Energy Efficiency Case Studies In Industry

7/30/2019 Energy Efficiency Case Studies In Industry

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Shashibhushan Subhash Agrawal, BE(MECH), Chartered Engineer (BEE Certified Energy Auidtor EA-1090)Email :- [email protected]; Mobile Number :- 09422161638

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1 Address :- AEEE Consultancy Services, 'Kapil' Building, Opposite Dr. Naik's X-rayClinic, New Bhagwat Plots, Akola (Maharashtra) 444005; Web Site : www.aeeec.com

Innovative Technologies Implemented / Under Active

Implementation for Energy Conservation During 2010-2012

Innovative Technology 1 :- Replacement of Asynchronous FrequencyConverter with Variable Frequency Drive.

Measure Heading = Replacement of Rotating Type AsynchronousFrequency Converter with Variable FrequencyDrive (VFD)

Brief Details of Measure = Energy Saving by Replacing Rotating TypeAsynchronous Frequency Converter (NC type)(Slip ring Motor based driven by squirrel cageinduction motor) for Ball pen tip making (PM-

20) machine with VFD.Brief Details of Existing System =

Currently a synchronous Rotating Type (slip ring type) converter of 2.5 kVA outputcapacity provided.

Specification of Existing Rating of Rotating Asynchronous Rotating Frequency

Converter is as given below
http://www.aeeec.com/http://www.aeeec.com/


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Input to Asynchronous Converter Output Required by LoadVoltage 220/380 Volts Kva 2.5

Amps 4.2/2.4 Amp Volts 125/94/79/39

Hz 50 Hz Amps 11.6 AmpHz 400/300/225/125

Other Parameters for Driving Motor :-Cos 0.8 RPM 1470/2890

The asynchronous frequency converter is an electric rotating machine consisting of anasynchronous motor with cage rotor and by an asynchronous generator with woundrotor co-axial coupled. Converts transform the electric energy at mains frequency inenergy with higher frequency and they used to feed high frequency motors. In NCseries converter, the excitation is supplied on generator stator terminals and output

voltage at the desired higher frequency on slip ring terminals.

The energy balance will be as given below

If going by claims of Manufacturer under normal & Ideal condition is as given below-In Asynchronous rotating frequency converter the energy loss as specified bymanufacturer is 25% of output power of 2.5 kVA. Thus total loss of rotating typeconverter is 0.625 kw against 6% loss of VFD of same rating i.e 0.15 kW. Thus savingof 0.475 kw per converter.

During actual field results the actual saving achieved is 0.7 to 0.9 kW per converterdue to variable actual loading, lower efficiency of existing system on account of

rewinding, maintenance issue etc. (Feedback with trial details from client attached)

After successful trial of the retrofit, it is replicated for other 22 machines andconsiderable savings in electricity achieved.

Special Remark about the measure :- The retrofit of VFD is not for usual reason. Ihope the measure will help lot of other industries utilizing rotating asynchronousfrequency converter to rethink on entire energy consumption and may help to save lotof energy.

Name & Address of Industry where Implementation :- One Engineering Industry inGujarat.

Current Status :- Implemented in Majority of similar machines (about 22 nos).Working successfully.


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Innovative Technology 2 :-Low Loss & Compact (Phase ChangeMaterial Based) Thermal Storage System in place of Higher Loss, Bulky

Thermal Storage System (Ice Bank) in Dairy Industry.

Measure Heading = Low Loss & Compact (Phase Change MaterialBased) Thermal Storage System in place ofHigher Loss, Bulky Thermal Storage System(Ice Bank) in Dairy Industry.

Brief Details of Measure = Existing Thermal Storage System used byDairy industry have higher thermal losses & isBulky. The same can be replaced by compactphase change material (PCM) based thermalstorage system to save energy on four countsi.e. Thermal loss minimization, avoiding heat

induced by mechanical stirrer in existingthermal storage system, better working loadcondition for compressor & by TOD benefits.

Brief Details of Existing System =

The existing thermal storage system in dairy industry is, conventional IBT (Ice BankTank) System is provided in all the milk chilling center and dairies. The conventionalIBT Tank is civil constructed tank provided with all civil constructed wall (exceptbottom side) thermal insulation. While top face of tank is open and covered by woodenplanks supported on MS angle fabricated support structure. The IBT tank is not airtight and top portion of tank covered with wooden planks have many gaps and thinspaces where out side atmospheric air comes directly in the contact of chilled waterinside the IBT Tank. These leakages are one of the major components of loss of IBTtank. Individual standing on top of IBT tank feels the air conditioning effect insurrounding.Mechanical stirrers (agitator) are provided (one in each section of IBT tank) for creatingforced circulation inside IBT tank for uniform cooling of water inside IBT Tank. Thesestirrers also induce heat inside the IBT tank proportional to BHP of shaft of stirrer atmotor end.


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The existing thermal storage system is resulting in considerable thermal energy loss &thus loss of electrical energy.

Proposed Low Loss & Compact (Phase Change Material Based) Thermal StorageSystem is as mentioned below-

The Proposed Low loss compact thermal Storage System is composed of a tank filledwith "nodules". The tank has upper manholes to allow the filling with nodules. A lowermanhole allows emptying. Inside the tank two diffusers (inlet and outlet) spread theheat transfer fluid along the tank. The pressure drop through the tank is 2.5 mWG.


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The inlet in charge mode must be via the lower diffuser in order to ensure the naturalstratification.

The tanks are manufactured in black steel (test pressure between 4.5 to 10 bar), are

delivered empty and positioned on site or, if the access to site is impossible,constructed on site. The nodules are spherical with a diameter of 77 mm, 78 mm or 98mm (depending on the nodule type).

The nodules contain the Phase Change Material (PCM). The mechanical and chemicalcharacteristics of the nodule shell (manufactured in polyolefin) are well adapted to theconditions encountered in Air Conditioning or Refrigeration systems.Once filled with PCM the nodule plugs are sealed by ultrasonics to ensure perfectwater tightness.The nodules are delivered in 22 kg bags. Tanks are filled on site. Thefilling is regular and homogeneous. A standard globule filling procedures are followed.

The tank shape is usually cylindrical in order to withstand service pressure higherthan 3 bar. The test pressure varies between 4.5 to 10 bar. The spherical shape allowsan easy filling.The nodule diameter has been calculated to meet economical and

technical requirements. The size allows high exchanges until the end of the cycle.

Special Remark about the measure :- The retrofit of Low Loss & Compact (PhaseChange Material Based) Thermal Storage System not only saves energy, the spacerequired is lesser as compared to conventional one.Name & Address of Industry where Implementation :- Under Active Implementationin Dairy Industries.Current Status :- The measure under active implementation in one of the DairyCluster


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Innovative Technology 3 :-Integrating MCDT (Machine Conditioning &Diagnostic Techniques) as Integral Part of Energy Audit to save Energy

Measure Heading = Utilization of MCDT (Machine Conditioning &Diagnostic Techniques) for Energy Conservation.

Brief Details of Measure = Utilization of MCDT (Machine Conditioning &Diagnostic Techniques) like Thermal Imaging for

Thermal insulation survey, steam trap survey, phaseimbalance study to save energy. Integrating the MCDT

Techniques in regular energy audit will result insubstantial energy savings.

Areas of Energy Auditwhere Thermal Imagingcan be useful

= 1) Thermal Insulation Survey to detect latent thermalleakages.2) Thermal leakages in Air condition system.

3) Steam Trap Survey.4) Waste Heat Recovery opportunity exploration.5) Misalignments and related problems detection.

I received special training for MCDT from JICA Japan under "Energy ConservationTechniques for India". Post training, I purchased thermal imaging camera (FLIR E-50)for integrating MCDT with energy conservation.Thermal Imaging is Integral Part ofall my current energy Audits.

Electrical System Imbalance Detection :-

Steam Trap Survey Using Thermal Imaging :-


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Thermal Insulation Leak Detect ion :-

Special Remark about the measure :- MCDT and in particular Thermal Imaging isintegral part of all energy audits for both electrical & thermal system. The results aresatisfactory one. In my opinion no energy audit in future will be completed withoutthermal imaging.

Name & Address of Industry where Implementation :- Many Industries where wehave carried energy audit have implemented findings of Thermal Imaging for energysavings.

Current Status :- The energy saving measures related to thermal imaging are already

successfully implemented by many clients.


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Innovative Technology 4 :- GPRS operated, cloud computing basedStreet Light operation SCADA System.Measure Heading = GPRS operated, cloud computing based Street Light

operation SCADA System.

Brief Details of Measure = SCADA system operating with Microprocessor basetimer (operating based on location such as longitude,latitude), with late night staggering feature, GPRS Baseddata acquisition system provided for Akola MunicipalCorporation.

Brief Details of System = GPRS Based data acquisition system with data storagein cloud is unique feature of system. The system wasconceptualized by me and currently working in manyfeeders at Akola Municipal Corporation Street Lightingsystem.

The advantages of GPRS based SCADA with data storage in clod are enormous. Multiusers can access data from various locations, even using mobile applications. Themicroprocessor based timer working on exact location of system, results in energysaving, operation of street light based on sun set & sun rise timing. The totaloperations becomes based on "Day of Year". Also features such as staggering (latenight hours & avoiding dark spots) result in additional energy saving. With dimmingenabled system, dimming in late hours results in additional energy saving. The projectis under implementation at Akola Municipal Corporation in Maharashtra. Few systems

have already been installed and their working has resulted in energy savings.

Special Remark about the measure :- GPRS Based SCADA with data storage incloud is new concept and better than GSM type system. Though the SCADA for streetlight is not so common, GPRS based SCADA with data storage in cloud may beprobably first case in India.Name & Address of Industry where Implementation :- Akola Municipal Council,Street Light Energy Saving Project under finance from MEDA.Current Status :- Implemented successfully by client working successfully.


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Renewable Energy Utilization :-

1) Fuel Switching from Coal to Bio-mass (Renewable Energy).

Measure Heading = Fuel Switching from Coal to Bio-mass.

Brief Details of Measure = The FBC Boiler utilizing pulverized coal has beentried with biomass pallets resulting in cost savingalong with reduction in carbon emission.

Brief Details of System = By shifting from conventional coal with 4000kca/kg calorific value to bio-mass briquets (finersize) of calorific value 3500 kcal/kg, Cost can besaved along with reduction in carbon emission.

At Gajanan Paper Mills Pvt Ltd., Malkapur (Dist:- Buldhana) in Maharashtra, Trialswere conducted for pallet type bio-mass for fuel switching from conventional coal. Theresults are encouraging and fuel switching is possible.

The fuel switching from fossils fuel to renewable energy is most desired in currentIndian atmosphere.

Special Remark about the measure :- Utilization of biomass in FBC Boiler in palletform is not so common in India. Utilization of bio-mass will lead to collection of agrowaste which is currently mostly burnt at farm site as waste.

Name & Address of Industry where Implementation One of the Medium Scale Paper

Mill in Maharashtra. I am currently exploring the option of utilization of renewalenergy in all energy audits.

Current Status :- Successful trials conducted & further arrangement of regularsupply and regular utilization under being stream lined.

2) Solar Water Heater for Industrial Process :-

Measure Heading = Solar Water Heater for Industrial Process waterheating.

Brief Details of Measure = The solar water heater can be provided in variousindustrial process for water heating requirement.

Brief Details of System = I have recommended solar water heater to manyindustries for process hot water requirement. InGujarat dairy cluster the solar water heating for milkchilling center have been implemented. The details ofthe milk chilling center are as given in schematicdiagram.

The solar water heaters have been recommended to majority of energy audit carried byme.


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Special Remark about the measure :- The utilization of solar water heating caneliminate the need of thermal energy for almost major months in year. I explore themeasure in all the energy audits carried by me.

Name & Address of Industry where Implementation :- Under Active Implementationin Dairy Industries.

Current Status :- The measure under active implementation in one of the Dairy

Cluster


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3) Methane Capture By Anaerobic Effluent Treatment Technology in DairyIndustry

Measure Heading = Methane Capture By Anaerobic Effluent TreatmentTechnology in Dairy Industry.

Brief Details of Measure = The COD & BOD of effluent of Dairy Industry aresuitable methane capture by Anaerobic Effluent

Treatment Technology in Dairy Industry. By capturingthe methane from the effluent both purpose ofenvironment protection and energy saving can beachieved.

Brief Details of System = Currently in many industries mechanical and chemicaleffluent treatment is provided which itself consumesenergy. By methane capture by anaerobic effluent

treatment energy can be harnessed from methane andenergy for treatment can be saved upto certain extent.

FLOW CHART FOR BIODIGESTOR SYSTEM

1000 m3/day


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The methane captured is used for boiler firing in dairy industry. The project is underactive implementation in BEE Sponsored Gujarat Dairy Cluster Project.

Special Remark about the measure :- Methane capture saves energy & benefitsenvironment also.

Name & Address of Industry where Implementation :- Under Active Implementationin Dairy Industries.Current Status :- The measure already implemented in one of the dairy in area ofDairy Cluster

Energy Efficiency Case Studies In Industry

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