ENERGY, ENERGY &

ENERGY
27-JUL-14

Why Energy is Important ?

Profit = Net Selling Price ( RM Cost+VC+FC)
Elements of Variable Cost :
Energy

Power
Steam
Air
Nitrogen
Water
Others

Packing
Stores & Spare
Consumables & other chemicals

Note : Effect of Waste/OG will be loaded

in VC

Why Do We Accept Energy

Waste?

Lack of awareness.

Energy users never see the utility bills

Dont realize the range of solutions

Lack of accountability.
Cost accrue to Dept A, savings to Dept B
Management turnover, short tenure
Not part of traditional job descriptions

Fear.
Were already as efficient as we can be
Thats the way weve always done it.

Sequence

Energy Efficiency in :
1.
2.
3.
4.
5.
6.
7.
8.

Motors
Boiler
Furnace
Steam
Air Compressors
Cooling Towers
Chillers
Miscellaneous

Specific Consumption

Need of the Hour

Energy Efficiency in Motors

Energy Efficient Motors:

Scope to improve 4 to 5 %

Reduce Under loading

60 to 70% optimum
Otherwise loss will be higher; PF and efficiency will be lower

Size to Variable Load

To be slightly lower than the Highest Load

Rewinding

Use Qualified Vendor

Maintain Original motor design
Replace 40 HP > 15 Yrs Service
Not worth rewinding more than twice.
Coil to coil resistance shall not vary > 0.3 Ohms
If rewinding is not OK, efficiency can be less by 3 to 5 %

Energy Efficiency in Motors

Improve Power Quality

Voltage shall not vary
Effect of Unbalance voltage :l
Example 1

Example 2

Example 3

Voltage unbalance (%)

0.30

2.30

5.40

Unbalance in current (%)

0.4

17.7

40.0

30

40

Temperature increase (oC)

Power Factor Correction :

Maintain Power Factor 0.9 or above
Introduce Capacitors

Improve Maintenance :
Lubrication / Alignment / Dust
Fan Cooling, Terminals

Energy Efficiency in Boilers

Stack Temp. Control

Keep as low as possible.
If > 200 Deg C, go for Heat Recovery

Feed Water Preheating Economizers

Recover heat from Flue Gas of 200 300 Deg C

Combustion Air Preheating

1% improvement in thermal efficiency for every 20 Deg C rise in
Combustion Air.

Minimise incomplete Combustion :

Causes :Air shortage, Fuel Surplus, poor fuel distribution, poor Mixing

Avoid Excess Air:

1% Excess air decreases 0.6% Efficiency

Energy Efficiency in Boilers

Radiation/Convection Heat Loss Minimisation
Improve Insulation in Exhaust

Variable Speed Drives

Introduce VFD for Fans, Blowers & Pumps, if loads are variable

Scaling & Soot Loss Reduction

1% efficiency reduction per 22Deg C increase in Stack temp.
2.5% fuel increase per 3 mm soot

Control Boiler Loading

Max Efficiency of Boiler at 65 85% loading
Poor efficiency at loads < 25%

Energy Efficiency of Furnaces

1. Complete combustion with minimum excess air
2. Proper heat distribution
3. Operation at the optimum furnace temperature
4. Reducing heat losses from furnace openings
5. Maintaining correct amount of furnace draft
6. Optimum capacity utilization
7. Waste heat recovery from the flue gases
8. Minimize furnace skin losses
9. Use of ceramic coatings
10.Selecting the right refractories

Energy Efficiency of Steam System

Manage Steam Traps
Visual, Sound, Temp,. Of discharge line
Routine Maintenance
Replacement of Internal Parts

Eliminate Steam Leaks

Repair/ Regular leak detection
To the extent possible go for Welded Joints

Dry Steam for Process

Wet steam reduces total heat content and prevents heat transfer
Improve Insulation
Provide Steam Separators

Energy Efficiency of Steam System

Minimise/Avoid Water hammer

Banging Noise by colliding condensate
Sources: low points in the Pipe Work
Solutions:
Steam lines with gradual fall in flow direction
Drain points at regular intervals
Avoid sudden openings of Condensates

Insulation
Improve Condensate Recovery
Saving Treated Water Cost
Saving Energy
1% fuel saving per 6 Deg C increase in the feed water

Recover Flash steam

Reuse Low Pressure Steam

Energy Efficiency in Air Compressors

Location of the Compressor

Higher the altitude lower the volumetric efficiency

Intake air to be free from Contaminants, Dust or Moist

Keep intake temp. lower

1% higher energy for every 5 Deg C rise in Tinlet

Keep DP across inlet Pressure Minimum

2% higher energy for every 250 mm WC DP

Use Inter/After Coolers

Eliminate Leakages
Leak thro 1 mm hole @ 7 Bar pressure is equivalent to 0.5 kW loss

Energy Efficiency in Air Compressors

Pressure Settings
High Pr : More Power , Lower Vol. Efficiency & Excessive Wear
Reduce Delivery Pressure, Reduction by 1 Bar wil reduce Power by 9%
Design for minimum DP in distributing lines
Optimum Pipe Size and bends
Ensure no corrosion
Keep Filters Clean

Condensate Removal
Good Maintenance
Regular Lubrication
Clean/Replace Air filters
Check Condensate traps
Clean After Coolers periodically

Energy Efficiency in Cooling Towers

Proper Selection of Fills
Proper Material, Surface Area, Contact time

CT Fans
Replacing metallic fans by FRP fans save 20 30% power
Blades with aerodynamic profile with optimum twist, taper..

Pumps and Water Distribution

Using drift eliminators brings down the loss from 0.02% to only
0.003 0.001%
Optimise Cooling water treatment
Clean the Spray Nozzles periodically

Energy Efficiency in Chillers

Let Condenser water inlet temp be as minimum as
designed
5.5 Deg C reduction will result in 20% Compressor power saving

Proper Insulation of Chilled water storage tank

Clean the Condenser periodically
1 mm scaling will increase energy by 40%

Miscellaneous

Variable Frequency Drives

Soft Starters to reduce high starting current
Avoid Excessive lighting
Upgrade obsolete fluorescent systems to compact fluorescents
and electronic ballasts
Consider daylighting, skylights, etc.
Consider painting the walls a lighter color and using less
lighting fixtures or lower wattages
Make sure that all of the utilities to redundant areas are turned
off-including utilities like compressed air and cooling water
Provide restriction orifices in purges (nitrogen, steam, etc.)