innovative RDCIS projects on energy conservation.

2.0 Efforts towards Energy conservation

SAIL has been formulating to introduce energy efficient technologies from time to time by modernization

programs. Some of the important energy efficient technologies introduced and under implementation are:

• Phasing out in-efficient processes like twin hearth furnaces by BOF

• Continuous casting in place of ingot casting

• Walking beam furnaces in place of pusher type furnaces

• Coke dry quenching to generate steam/power in new coke oven batteries recovering sensible heat of

hot coke

• Introduction of auxiliary fuels like pulverized coal & tar in blast furnaces

• Top recovery turbines to generate power utilizing blast furnace top gas pressure

• Up-gradation of blast furnace stoves using improved stove design and computerized control for stove

change-over

• Waste heat recovery system to preheat combustion air in ignition hood of sinter machine utilizing

sensible heat of hot sinter

RDCIS has also been/will be contributing for reduction of specific energy consumption and GHG emission by:

• Introduction of supervisory computer control system in BF stove operation

• Introduction of BF gas burner in Boiler#6 of PBS to utilize surplus BF gas at BSP

• Introduction of Curtain Flame burners in sinter plants of SAIL

• Modification of combustion system in reheating furnaces of R & S Mill, BSP

• Introduction of efficient ladle heating systems in SAIL plants

• Improvement in furnace efficiency of heavy structural mill by regulation of gas and air at ISP



• Waste heat recovery system in sinter plant to generate hot water for preheating sinter mix under RDCIS

project

There has been a steady improvement in the specific energy consumption (SEC) per tonne of crude steel in

SAIL (Fig. 1). SEC reduced from 7.76 to 6.73 Gcal/tcs during the period from 2001-02 to 2009-10. During the

last decade the energy intensive open hearth furnaces have been replaced with twin-hearth or basic oxygen

furnaces (BOF). Continuous casting has been introduced in all the steel plants. In addition to the above major

modernisation programs, various medium and low capital investment schemes and indigenous technologies have

been introduced.

3.0 R & D Innovations towards Reduction in Energy Consumption in SAIL Plants

3.1 Supervisory computer control in BF stove operation

Supervisory computer control system was introduced in BF stove operation in Blast Furnace No. 3 of Durgapur

Steel Plant. Stoves of BF#3 is designed for hot blast temperature of 1050OC. The stoves have a blast rate of

around 1,700-2,000 Nm3/min. The fuel fired is BF gas enriched with BOF gas (CV = 750-780 kcal/Nm3) and

throughput capacity of 35,000 Nm3/hr per stove. The designed maximum dome temperature of the stoves is

1250 OC. Distributed control system (Toshiba make CIE 1200) is provided for Level-I control. Over this Level-

II supervisory control using mathematical model was introduced under R & D project.



An on-line mathematical model for BF Stoves operation was developed considering input parameters like dome

temperature, blast rate, cold blast temperature, duration of on-gas and on-blast periods. The model computes

checker and gas/blast temperature as function of time and height of checker work. During on-gas period, waste

gas temperatures and during on-blast period, hot blast temperatures are predicted by the model. Model predicts

on-line thermal status of individual stoves in different conditions.

The checker temperature distribution along the height predicted by model is utilized to calculate actual residual

heat of checker, which is dependent on blast rate and on the history of heating rate during “On Gas” period.

Evaluation of desired residual heat is done based on desired HBT and blast rate. Stove changeover for the

current cycle is predicted based on comparison of actual and desired residual heats.

Model generates audio-visual signal for the heater whenever stove changeover condition is met. Implementation

of the same resulted in lower coke rate due to consistency and increase in HBT. The trial results showed that

HBT and coke rate were 945OC and 535 kg/thm respectively as against 919OC and 553 kg/thm before

innovation as shown in Fig 2 & 3 below:

FIG. 2: VARIATION OF HBT & CB FLOW BEFORE INNOVATION (15-11- 2005)

900

920

940

960

980

1000

1020

1040

1060

1080

1100

6:07

7:03

8:04

9:0010

:0311

:0212

:0213

:0114

:0215

:0316

:0017

:0418

:0219

:0020

:0421

:0322

:0123

:05 0:03

1:02

2:00

3:04

Time

HB

Tem

p

60000

70000

80000

90000

100000

110000

120000

130000

140000

CB

Flo

w,

Nm

3/hr

HBTemp Avg HBT

CBFlow Avg CBFlow

940 Co

120460 Nm /hr3



FIG. 3: VARIATION OF HBT & CB FLOW AFTER INNOVATION (19- 01- 2006)

900

920

940

960

980

1000

1020

1040

1060

1080

1100

6:08

7:04

8:00

9:01

10:02

11:02

13:03

14:04

15:00

16:01

17:01

18:02

19:03

20:04

21:00

22:01

23:01 0:0

71:0

32:0

43:0

04:0

15:0

16:0

0

Time

HB

Tem

p

60000

70000

80000

90000

100000

110000

120000

130000

140000

CB

Flo

w,

Nm

3/hrHBTemp Avg HBT

CBFlow Avg CBFlow

960 Co

129000 Nm /hr3

The similar project is being implemented in Blast Furnace No. 4 of Bhilai Steel Plant.

3.2 Design, Development and Introduction of High Capacity Blast Furnace Gas Burner

This unique burner design for firing Blast Furnace Gas (BFG) at high rate (10,000Nm3/hr) was developed for

boiler no. 6 of Power Plant-I of Bhilai Steel Plant (BSP) to use surplus BFG and replace purchased coal. BFG

being a lean gas (calorific value ~ 800 Kcal/Nm3) has low flame temperature and poor in-flammability etc. for

which pure BFG is used mainly in blast furnace stoves and boilers. BFG burners used in boilers are normally

fired along with other rich fuels like furnace oil, coke oven gas (COG) or pulverized coal. To generate desired

bushy type stable flame within the width of the firing chamber of the boiler, high rate of mixing of the out-

coming BFG and air streams has been achieved by increasing interfacial surface area between gas and air

streams (Fig. 4). The introduction of burners has resulted in:

i) Reduction in fly ash and green house gas emissions by 15,000 and 100,000 ton/year respectively due to

utilization of surplus by-product gases generated in the steel plant.

ii) Annual benefit of Rs 1,080 Lakh due to elimination of purchased coal.



Fig. 4: Burner Nozzle

3.3 Design, Development &Introduction of Curtain Flame Ignition System

Curtain type flame based ignition system was developed to improve the ignition of top layer of sinter mix and to

reduce the specific gas consumption. The concept involves mounting several small capacity burners close to one

another on the roof across the sinter bed to generate curtain shaped continuous flame across the sinter bed,

which ignites the top layer of the sinter bed. All the burners are mounted in a single row perpendicular to the

direction of strand movement. In the conventional system, side burners are used on both the side walls of sinter

hood and this has an inherent problem of slow and uneven heat distribution across the sinter bed. To avoid this,

several side burners are used, which requires large furnace (ignition hood) length and consumes higher quantity

of heat

In the curtain flame burner, primary air is sent through swirls for better mixing of gas and air and secondary air

slots are provided in the burner module to obtain curtain flame configuration (Figs. 5). In this system higher

quantity of heat transfer to the top layer of sinter bed takes place by convection instead of radiation as in case

with conventional side burner. The curtain flame ignition system were installed in sinter machines of RSP,

Rourkela, BSL, Bokaro, BSP, Bhilai and presently being implemented at DSP, Durgapur. It has resulted in

reduction in specific fuel consumption and also furnace volume by more than 80%, thereby reducing the cost

towards refractory consumption and increase in productivity by extra furnace length available for sintering

process.

Benefits:

Reduction in specific fuel consumption by 30 to 40% (from 0.042 to 0.027 Gcal/t). Annual saving of Rs 1000

Lakh Reduction in GHG emission by 1,87,000 t/year.



.

Fig.5: Curtain flame Ignition Hood

4.0 Conclusion

RDCIS is a nodal agency for working out measures for reduction of energy consumption in SAIL’s steel plants.

RDCIS have made immense contribution towards energy conservation and improvement in furnace productivity

and product quality in SAIL plants by implementing innovative ideas, introducing in-house developed energy

efficient combustion systems and optimisation of thermal regimes. RDCIS has been playing a lead role in

identifying energy conservation schemes for reduction in energy consumption in SAIL plants. Joint efforts of

RDCIS and SAIL plants have resulted in reduction of specific energy consumption to a level of 6.73 Gcal/tcs.

Potential exists for further reduction of specific energy consumption in SAIL by maintaining technological

discipline, regular energy audits, beneficiation of raw material to improve its quality, phasing out obsolete

technologies like twin hearth, ingot route etc. and adopting newer technologies like CDQ, TRT, alternate fuel

injection in BF, Continuous casting etc.

Acknowledgement

The authors are thankful to the concerned officials and staff of different shops of SAIL Steel Plants at Bhilai,

Bokaro, Rourkela & Durgapur for their co-operation during the investigation and implementation of energy

efficient combustion systems. The authors are grateful to the Management of RDCIS for granting permission to

present the paper.



References:

• Achievement of higher HBT in BF#3 by incorporating supervisory computer control system based on

mathematical model, Durgapur Steel Plant, Report No. R & D: 81.02.3516.01.2006, January’06

• Introduction of blast furnace gas firing in boiler No. 6, PP – I, Bhilai Steel Plant, Report No. R & D:

81.02.3423.01.2005, March’05

• Introduction of curtain type flame for ignition of sinter-mix in Band # 2 & 3 of Sinter Plant at Bokaro

Steel Plant, Report No. R & D: 81.02.3371.01.2004, Dec’04

01 Technical Session One

Documents

Transcript of 01 Technical Session One