tips for energy conservation in industrial sector

8/14/2019 Tips for Energy Conservation in Industrial Sector

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TIPS FOR ENERGY CONSERVATIONTIPS FOR ENERGY CONSERVATION

IN INDUSTRIAL SECTORIN INDUSTRIAL SECTOR

By,By,

NAGARAJAN.SNAGARAJAN.SManager M&OManager M&O

MacLellan IndiaMacLellan India


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BOILERS :

1. Increasing the steam output / Kg of fuel burnt throughimproved efficiency, by way of avoiding heat lossencountered through insulation and refracting, improvesboiler efficiency from 20% to 80%.

2. Install economizer in Boiler for preheating feed waterwherein the temperature is raised from 70 Degrees to 120Degrees. This results in 3% saving in fuel.

3. Improve the efficiency of boiler by soot blowing andcontrolling excess air. This results in 2% increase in boilerefficiency.

4. Using treated water in boilers, avoids scale formationresulting in decrease in fuel consumption by five percentto eight percent.

Cont.


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BOILERS : 5. Installing air pre-heater to the boiler enhances

effectiveness of combustion of oil by aiding atomization.

6. Convert grate fired boiler into fluidized bed boiler forimproving efficiency.

7. Usage of fuel oil additive for LSHS.8. Reducing the blow down frequency of feed water avoidsloss.

9. Arresting steam leakage in the pipelines.

10. Recover heat from steam condensate.

11. All possible attention should be paid to control excessair by monitoring oxygen level in flue gas and also by

visual inspection of flame color.


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FURNACE:FURNACE: 1. Improvement in furnace efficiency can be achieved by using

optimum excess air and reduction of radiation loss byapplication of insulation bricks or increasing the wall thickness.

2. Improve insulation if the surface temperature exceeds 20degrees above ambient.

3. Minimize the heat loss through the exhaust fans and openingat the entrance and exit.

4. Replace the control panels of resistance heating ovens andfurnaces by thyristor control panel.

5. Proper design of lids of melting furnaces and training of

operators to close lids helps reduce losses by 10-20% infoundries.

6. Recover and utilize waste heat from furnace flue gases forpreheating of combustion air. Every 21degree Centigrade rise incombustion air temperature results in one percent fuel oil

savings.


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COMPRESSED AIR:COMPRESSED AIR:

1. Reduce the temperature inside the compressorhouse by providing bigger windows and openings inthe compressor room or extend suction pipe to outside

the building.

2. Replace absorption type air dryers with refrigerationtype dryers.

3. Arresting of air leakage at air receivers, relief valves,pipes and house shut off valves, quick relief couplings,tools and equipments of the compressed air system.

4. Avoid usage of compressed air for purposes forwhich compressed air is not a necessity. Use blowersfor removing the water from chill rolls.5. Replace single stage compressors with double stagecompressors


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PUMPS:PUMPS:

Improper selection of pumps can lead to large wastage ofenergy. A pump with 85% efficiency at rated flow may haveonly 65% efficiency at half the flow. Select a pump of the right

capacity in accordance with the requirement.

Use of throttling valves instead of variable speed drives tochange flow of fluids is a wasteful practice. Throttling cancause wastage of power to the tune of 50 to 60%.

Drive transmission between pumps & motors is veryimportant. Loose belts can cause energy loss unto 15-20%.Use efficient transmission system. Maintain right tension andalignment of transmission belts.

Modern synthetic flat belts in place of conventional V beltscan save 5% to 10% of energy.

Matching of the motor with the appropriate-sized pump isessential.

Cont


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PUMPS:

It is advisable to use a number of pumps in series andparallel to cope with variations in operating conditions byswitching on or off pumps rather than running one largepump with partial load.

Proper installation of the pump system, including shaftalignment, coupling of motor and pump is a must.

Properly organized maintenance is very important.Efficiency of worn out pumps can drop by 10 per cent to 15

per cent, unless maintained properly.

Periodically check pump system and carry out correctivemeasures such as lubrication, alignment, tuning of enginesand replacement of worn-out parts.


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1. The motors should be energy efficient.

2. Convert delta to star connection for lightly loaded motors.

3. Install soft start-cum-energy saver for lightly loaded motors.

4. In case of centrifugal blower pump, install variable voltagefrequency (VFD) drives for speed control of motors.

5. Replace eddy current controls / fluid coupling drives withvariable frequency drives for varying speed driven equipment.

6. Provide interlock for electric motor to avoid idle running.

7. Avoid frequent rewinding of motors. Greater the number of

rewind, lesser the efficiency.

8. Replace metal cooling fans of motors with FRP blades.

9. Replace V-belt drives by flat belt drives.

10. Carry out preventive maintenance and condition monitoring

MOTORS


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Advantages of Energy Efficient MotorsAdvantages of Energy Efficient Motors 1. Reduced operating costs.

2. Less heat losses.

3. Extended winding lifespan. Extended lubricating greaseservice life.

4. Lower noise levels than other motors.

5. Reduced energy costs. The higher purchase priceinvestment pays off.

6. Reduction in green house gas emissions resulting fromreduced energy consumption.


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COOLING TOWERSCOOLING TOWERS

1. Replacement of inefficient aluminum or fabricated steelfans with molded FRP fans with aerofoil designs results inelectricity savings in the range of 15 percent to 40 per cent.

2. A study on a typical 20 feet diameter fan revealed thatreplacing the wooden blade drift eliminators with newlydeveloped cellular PVC drift eliminators reduces the driftlosses from 0.01 per cent to 0.02 per cent with a fan power

energy saving of 10 per cent.

3. Install automatic ON-OFF switches on cooling tower fansand save up to 40 per cent on electricity costs

4. Centralize utilities by providing a common chilled waterline, chilled brine line, cooling water line and compressedair line.

5. Reduce scaling in cooling towers by adopting properwater quality management.


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REFRIGERATION & AIR CONDITIONINGREFRIGERATION & AIR CONDITIONING 1. Use of double doors, automatic door closures, air curtains,

double glazed windows, polyester sun films etc. reduces heatingress and air-conditioning load of buildings.

2. Maintain condensers for proper heat exchange. A 5C decreasein evaporator temperature increases specific power consumptionby 15%.

3. Utilization of air conditioned/ refrigerated space should beexamined and efforts made to reduce cooling load as far aspossible.

4. Utilize waste heat of excess steam or flue gases to change ovefrom gas compression systems to absorption chilling systems an

save energy costs in the range of 50-70%.

5. Specific power consumption of compressors should bemeasured at regular intervals. The most efficient compressors tobe used for continuous duty and others on standby.


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DG SETSDG SETS

1. A poorly maintained injection pump,faulty nozzle increases fuel consumption.

2. Blocked filters increase fuelconsumption.

3. Measure fuel consumption per kWh of

electricity generated regularly. Takecorrective action in case this shows a risingtrend.

tips for energy conservation in industrial sector

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