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Tips for Thermal Energy
Conservation |
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| General |
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- Undertake regular energy audits.
- Plug all oil leakage. Leakage of one drop of oil
per second amounts to a loss of over 2000 liters/year.
- Filter oil in stages. Impurities in oil affect combustion.
- Pre-heat the oil. For proper combustion, oil should
be at right viscosity at the burner tip. Provide adequate
Pre-heat capacity.
- Incomplete combustion leads to wastage of fuel.
Observe the colour of smoke emitted from chimney.
Black smoke indicates improper combustion and fuel
wastage. White smoke indicates excess air & hence
loss of heat. Hazy brown smoke indicates proper combustion.
- Use of Low air pressure “film burners”
helps save oil upto 15% in furnaces.
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| Furnace |
- Recover & utilize waste heat from furnace
flue gase for preheating of combustion air. Every
210C rise in combustion air temperature results
in 1% fuel oil savings.
- Control excess air in furnaces. A 10% drop in
excess air amounts to 1% saving of fuel in furnaces.
For an annual consumption of 3000 kl. of furnace
oil. This means a saving of Rs 3 Lacs. (Cost of
furnace oil-Rs. 10 per litre).
- Reduce heat losses through furnace openings. Observations
show that a furnace operating at a temperature of
10000C having an open door (1500mm*750mm) results
in a fuel loss of 10 lit/hr. For a 4000 hrs. furnace
operation this translates into a loss of approx.
Rs. 4 Lacs per year.
- Improve insulation if the surface temperature
exceeds 200C above ambient. Studies have revealed
that heat loss form a furnace wall 115mm thick at
6500C amounting to 2650 Kcal/m2/hr can be cut down
to 850 kcal/m2/he by using 65 mm thick insulation
on the 115 mm wall.
- Proper design of lids of melting furnaces and
training of operators to close lids helps reduce
losses by 10-20% in foundries.
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| Boiler |
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- Remove soot deposits when flue gas temperature raises
400C above the normal. A coating of 3mm thick soot
on the heat transfer surface can cause an increase
in fuel consumption of as much as 2.5%.
- Recover heat from steam condense. For every 60C
rise in boiler feed water temperature through condense
return, there is 1% saving in fuel.
- Improve boiler efficiency. Boilers should be monitored
for flue gas losses, radiation losses, incomplete
combustion, blow down losses, excess air etc. Proper
control can decrease the consumption upto 20%.
- Use only treated water in boilers. A scale formation
of 1mm thickness on the waterside would increase fuel
consumption by 5-8%.
- Stop steam leakage. Steam leakage from a 3 mm-diameter
hole on a pipeline carrying steam at 7kg/cm2 would
waste 32 kl of fuel oil per year amounting to a loss
of Rs. 3 Lacs.
- Maintain steam pipe insulation. It has been estimated
that a bare steam pipe, 150 mm in diameter and 100m
in length, carrying saturated steam at 8kg/cm2 would
waste 25 kl of furnace oil in a year amounting to
an annual loss of Rs. 2.5 Lacs.
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| DG Sets |
- Maintain diesel engines regularly.
- A poorly maintained injection pump increases fuel
consumption by 4Gms/KWH.
- A faulty nozzle increases fuel consumption by 2Gms/KWH.
- Blocked filters increase fuel consumption by 2Gms/KWH.
- A continuously running DG set can generate 0.5 Ton/Hr
of steam at 10 to 12 bars from the residual heat of
the engine exhaust per MW of the generator capacity.
- Measure fuel consumption per KWH of electricity
generated regularly. Take corrective action in case
this shows a rising trend.
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Tips for Electrical
Energy Conservation |
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| General |
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- Improve power factor by installing capacitors to
reduce KVA demand charges and also line losses within
plant.
- Improvement of power factor from 0.85 to 0.96 will
give 11.5% reduction of peak KVA and 21.6% reduction
in peak losses. This corresponds to 14.5% reduction
in average losses for a load factor of 0.8.
- Avoid repeated rewinding of motors. Observations
show that rewound motors practically have an efficiency
loss of upto 5%. This is mainly due to increase in
no load losses. Hence use such rewound motors on low
duty cycle applications only.
- Use of variable frequency drives, slip power recovery
systems and fluid couplings for variable speed applications
such as fans, pumps etc. helps in minimizing consumption.
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| Illumination |
- Use of electronic ballast in place of conventional
choke saves energy upto 20%.
- Use of CFL lamp in place of GLS lamp can save energy
upto 70%.
- Clean the lamps & fixtures regularly. Illumination
levels fall by 20-30% due to collection of dust.
- Use of 36W tubelight instead of 40 W tubelight saves
electricity by 8 to 10%.
- Use of sodium vapour lamps for area lighting in
place of Mercury vapour lamps saves electricity upto
40%.
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| Compressed Air |
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- Compressed air is very energy intensive. Only 5%
of electrical energy are converted to useful energy.
Use of compressed air for cleaning is rarely justified.
- Ensure low temperature of inlet air. Increase in
inlet air temperature by 30C increases power consumption
by 1%.
- It should be examined whether air at lower pressure
can be used in the process. Reduction in discharge
pressure by 10% saves energy consumption upto 5%.
- A leakage from a ½” diameter hole from
a compressed air line working at a pressure of 7kg/cm2
can drain almost Rs. 2500 per day.
- Air output of compressors per unit of electricity
input must be measured at regular intervals. Efficiency
of compressors tends to deteriorate with time.
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| Refrigeration & Air Conditioning |
- Use of double doors, automatic door closers, air
curtains, double glazed windows, polyester sun films
etc. reduces heat ingress and air-conditioning load
of buildings.
- Maintain condensers for proper heat exchange. A
50C decrease in evaporator temperature increases the
specific power consumption by 15%.
- Utillisation of air-conditioned/refrigerated space
should be examined and efforts made to reduce cooling
load as far as possible.
- Utillise waste heat of excess steam or flue gases
to change over from gas compression systems to absorption
chilling systems and save energy costs in the range
of 50-70%.
- Specific power consumption of compressors should
be measured at regular intervals. The most efficient
compressors to be used for continuous duty and others
on standby.
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| Cooling Towers |
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- Replacement of inefficient aluminum or fabricated
steel fans by moulded FRP fans with aerofoil designs
results in electricity savings in the range of 15-0%.
- A study on a typical 20ft. diameter fan revealed
that replacing wooden blade drift eliminators with
newly developed cellular PVC drift eliminators reduces
the drift losses from 0.01-0.02% with a fan power
energy saving of 10%.
- Install automatic ON-OFF switching of cooling tower
fans and save upto 40% on electricity costs.
- Use of PVC fills in place of wooden bars results
in a saving in pumping power of upto 20%.
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| Pumps |
- Improper selection of pumps can lead to large wastage
of energy. A pump with 85% efficiency at rated flow
may have only 65% efficiency at half the flow.
- Use of throttling valves instead of variable speed
drives to change flow of fluids is a wasteful practice.
Throttling can cause wastage of power to the tune
of 50 to 60%.
- It is advisable to use a number of pumps in series
and parallel to cope with variations in operating
conditions by switching on or off pumps rather than
running one large pump with partial load.
- Drive transmission between pumps & motors is
very important. Loose belts can cause energy loss
upto 1-20%.
- Modern synthetic flat belts in place of conventional
V-belts can save 5% to 10% of energy.
- Properly organized maintenance is very important.
Efficiency of worn out pumps can drop by 10-15% unless
maintained properly.
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| Promotional Schemes |
- Energy Auditors empanelment scheme
- Energy Audit subsidy scheme
- Soft loan for purchase of energy audit equipment's &
instruments.
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Besides these, PCRA also conducts Energy audits, Fuel Oil
diagnostic studies, Studies in small scale industries, Follow-up’s;
Organizes technical meets, Consumer meets, Seminars, Institutional
training programmers, Workshops, Clinics; helps in organizing
Action Group meetings and puts up stalls in exhibitions on
conservation of petroleum products |
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