DCCI Training Need Assessment 05.08.2013

Nepal Energy Efficiency Programme (NEEP) Component 3:

Energy Efficiency in Industry

TS3: EE in Thermal System/ Case Studies

Bhishma PanditLong term Energy Efficiency ExpertGIZ/Integration

Introduction to Thermal Energy• Energy in the form of the vibrations and

movements of microscopic particles• Heat is the common name for thermal energy

of an object that is due to the motion of the atoms and molecules that constitute the object.

Combustion

Fuel + Oxygen Oxides + HeatCombustion

Combustion

Combustion reaction and heat liberation for One kg of molecule When there is complete combustion:

 

C + O2 CO2 + 7448 KCal/kg

 

2 H2 + O2 2H2O + 31500 KCal/kg

 

S + O2 SO2 +537.5 KCal/kg

Calorific Value• The calorific value is the measurement of heat or energy

produced, and is measured either as gross calorific value or net calorific value.

• The difference being the latent heat of condensation of the water vapour produced during the combustion process.

Water vapourCarbon

Hydrogen

Sulphur

Moisture

GCV – 10,500 Kcal/kg

Water Vapour

Water Vapour

NCV – 9800 Kcal/kg

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Energy Costs and Heating Values

Type of Energy

Gross Calorific Value, KCal

Cost per Unit, NRs. Cost Per KCal

Coal 5000 / kg NRs. 24.0 / kg NRs 0.0048

Rice Husk 3200 / kg NRs. 6.25 / kg NRs. 0.002

Furnace Oil 9900 / liter NRs. 75 / liter NRs. 0.0075

HSD 9400/ liter NRs. 100/ liter NRs. 0.0107

Electricity 860 / kWh NRs. 7.10 / kWh NRs. 0.0083

TOTAL - - -

Energy Cost for Dairy industryAverage specific fuel oil consumption of 8 liters per 1000 liters milk for the reference year 2011/12.

Group Work: Rice Husk-??CV: 3200 kcal/kgHSD: 9400 kcal/liter

Thermal Equipments Used in Industries

•Boilers•Furnaces •Refrigeration & Air Conditioning•Hot water Generators

Introduction• It is an enclosed Pressure

Vessel• Heat generated by

Combustion of Fuel is transferred to water to become steam

• Process: Evaporation

• Steam volume increases to 1,600 times from water and produces tremendous force

• Care is must to avoid explosion. What is a boiler?

Boilers

Typical Boiler Specifications

• Boiler Make & Year :XYZ & 2003

• MCR(Maximum Continuous Rating) :10TPH (F & A 100oC)

• Rated Working Pressure :10.54 kg/cm2(g)

• Type of Boiler : 3 Pass Fire tube

• Fuel Fired : Fuel Oil• Heating surface : M2

Furnace

Performance Evaluation of a typical Furnace

Figure 4.10 Heat losses in industrial heating Furnaces

INTRODUCTION

Refrigeration deals with the transfer of heat from a low temperature level at the heat source to a high temperature level at the heat sink.

– Air conditioning for comfort– Refrigeration for process

TON OF REFRIGERATION

1 ton of refrigeration = 3024 kCal/hr heat

rejected.

The cooling effect produced is quantified as tons of refrigeration.

VAPOUR-COMPRESSION REFRIGERATION SYSTEM (R-22)

VAPOUR – ABSORPTION REFRIGERATION SYSTEM

EVAPORATOR

CONDENSOR

PUMP

GENERATOR

ABSORBER

STRONG

SOLUTION

WEAK

SOLUTION

COOLING WATER IN

HOT WATER OUT

THROTTLING VALVE

Regulating Valve

Waste Heat/

Direct Fired

Heat load In

Efficiency

Boiler Flue gas

Steam Output

Efficiency = 100 – (1+2+3+4+5+6+7+8)

(by In Direct Method)

Air

Fuel Input, 100%

1. Dry Flue gas loss2. H2 loss3. Moisture in fuel4. Moisture in air5. CO loss

7. Fly ash loss

6. Surface loss

8. Bottom ash loss

What are the losses that occur in a boiler?

Trial DataFlue gas temperature after air preheater = 750oCAmbient temperature = 40oCPreheated air temperature = 190oC

Specific gravity of oil = 0.92Average fuel oil consumption = 400 Litres / hr

= 400 x 0.92 =368 kg/hrCalorific value of oil = 10000 kCal/kg

Average O2 percentage in flue gas =12%

Weight of stock = 6000 kg/hrSpecific heat of Billet = 0.12 kCal/kg/0CSurface temperature of roof and side walls = 122 oCSurface temperature other than heating and soaking zone = 85 oC

Furnace Efficiency (Direct Method) Furnace Efficiency (Direct Method)

Fuel input = 400 litres / hr = 368 kg/hr Heat Input =368x10,000=3680000 kCal

Heat output = m x Cp x Δ T = 6000 kg x 0.12 x (1340 – 40) = 936000 kCal

Efficiency = Output x 100 Input

Efficiency = 936000 x 100 3680000

= 25.43 % = 25% (app) Losses = 75% (app)

PERFORMANCE ASSESSMENT

The specific power consumption kW/TR is a useful indicator of the performance of refrigeration system. By messing refrigeration duty performed in TR and the Kilo Watt inputs measured, kW/TR is used as a reference energy performance indicator.

The refrigeration TR is assessed as TR = Q Cp (Ti – To) / 3024

Where TR is cooling TR duty Q is mass flow rate of coolant in kg/hr Cp is coolant specific heat in kCal /kg / 0C Ti is inlet. Temperature of coolant to evaporator (chiller) in 0C.To is outlet temperature of coolant from evaporator (chiller) in 0C.

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ENERGY AUDIT INSTRUMENTSRole : Instruments Play a vital role in energy audit to characterize and quantify energy.

To conserve energy, it is necessary to know how & how much energy is being consumed

Instruments also provide a means to monitor equipment performance and check condition

In order to arrive at the quantitative assessment, several fixed and portable instruments are used to measure the parameters related to.

Energy consumption data

Efficiency related data

Operation & control data

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Various Energy Audit Instruments

Various categories of portable energy audit instruments are

Thermal

Mechanical

Chemical

Electrical

Lighting

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Temperature can be measured by

Thermometer Thermocouple & Indicator Thermograph Data-logger Pyrometer Hygrometer

Thermal Measurements

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Flow Vane Anemometer

Pitot Tube

Ultra Sonic Flow Meter(For Liquids)

Multi Function KitFlow/VelocityPressureTemperatureRH

Contd..

Mechanical Measurements

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Pressure Bourden Gauge U Tube Manometer with pitot tube Pressure Recorder

Leaks Ultra Sonic Leak Checker

Speed Stroboscope Meter Contact Tachometer

Contd..

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Multifunction kit

Sound dB Meter

Time Stop watch

Measuring tape

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Flue Gas Analysis Oxyliser (O2, CO2 Temp, Efficiency)

Fyrite Kit (CO2 & O2)

Flue Gas Analyzer (CO2 & O2, CO, Temp, Efficiency)

Chemical measurements

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Application: Flow measurement of Liquids Parameters measured: Velocity & discharge of liquid flow Make: Panametrics, Ireland No of Sets: 01Range: 0.03 to 12.2 m/s (pipe size 2 to 24 inches)

Ultra-sonic Flow Meter

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Ultra-Sonic Flow Meter

Application: Flow measurement of Liquids Parameters measured: Velocity & discharge of liquid flow Make: Fuji, Japan No of Sets: 01Range: 0 to 32 m/s

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Application: Thermal and mechanical Parameters - velocity, temperature, pressure, humidity Make: Testo, Germany No of Sets:02 Range: 0.4 to 60 m/s, -200 to 1200oC, 0 to 100 hpa, 0 to 100% RH

Multi Function Kit

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Application: Speed Measurements Parameters measured: Speed of Rotating Element Make: Testo, Germany No of Sets: 2 Range: 20 to 20000 rpm

Non Contact Tachometer -Stroboscope

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Application: Measurement of Speeds Parameters measured: Speed (rpm) No of Sets:01

Contact Type Tachometer

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Application: Measurement of Air, gas velocity Parameters measured: Velocity Make: Lutron, Taiwan No of Sets:04 Range: 0 – 30 m/s

Digital Anemometer

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Application: Gas and air velocity, temperature in ductsMake: Airflow, England No of Sets:01 Range: 0.25 to 30 m/s and 0 – 80oC

Digital Hot wire Anemometer

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Application: Measurement of static, dynamic and total pressure in gas and air ducts Make: Air Flow, UK No of Sets: 1

Gas and Air Pressure measurement

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Application: Measurement of Air Leakages Parameters measured: Air Leakage Make: Air Flow, UK No of Sets:01

Leak Detector

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Application: Measurement liquid, gas and air pressureParameters measured: Pressure Make: Syscon, India No of Sets:01 Range: 0-50 bar

Digital Pressure Gauge

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Application: Measurement of Pressure Parameters measured: Pressure No of Sets: 3Range: 0 to 21 kg/cm2

Pressure & Vacuum Gauges

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Parameters measured: Dry bulb temperature & humidityMake: Gemini, USA No of Sets:04 Range: -15 to 150oC and 0-99 % RH

Digital temperature & humidity data logger

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Application: Measurement of Temperatures Parameters measured: Temperatures (8 temp. channels) Make: Grant, UK No of Sets:01Range: 0-1200oC

Temperature Data Logger

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Application: Measurement of Surface Temperatures Parameters measured: Surface Temperatures Make: Raytek, USA No of Sets:01 Range: -18 to 870oC

Non Contact Type Infrared Temperature Indicator

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Infrared Pyrometer

Application: Measurement of Surface Temperatures Parameters measured: Surface Temperatures Make: Raytek, USA No of Sets:02Range: -18 to 870oC

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Application: Measurement of temperatureParameters measured: Surface, gas and liquid temperaturesMake: Center, Taiwan No of Sets: 1Range: -50 to +400oC

Thermocouples & Temperature Indicator

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Application: Measurement of Temperature Parameters measured: Surface, gas and liquid temperatures Make: OMEGA No of Sets: 04Range: -50 to +1200 oC No of couples: 20

Digital Temperature Indicator

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Application: Measurement of Temperatures & humidity Parameters measured: Dry bulb temperature & humidity Make: Center, Taiwan No of Sets:01 Range:-20 to 60oC, 0 to 100% RH

Digital Temperature & Hygrometer

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Application: Measurement of Temperatures & humidity Parameters measured: Dry bulb temperature & humidity Make: IRA, India No of Sets:01 Range:0 to 50oC, 10 to 95% RH

Digital Temperature & Hygrometer

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Parameters measured: Dry bulb and Wet bulb temperatureMake: Lawrance & Mayo No of Sets:04 Range: 0- 50oC

Sling Hygrometer

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Application: Measurement of Flue Gas quantities Parameters measured: Co2 & O2 Make: Testo, Germany No of Sets:06 Range: 0 to 20% Co2; 0 to 21% O2

Combustion Test (Fyrite) Kit

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Application: Measurement O2 temperature and CO in flue gas pathsMake: Kane May, UK No of Sets: 1Range : O2 0-21% and CO upto 10000 ppm

Flue Gas Analyser

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Application: Measurement O2 temperature and CO in flue gas pathsMake: Neotronics, UK No of Sets: 1Range : O2 0-21% and CO upto 10000 ppm

Flue Gas Analyser

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Application: Measurement of Flue Gas Parameters Parameters measured:Co, Co2, No, No2, So2, Pressure, Efficiency Make: Krykard, Italy Range: O2-0 to 25%, CO-0 to 4000ppm,CO2- 0 to 20%, NO- 0 to 5000,No2-0 to 800 ppm, So2-0 to 500ppm, pressure- 0 to 150mbar/hpa, etc

Combustion Gas Analyser

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Flue Gas Analyser

Application: Measurement of Flue Gas Parameters Parameters measured:o2, Co, No, No2, So2, Humidity Make: TESTO, GermanyRange:02-0 to 21%, CO-0 to 20000 ppm, NO- 0 to 3000,No2-0 to 500 ppm, Humidity- 0 to 100%

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Application: Measurement of single phase Electrical Parameters Parameters measured: V, A, kW, kWh Make: Sagatron No of Sets:10 Range: 16A, 250V, 4 kW

Energy Monitor

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: Chauvan Arnaoux, France No of Sets: 01 Range: 830V, 3000A

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: RCC Technologies, Canada No of Sets: 01 Range: 600V, 1000A

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, Harmonics (first 25th) Make: Dossena, Italy No of Sets: 01Range: 600V, 1000A

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Portable Load Management System

Application: Measures all Power Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz Make: ALM-03 Krykard No of Sets: 01 Range: 750V, 1000A

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Application: Measures all power and Harmonic Parameters Parameters measured: V, A, PF, kW, kVA, kVAr, Hz, Harmonics Make: Fluke, WA No of Sets:02Range: Up to 600V, 1000A, 600 kW, up to 31st Level harmonics Accuracy

Handheld Power Harmonic Analyser

Suppliers Challenges / Performance Monitoring and Guarantee

• Output performance test• Guarantee – efficiency• How to monitored the performance• Out put and input performance

CasesCOST ECONOMICS OF REPLACING SMALL OIL-FIRED BOILER WITH RICE HUSK-FIRED

Heat Recovery from ammonia compressor discharge

Desuperheater

Condenser

Compressor

Evaporator

Refrigerant

Water

Oil

Expansion valve

Oil Separator

Water In

Chilled Water

In Out

Water Out Hot Water Out

Cold Water in

Annual savings due to heat recovery – 6000 x 50/(0.85 x 10500) = 35 liters/day - 35 x Rs.75 x 350 - NRs. 9.2 lakhs

Thank you . Thank you . Thank you . Thank you

Any Questions?