ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING
COURSE TITLE: ENERGY UTILIZATION AND AUDIT
PROJECT: ENERGY AUDIT ON BOILER (CAFETERIA)
5th year
NAME OF STUDENTS ID NO
1 FANUS ALEMU 0485/06
2 LETEBRHAN BAHTA 0963/06
3 GETACHEW DESTA 0619/06
4 GIETACHEW TEGEGNE 0639/06
5 MEBRAHTOM AYELGN 1025/06
6 TEKLAY GODEFA 1129/06
7 ZERAY ZENFO 1705/06
SUBMITTED TO INSTRUCTOR HAILU B.
SUBMISSION DATE 01/10/2010 E.C
TABLE OF CONTENT PAGE
TABLE OF CONTENT ................................................................................................................... I

1. INTRODUCTION..................................................................................................................... 1

1.2 OBJECTIVE ........................................................................................................................ 2

1.2.1 GENERAL OBJECTIVE ............................................................................................ 2

1.2.2 SPECIFIC OBJECTIVE ............................................................................................. 2

1.3. Scope of the study ............................................................................................................... 2

2. Description of boiler .............................................................................................................. 3

2.1 BOILER EFFICIENCY ..................................................................................................... 4

2.2 Factors affecting Boiler efficiency ..................................................................................... 5

2.3. Energy performance assessment of boilers ...................................................................... 6

2.4. COMBUSTION SYSTEMS .............................................................................................. 9

2.5. Equipment / Utility Related ............................................................................................. 11

2.6. Formula for energy calculation ....................................................................................... 13

3. ENERGY MANAGEMENT OPPORTUNITY .................................................................... 14

4. Economic analysis ................................................................................................................... 16

CONCLUSIONS ......................................................................................................................... 17

Recommendation......................................................................................................................... 18

REFERENCES ............................................................................................................................ 19

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 1. INTRODUCTION
Energy Audit is a systematic approach to decision-making in the area of energy management. An
energy audit is to identify the opportunities to reduce energy expenses applicable to domestic or
industrial. It attempts to balance the total energy inputs with its use, and serves to identify all the
energy streams in a facility.

An energy audit is a technique for identifying energy losses, quantifying them, estimating
conservation potential, evolving technological options for conservation and evaluating techno-
economics for the measures suggested.

Energy is the capacity to do work and work is the transfer of energy from one form to another
form of energy. Energy sources are available as electrical, thermal, light, chemical, mechanical,
solar, wind, tidal, nuclear energy and so on. The coal and the crude fuel are the major natural
resources are meeting 85% of the society need which will deplete soon. The fundamental goal of
energy management is to produce goods and provide services with the least cost and least
environmental effect. The term energy management means many things to many people. The
simple definition is" The judicious and effective use of energy to maximize profits (minimize
costs) and enhance competitive positions" (Cape Hart, Turner and Kennedy).Energy audits thus
highlight the Plant Energy Performance Plant energy performance (PEP) is the measure of
whether a plant is now utilizing more to produce the products than in the previous years rather it
is a measure of how well the energy management is effectively applied in practice. It compares
the change in energy consumption from one year to the other years.
The objectives of an energy audit are universally accepted, the methodology is not standardized.
In this paper, an attempt is made to standardize the methodology of an energy audit by
determining the circuit efficiency as a product of the various sub-system efficiencies.
By so doing, losses and efficiencies of each segment in the system can be determined
independently. This would provide a clue as to where to act on improving the energy efficiency
of the system.

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1.2 OBJECTIVE
1.2.1 GENERAL OBJECTIVE
Energy audit in boiler in ADU GC café.

1.2.2 SPECIFIC OBJECTIVE

 The objective of a boiler efficiency project protocol is to develop a methodology to
quantify a reduction of GHG emissions that is attributed to boiler systems.
 To identify the energy consumption in boiler
 To reduce the energy lost in boiler
 To increase the boiler efficiency
 To identify potential problem and improvement areas
 Identifying reasons for boiler inefficiency
 To verify the feedback from online instruments
 Root cause analysis of different problems

1.3. Scope of the study

This study used to increase the boiler efficiency and to reduce energy cost. The procedure
describes routine test for both oil fired and solid fuel fired boilers using coal, agro residues etc.
Only those observations and measurements need to be made which can be readily applied and is
necessary to attain the purpose of the test.
The scope of the performance test is to determine actual performance and efficiency of the boiler
and compare it with design values or norms. It is an indicator for tracking day to-day and season-
to-season variations in boiler efficiency and energy efficiency improvements.

This procedure is intended to give guidance to the plant inspector to check, evaluate, and asses
the condition of the water tubes boiler components and recommend any necessary repair.

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 2. Description of boiler
Boiler is a closed vessel in which water or other fluid is heated under pressure. The steam or hot
fluid is then circulated out of the boiler for use in various process or heating applications. Source
of heat for the boiler can be combustion of fuel such as wood biomass, coal, oil or natural gases.
Electric boilers uses resistance or immersion type heating element. Nuclear fusion also used as
heat source for generating steam. Waste heat boilers or heat recovery steam generators use the
heat rejected from other process such as gas turbins.construction of boiler mainly limited to
cupper, steel and cast iron.
This is also known as ‘input-output method’ due to the fact that it needs only the useful output
(steam) and the heat input (i.e. fuel) for evaluating the efficiency. This efficiency can be
evaluated using the formula:

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2.1 BOILER EFFICIENCY
In general, efficiency is defined as the ratio of output to input.

Boiler Efficiency= (output/input) ×100 Boiler efficiency is defined as the ratio between the
powers produced from the boiler and the fuel supplied to the boiler. In another way boiler
efficiency is obtained by subtracting all the losses affecting boiler performance from 100.

Direct or Input / Output method Measures the heat absorbed by water & steam& compares it
with the total energy input based on HHV of fuel.

Disadvantages:

1. it’s difficult to accurately measure coal flow and heating value on real time basis

2. The extent & nature of the individual components losses is not quantified in direct method.

Efficiency = (Input-losses) A phenomenon which affects the boiler performance or efficiency is

known as loss.

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The losses in the boilers are classified into two types

1. Controllable losses

2. Uncontrollable losses

Controllable losses

Controllable losses are the losses which can be controlled by maintaining optimum parameter.
The following are controllable losses.

 Dry gas loss

 Mill rejection loss
 Carbon loss

Uncontrollable losses Uncontrollable losses are the losses which cannot be controlled. The
following are uncontrollable losses.

 Loss due to moisture in fuel

 Loss due to hydrogen in fuel
 Loss due to moisture in air
 Loss due to sensible heat of ash
 Loss due to radiation

2.2 Factors affecting Boiler efficiency

The various factors affecting the boiler performance are listed below:

 Periodical cleaning of boilers

 Periodical soot blowing
 Proper water treatment programme and blow down control
 Draft control
 Excess air control
 Percentage loading of boiler
 Steam generation pressure and temperature
 Boiler insulation

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All these factors individually/combined, contribute to the performance of the boiler and reflected
either in boiler efficiency or evaporation ratio. Based on the results obtained from the testing
further improvements have to be carried out for maximizing the performance. The test can be
repeated after modification or rectification of the problems and compared with standard norms.
Energy auditor should carry out this test as a routine manner once in six months and report to the
management for necessary action.

The energy output (losses) associated with the burning of furnace oil in the boiler.

The energy loss due to:

• Dry flue gases loss, ii. Heat loss due to evaporation of water, resulted from the
formation of H2 in fuel, iii. Heat loss due to moisture content of air
• Heat loss due to radiation and convection from the boiler surface

Key principles of efficient boiler operation:

• Feed boilers with billeted wood to aid combustion

Do not unnecessarily open boiler door - this disrupts combustion
• Open only 1 door when feeding boiler
• Eliminate leakages in the steam and condensate system
• Install a float valve in the condensate tank to regulate water addition
• Measuring boiler energy use: Monitoring and measuring fuel wood consumption is important
for analysis of boiler efficiency. Measure wood in a wood cage before use and record the amount
used.
2.3. Energy performance assessment of boilers

Boilers typically operate to meet a desired heating load, which is to say that the output of the
boiler can be easily adjusted to meet a load that is not constant. Industrial boilers operate to meet
a process load that is driven by the production output for a product. Thus the level of production
affects the annual output required from the boiler. Industrial boiler applications are usually a
multiple boiler configuration that include a lead boiler that meets the base load requirements
supported by a lag boiler that that supports the load that is in excess of the lead boiler capacity.
In some case there is also a standby boiler that is ready for operation in the case of a failure of
the lead or lag boiler or to support the process when one of the other boilers is out of service for
scheduled routine maintenance. Note that during the course of the year, the designation of lead,
lag and standby rotates through the boilers so that they have similar hours of operation over the

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course of year. While industrial boilers can load follow, they cannot be frequently cycled on and
off as thermal cycling can damage the units. To accommodate this requirement, the lag and
standby boilers are typically in a warm standby mode where the boiler is maintained at a
temperature that will allow it to be placed into service in a short period of time. Note that in a
warm standby mode of operation, fuel is consumed and no usable output is produced.

Introduction Performance of the boiler, like efficiency and evaporation ratio reduces with time,
due to poor combustion, heat transfer fouling and poor operation and maintenance.
Deterioration of fuel quality and water quality also leads to poor performance of boiler.
Efficiency testing helps us to find out how far the boiler efficiency drifts away from the best
efficiency. Any observed abnormal deviations could therefore be investigated to pinpoint the
problem area for necessary corrective action. Hence it is necessary to find out the current level of
efficiency for performance evaluation, which is a pre requisite for energy conservation action in
industry.
The purpose of the performance test is to determine actual performance and efficiency of the
boiler and compare it with design values or norms. It is an indicator for tracking day to-day and
season-to-season variations in boiler efficiency and energy efficiency improvements
Measurements Required for Performance Assessment Testing
The following parameters need to be measured, as applicable for the computation of boiler
efficiency and performance.
a) Flue gas analysis
1. Percentage of CO2 or O2 in flue gas
2. Percentage of CO in flue gas
b) Flow meter measurements for
1. Fuel
2. Steam
3. Feed water
4. Condensate water
5. Combustion air

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c) Temperature measurements for
1. Flue gas
2. Steam
3. Makeup water
4. Condensate return
5. Combustion air
6. Fuel
7. Boiler feed water
d) Pressure measurements for
1. Steam
2. Fuel
3. Combustion air, both primary and secondary
4. Draft
e) Water condition
1. Total dissolved solids (TDS
2. PH
Four factors are critical for assessing energy efficiency in the powerhouse supplying energy to
make products for the benefit of customers in a highly competitive international market place.
These are:
1. Fuel type,
2. Combustion system limitations,
3. Equipment design, and steam system operation requirement
FUEL TYPE
Mother Nature is miraculous. Naturally occurring fuel (gas, oil, wood, coal and biomass) is
variable. The plants, animals, bugs and other critters that formed the fuel underwent tremendous
change at different locations and over different time periods. Elemental compositions of fuel
[moisture (H2O), carbon (C), hydrogen (H), nitrogen (N), chlorine (Cl), sulfur (S), oxygen (O)
and ash] can vary as much as 30% or more from an annual average basis depending upon their
inherent composition and degree of fuel refining or preparation. Any variations in fuel
composition from the original design of the system will directly affect boiler efficiency.

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In most cases with boiler design these days, variations of less than 1 or 2 percent from the
design fuel composition will have virtually no perceptible impact on efficiency. For this
discussion, the Btu per pound, gallon, or cubic foot of the coal, oil, or gas respectively may be a
better, however over simplified, way of looking at it. Even natural gas can vary between 900 and
1100 Btu/ cu. Ft. depending upon the methane content. Over the years technology has allowed
gas companies to blend gas and control its Btu and composition to a level of around 1000 Btu/cu.
Ft. (+ or – 1 or 2%) on an annual average and hourly average basis. This along with its
deliverability, ignitability and controllability are good reasons why natural gas is used as a
primary fuel for home heating, hospitals and commercial installations. The very high hydrogen
content (high hydrogen to carbon ratio) of natural gas that burns to form water removes a
significant amount of heat from the process and can seriously impact the overall efficiency of the
boiler as compared with other fuels. Crude oil is refined to remove the highly valuable portion
for industrial feed stocks for plastics and other products, for gasoline, aviation fuel and diesel
fuel for transportation, and for home heating oil with very low variability. The variability of each
of these premium products can be equal to or better than that of natural gas. Industrial fuel
products are the leftovers from refining and can have increasing variability as the quality. Steam
system.

2.4. COMBUSTION SYSTEMS

Efficient fuel burning (combustion) requires attention to the entire combustion apparatus.
Because some problem areas are common to all types of combustion systems, those areas will be
discussed before reviewing specific system problems. Good combustion is the ability to mix air
and fuel, with as little excess air as possible, at a high enough temperature to sustain the process
and completely burn the fuel (complete carbon conversion) with minimum environmental
emissions. Good combustion also includes the ability to generate maximum usable energy
consistent with process needs, safety, and economics. This is a complex process of matching fuel
combustion characteristics, ignition, including pyrolysis, and char burn out for heavy liquid and
solid fuels, with the time, temperature and turbulence available from the furnace absorption
profile and combustion system capabilities design. All this has to be accomplished with the
safety of operators and facility personnel in mind.

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Preliminary Energy Audit
In which the details of energy consumption, estimation of scope for saving, identifying the area
of study, identifies the immediate area of focus and identify the area where detailed study to be
done.
Detailed Energy Audit
A detailed energy audit done in major systems using energy balance, based inventory of systems
used,
Observation, calculations of energy use and energy loss.
The various factors affecting the boiler performance are listed below: ƒ Periodical cleaning of
boilers, ƒ
Periodical soot blowing, ƒ Proper water treatment programme and blow down control, ƒ Draft
control, and ƒ Excess air control,
Ƒ Percentage loading of boiler, ƒ Steam generation pressure and temperature ƒ Boiler insulation
ƒ Quality of fuel
The data related to steam generation of the boiler were obtained by in the production process.
There are ways to stud
 Direct measurement by portable instruments
 Direct recording from boiler control room
 Referring to factory log sheets and data record file
Mass Balance for the Combustion Process
The mass balance of the combustion process is consisting of actual air supplied and furnace oil
as an input mass and excess oxygen, nitrogen, carbon dioxide and sulfur dioxide as an output
mass.
Analysis of Furnace Oil Combustion
To find the amount of energy liberated during furnace oil combustion, the following mass and
energy analysis of the furnace oil, the combustion air and the combustion products are very
important.

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Excess Air Supplied (EA)
The amount of moisture content of the air used for combustion can be found by calculating the
absolute humidity.
The excess air supplied to the boiler/furnace may be computed using the percentage of oxygen
present
Excess air supplied (EA) = 100

2.5. Equipment / Utility Related

• KW/ton of refrigeration (Air conditioning plant)
• % thermal efficiency of a boiler plant
• % cooling tower effectiveness in a cooling tower
• KWh/NM3 of compressed air generated
• KWh / liter in a diesel power generation plant. While such benchmarks are referred to, related
crucial process.
• The crucial process parameters need mentioning for meaningful comparison among peers. For
instance,
• For a cement plant - type of cement, Blaine number (fineness) i.e. Portland and the process
used (wet/dry) are to be reported alongside kWh/MT figure.
• For a textile unit - average count, type of yarn i.e. polyester/cotton, is to be reported alongside
kWh/square meter.
• For a paper plant - paper type, raw material (recycling extent), GSM quality is some important
factors to be reported along with kWh/MT, kCal /kg figures.
• For a power plant / cogeneration plant - plant % loading, condenser vacuum, inlet cooling
water temperature, would be important factors to be mentioned alongside heat rate (kCal/kWh).

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Overall energy losses in a plant can result from losses due to designs that do not incorporate
energy efficient specifications such as:
• Heat recovery option
• Operations that run on inefficient methods
• Poor or non-energy efficiency-conscious maintenance
Energy loss programme
Reducing these losses will substantially increase the plant's efficiency, but we need data to
identify and quantify the losses and subsequently suggest suitable techno-economic solutions to
minimize the losses. This data can be acquired through energy audits.

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2.6. Formula for energy calculation
These are the standard formula for calculating a various energy losses in the boiler .by
minimizing them the efficiency of boiler can be increased
Heat given by fuel
This is the heat which is supplied by the fuel in compos ion. The better the quality of fuel more
heat it will liberate after burning and the percentage of carbon in ash will be very less.
Heat given by fuel=m
=45208.333kw
Where, gross calorific value of fuel in kilo joule per kg=1320
Number of truck =30
Quintals of rice per truck=100
Loss due to moisture
Water is formed due the oxidation of hydrogen present in the fuel in water which is estimated by
the following formula;
Hwc=cwt.
Hwc=0.54
Where,
WC=weight of moisture formed in kg per kg of dry fuel
L=latent of vaporization at the dew point flue gas, KJ/KG
Hwc=heat loss due to water of compos ion, KW

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3. ENERGY MANAGEMENT OPPORTUNITY
The first of these is to control the costs of the energy function or service provided, but not the
Btu of energy. As most operating people have noticed, energy is just a means of providing some
service or benefit. With the possible exception of feed stocks for petrochemical production,
energy is not consumed directly. It is always converted into some useful function. The existing
data are not as complete as one would like, but they do indicate some surprises.
A second principle of energy management is to control energy functions as a product cost, not as
a part of manufacturing or general overhead. It is surprising how many companies still lump all
energy costs into one general or manufacturing overhead account without identifying those
products with the highest energy function cost. In most cases, energy functions must become part
of the standard cost system so that each function can be assessed as to its specific impact on the
product cost.
In comparing actual values with minimum values, four possible approaches can be taken to
reduce the variance, usually in this order:
1. An hourly or daily control system can be installed to keep the function cost at the desired
level.
2. Fuel requirements can be switched to a cheaper and more available form.
3. A change can be made to the process methodology to reduce the need for the function.
4. New equipment can be installed to reduce the cost of the function.
ENERGY POLICY
A well written energy policy that has been authorized by management is as good as the
proverbial license to steal. It provides the energy manager with the authority to be involved in
business planning, new facility location and planning, the selection of production equipment,
purchase of measuring equipment, energy reporting, and training -things that are sometimes
difficult to do. If you already have an energy policy, chances are that it is too long and
cumbersome. To be effective, the policy should be short—two pages at most.

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PLANNING
Planning is one of the most important parts of the energy management program, and for most
technical people is the least desirable. It has two major functions in the program. First, a good
plan can be a shield from disruptions. Second, by scheduling events throughout the year,
continuous emphasis can be applied to the energy management program, and will play a major
role in keeping the program active. Almost everyone from top management to the custodial level
will be happy to give an opinion on what can be done to save energy.
Management Training
It is difficult to gain much of management’s time, so subtle ways must be developed to get them
up to speed. Getting time on a regular meeting to provide updates on the program is one way.
When the momentum of the program gets going, it may be advantageous to have a half or one
day presentation for management. A good concise report periodically can be a tool to educate
management. Short articles that are pertinent to your educational goals, taken from magazines
and newspapers can be attached to reports and sent selectively. Having management be a part of
a training program for either the energy team or employees, or both, can be an educational
experience since we learn best when we have to make a presentation.

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4. Economic analysis
According to cost analysis the estimated cost for repairing their water treatment plant is ranges
from
20,000birr - 30,000 birr. And the cost of a typical rotating cleaning equipment for fire tube
boilers ranges from $3,000
$5,000 (27,600-46,000 Birr) depending on size and feature.

Payback Period

The minimum length of time theoretically necessary to recover the original fixed capital
investment in the form of cash flow is called payback period. The simple payback period can be
found by dividing the cost saved with the cost of the boiler. Adding 47% additional cost of the
direct maximum cost of purchasing the boiler for transportation and other related costs, the cost
of having new boiler will be 1.47 x 2,760,000 = 4,057,200 Birr.

Subtract the salvage value the implementation cost will be =2,057,200Birr

Simple payback Period = Implementation Cost / Cost Saved
= 2,057,200 Birr / 1,078,634.5Birr
= 1.9 years
Percent of profit

% profit = x100%

=20%

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 Percent rate of return

The yearly profit divided by the total initial Investment necessary represents Return on
Investment. Taking the risk factor Mar = 12%, to be the plant feasible RoI>Mar (must).

Net income =718,902

Total capital investment (TCI) = 4,255,341

-Rate of return, % ROR x100%

X100% =17% > 12% it is acceptable

CONCLUSIONS
The objective of the study was to analyze the overall efficiency and the thermodynamic analysis
of boiler. There are many factors, which are influencing the efficiency of the boiler. The fuel
used for combustion, type of boiler, varying load, power plant age, heat exchanger fouling they
lose efficiency. Much of this loss in efficiency is due to mechanical wear on variety of
components resulting heat losses. Therefore, it is necessary to check all the equipment
periodically. Moreover, it is noticed that the overall efficiency of any boiler depends upon the
technical difficulties under unpredictable conditions. Hence, a viable study is carried out to
assess the performance of boiler plant in this context. The paper set to show the weakness of
depending on energy analysis only boilers as a performance measure that will help improve
efficiency. The Energy audit concludes that the possible ECOs’ for water treatment plant, motor
replacement of a new boilerto meet the customer demand the cost saved is as given below;

According to the energy study conducted for the boiler, the increased efficiency of water
treatment plant is by2.8%, the increased efficiency of the boiler by 3.7% and the energy saved by
erecting suitable boiler is 413.58kW, thesaving is by 52 % and considerable cost saving is nearly
one million Birr /year [41,670 USD]
 Repairing water treatment plant,
 Keeping the percentage of the excess air within the recommended range, and
 Replacing the existing boiler with proper sized boiler

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Recommendation
Based on the current investigation the following recommendations are forwarded:
 Energy audit on cafeteria in the boiler is efficient is efficient. If there were provided all
the applicable information on boiler. But we have done by assumption. Its energy rate
operating hour and its energy consumption.
 Detailed economic feasibility studies in the production process are recommended, since it
is critical for the rationale of commercialization.
 Energy conservation helps to ensure energy loss on energy consumption equipment and
improving energy efficiency by reducing operating cost.

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REFERENCES
1. Barney L.Capehart, Ph.Ds., CEM; Guide to Energy management, 2nd edition
2. http//:www.Bureau of Energy Efficiency: Performance Analysis of Boiler.pdf
3. www.em-ea.org/GuideBooks/Books-1/13:Combustion Analysis.pdf
4. Dr. G.G.Raian /Cochin/India: Energy Saving in Steam System
5. Energy Efficiency Handbook, prepared by the Council of Industrial Boiler Owners (CIBO),
edited by Ronald A. Zeitz, November 1997
6. Energy Efficiency Project Management Handbook, Organized by California energy
commission, California, 2000
7. Ms. Shardha Chandrakant Deshmukh, Ms. Varsha Arjun Patil, “Energy Conservation and
Audit,” International journal of
Scientific and research Publication, Vol 3,Issue 8,Aug 2013
8. An Approach Towards Efficient Operation Of Boilers ,Amit Kumar Jain, International Journal
of Scientific & Engineering Research, Volume 3, Issue 6, June-2012 1 ISSN 2229-5518.
http://www.tneb.in/linkodf/tmtps.pdf
9. http://en.wikipedia.org/wiki/mettur
10. http://www.apgenco.gov.in/administrator/uploaded files/thermal power plant.pdf

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