KNOWLEDGE MANAGEMENT FOR PRODUCTIVITY

TIPS FOR ENERGY EFFICIENCY

PREM BABOO

SR.MANAGER (PROD)

NATIONAL FERTILIZERS LTD, INDIA,

FIE, INSTITUTION OF ENGINEERS (INDIA)

TECHNICAL ADVISOR AND AN EXPERT FOR

www.ureaknowhow.com

BOILERS:

22ºC REDUCTION IN FLUE GAS TEMPERATURE INCREASES

BOILER EFFICIENCY BY 1%.

5% REDUCTION IN EXCESS AIR INCREASES BOILER

EFFICIENCY BY 1% OR 1% REDUCTION OF RESIDUAL

OXYGEN IN STACK GAS INCREASES BOILER EFFICIENCY BY

1%.

A 1 MM THICK SCALE (DEPOSIT) ON THE WATERSIDE

COULD INCREASE FUEL CONSUMPTION BY 5 TO 8%.

A 3 MM THICK SOOT DEPOSITION ON THE HEAT TRANSFER

SURFACE CAN CAUSE AN INCREASE IN FUEL CONSUMPTION

TO THE TUNE OF 2.5%.

STEAM SYSTEM:

A 3 MM DIAMETER HOLE ON A PIPE LINE

COMPRESSED AIR LEAK FROM 1 MM HOLE DIA SIZE AT 7

KG/CM2 PRESSURE WOULD RESULT MEAN POWER LOSS

EQUIVALENT TO 0.5 KW.

EVERY 50 C REDUCTION IN INTAKE AIR TEMPERATURE

WOULD RESULT IN 1% REDUCTION IN COMPRESSOR

POWER CONSUMPTION.

CHILLERS:

CARRYING 7 KG/CM2 STEAM WOULD WASTE 33 KILO

LITRES OF FUEL OIL PER YEAR.

6ºC RISE IN FEED WATER TEMPERATURE BY ECONOMIZER

/ CONDENSATE RECOVERY CORRESPONDS TO A 1%

SAVING IN FUEL CONSUMPTION, IN BOILER.

0.25 MM THICK AIR FILM OFFERS THE SAME RESISTANCE

TO HEAT TRANSFER AS A 330 MM THICK COPPER

WALL……..!

INSULATION:

A BARE STEAM PIPE OF 150 MM DIAMETER & 100-METER

LENGTH, CARRYING SATURATED STEAM AT 8 KG/CM2

WOULD WASTE 25000 LITERS FURNACE OIL IN A YEAR…..!

70% HEAT LOSSES CAN BE REDUCED BY FLOATING A

LAYER OF 45 MM DIAMETER POLYPROPYLENE (PLASTIC)

BALLS ON THE SURFACE OF 900 HOT LIQUID /

CONDENSATE.

MOTORS:

HIGH EFFICIENCY MOTORS OFFER 4-5% HIGHER

EFFICIENCY THAN STANDARD MOTORS.

FOR EVERY 100 C INCREASE IN MOTOR OPERATING

TEMPERATURE OVER RECOMMENDED PEAK, THE MOTOR

LIFE IS ESTIMATED TO BE HALVES.

IF REWINDING IS NOT DONE PROPERLY, THE EFFICIENCY

CAN BE REDUCED BY 5-8%.

COMPRESSED AIR:

REDUCTION OF 1 KG/CM2 AIR PRESSURE (8KG/CM2 TO 7

KG/CM2) WOULD RESULT IN 9% INPUT POWER SAVINGS.

THIS WILL REDUCE COMPRESSED AIR LEAKAGE RATES BY

10%.

REDUCING CONDENSING TEMPERATURE BY 5.50 C

RESULTS IN 20-25% DECREASE IN COMPRESSOR POWER

CONSUMPTION.

5.50 C INCREASE IN EVAPORATOR TEMPERATURE

REDUCES COMPRESSOR POWER CONSUMPTION BY 20-

25%.

1 MM SCALE BUILD UP ON CONDENSER TUBES CAN

INCREASE ENERGY CONSUMPTION BY 40%.

COST OF ENERGY

AVERAGE COST--- ` 2400/G.CAL

Do you know?

A mature tree absorbs between 54.43 to 108.86 kg/year of particles

and gases like CO2, which are released in to air by automobiles and

industrial facilities.

A single tree can store an average of 5.9kg of Carbon annually. A

Community forest can store 2.6 tons of carbon per acre per year.

A single tree produces nearly three quarters of Oxygen required for one

person and a mature tree produces as much as Oxygen in a season as 10

people in a year. Making cans from recycled aluminum cuts related

water pollution by 97%.

Recycling one aluminum can saves enough energy to run a television

for three hours.

Manufacturing new aluminum can from used bewa rage containers

uses 95% less energy than producing them from virgin materials; an

energy saving equivalent to tens of millions of barrels of oil each year.

The average motor vehicle battery contains between 18-22 pounds of

recoverable lead, a gallon sulfuric acid and about three pounds of

polypropylene casting.

Every tone of recycled paper saves 17 trees, 7000 gallons of water and

4100kWh of electricity.

All steel products contains at least 25% of recycled content. One

recycled glass product would save energy to power a computer for 25

minutes.

70% less energy is required to recycle paper compared with making it

from raw materials. Glass is 100% recyclable and it can be used again

and again. It takes 24 trees to make one tone of newspaper. One

recycled plastic bottle would save enough energy to power a 60W bulb

for 3 Hours.

Plastic can takes up to 500 years to decompose. £36000000 worth of

aluminum is thrown away each year. Aluminum cans can recycle and

ready to use in just 6weeks. It takes half a barrel of crude oil to produce

the rubber in just one tire.

1 Gca1of NG can produce 0.240 te of CO2 1 Gcal of Naphtha can produce

0.30 te of CO2 1SM³ NG when used as fuel produces approx. 2kg of CO2

1kg Naphtha when used as fuel produces approx. 3.10kg of CO2 .