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By R.K.Kulkarni Dr. S.P.S. Rajput Research Scholar Asst. Professor Mechanical Engineering Department M.A.N.I.T. Bhopal(MP) India
Overview of Presentation
Introduction Identifying Waste Heat Sources Present System for Cooling Condenser Water Proposed Cooling System Model Working of Proposed System Benefits of Proposed System Conclusions
Introduction
Sugar Industry- Second Largest processing industry Stages in Sugar Manufacture-Extraction of Juice -Clarification -Evaporation and Concentration -Forming and separating crystals Energy Consumed- Mill Driving Turbines- Mechanical Driving auxiliary units- Electrical Energy Evaporation and Concentration of juice- Heat Energy Ways to Conserve Energy 1)Modernization of Old equipment/ machines 2)Adding of new systems like- Spiral juice heaters, Condensate flashing system, Continuous vacuum pans, Auto feeding of bagasse 3)Co generation. 4)Appropriate insulation of equipments 5)Efficient cooling system 6)Waste heat recovery systems
Evaporator Bodies Flue Gas De Super heater Fuel Boilers 40 T 15 T 15 T Power Turbines 2000 kW 1600 kW
II
III
IV
Blow down Common Header Fuel Boilers 20 T 15 T Mill Turbines 375kW X 5 1500 kW X 1
Jet Condenser
195.7
Hot water
224.5
Vapors
IV Body
Pans
3 pumps 189 kW
Jet Condenser
Spray Pond
Cold water 30-35 deg C Hot water 4045 deg C
2 pumps 124 kW
Flue Gases
Boilers
Heat Exchanger
Absorption Chiller
Water out
Hot Water
Proposed System
Aim-Reduction in the inlet temp of cooling water by incorporating a vapor absorption unit which runs on waste heat in boiler flue gases. Components1) Scrubbing system to remove suspended matter from hot flue gases. 2) A heat exchanger between flue gas and water. 3) Absorption cooling unit. 4) Pumps and fans. The hot flue gases from boiler contain soot etc. Full scrubbing of gas is not needed at this stage and only large particles need be removed. The upper spray chamber is of standard construction for even distribution of working fluid. (scrubbing liquid return.) A cross flow heat exchanger or shell and tube heat exchanger will be suitable for the heat exchange between gas and water.
Proposed System
Flue gases from boiler will be passed through a scrubbing system where the suspended matter and un burnt particles will be removed. Then this gas will be passed through a heat exchanger where the water will be heated by flue gases. This hot water will be then used as heat source for the absorption refrigeration system. The hot water from the condenser will be passed through the absorption refrigeration machine where its temperature will be decreased. This cold water will be then passed to the condenser for cooling purpose. The low temperature hot gases can be then diverted towards chimney.
Conclusions
Energy audit is an important tool to identify the areas of energy conservation in sugar factory. Waste heat sources in sugar factory are- Boiler flue gases Boiler blow down Hot condensate Most important waste heat source- Boiler flue gas Boiler flue gas heat can be utilized to run an absorption chiller. The chiller will cool condenser water. The power required in spray pond can be reduced. There will be improvement in condensation of vapors in condenser. Low boiling point of juice in evaporator can save steam and bagasse.
Acknowledgements:
1) The Malegaon Sahakari Sakhar Karkhana Ltd. Shivnagar , Tal. Baramati, Dist.Pune. 2) Vasantdada Sugar Institute Manjari (bk) Pune.
References
1) Jadhav M.G.2002, Some findings on heat energy audit for sugar factory, Cooperative Sugar 33,635642. 2) Damodaran C., N.Thirurumorthy, P.Parthsarathy,2004, Energy audit in sugar industry- a passport to prosperity, proceedings of Annual Convention of the South Indian Sugarcane and Sugar Technologist Association,97-104 3) Valagadde S.A., C.G.Mane, M.S.Bashetti, 2002, Energy conservation measures at Shri Renuka Sugars Ltd. Proc. of 34th annual convention of SISSTA at Banglore, 129-136 4) Chitale M.A., Use of efficient cooling system in sugar industries and cogeneration power plants, proceedings of 8th joint convention of STAI, SISSTA, DSTA at Hyderabad, 13-15 Aug.2005, 109119 5) Lavarack B.P., J.J. Hodgson, R. Broadfoot, S. Vigh, J. Venning, 2004, Improving energy efficiency of sugar factories, case study for pioneer sugar mill, International Sugar Journal 106, 337-342. 6) Talbi M., B. Agnew, 2002, Energy recovery from diesel engine exhaust gases for performance enhancement and air conditioning, Applied Thermal Engineering 22 693-702. 7) Stehlik Peter, 2007, Heat transfer as an important subject in waste to energy systems, Applied Thermal Engineering 27, 1658-1670. 8) Bhatt M.S., N Rajkumar,2001, Mapping of combined heat and power systems in cane sugar industry, Applied Thermal Engineering,21, 1707-1709.
References contd..
9) Lu Y.Z., R.Z.Wang, S.Jainzhou, Y.X.Xu, J.Y.Wu, 2004, Practical experiments or an
adsorption air conditioner powered by exhaust heat from diesel locomotive, Applied Thermal Engineering, 24,1051-1059. 10) Bhatt M.S.2000, Energy audit case studies I- steam systems, Applied Thermal Engineering, 20,285-296 11) Hugot H.1986, Hand book of cane sugar engineering, 3rd ed, Elsevier Newyork. 12) Ben-Shumen Dan, Philip Zacuto, Process for recovering heat from stack or flue gas, U.S.Patent # 4340572, 13) Websites- www.thermax-usa.com www.sucrose.com www.powerengineering.ca www.epa.gov www.tsi.com www.walchand.com
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