Project Report

ME4422

ENERGY AUDIT FOR THERMIC FLUID

HEATER

By
J.R.M. Bogahawatte
100062P

Module code ME 4422

Module name Energy conservation

Semester 08

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka

13th March 2015

Table of Contents
1 Introduction .........................................................................................................................1
1.1 System specifications ....................................................................................................3
2 Methodology........................................................................................................................5
3 Energy saving opportunities .................................................................................................5
3.1 Recover waste material using waste heat recovery.........................................................5
3.2 Heating the thermic fluid using the flue gas ...................................................................6
4 Current scenario calculation .................................................................................................6
5 Heat recovery potential ........................................................................................................8
5.1 Economizers .................................................................................................................8
6 Waste heat recovery ........................................................................................................... 10
6.1 Energy recoverable from flue gas ................................................................................ 10
6.2 Heating the thermic fluid using the flue gas ................................................................. 12
6.3 Recover waste material using waste heat recovery....................................................... 13
7 Conclusion ......................................................................................................................... 15
8 References ......................................................................................................................... 16
List of Tables
Table 1: Thermic oil inlet temperature .........................................................................................6
Table 2: Flue gas anlysis ........................................................................................................... 11

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Table of Figures
Figure 1: Schematic Diagram of thermic fluid heater ...................................................................1
Figure 2: Decanter .......................................................................................................................2
Figure 3: Bitumen Reservoirs ......................................................................................................2
Figure 4: Heater Information plate ..............................................................................................3
Figure 5: Thermic Fluid heater ....................................................................................................3
Figure 6: Hot oil pump ................................................................................................................4
Figure 7: Sulfur content vs dew point of flue gas .........................................................................9

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1 Introduction
Thermic fluid heaters are used in many industrial applications for indirect process heating.
Thermic fluid is used as the heat carrier. In the heating process the thermic fluid is heated up and
circulated through the applications providing the heat required for the applications. Thermic
Fluid is circulated by using a pump. The thermic fluid transfers the heat to the application
through a heat exchanger. Then thermic fluid is returned to the heater.

Figure 1: Schematic Diagram of thermic fluid heater

Thermic Fluid heater situated in Urapola, Gampaha is considered. This is a part of the asphalt
plant belongs to Finite Lanka private limited. The system considered is as follows.

Thermic fluid heater is used to heat the bitumen in an asphalt mixing plant. This heater is used in
heating the bitumen in reservoirs and heating the bitumen barrels and bulk bitumen that are
coming out of barrels in the decanter. Thermic fluid is used to convey the heat from the heater to
these two applications.

 Decanter
 Bitumen reservoir

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Figure 2: Decanter

Figure 3: Bitumen Reservoirs

The 2 bitumen reservoirs are used to pump the hot bulk bitumen to the plant. The decanter pump
the bitumen to the plant. The bitumen in the reservoir should be heated up to 160 0C in order to be
pumped up to the plant. And the bitumen in the decanter should also be heated up to the same
temperature. The reservoir should be filled with hot bitumen from the decanter as the plant
consumes the bitumen. The rate of consumption can be higher than the supply to the reservoir.

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1.1 System specifications

Thermic oil Heater

Figure 4: Heater Information plate

Thermic fluid -Texatherm 46

Rated output – 700kW

Max temperature – 3200C

Working pressure- 0.8MPa

Figure 5: Thermic Fluid heater

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Hot oil pump

Figure 6: Hot oil pump

Model – WRY 100-65-200

Rated shaft power- 12.5kW

Matched power – 15kW

Rotational Speed- 2930 rpm

Rate of flowat the operating point – 80 m3/h

Head at the operating point -40m

Efficiencyat the operating point - 70%

Light oil burner

Model- RL 70

Fuel- Light oil

Fuel net Calorific value- 11.8kW/h

Power of the electrical motor -1100W

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2 Methodology

In this particular scenario the methodology is first observing the energy saving opportunities,
after concluding that the potential for energy saving is tested. After checking the potential the
current scenario is analyzed in order to obtain certain data for the calculations and to evaluate the
current scenario. Then the energy saving opportunities are calculated and the paybacks are
calculated in order to evaluate the energy saving opportunities.

3 Energy saving opportunities

The flue gas of the heater is released without using in order to do any useful work. Flue gas is a
main source that take the supplied heat out. There is a possibility to use the flue gas in order to
waste heat recovery. Waste heat recovery can be obtained in order to be used in various
applications.

Waste heat recovery is a main energy conservation method that is listed in the energy
conservation hand book.

3.1 Recover waste material using waste heat recovery

There are a bitumen layer left in the barrel lid and the barrel wall. Flue gas can either be used to
recover bitumen remaining in the lid and the wall of the cylinder. This small volume of bitumen
has to be heated up and recovered in order to be used again.

Wastage quantification

Data

Barrel height: 980mm

Barrel diameter: 520-550mm

Thickness of bitumen left inside: approximately 2mm to 3mm

Cost: Rs. 86.00 per kg

Density of bitumen at 25°C: 1000-1050kg/m3

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Assuming the bitumen thickness of the cylinder wall is 2mm and the internal diameter is 520mm

Bitumen volume left inside= Bitumen left in the cylinder wall + Bitumen left in the lid

=(980×π×520×2×10-9+ π×5202/4×2×10-9)m3

=3.626×10-3 m3

Worst case scenario: If the 50% of the bitumen left adhered is recovered.

Saving: 3.626×10-3 m3×1000kg/m3×Rs. 86 ×50%

=Rs. 155.94 per barrel

3.2 Heating the thermic fluid using the flue gas

There is a possibility to heat up the thermic fluid using the flue gas economizer. This will reduce
the heat loss due to the releasing the flue gas. Ultimately the heated feed oil will reduce the
energy consumption of the thermic fluid heater. And this will increase the efficiency of the
heater as well.

The potential waste heat recovery from the above methods will be discussed in a latter section.

4 Current scenario calculation

The temperature is drop after only the decanter operation is as bellows.

Table 1: Thermic oil inlet temperature

Observation Temperature(0C)
1 181
2 180
3 180
4 182

Temperature drop is taken as the 1900C to 180 0C. In the decentering process the energy
consumption per hour of the decanter is calculated as below.

Decanter

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The main objective of the decanter is to heat the bitumen barrels and the bulk bitumen in the
decanter. This is done by using the tubes in the decanter. Thermic fluid flow through theses tubes
so using the flow rate and the temperature drop the energy consumption of the decanter can be
calculated.

Density of the thermic fluid (at 2000C)=0.73kg/l

The mass flow rate of the hot oil pump= 80m3/h*0.73kg/l*1000 l/m3

= 58400 kg/h

Thermic fluid flow rate of the main pipe= 58400kg/h

Diameter of the main pipe=105mm

𝑑
The cross sectional area of the main pipe =𝜋 × ( 2 )2 =0.00866m2

Diameter of the distribution pipes in the decanter= 50mm

𝑑 2
The cross sectional area of the decanter pipes =𝜋 × ( 2 ) =0.00502m2

Number of decanter pipes – Aligning to the walls-3*9=27

- In the bottom -16

The length of the decanter pipes- 6400mm

One pipe goes to other corner and comes back to the origin in U formation. So the effective
length of the decanter pipes are 12800mm.

The mass flow rate of the distribution pipes (mass flow rate of all the pipes as an equivalent) =
58400kg/h

Specific heat of Texatherm 46 at 2000C [1] = 2.74 kJ/kgK

The heat dissipated from the decanter pipes per hour = 2.74kJ/kgK*58400kg/h* 10K

=1600160kJ/h

Power output of the thermic fluid heater = 444.48 kW

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Energy input to thermic fluid heater

Net calorific value of the fuel= 11.8 kWh/kg

At steady state the burner operates at notch 2

At notch 2 the fuel delivery in 2 nd stage = 48kg/h

The power supplied from the fuel = 11.8kWh/kg*48kg/h

=566.4kW

Power consumption of the pump motor= 15 kW

Burner electrical motor power consumption = 1.1kW

444.48
Efficiency of the thermic fluid heater = (566.4+15+1.1) × 100% = 76.30%

Energy consumption by the bitumen tanks is also the same as the previous operation. Pipe sizes
and the temperature drop is also the same. So the conditions don’t change from the previous
scenario.

5 Heat recovery potential

Waste heat can be recovered to the thermic fluid by economizers. Though this seemed to be
possible, the potential of waste heat recovery has to be evaluated in order to process further
more. According to the energy management hand book.

5.1 Economizers

In order to economizers to have a heat recovery potential when the fuel oils are used, the system
should poses particular characteristics. These qualities and the characteristics are checked with
the current system in order to find the heat recovery through economizers.

Heat transfer criteria [1]

Tg= (T1+ 100)0F

Tg = Final stack flue temperature

T1= Process liquid feed temperature
T1= 1800C=3560F
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Tg,Actual =2400C=4640F
Tg. Required=4560 F
𝑇𝑔, 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 < 𝑇𝑔, 𝐴𝑐𝑡𝑢𝑎𝑙
So the Tg,Actual is acceptable.
Flue gas dew point
This can be obtained by the graph in the energy conservation hand book. The percent of sulfur in
diesel is 3000ppm. So the percent is 0.3%.
The graph in the figure can be used to obtain the dew point of the diesel [1].

Figure 7: Sulfur content vs dew point of flue gas

Flue gas dew point for a particular sulfur level (0.3%) is 1210C.

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6 Waste heat recovery
6.1 Energy recoverable from flue gas

Mass flow rate of the flue gas is obtained by the summation of mass flow rate of fuel and the
mass flow rate of air supplied.

Mass balance equation

Mass flow rate of flue gas = mass flow rate of flue+ mass flow rate of air

Mass flow rate of the fuel

Mass flow rate of the fuel is obtained by the steady state fuel consumption. First the burner
operates in the notch 4. This is only until the thermic fluid heater reaches the steady state level.
After the steady state level the heater is only operates in the notch 2.

In the notch 2 the light oil mass flow rate is obtained from the burner manual. When the burner
is operating in second stage notch 2 is the steady state.

The fuel flow rate of the burner in the steady state is 48kg/h [2].

Air mass flow rate of the fan

The Air flow rate of the fan is taken from the following calculation. RL 70 model operating at
notch 2, for the above fuel mass flow rate the pressure difference is calculated as follows. Fan
efficiency is unknown. It is taken assumed as 40%.

From the burner manual pressure difference [2]= 8.5 + 0.1(8 ÷ 10) mbar = 8.58 mbar

=858 Pa

Power consumed by fan * efficiency of the fan = Volumetric flow rate * pressure difference

𝑃𝑜𝑤𝑒𝑟 × 𝜂 = 𝑄̇ × (𝑃1 − 𝑃2 )

̇ Pa
1100𝑊 × .4 = 𝑄̇ × 858

𝑄̇ = 0.512m3/s

Air density at 250C =1.166kg/m3

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Air mass flow rate =1.166kg/m3*0.512m3/s= 0.5969kg/s

Mass flow rate of flue gas = mass flow rate of flue+ mass flow rate of air

=0.5969 kg/s +0.0133 kg/s

=0.6102 kg/s

Gas analysis

The diesel is assumed to be having the chemical composition C13H28. So, combustion equation is
as follows [3].

C13H28 + 20 O2 13CO2 +14 H2O

Table 2: Flue gas anlysis

Flue gas percentage
volume
O2 12%
CO2 10%
N2 69.6%
H2O 10.76%

In order to find the H2O percentage volume, the stoichiometric ratio is used.

The stoichiometric ratio of CO2: H2O is 13:14

The H2O volume percentage is 12% ÷ 20 × 14 = 8.4%

N2 percentage volume is (100-12-10-8.4) % = 69.6%

Specific heat for the above composition is calculated from a calculator [4].

Specific heat =1.0760076 kJ/kg*K

Wastage which can be recovered

From the above waste heat recovery potential section, the temperature can be reduced to 1800C.

So the temperature drop is 60K.

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The energy can be recovered is as follows.

𝑄̇ = 𝑚𝐹𝑙𝑢𝑒𝑔𝑎𝑠
̇ × 𝐶𝑃 × ∆𝑇

=0.6102 kg/s*1.076 kJ/kg*K*60K

=39.39 kJ/s

This can be used to 2 options discussed in the energy saving opportunities.

6.2 Heating the thermic fluid using the flue gas

Heating the thermic fluid can be using an economizer. The thermic fluid is normally in 180 0C.
So the thermic fluid can be heated up using the energy recovered. And the heat exchanger
efficiency is assumed to be 100%.

Energy recovered is equal to energy needed to increase the temperature of the thermic fluid.

𝑄̇ = 𝑚 𝑇ℎ𝑒𝑟𝑚𝑖𝑐
̇ 𝐹𝑙𝑢𝑖𝑑 × 𝐶 × ∆𝑇

39.39 𝑘𝐽/𝑠 = 58400/3600𝑘𝑔/𝑠 × 2.74kJ/kg ∗ K × ∆T

∆𝑇 = 0.886𝐾

Assuming the thermic fluid heater efficiency doesn’t change. Fuel saving is calculated.

The heat dissipated from the decanter pipes per hour = 2.74kJ/kgK*58400kg/h* (10-0.8862) K

= 1458353.82 kJ/h

=405.09kW

The required fuel flow (X)

405.09kW ×100/76.3=11.8kWh/kg*X kg/h

X= 44.99kg/h

The fuel saving is (48-44.99)kg/h= 3.006 kg/h

Fuel Saving per day = 3.006 kg/h*4h

= 12.024kg

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Fuel volume saved= 12.024kg/L/0.832kg=14.45L

Saving per day = 14.45L* Rs. 95.00/L= Rs 1372.93

Assuming the working days per month =20

Saving per month= Rs. 27458.00

The heat recovery unit is priced at $ 2500.00. [5]( For the specifications needed.)

Simple payback period=Rs. (2500*133.15)/27458.00= 332862.5/27458.00=12.12 months

The simple payback period is one year. This is favorable as the payback is one year. There are
heat recovery units cheaper than the above selected one. This will further reduce the payback
period of investment.

6.3 Recover waste material using waste heat recovery

Next the second option is the Recover waste material using waste heat recovery. The waste heat
recovery from the flue gas can be used to recover the waste material that is remaining in the lid
and the walls of the barrels.

The temperature of the flue gas can be again reduced to 170 0C.

𝑄̇ = 𝑚𝐹𝑙𝑢𝑒𝑔𝑎𝑠
̇ × 𝐶𝑃 × ∆𝑇

=0.6102 kg/s*1.076 kJ/kg*K*10K

𝑄̇ = 6.56 kJ/s

The temperature that is needed to heat the bitumen in order to recover the material in the lid and
the walls is taken as 900C. The efficiency of the heat exchanger is taken as 60%. Since heat is
supplied from flue gas to the solid [6].

𝑄̇ = 𝑚𝐵𝑖𝑡𝑢𝑚𝑒𝑛
̇ × 𝐶 × ∆𝑇

kJ 2.1𝑘𝐽
0.6*6.56 = 𝑚𝐵𝑖𝑡𝑢𝑚𝑒𝑛
̇ × 𝑘𝑔∗𝐾 × 75𝐾
s

𝑚𝐵𝑖𝑡𝑢𝑚𝑒𝑛=
̇ ̇
0.025𝑘𝑔/𝑠
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If the waste bitumen is unlimitedly available recovered material for 4hrs per day is as follows.

Mass recovered per day = 0.025kg/s*3600s*4

= 360.11kg

Volume= 360.11 kg/1000kgm-3

= 0.36011 m3

Number of barrels = 0.36011 m3/0.11924m3= 3.02 barrels

Cost saving per day = 3.02 barrels* Rs. 15,000.00

= Rs. 45,300.00

But this is restricted by the waste material being limited due to the demand. So the cost saving
cannot be reached to Rs. 45,300.00.

Cost saving per batch

Batch nearly consumes 40 barrels per day.

Daily wastage of bitumen =3.626×10-3*40=0.145m3

Cost saving per day=0.145/ 0.1192*Rs. 15,000.00= Rs.18, 251.67

The economizer can be made using Rs. 100,000.00.

So, the payback period for this will be only 5.47 days. But the recoverable bitumen volume is
significantly lower than theoretically calculated figure. Since the lids are the only option that can
be used to recover waste material. So this values cannot be achieved in the practical scenario.But
there is a potential in this option.

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7 Conclusion
Thermic fluid heater, which is considered is assembled in 2011. And there are no obvious energy
saving opportunities observed. Since The energy audit is conducted to improve the efficiency.
The main idea is to use the waste heat recovery to improve the efficiency.

Out of the two waste heat recovery solutions, the first one waste heat recovery by an economizer
is a good investment. Since the payback period of the solution is only 12 months. This is a very
good investment to a plant like this since the operation period of this plant is estimated to be
more than 20 years. This will results in savings after one year.

Second waste heat recovery option is having restrictions due to the demand of the plant. This
will not result in the savings of that magnitude due to practical reasons. But this option has the
potential to result in such savings.

After all the first option is more reliable. After conducting an Inquiry of the second option it was
clear that the second option is also possible. And there are plants which the second option is
successfully carried out. But the material recovery rate is about 1 barrel a day with 100%
operating cycle.

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8 References

[1] W. C. Turner and S. Doty , Energy management handbook, 6 ed.

[2] Riello, "Light oil burner," 2010.

[3] "Gas anlysis report".

[4] "FGKH," [Online]. Available: http://fluegasknowhow.com/flue-gas-properties/flue-gas-

specific-heat-calculator/.

[5] "Heatec," [Online]. Available: http://www.heatec.com/other-products/heater-

economizers.html.

[6] J. Bražiūnas and . H. Sivilevičius, "Heat Transfer and Energy Loss in Bitumen Batching
System of Asphalt," in International Conference “ENVIRONMENTAL ENGINEERING”.

[7] Caltex Lubricants, "Texatherm 46".

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