This presentation was held in the context of DCCI Capacity development Workshop December 2013 in Nepal. For further information go to our website.

1. Nepal Energy Efficiency Programme (NEEP)
Component 3:
Energy Efficiency in Industry
DCCI Training Need Assessment
05.08.2013

2. TS3: EE in Thermal System/
Case Studies
Bhishma Pandit
Long term Energy Efficiency Expert
GIZ/Integration

3. 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.

5. Combustion
Combustion
Fuel
+
Oxygen
Oxides
+
Heat

6. 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

7. 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.
Carbon
Hydrogen
Water Vapour
Sulphur
Moisture
Water
vapour
Water Vapour
GCV – 10,500 Kcal/kg
NCV – 9800 Kcal/kg
2

8. 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
-
-
-

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

10. Group Work: Rice Husk-??
CV: 3200 kcal/kg
HSD: 9400 kcal/liter

11. Thermal Equipments Used in
Industries
•Boilers
•Furnaces
•Refrigeration & Air Conditioning
•Hot water Generators

12. 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?

13. Boilers

14. 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
• Heating surface
: Fuel Oil
: M2

15. Furnace

16. Performance Evaluation of a typical
Furnace
Figure 4.10 Heat losses in industrial heating Furnaces

17. 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

18. TON OF REFRIGERATION
The cooling effect produced is quantified as
tons of refrigeration.
1 ton of refrigeration
= 3024 kCal/hr heat rejected.

19. VAPOUR-COMPRESSION REFRIGERATION SYSTEM (R22)

20. VAPOUR – ABSORPTION REFRIGERATION SYSTEM
CONDENSOR
GENERATOR
Regulating
Valve
Waste Heat/
Direct Fired
THROTTLING
VALVE
WEAK
SOLUTION
ABSORBER
EVAPORATOR
Heat load In
COOLING
WATER IN
HOT WATER OUT
STRONG
SOLUTION

21. Efficiency

22. What are the losses that occur in a boiler?
S tea m O utp u t
6 . S urface loss
1.
2.
3.
4.
5.
D ry F lu e gas loss
H 2 loss
M oisture in fu el
M oisture in air
C O loss
7 . F ly ash loss
Fu el In p u t, 10 0 %
B o iler
F lue gas
A ir
8 . B ottom ash loss
E fficien cy
(b y In D irect M eth o d)
= 10 0 – (1 + 2 +3 +4 + 5 +6 + 7 +8 )

23. Trial Data
Flue gas temperature after air preheater
Ambient temperature
Preheated air temperature
= 750oC
= 40oC
= 190oC
Specific gravity of oil
Average fuel oil consumption
Calorific value of oil
= 0.92
= 400 Litres / hr
= 400 x 0.92 =368 kg/hr
= 10000 kCal/kg
Average O2 percentage in flue gas
=12%
Weight of stock
= 6000 kg/hr
Specific heat of Billet
= 0.12 kCal/kg/0C
Surface temperature of roof and side walls = 122 oC
Surface temperature other than heating and soaking zone = 85 oC

24. Furnace Efficiency (Direct Method)
F u rn a ce E fficien cy (D irect M eth o d )
F u el in p u t
H eat In p u t
H eat o u tp u t
E fficien cy
E fficien cy
L o sses
= 4 0 0 litres / h r
= 3 6 8 k g /h r
= 3 6 8 x 1 0 ,0 0 0 = 3 6 8 0 0 0 0 k C al
= m x Cp x Δ T
= 6 0 0 0 k g x 0 .1 2 x (1 3 4 0 – 4 0 )
= 9 3 6 0 0 0 k C al
= O u tp u t x 1 0 0
In p u t
= 936000
x 100
3680000
= 2 5 .4 3 % = 2 5 % (ap p )
= 7 5 % (ap p )

25. 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.

26. ENERGY AUDIT INSTRUMENTS
Role : 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
26

27. Various Energy Audit Instruments
Various categories of portable energy audit instruments are

Thermal

Mechanical

Chemical

Electrical

Lighting
27

28. Thermal Measurements
Temperature can be measured by

Thermometer

Thermocouple & Indicator

Thermograph

Data-logger

Pyrometer

Hygrometer
28

29. Mechanical Measurements
 Flow

Vane Anemometer

Pitot Tube

Ultra Sonic Flow Meter(For Liquids)

Multi Function Kit
 Flow/Velocity
 Pressure
 Temperature
 RH
Contd..
29

30.  Pressure



Bourden Gauge
U Tube Manometer with pitot tube
Pressure Recorder
 Leaks

Ultra Sonic Leak Checker
 Speed


Stroboscope Meter
Contact Tachometer
Contd..
30

31. 
Multifunction kit

Sound


Time


dB Meter
Stop watch
Measuring tape
31

32. Chemical measurements
 Flue Gas Analysis

Oxyliser (O2, CO2 Temp, Efficiency)

Fyrite Kit (CO2 & O2)

Flue Gas Analyzer (CO2 & O2, CO, Temp, Efficiency)
32

33. Ultra-sonic Flow Meter
Application: Flow measurement of Liquids
Parameters measured: Velocity & discharge of liquid flow
Make: Panametrics, Ireland
No of Sets: 01
Range: 0.03 to 12.2 m/s (pipe size 2 to 24 inches)
33

34. Ultra-Sonic Flow Meter
Application: Flow measurement of Liquids
Parameters measured: Velocity & discharge of liquid flow
Make: Fuji, Japan
No of Sets: 01
Range: 0 to 32 m/s
34

35. Multi Function Kit
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
35

36. Non Contact Tachometer -Stroboscope
Application: Speed Measurements
Parameters measured: Speed of Rotating Element
Make: Testo, Germany
No of Sets: 2
Range: 20 to 20000 rpm
36

37. Contact Type Tachometer
Application: Measurement of Speeds
Parameters measured: Speed (rpm)
No of Sets:01
37

38. Digital Anemometer
Application: Measurement of Air, gas velocity
Parameters measured: Velocity
Make: Lutron, Taiwan
No of Sets:04
Range: 0 – 30 m/s
38

39. Digital Hot wire Anemometer
Application: Gas and air velocity, temperature in ducts
Make: Airflow, England
No of Sets:01
Range: 0.25 to 30 m/s and 0 – 80oC
39

40. Gas and Air Pressure measurement
Application: Measurement of static, dynamic and total pressure in
gas and air ducts
Make: Air Flow, UK
No of Sets: 1
40

41. Leak Detector
Application: Measurement of Air Leakages
Parameters measured: Air Leakage
Make: Air Flow, UK
No of Sets:01
41

42. Digital Pressure Gauge
Application: Measurement liquid, gas and air pressure
Parameters measured: Pressure
Make: Syscon, India
No of Sets:01
Range: 0-50 bar
42

43. Pressure & Vacuum Gauges
Application: Measurement of Pressure
Parameters measured: Pressure
No of Sets: 3
Range: 0 to 21 kg/cm2
43

44. Digital temperature & humidity data logger
Parameters measured: Dry bulb temperature & humidity
Make: Gemini, USA
No of Sets:04
Range: -15 to 150oC and 0-99 % RH
44

45. Temperature Data Logger
Application: Measurement of Temperatures
Parameters measured: Temperatures (8 temp. channels)
Make: Grant, UK
No of Sets:01
Range: 0-1200oC
45

46. Non Contact Type Infrared Temperature Indicator
Application: Measurement of Surface Temperatures
Parameters measured: Surface Temperatures
Make: Raytek, USA
No of Sets:01
Range: -18 to 870oC
46

47. Infrared Pyrometer
Application: Measurement of Surface Temperatures
Parameters measured: Surface Temperatures
Make: Raytek, USA
No of Sets:02
Range: -18 to 870oC
47

48. Thermocouples & Temperature Indicator
Application: Measurement of temperature
Parameters measured: Surface, gas and liquid temperatures
Make: Center, Taiwan
No of Sets: 1
o
Range: -50 to +400 C
48

49. Digital Temperature Indicator
Application: Measurement of Temperature
Parameters measured: Surface, gas and liquid temperatures
Make: OMEGA
No of Sets: 04
Range: -50 to +1200 oC
No of couples: 20
49

50. Digital Temperature & Hygrometer
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
50

51. Digital Temperature & Hygrometer
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
51

52. Sling Hygrometer
Parameters measured: Dry bulb and Wet bulb temperature
Make: Lawrance & Mayo
No of Sets:04
Range: 0- 50oC
52

53. Combustion Test (Fyrite) Kit
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
53

54. Flue Gas Analyser
Application: Measurement O2 temperature and CO in flue gas paths
Make: Kane May, UK
No of Sets: 1
Range : O2 0-21% and CO upto 10000 ppm
54

55. Flue Gas Analyser
Application: Measurement O2 temperature and CO in flue gas paths
Make: Neotronics, UK
No of Sets: 1
Range : O2 0-21% and CO upto 10000 ppm
55

56. Combustion Gas Analyser
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,No20 to 800 ppm, So2-0 to 500ppm, pressure- 0 to 150mbar/hpa, etc
56

57. Flue Gas Analyser
Application: Measurement of Flue Gas Parameters
Parameters measured:o2, Co, No, No2, So2, Humidity
Make: TESTO, Germany
Range:02-0 to 21%, CO-0 to 20000 ppm, NO- 0 to 3000,No2-0 to
500 ppm, Humidity- 0 to 100%
57

58. Energy Monitor
Application: Measurement of single phase Electrical Parameters
Parameters measured: V, A, kW, kWh
Make: Sagatron
No of Sets:10
Range: 16A, 250V, 4 kW
58

59. 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
59

60. 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
60

61. 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: 01
61
Range: 600V, 1000A

62. 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
62

63. Handheld Power Harmonic Analyser
Application: Measures all power and Harmonic Parameters
Parameters measured: V, A, PF, kW, kVA, kVAr, Hz, Harmonics
Make: Fluke, WA
No of Sets:02
Range: Up to 600V, 1000A, 600 kW, up to 31st Level harmonics
Accuracy
63

64. Suppliers Challenges / Performance
Monitoring and Guarantee
•
•
•
•
Output performance test
Guarantee – efficiency
How to monitored the performance
Out put and input performance

65. Cases
COST ECONOMICS OF REPLACING SMALL OIL-FIRED BOILER WITH RICE HUSK-FIRED

66. Heat Recovery from ammonia
compressor discharge
Cold Water in
Hot Water
Out
Water Out
Water In
Desuperheater
Condenser
Refrigerant
Oil Separator
Expansion
valve
Water
Evaporator
Oil
Compressor
In
Chilled
Water
Out
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

67. Any Questions?
Thank you . Thank you . Thank you . Thank you