ßf'k{kk ekuo dks cU/kuksa

ls eqDr djrh gS vkSj vkt ds

;qx esa rks ;g yksdra= dh
Hkkouk dk vk/kkj Hkh gSA
tUe rFkk vU; [Link] ls
mRiUu tkfr ,oa oxZxr
fo"kerkvksa dks nwj djrs
gq, euq"; dks bu lcls Åij
mBkrh gSAÞ
µ
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ßEducation is a liberating force,

and in our age it is also a
democratising force, cutting
across the barriers of caste and
class, smoothing out inequalities
imposed by birth and other
circumstances.Þ
µ Indira Gandhi
 Indira Gandhi OEY-003
National Open University
School of Engineering and Technology ENERGY MANAGEMENT :
AUDIT AND CONSERVATION

Block

3
ENERGY CONSERVATION MEASURES-I
UNIT 1
Energy Audit and Conservation in Steel Company 5

UNIT 2
Energy Audit and Conservation in a Pharmaceutical Industry 13

UNIT 3
Medium and Long Term Energy Conservation Measures in
Pharmaceutical Industry 23
GUIDANCE

Prof. V. N. Rajasekharan Pillai, Vice Chancellor, IGNOU

COURSE CURRICULAM DESIGN COMMITTEE

Prof. Ajit Kumar Dr. Ashwani Kumar Dr. S.P. Singh

Director Scientist ‘F’ / Director Head, School of Energy and
SOET, IGNOU Solar Thermal (ST) Environmental Studies
Maidan Garhi Ministry of New and Devi Ahilya Vishwavidyalaya
New Delhi-110 068 Renewable Energy Khandwa Road Campus
Block. No. 14, CGO Complex Indore-452 001
Lodi Road, New Delhi-110003 Madhya Pradesh
Dr. Ram Chandra Dr. Jugal Kishor Prof. Santosh Kumar
Regional Director Scientist ‘F’/ Director Professor and Head (Retd.)
IGNOU, Regional Centre Ministry of New and NIT
Delhi-I Renewable Energy Patna
Block. No. 14, CGO Complex Bihar
Lodi Road, New Delhi-110 003
Prof. S. Maji Prof. R.R. Gaur Dr. A.S. Guha
SOET, IGNOU Dept. of Mechanical Engineering Joint Director, RSD, IGNOU
Maidan Garhi IIT, Hauz Khas Maidan Garhi
New Delhi-110 068 New Delhi-110 016 New Delhi-110 068

Dr. S. C. Sinha Mr. Sitaram Singh Mr. J.K. Sinha

Project Officer Principal Director
Bihar Renewable Energy Govt. Polytechnic Bihar Renewable Energy
Development Agency Patliputra Colony Development Agency
Sone Bhawan, 3rd Floor Patna Sone Bhawan, 3rd Floor
Birchand Patel Marg Bihar Birchand Patel Marg
Patna, Bihar Patna, Bihar

BLOCK PREPARATION TEAM

Dr. Ram Chandra
Regional Director
IGNOU, Regional Centre, Delhi-1

BLOCK EDITED BY

Dr. V. P. Rupam
Assistant Regional Director (Selection Grade)
Regional Centre, Delhi-1

PRINT PRODUCTION

Mr. A. S. Chhatwal Mr. S. C. Pant

Asstt. Registrar (P), Sr, Scale CRC Preparation

September 2010
ISBN :
© Indira Gandhi National Open University, 2010
All rights reserved. No part of this work may be reproduced in any form, by mimeograph of any other means,
without permission in writing from the Indira Gandhi National Open University.
Further information on the Indira Gandhi National Open University courses may be obtained from the University’s
office at Maidan Garhi, New Delhi – 110 068.
Printed and published on behalf of Indira Gandhi National Open University, by Director, SOET, IGNOU.
Printed at : M/s Public Printing (Delhi) Service, C-80, Okhla, Phase –I, New Delhi-110 020
 ENERGY CONSERVATION MEASURES
The adequate and right kind of energy is necessary for the sustainable development of human
society. Today, we need energy for various activities like cooking, lighting, heating,
air-conditioning, transport, agriculture and industrial applications. Most of the energy for
these applications is derived from burning of fossil fuels (coal, oil and natural gas).The
excessive use of these finite sources is posing a serious challenge to human society. On one
hand, their use is deteriorating the environment and on the other hand their stock is fast
depleting. The only option left to human society is to adopt the policy of interaction of 3E’s
(Energy, Economy and Environment). In its simplest form, it refers to adopting the policy of
Energy Conservation and Energy Substitution. Energy conservation means to use energy
efficiently and hence cutting out waste to zero level. Energy substitution means to make use
of renewable energy so that dependence on fossil fuels is reduced. In this course, you will
learn about various energy audit techniques, energy conservation measures.
When you look around at all the machines that are running, the lights, fans, cars, etc., you
simply cannot imagine life without all these. But can you imagine the amount of energy that
is being used to run all this? Fortunately, people all over the world are becoming aware of the
problem of consuming too much energy and are making a conscious effort to conserve it and
thereby put less pressure on the earth. By conserving energy we also lower the amount of
pollutants we release into the air and thereby help to keep the air clean.
The interaction between the natural resources and the population has to be maintained at a
balance in order to ensure the continuity of the human race. Energy is essential to life and its
conservation has become an absolute necessity.
India’s overall consumption of energy is very low, but compared to its gross domestic
production its relative consumption is very high. The cost of commercial energy is also high
compared to that in most other countries. The industrial sector consumes about 50% of the
total commercial energy produced. There is a growing need to bring about improvement in
the efficiency of energy use in the industrial sector.
Concerns over the negative environmental impacts of inefficient uses of energy are growing,
both globally and regionally. Such concerns require greater national efforts and greater
international cooperation to promote energy efficiency and energy conservation. Local air
pollution, emissions of greenhouse gases, and acidification of soil and water can all be
reduced if energy and resource conservation concepts are more widely applied. More efficient
energy use can increase productivity and economic competitiveness as well as lower
greenhouse gas emissions per unit of output.
Energy conservation has been recognized as a national priority for a very long time, but
concrete steps have not been taken seriously. The growth and demand for energy is increasing
at a very fast rate, specially in the industrial sector, transport sector and the house hold sector,
thereby putting a great deal of pressure on the available resources. The need of the hour has
now become energy conservation. Conservation and efficient use of energy in industry has
for a long time been a priority of the Government of India. People on their part should
become aware of the seriousness and do their best to conserve and preserve this
energy.
The concern for energy conservation and the insight into various energy related processes
gained over the years has led to development of variety of energy conservation measures.
Some of them are :
· Housekeeping measures to use the available sources in an optimum way,
· New energy efficient systems for improving efficiency of energy supply and
consumption, and
· Renewable energy systems to promote energy substitution for energy
conservation.
There are several reasons to conserve energy. Using less conventional fuels like oil, gas and
electricity, we will save not only money but also pollution associated with extracting fossil
fuels and using fossil fuels. Reducing greenhouse gases will reverse global warming. The
conservation of energy is a movement in which each one of us can contribute.
In this unit, we will discuss various short term energy conservation measures. Usually, short
term energy conservation are good house keeping measures which requires no expenditure or
minimum expenditure but lead to huge savings.
 Energy Audit and
UNIT 1 ENERGY AUDIT AND CONSERVATION Conservation in Steel
Company
IN STEEL COMPANY

Structure
1.1 Introduction
Objectives
1.2 Process
1.3 Energy Consumption
1.4 Energy Balance
1.4.1 Electrical Energy Balance
1.4.2 Thermal Energy Balance
1.5 Energy Conservation Measures
1.5.1 Electrical Energy Conservation Measures
1.5.2 Good Housekeeping Measures
1.6 Let Us Sum Up
1.7 Answers to SAQs

1.1 INTRODUCTION

So far you have learnt about energy audit, instruments of energy audit,
development of energy balance and identification of energy conservation
measures. You have also learnt about how to carry out energy audit of your home.
Findings from the energy audit of a few industries have also been discussed. In
this Unit we shall discuss the energy audit and the conservation measures in a
steel manufacturing company.
You have learnt that energy audit quantifies energy used for various discrete
functions and identifies areas of energy wastage. The main object is to find
specific consumptions, i.e. energy consumed per unit production, to identify the
areas of energy wastage and to suggest some energy conservation measures.
You are perhaps aware that there is a huge gap between demand and supply of
commercial energy. Bridging this gap requires increasing energy production, for
which enormous investments are needed. This problem can be overcome to a
large extent by judicious use of energy, i.e. making use of energy efficiently. This
can only happen if one has proper energy audit of a given energy consuming unit.
The company under consideration produced steel by using mild steel scrap. The
preliminary energy audit of the company was done to identity the energy
conservation opportunities. The following data were recorded during the energy
audit.
1. The company was using mainly two fuels (coal and electricity). The
percentage distribution of coal and electricity in total energy
consumption was as below :
Coal consumption : 90.44%
Electricity consumption : 9.56%

5
Energy Conservation
Measures-I
2. Specific energy consumption (energy consumption per unit
production) = 8.192 ´ 105 KCal/Tonne.
3. Average maximum demand : 264 KVA.
4. Most of the motors were running in under-loaded condition.
5. About 42.5% of heat supplied was lost through M. S. block covers.
The following recommendations were made.
1. Use of energy efficient lamps
A. Replacing 100 W bulbs by FL tubes (with electronic ballast).
B. Replacing conventional ballast by electronic ballast.
2. Use of alumina bricks instead of M.S block covers for reducing heat
losses significantly, i.e. about 4% from existing 42.5%.
You will learn various steps in arriving at the above recommendations.
Objectives
After studying this Unit, you will be able to understand the following:
· Energy audit of a steel company,
· Developing energy balance in such a company, and
· Identifying energy conservation measures in such a company.

1.2 PROCESS
Steel is produced in the form of round bars by using scrap which is obtained from
various industries. Firstly scrap (which is generally in the form of round or
rectangular bar is cut into pieces having length 1 to 2 feet. This cutting of scrap is
done on shearing machines. This scrap is kept on pusher which feeds the scrap
into the furnace where it is heated up to a temperature of about 1400ºC. After this,
these red hot bars are passed to hot drawing machines where the length of the red
hot bar is increased and its diameter is reduced as per the requirements.
In hot drawing machine (run by 250 HP motor) bars are passed between two
rollers and in this way an increase in length and reduction in diameter takes place.
Now these bars are passed through twisting machines where twisting of bars takes
place and the final product (round bars) is prepared. The complete process
flowchart is given in the Figure 1.1.

Scrap Shearing Pusher

Twisting Hot Furnace

Machine Drawing
Machine

Final
Product

Figure 1.1 : Process Flow Chart

6
 Energy Audit and
1.3 ENERGY CONSUMPTION Conservation in Steel
Company

All the energy needs of the plant are met by coal and electricity. Monthly
variation of electricity consumption, maximum demand and power factor are
shown in Table 1.1.
Table 1.1 : Monthly Electricity Consumption, Maximum Demand, Power
Factor and Bill Amount
Electricity Maximum Power Cost of
Month
Consumed (KWh) Demand (KVA) Factor Electricity (Rs.)
May 34020 247 0.94 68245
June 35970 261 0.93 71888
July 37830 249 0.94 76761
August 31080 276 0.97 62401
September 34482 266 0.92 69231
October 33780 261 0.91 72486
November 35482 273 0.92 71183
December 28229 298 0.90 70278
January 44280 255 0.94 96106
February 40740 258 0.94 89552
March 29220 268 0.91 65339
April 38070 255 0.95 84455

The contract demand for electricity is 308 KVA. The annual electricity
consumption during the audit period was 423183 KWh. The actual maximum
demand varies between 247 KVA to 298 KVA.
The coal consumption, electricity consumption and specific energy consumption
are shown in Table 1.2. The calorific value of the coal is 5800 KCal/Kg. The
percentage of coal and electricity in the total energy consumption is shown in
Figure 1.2.
Table 1.2 : Coal Consumption, Electricity Consumption
and Specific Energy Consumption
Equivalent Specific
Coal Equivalent Electricity
Month Electricity Production Energy
Cons. Coal Cons. Cons.
Cons. Cons.
(Kg.) (KCal) ´ 108 (KWh) (KCal) ´ 106 (Tonnes) KCal/Tonnes
´ 105
May 74430 4.32 34020 29.26 593.723 7.769
June 75160 4.36 35970 30.93 540719 8.635
July 64875 3.76 37830 32.53 556.436 7.345
Aug 63760 3.70 31080 26.76 607.238 6.542
Sept 60120 3.49 34482 26.65 462.465 8.192
Oct 35830 2.08 33780 29.05 259.637 9.151
Nov 37510 2.18 35482 30.51 275.808 9.028
Dec 28920 1.68 28229 24.28 204.221 9.416
Jan 55310 3.21 44280 38.08 456.353 7.871
Feb 38110 2.21 40740 35.04 262.827 9.743
March 27488 1.59 29220 25.13 182.313 10.114
April 31820 1.85 38070 32.74 248.593 8.761
Average 49444 3 35265 30 45402 9

7
Energy Conservation
Measures-I 9.07

Electricity
Consumption

Coal Consumption

90.93

Figure 1.2 : Percentage of Coal and Electricity Consumption in Total Energy Consumption
Example 1.1
The energy audit data for a steel company for a typical month is :
Coal consumption = 74430 Kg
Electricity consumption = 34020 KWh
Steel production = 593.723 Tonne
Calorific value of coal = 5800 KCal/Kg
Determine the specific energy consumption.
Solution
Let us first convert coal and electricity consumption into a common unit,
say KCal.
Coal consumption = 74430 Kg ´ 5800 KCal/Kg
= 431.694 ´ 106 KCal
Total consumption = 431.694 ´ 106 KCal + 29.257 ´ 106 KCal
= 460.951 ´ 106 KCal
Energy Consumption
Specific Energy Consumption =
Production
6
460.951 ´ 10 KCal
= = 7.763 ´ 105 KCal/Tonne
593.723 Tonne

SAQ 1
Differentiate between energy consumption and specific energy consumption.
………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………

8
 Energy Audit and
1.4 ENERGY BALANCE Conservation in Steel
Company
1.4.1 Electrical Energy Balance
In order to carry out electrical energy balance, you need the data regarding the
total connected load of each device and their operating hours. The energy
consumption is then evaluated and compared with the consumption recorded
during audit. The connected load and energy consumption is given in Table 1.3.
Table 1.3 : Connected Load of Electricity
Device H.P. No. KW Operating KWh/Day
Hrs./Day
Hot Drying 250 1 186.5 6 1119
Shearing 25 1 18.65 3.5 65.28
Shearing 15 1 11.19 3.5 39.17
Twisting 15 1 11.19 3 33.57
Twisting 10 1 7.46 3 22.38
Blower 5 1 3.73 6 22.38
Pusher 5 1 3.73 6 22.38
Lathe 5 1 3.73 2 7.46
Shaper 3 1 2.24 2 4.48
Pump 5 1 3.73 6 22.38
Fan 2 1 1.49 6 8.94
Fan 1 2 1.47 6 8.94
FL Tubes (54 - 20 1.08 6 6.48
W)
Bulbs (100 - 20 2.00 6 12.00
W)
Total Energy 1394.86
Consumption

The working days of the industry are 25 per month.

Total monthly consumption = 1394.86KWh/day ´ 25 days = 34872 KWh
Average monthly electrical consumption = 35265 KWh (Table 1.2)
The electrical energy balance may be worked as follows :
Average electricity consumption = Estimated electricity consumption
+ Unaccounted electricity consumption
or 35265 KWh = 34872 KWh + Unaccounted electricity consumption
or Unaccounted electricity consumption = 393 KWh which is about 11% of the
average electricity consumption.
The difference of 393 KWh may be due to incorrect recording of operating hours
of electricity consuming devices given in Table 1.3.

9
Energy Conservation
Measures-I 1.4.2 Thermal Energy Balance
Coal is the only source of energy used for thermal energy. It is used in a furnace,
which is made up of fire bricks. The data used in developing thermal energy
balance is given in Table 1.4.
Table 1.4 : Thermal Energy Balance
Energy Audit Data Value
1. Coal flow rate 329.6 Kg/hr.
2. Calorific Value of coal 5800 KCal/Kg

3. Steel flow rate, M 2583.78 Kg/hr.

4. Specific heat of steel, Ct 0.116 KCal/Kg ºK
5. Air flow rate 3984.5 Kg/hr

6. Mass of flue gases = (1) + (5), m 4314.1 Kg/hr

7. Specific heat of flue gases 0.26 KCal/Kg ºC
8. Thermal Conductivity of M.S. block, Cf 46.1 KCal/m ºC hr

9. Thermal conductivity of fire brick 0.1204 KCal/m ºC hr

10. Flue gas temperature 300ºC
11. Ambient air temperature 30ºC
12. Furnace temperature 1400ºC

We will now estimate heat energy generated and then used for various
applications :
A : Heat in = Coal consumption rate (Kg/hr) ´ calorific value of coal (KCal/Kg)
= 329.6 ´ 5800 = 1911680 KCal/hr
B : Heat taken by steel = M ´ Ct ´ ΔT
= 2583.78 ´ 0.116 ´ (1400 – 30)
= 410614 KCal/hr
You can now estimate the percentage share of this heat with the total heat
released. Thus,
% share of heat used by the steel
Heat taken by steel 410614
= = ´ 100
Heat in 1911680
= 21.5 % of heat in
C : Heat taken away by flue gases
= m Cf ΔT
= 4314.1 ´ 0.26 ´ (300 − 30)
= 302850 KCal/hr
% share = (302850/1911680) ´ 100
= 15.84 % of heat in
10
 Energy Audit and
D : Heat lost through conduction, convection and radiation Conservation in Steel
The detailed analysis is beyond the scope of this Unit. We summarise the results Company
below :
Heat loss through these processes
= 887890 KCal/hr
= 46.44 % of heat in.
Thus, thermal energy balance gives
Heat in = Heat out
1911680 (100 %) = 410614 (21.5 %) + 302780 (15.84 %)
+ 887890 (46.44 %)
+ Heat loss due to radiation when the blocks are open
or Heat loss due to radiation when the blocks are open = 16.22%.
Thus, the remaining 16.22 % of heat is lost through radiation when the blocks are
open for coal feeding and for taking out red hot bars.

1.5 ENERGY CONSERVATION MEASURES

1.5.1 Electrical Energy Conservation Measures
Most of the electrical load is that of the motors. The loading of motors was tested
by Tong tester. The measured data is shown in Table 1.5.
Table 1.5 : Performance Data of Motors

Rated Current at Current at

Devices H.P. Current No Load Full Load
(Amp.) (Amp.) (Amp.)

1) Hot Drawing 250 339 83 206

2) Shearing 25 36 21.3 26
3) Shearing 15 21 5.4 6
4) Blower 5 9 7 7.45
5) Lathe 5 9 2.57 3.7
6) Pump 5 9 2.89 3.84

It is clear from the above table that most of the motors are under loaded. Motors
of correct size should be used so as to make optimal use of electrical energy.

1.5.2 Good Housekeeping Measures

You have read about good housekeeping measures. Some of the well known good
housekeeping measures for lighting and cooling are :
In Lighting
· Turn off unnecessary lights wherever possible.
· Reduce lighting levels to minimum for task to be performed.
· Use energy efficient fluorescent/LED lighting fixtures

11
Energy Conservation
Measures-I
In Cooling
· Avoid direct sunshine on the outdoor heat exchanger of an air
conditioner to improve its work efficiency by about10%.
· Remove regularly, obstructions from front of air conditioners or their
grills and registers, to effect energy savings of the order of 5-15%.
· Clear air filter on room units and grills and registers of central unit,
every 2-3 weeks. It can save energy up to 5-10%.
· Air leaks in air-conditioned rooms should be sealed for stopping
energy wastage. This does not require much expenditure. This can
lead to energy savings of the order of 5-20%.
· Clean and calibrate thermostats, this results in energy savings of the
order of 5%.
· Select an energy efficient air-conditioning unit of the proper size for
space to be cooled. It is wise to buy a slightly undersized unit, rather
than oversized one.
· Follow the maintenance instructions suggested by the manufacture.
Properly maintained air conditioning units consume 5-10% less
energy.
Some of the energy conservation measures in air-conditioners are given in Table 1.6.
Table 1.6 : Energy Conservation Measures for Using Air-Conditioner
Savings Potential
Conservation Measure Frequency
(%)
Remove obstruction from front of air Regularly 5-15
conditioner or their grills and registers
Clean air filter on room units and grills Every 2-3 weeks 5-10
and registers of central units
Check for air leaks Yearly 5-20
Balance the system Yearly or as needed 5-10
Clean and calibrate thermostats Yearly 5

Follow manufacturer’s suggested Regularly 5-10

maintenance
Replace old unit with more efficient unit - Varies

1.6 LET US SUM UP

Various short term energy conservation measures have been discussed. Short term
energy conservation are good housekeeping measures which require no
expenditure or minimum expenditure but lead to huge savings.

1.7 ANSWERS TO SAQs

SAQ 1
In any energy consuming industry, the energy is consumed to produce the
desired products. The energy consumption can be calculated either on daily
basis, weekly, monthly or annual basis. Likewise the production data can also
be calculated. The energy consumed per unit of production is called specific
energy consumption.
12
 Energy Audit and
UNIT 2 ENERGY AUDIT AND Conservation in a
Pharmaceutical Industry
CONSERVATION IN A
PHARMACEUTICAL INDUSTRY

Structure
2.1 Introduction
Objectives
2.2 Preliminary Energy Audit
2.3 Analysis of Energy Usage
2.3.1 Carpet Losses
2.3.2 Heat Losses in the Flue Gases
2.3.3 Heat Loss Associated with Water Vapour in the flue gases
2.3.4 Boiler Efficiency
2.3.5 Blow down Losses
2.3.6 Sankey Diagram
2.4 Energy Conservation Measures
2.5 Short Term Measures
2.5.1 Tuning of Boiler
2.5.2 Control of TDS in Feed Water
2.5.3 Maximum Demand Control
2.6 Let Us Sum Up

2.1 INTRODUCTION

So far you have learnt about energy conservation in different industrial units like
a printing press, an oil mill and a steel-manufacturing company. In this Unit we
shall take up yet another case study of energy conservation in an industry.
The industry under consideration was a pharmaceutical company that
manufactured pyrogen-free distilled water and dextrose powder. The former was
based on what has come to be known as Heat Trap Technology. The set-up
consisted of multi-column stills working on the principle of an inter-stage heat
exchanger. The feed water was fed into a heat exchanger wherein 30% of it got
converted under pressure into steam around 155ºC, enough to kill existing
pyrogens.
The prevailing pressure pushed the steam produced as also the remaining feed
water into the next column. High temperature bacteria-free steam helped vaporize
the remaining feed water, and during the process got partially condensed into
water due to cooling. There was thus an additional steam produced without any
external source of heat. The process was repeated in up to three columns each
working at a slightly lower pressure than the one before it.
The steam produced in the first column was condensed in the second. This was
repeated column after column till the last column wherein it was condensed in a
dual function condenser mainly by feed water and if needed, then by external
cooling water. The condenser thus acts as both as pre-heater for feed water and
13
Energy Conservation
Measures-I
cooler for the steam in the last column. Most of the steam produced was cooled
within the system itself. The need of external water for cooling arose only for a
part of the steam produced in the last column.
The steam required for the distilled water plant was supplied by a 1.5-ton rating
boiler. It was designed for burning smaller size broken coal. The “as received”
coal stored on soft earthy ground was fed into a hopper that fed it to a pounding
equipment that broke the original coal into smaller size pieces. In this process
inevitably some powdered coal was also produced. This jumble of powdered coal
along with larger pieces of 15-20 mm size was pushed by a blower, delivering the
mixture of primary air and coal to the burner in a semi-continuous operation.
The boiler did not has any provision for the removal of ash without opening the
main furnace door, even while using the broken coal. The door had thus to be
opened both for feeding the coal as well as for ash removal. This had to be done a
number of times during an operational day. On each such occasion fully charged
furnace of the boiler was suddenly cooled. Accumulative effect of this wasteful
practice affected adversely the performance of the boiler resulting in very poor
working efficiency.
Objectives
After studying this unit, you will be able to understand
· energy audit of a Pharmaceutical Company,
· energy conservation measures in Pharmaceutical Company, and
· areas where these measures may be effective.

2.2 PRELIMINARY ENERGY AUDIT

Coal and electricity were the only energy sources used in the plant. The former
fed a 1.5-ton rating boiler which in turn supplied steam to the distillation and
dextrose section. The block diagram of distribution of steam and distilled water in
various sections of the plant is given in Figure 2.1. The coal was consumed at the
rate of 1.5 ton per day. The electricity was used for lighting, running motors,
pumps, fans and blowers, etc.
Scrutiny of electric bills for a period of one year showed penalties both due to
maximum demand charges as well as due to low power factor. The total
connected load in the plant was 132 KVA.
A preliminary energy audit of the plant helped in the identification of equipment
and services where energy conservation was possible :
· The coal was stored on moist soft ground where there was a lot of
scope of mixing of earth with the coal fines leading to carpet losses
that could be up to 2-3%.
· There was no provision of periodic flue gas analysis nor control or
fine tuning of primary air for combustion.
· There was a surplus of condensate with temperatures ranging between
60ºC and 70ºC, available at the ground level, arising due to the use
of normal tap water for cooling in the distillation plant and about
150 liters of similar water form the sterilization plant and mixing this
with the condensate. Its collection in right amount in one place and
feeding it back into the feed water circuit needs careful attention.
14
 Energy Audit and
Conservation in a
Boiler Distillation Pharmaceutical Industry
House Plant

Dextrose Plant

Figure 2.1 : Block Diagram of Steam Distribution

· The flue gases at high temperature were going out of the chimney
without being passed through any heat recovery device. Detailed
measurements indicated that they have temperature of about 270ºC.
· There existed a frequent problem of scaling of boiler surfaces. Fine
tuning of boiler system and basic housekeeping include proper
adjustment of combustion-control systems and a good maintenance
programme for steam traps, lines and vents. Apart from this the
energy conservation measure must include the maximum return of
condensate, the most expensive water in a plant, and the use of flash
tanks and heat exchangers to reclaim some of the energy wasted in
boiler blow down. Excessive blow down to maintain TDS in boiler
within prescribed safe limits was the largest single water related
energy wastage.
· The efficiency of the cooling towers could be improved by replacing
the existing fan with a FRP fan and lower HP motor.
· The maximum demand and low power factor needed careful attention.
There were no separate meters installed to identify sections
consuming more power than others; this information proves useful in
controlling demand by shifting some of this load to off peak hours.
· Energy efficient lighting systems needed to be used.

2.3 ANALYSIS OF ENERGY USAGE

In order to identify energy conservation measures, it is necessary to prepare an
energy balance. In this Section we shall discuss thermal energy balance.
The principle components of energy balance are :
· Carpet losses associated with storage of coal on the open on loose soft
ground;
· Heat losses associated with dry flue gases;
· Heat losses arising due to the presence of water vapour in the flue
gases;
· Energy taken up by the boiler to generate steam at the working
efficiency of the boiler;
· Losses springing from the boiler not always working at its rated value
or what has been called the load factor;
· Blow down losses, and
· Losses due to incomplete combustion and radiation from the body of
the boiler and furnace mouth.
15
Energy Conservation
Measures-I
These losses are discussed in the following sections :
2.3.1 Carpet Losses
The coal required for the boiler furnace was stored behind the boiler house on
open loose soft ground. This resulted in the mixing of the coal fines with loose
earth and eventual loss that could be up to 3% or so.
2.3.2 Heat Losses in the Flue Gases
A graphical representation of the combustion in the boiler furnace is shown in
Figure 2.2. C H O N S A W are the percentages of carbon, hydrogen, oxygen,
nitrogen, sulfur, ash, and mechanical water present in the coal. This information is
supposed to be obtained from the combustion products formed by the burning of
coal. In addition to these components water vapour is also produced during
combustion due to the presence of hydrogen in coal.
Heat losses in the flue gases can be estimated from the actual measurement of the
constituents of flue gases. These measurements were taken several times with the
help of IMR 300 (an instrument capable to measure all possible constituents of
flue gases). The results for a typical test run are given in the Table 2.1.

External Air for

Combustion
CO2

Dry Flue Gases

CO
O2
C N2
Nitrogen H
Oxygen Moisture
Actual Air

O
Moisture N
Ash +
S
Water A
Vapour W Solid Refuse

Ash +
Combustion

Figure 2.2 : Schematic Diagram of the Combustion in Boiler

These measurement figures are on volume basis. In order to make use of this data
for quantitative analysis the parentages of flue gas components must be known on
weight basis.
Table 21 : Flue Gas Analysis by IMR 300
Component Value
CO2 12.6%
Co 30 ppm (parts per million)
H2S 0 ppm
NO 0 ppm
O2 11.2%
SO2 204 ppm
NO 116 ppm
Excess Air Factor 1.48
16
The heat losses associated with the flue gases were estimated from the coal Energy Audit and
Conservation in a
consumption data provided by the management. Pharmaceutical Industry
During energy audit, it was observed that there was no quantitative data available
on the primary air being supplied for combustion. A 7.5 HP blower was used for
pushing the mixture of coal and air and feeding it to the burner. Another
supplementary 3 HP blower augmented the primary air supply occasionally. We
have estimated air demand for combustion from theoretical air for coal and
assuming a 50% excess air factor. A 7.5 HP blower has a discharge capacity of
about 3700 kg/hr.
In the absence of a detailed composition of coal, the following relevant properties
were assumed. The analysis was based on the data supplied by the management
and also on the measurements reported above.
Ash + moisture content = 30%
Calorific value of coal = 4500 kCal/kg
Burning rate of coal = 1.5 Tonnes/day
= 62.5 kg/hour (assuming 24-hour operation)
Heat released per hour = 62.5 kg/hr ´ 4500 kCal/kg.
= 2.81 ´ 05 kCal/hr
Specific heat of flue gases (Cp) = 0.24 kCal/kgoC
Theoretical amount of air for coal = 11 kg/kg
Actual air being used up in view of the above excess air factor (see Table 2.1)
= 11 ´ 1.48 = 16.28 kg/kg
Mass flux in the flue gases = 62.5 ´ 16.28 + 62.5
= 1080 kg/hour
Hence, Heat flux in the flue gases
= m Cp ΔT
= 1080 ´ 0.24 ´ (270 − 30)
= 62.21 ´ 103 kCal/kg.
Percentage of heat loss in the flue gases
= 62.21 ´ 103/2.81 ´ 105
= 22.1%
2.3.3 Heat Loss Associated with Water Vapour in the Flue Gases
The water vapour in the flue gases enters from the following three sources :
(1) Mechanical water present in the composition of coal.
(2) Water formed in the composition of coal due to the presence of
hydrogen in coal.
(3) Water vapour that is a constituent of external air supplied for the
combustion.
The components of first two categories are liquid water that get converted into
water vapour when these are brought to the state of the flue gases. The amount of
water vapour present will depend upon the dry and wet bulb temperatures of the
air or on its relative humidity, and is obtainable from the psychometric charts.
Assuming hydrogen and external moisture in the coal to be 5% and 10%
respectively, the amount of water formed per Kg of coal during combustion may
be computed by using the following formula :
17
Energy Conservation
Measures-I
The amount of water formed per Kg of coal during combustion
= 9 ´ 0.05 + 0.1 = 0.55 kg.
Latent heat of water vapour = 546 kCal/kg
Hence, heat lost due to latent heat of vapourisation in the flue gases
= 0.55 ´ 546 = 300.3 kCal
Specific heat of water vapour = 0.48 kCal/kg ºC
Heat lost due to sensible heat of water vapour
= m Cp ΔT
= 0.55 ´ 0.48 ´ (270 – 30) = 63.4 kCal/kg
Assuming 40% relative humidity of the external air, the amount of water vapour
present per kg of air is 0.008 kg. The amount of air being supplied for the
combustion of one kg of coal is 16.26 kg.
Hence, the amount of water vapour present in the air required for the combustion
of 1 kg. of coal
= 16.26 ´ 0.0008 = 0.13 kg.
The amount of heat spent to bring it to the state of the flue gases will be
= 0.13 ´ (270-30) x 0.48 = 15.0 kCal
Thus, total heat loss associated with the water vapour in the flue gases
= 300.3 + 63.4 + 15 = 378.7 kCal/kg of coal burnt.
Percentage loss due to water vapour
62.5 ´ 378.7 ´ 100
= = 8.4%
5
2.81 ´ 10
2.3.4 Boiler Efficiency
The boiler efficiency η was determined to be equal to 48.9%.
The boiler was not found to be working at its rated capacity of 1.5 ton/hr. During
the survey of the plant on several occasions, it was found to be operating on the
average at less than 50% of the rated load. Figure 2.3 shows the reduction in the
efficiency with varying loads. This is also one of the reasons for its low working
efficiency.
2.3.5 Blow down Losses
In spite of pre-treatment, boiler feed water often contains some impurities, such as
suspended and dissolved solids. The impurities can remain and accumulate inside
the boiler over a period of time. The increasing concentration of suspended solids
can form sludge, which reduces boiler efficiency. To avoid boiler problems, water
must be periodically discharged or “blown down” from the boiler to control the
concentrations of suspended and total dissolved solids in the boiler
The blow down was reportedly carried out three times in a shift of 12 hours or a
total of six times is 24 hours. The resulting losses were estimated to be about
10%. Ideally, the blow down should be done once in a shift.
18
Thus to summarize the energy balance terms, we have Energy Audit and
Conservation in a
Carpet losses = 3% Pharmaceutical Industry

Process heat = 48.9%

Heat loss in dry flue gases = 22.1%
Heat loss due to water vapour in the flue gases = 8.4%
Estimated blow down losses = 10%
Total of clearly definable heat losses = 92.4%
The remaining heat loss of 7.6% could be on account of incomplete combustion,
fouling of heat transfer surfaces, radiation losses arising from the wasteful
practices of frequently opening the door of the furnace for loading and ash
removal.

100

80

60
Efficiency (%)
40

20

0 25 50 75 100
Load (%)
Figure 2.3 : Efficiency of Steam Boiler at Various Loads

2.3.6 Sankey Diagram

The above losses are represented in a Sankey diagram shown in Figure 2.4.

Process Steam 48.9%

Coal : 20.25 ´ 108 Kcal
100%
Unaccounted losses 7.6%
Dry Flue gas losses 22.1%
Losses due to water vapour
in Flue gas 8.4%
3%
Carpet losses

Blow down losses 10%

Figure 2.4 : Sankey Diagram : Thermal Energy

19
Energy Conservation
Measures-I 2.4 ENERGY CONSERVATION MEASURES

Based on the above observations relating to energy audit and energy balance, the
following energy conservation measures may be identified. These are classified
under three categories, namely short term, medium term and long term measures.
The following may be considered as the short term measures :
· Tuning of the boiler;
· Blow down control through estimation of TDS by measurement of
conductivity or specific gravity of feed water, and
· Rephrasing of loads to escape penalty on account of exceeding
maximum demand.
The medium term measures are
· Storing of coal on a concrete floor to avoid carpet losses;
· Management of condensate recovery;
· Installation of power capacitors;
· Use of energy efficient lighting systems, and
· The heat recovery device in the form of an air pre-heater.
The long term measures are
· Use of surplus condensate in future expansion plans, and
· Replacement of the existing fan of the cooling tower whenever it
needs to be replaced.

2.5 SHORT TERM MEASURES

2.5.1 Tuning of the Boiler

In the operation of the boiler no attention was paid to the control of combustion
air. There was no organized practice of controlling excess air through analysis of
the flue gases. The excess air supplied to the furnace of the boiler was much more
than the optimum required.
In the absence of on-line flue-gas analyzers, the only flue-gas characteristics that
the boiler operator could use continuously were opacity and temperature. Or, he
could look at the appearance of the flame, and use other subjective judgments to
decide when the boiler was operating at the best excess-air level. However,
through these techniques one could only make an approximate assessment. Use of
flue-gas analyzers can provide accurate results.
All boilers need some excess air to ensure proper combustion of the fuel. While a
range of sophisticated microprocessor based controls are available, their cost may
not justify their installation on small boiler. In view of this it can be suggested
that apart from depending on the wisdom and intuition of the operator, periodic
checks once a day by a portable Orset apparatus be conducted to look for the
optimum amounts of O2 and CO2 in the flue gases.
Oxygen content of the flue gas is roughly proportional to the amount of air blown
into the furnace. It is directly proportional to excess air over the range 0-8% O2.
20
Operators may be advised to keep O2 above a level that is predetermined for the Energy Audit and
Conservation in a
anticipated load. This would be feasible when this is practiced over a period of Pharmaceutical Industry
time.
More excess oxygen is needed at low loads, because of poorer mixing of air and
fuel. A problem with O2 monitoring that must be mentioned is that the reading is
drastically distorted by air infiltration into the furnace and the convection
passages downstream of the burners.
Carbon monoxide in the flue gas (measured in ppm of CO) stays at a fairly low
constant level at high excess air, but rises sharply as excess air is reduced below
the optimum level. Flue-gas carbon monoxide is unaffected by air infiltration, and
thus gives a more certain indication of combustion. The CO level in the flue gas
depends solely on combustion efficiency and not on the fuel, the burners, or the
design of the boiler. However, with all these merits, its measurement is an
expensive proposition.
Carbon dioxide in the flue gas increases to a maximum approximately at the ideal
air/fuel ratio, and falls off both with increasing with decreasing excess air.
However, it is not suitable as a primary control signal, because a peak value is
less definitive than a present value. The peak value also varies with load, fuel, and
boiler type and condition.
Unburned hydrocarbons in the flue gas provide the greatest threat of
boiler-furnace explosion. They can be measured with the type of measuring
gadget mentioned above. They are sometimes used to control combustion.
Oxides of nitrogen and sulfur in the flue gas are all increased with increased
levels of excess air. Thus, a benefit of minimizing excess air to improve
combustion efficiency is that pollutants are reduced, and sulfuric acid corrosion of
stack equipment is minimized.
A couple of years old coal-fired boiler without any heat recovery or condensate
recovery devices is expected to have an efficiency in the range of 60-70%. With
the installation of heat recovery devices the efficiency can go up to 80%. In the
present case, therefore, with appropriate control of air for combustion, based on
daily testing as stated above, the efficiency of the boiler may be increased by at
least 10%. This would amount to a saving of about 45 tonnes of coal or
Rs. 56250. The only cost involved is that of the Orset apparatus that costs about
Rs. 5000. This cost is recoverable within about 5 months.

2.5.2 Control of TDS in Feed Water

For a boiler of the size discussed above, the TDS (total dissolved solids) have to
be about 3500 ppm. There was no provision for estimating this and maintaining it
at the desired level. The manual conductivity measurement of feed water and
adjustment of valve need to be carried out every four to six hours so as to
maintain water conductivity in the range of 2400-2800 micromhom-1. A simpler
alternative exists in terms of specific gravity test. The resultant increase in boiler
efficiency is expected to be about 5%.

2.5.3 Maximum Demand Control

It was found from the electricity bills of the company that they had incurred
penalties arising from exceeding the contract demand at times. This could be
avoided by shifting some of the load to non-peak hours, say night time.

21
Energy Conservation
Measures-I 2.6 LET US SUM UP
Coal and electricity are the only energy sources used in the plant. Coal is
consumed at the rate of 1.5 ton per day. The electricity is used for lighting,
running motors, pumps, fans and blowers, etc.
The principle components of energy balance are :
· Carpet losses associated with storage of coal in the open on loose soft
ground;
· Heat losses associated with dry flue gases;
· Heat losses arising due to the presence of water vapour in the flue
gases;
· Energy taken up by the boiler to generate steam at the working
efficiency of the boiler;
· Losses springing from the boiler not always working at its rated value
or what has been called the load factor;
· Blow down losses, and
· Losses due to incomplete combustion and radiation from the body of
the boiler and furnace month.
Based on the energy audit and energy balance, the following energy conservation
measures are recommended :
· Tuning of the boiler;
· Blow down control through estimation of TDS by measurement of
conductivity or specific gravity of feed water, and
· Rephrasing of loads to escape penalty on account of exceeding
maximum demand.

22
 Medium and Long Term
UNIT 3 MEDIUM AND LONG TERM ENERGY Energy Conservation
Measures in
CONSERVATION MEASURES IN Pharmaceutical Industry

PHARMACEUTICAL INDUSTRY

Structure
3.1 Introduction
Objectives
3.2 Installation of Correctly Rated Motors
3.3 Storage of Coal on Concrete Floor
3.4 Power Factor Improvement
3.5 Condensate Recovery from Boiler Feed Water
3.6 Waste Heat Recovery
3.7 Use of Energy Efficient Lights
3.8 Excess Demand
3.9 Let Us Sum Up

3.1 INTRODUCTION

The rate at which the energy demand and energy prices are increasing, it may
become difficult to sustain the present rate of development. The environmental
implications of inefficient use of energy are causing serious concern. Greenhouse
effect, acid rain, deforestation, shift in climatic conditions, etc. are some of the
indicators of the environmental degradation. Setting up additional generating
capacities to meet increasing energy demands is not only a very expensive but
also a time-consuming alternative. Additional power plants also mean additional
pollution and further degradation of the environment. Thus, energy conservation,
besides being a quick and economical approach has the potential to provide an
effective solution to emerging environmental concerns.
In any energy consuming industrial unit, there is a lot of scope for short, medium
and long term energy conservation measures. In Unit 3.3.2, you have learnt about
short term energy conservation measures in a pharmaceutical company. In this
Unit we shall continue with the same case study and shall discuss medium-term
and long-term energy conservation measures.
Objectives
After studying this unit, you will be able to
· understand medium term conservation measures,
· understand long term conservation measures, and
· evaluate the payback periods of these measures.
23
Energy Conservation
Measures-I 3.2 INSTALLATION OF CORRECTLY RATED
MOTORS

There were a large number of electrical motors used in the plant for a variety of
purposes as described in Table 3.1. During the energy audit, measurements of
actual currents being drawn by the large sized motors (7.5 HP and above) were
made by a tong tester and the findings are given in Table 3.1. It was found that
some of them were running up to 65% below the rated current. You have learnt
earlier, that an induction motor should always be loaded to its maximum capacity,
as these motors are designed to be efficient at full rated load. The motor
efficiency reduces drastically when the load factor on the motor is less than
50-60% of rated load. Hence, it was recommended that the measurement of
currents of motors while in operation be made regularly. This data should be well
documented over a period of time so as to cover all likely loads. On the basis of
this information collected if some of the motors are found to consistently over
rated these be replaced by adequately matched efficient motors.
Table 3.1 : Loading Pattern of Selected AC Motors

Sl. Rated Full

Motor Actual Load Loading
Section Load
No HP (Amp) (%)
(Amp)
1. Muddling 7.5 10.5 8.05 76.6
Section
2. Air compressor 7.5 11.57 7.07 61.1

7.5 11.57 7.53 65.0

7.5 11.0 5.0 45.4
3. Dextrose 10.0 15.5 4.19 27.0
Section
7.5 10.5 3.0 28.6
7.5 10.5 3.0 28.6
4. Filling Room 5.0 7.6 3.76 49.5

5. A.C. Room 20.0 N/A 21.5 --------

10.0 14.5 9.47 65.3

6. Tube Well 7.5 11.57 11.57 8.9

7. Boiler Section 7.5 10.9 9.61 88.1
10.0 14.4 9.70 67.4
8. Centrifuge 55 230 45 (Without 19.5
Load)

Any motor should give the required performance at the minimum cost. There are
two costs involved, i.e. capital cost and running cost. The running cost of a motor
depends upon its efficiency.

3.3 STORAGE OF COAL ON CONCRETE FLOOR

As discussed in the earlier Unit, the coal was being stored on loose moist soft
ground, leading to carpet losses of about 2-3%, amounting to annual loss
exceeding Rs. 15000. This could be avoided by constructing a concrete floor of
24
 Medium and Long Term
25 m2 at a cost of about Rs. 10000. As you can see, this cost could be recovered Energy Conservation
in less than a year. Measures in
Pharmaceutical Industry
3.4 POWER FACTOR IMPROVEMENT

You have learnt about power factor in Block 1 of OEY-001. Power factor is the
ratio of real power (watt) and apparent power (volt amp). In an electrical circuit
having pure resistive loads, real power and apparent power are the same.
However, in a circuit having inductors (as in motors) they are different. For
example, if the real power is 1700 watt and the apparent power is 1200 volt amp,
the power factor is 0.85. With low power factor load, the current flowing through
the device components is higher than necessary to do the required work. This
results in excess heating which may damage the device or reduce its life. Low
power factor may also cause low-voltage conditions, which results in dimming of
lights and sluggish motor operations.
The reactive load component (KVAr) must be reduced to improve the P.F. of a
given load. The reactive power component lags the power component (KW) by
90º and therefore one way to reduce the effect of this component is to introduce
another reactive power component that leads the power component by 90º. This
can be done by power capacitor. The amount and location of the corrective
capacitance may be determined from a survey of the distribution system and the
source of the low power factor loads. In order to reduce the system losses, the
power capacitors should be electrically located as close to the low power factor
loads as possible or just across the load. The power factor capacitors are
connected across the power lines in parallel with the low-power-factor loads.
The maximum demand, energy consumption, power factor and penalty due to low
power factor found through an audit of a unit are given in Table 3.2.
Table 3.3 gives the multiplier to be applied to the KW load to determine the
capacitive KVAr required for obtaining the desired corrected power factor.
The operating power factor during the survey period was 0.7, total connected load
being 184 KW. The rating of power capacitors required to improve the power
factor to 0.95 works out to be 127.5 KVAr, as shown below :
Original power factor is given by
Re al Power 184
Cos j1 = 0.7 = =
Apparent Power Apparent Power
184
Apparent Power = = 262.86 KVA
0. 7
The reactive power is then given by
Re active Power = 262.86 2 - 1842 = 187.72 KVAr
For the improved power factor of 0.95, the apparent power and reactive power are
given by
184
Apparent Power = = 193.68 KVA
0.95
Re active Power = 193.682 - 1842 = 60.5 KVAr
The rating of power capacitor required = 188 – 60.5 = 127.5 KVAr.
Assuming the average cost of the capacitor to be Rs. 125/KVAr, the cost of the
capacitor to be connected comes out to be Rs. 15938.
25
Energy Conservation
Measures-I Table 3.2 : Details of Electrical Loads
Maximum Energy Total Low P.F.
Power
Month Demand Consumption Energy Charges
Factor
(KVA) (KWh) Charges (Rs.) (Rs.)
March 63.00 9510 0.66 8368.80 3071.73

April 61.50 10440 0.64 9187.20 3727.20

May 76.50 12420 0.71 10929.60 2955.96

June 102.75 24117 0.72 10560.00 4488.00

July 102.75 24117 0.72 21222.96 5329.86

August 106.50 192936 0.66 16977.84 6231.64

September 115.50 22079 0.64 19429.52 7822.20

October 151.50 27138 0.62 33387079 14090.26

November 99.00 15555 0.57 16954.95 8710.80

December 132.75 16943 0.54 29444.00 16797.00

January 139.50 25827 0.56 29665.44 15785.28

February 139.50 31610 0.58 36061.26 21317.76

Table 3.3 : Power Factor Correction Factors

Existing Power Corrected Power Factor

Factor (%)
100% 95% 90% 85% 80%
50 1.732 1.403 1.247 1.112 0.982
52 1.643 1.314 1.158 1.023 0.893

54 1.558 1.229 1.073 0.938 0.808

56 1.479 1.150 0.994 0.859 0.799

58 1.404 1.075 0.919 0.784 0.654

60 1.333 1.004 0.848 0.713 0.583
62 1.265 0.936 0.780 0.645 0.515
64 1.201 0.872 0.716 0.581 0.451

66 1.139 0.810 0.654 0.519 0.389

68 1.078 0.749 0.893 0.458 0.328

70 10.20 0.691 0.535 0.400 0.270
72 0.964 0.635 0.479 0.344 0.214
74 0.909 0.580 0.424 0.289 0.195
76 0.855 0.526 0.370 0.235 0.105
78 0.802 0.473 0.370 0.235 0.105
80 0.750 0.421 0.265 0.130 0.052
82 0.698 0.369 0.213 0.078 -
84 0.646 0.317 0.161 -
86 0.594 0.265 0.109 -
88 0.540 0.211 0.055 -
90 0.485 0.156 - -
26
 Medium and Long Term
The penalty on low power factor during the month of energy audit was Rs. 21317. Energy Conservation
If we take the average penalty, it comes out to be Rs. 18551/per month or Measures in
Rs. 222600 per year. Pharmaceutical Industry

The estimated payback period is less than two months.

Connecting the power capacitors to the motor terminals and switching the
capacitors with the motor load is a very effective method for correcting the power
factor. The benefits of this type of installation are the following :
· No extra switches or protective devices are required.
· Line losses are reduced from the point of connection back to the
power source.
· Corrective capacitance is supplied only when the motor is operating.
In addition, the correction capacitors can be sized based on the motor
nameplate information, as previously discussed.
Example 3.1
Determine the rating of power capacitor required in the above case by using
Table 3.3.
Solution
You need three things. The connected load (KW), existing power factor and new
power factor. In the above case, these are
Connected load = 184 KW
Existing power factor = 0.7
New power factor = 0.95
From Table 3.3, the multiplier factor is 0.691. The capacitor rating required to
increase power factor from 0.7 to 0.95 is 0.691 ´ 184 = 127.14 KV Ar which is
close to 127.5 calculated above.

3.5 CONDENSATE RECOVERY FROM BOILER

FEED WATER

Recovery and collection of the condensate from different points in the network
and pumping it back into the feed water tank is an attractive proposition
(see Figure 3.1). Estimated temperature of the condensate is in the range of
60-70ºC. Assuming that about 75% of the condensate can be retrieved, average
steam demand being 625 Kg per hour, an estimated 469 Kg of condensate can be
pumped back into the feed water circuit. Normally this would put a demand of the
make-up water of about 256 Kg/hr. Instead 400 Kg of DM water used as cooling
water in place of normal tap water plus about 150 Kg/hr from the sterilization
plant was being pumped into the condensate tank every hour. This was the total
water source, there being no other make-up water. Thus, there is an excess of
condensate of DM water to the extent of 300 Kg per hour being added to the
source tank, i.e. the condensate tank. This excess hot water could be used for
various productive purposes. Following steps would help conserve energy :
(i) It should be covered to avoid heat losses from the water surface.
(ii) The sides of the tank should be insulated to avoid conduction losses to
the ground.
27
Energy Conservation
Measures-I
Estimated minimum rise in water temperature by (i) and (ii) is 10ºC.
The heat saved by this measure is 625 ´ 10 ´ 1 = 6250 KCal/hr.
Equivalent coal saving is = 1.39 Kg/hr or roughly 10 tons in a year. The resulting
annual saving is Rs. 13500.
The estimated cost of (i) and (ii) is about Rs. 10000/-. Thus, the cost is
recoverable in about a year.
The condensate collected in the properly insulated covered tank should be
pumped to the feed water tank before being fed to the boiler.
Rate of water to be pumped = 700Kg/hr
The height to which it has to be pumped = 5 m
Rate of doing work = 3500 Kg m/hr
One HP = 44760 J/minute
This works out to be roughly 0.5 KW. At 50% efficiency the power required for
the pump is about 1 KW.
Capital cost of the pump = Rs. 2500
Running cost @ Rs. 2/- per KWh = Rs. 48 per day
= Rs. 14400 in a year.

Steam Steam used in Condensate

625 Kg./hr different 60-70ºC
sections

75%
Excess Water = 469 + 400 + condensate
Boiler 150 – 700 = 319 Kg/hr could be
recovered
(= 625 ´ 0.75
= 469 Kg/hr)

Feed Water
Tank Condensate
700 Kg/hr Tank

150 Kg/hr from sterilization plant

400 Kg/hr water used in cooling water

Figure 3.1 : Condensate Recovery

Rate of condensate available = 625 Kg/hr
Temperature of the condensate = 70ºC
Equivalent heat saved = 625 ´ (70 − 30) ´ 1
= 25000 KCal/hr
28
 Medium and Long Term
Coal saved in a year = (25000/4500) ´ 7200 Energy Conservation
Measures in
= 40000 Kg
Pharmaceutical Industry
Annual savings @ Rs. 1250 per ton = Rs. 50000
Thus, the capital and the running cost is recoverable in less than a year.

3.6 WASTE HEAT RECOVERY

Use of heat recovery device based on exploitation of the heat contained in the flue
gases is another attractive option. It has been shown that an air pre-heater is very
cost effective leading to an annual saving of about Rs. 62,000/- with a payback
period of less than two years. A layout of waste heat recovery system is outlined
in Figure 3.2.

Flue gases cooled after heat recovery

150 ºC

Cold Air from the

Boiler
30 ºC

Hot Air to the

Furnace
113 ºC

270 ºC

Hot flue gases from furnace

Figure 3.2 : Cross Sectional View of Waste Heat Recovery

The flue gases coming out of the chimney have a temperature of about 270ºC.
The fuel being used was coal which was likely to have sulfur as an impurity. In
fact the flue gas analysis showed the presence of 204 ppm of SO2, which when
dissolved in water vapour in the flue gases would lead to the formation of sulfuric
acid. This in turn set a limit up to which the flue gases could be cooled, due to
corrosion problems connected with condensation of sulfuric acid. The safe limit
29
Energy Conservation
Measures-I
chosen in such cases was temperature T2 = 150ºC. Thus the flue gases can be
cooled by about 120ºC. The heat flux available in the flue gases may be calculated
from the rate of burning of coal and allied data as discussed below :
Rate of burning of coal = 62.5 Kg/hr
Estimated air required for burning = 16.28 Kg./Kg
Mass flux of air required for combustion = 16.28 * 62.5 = 1017 Kg./hr
Initial temperature of external air, To = 30ºC
Initial temperature of flue gases, T1 = 270ºC
Specified heat of flue gases = 0.24 KCal/Kg ºC
Outlet temperature of external air, To = 113ºC
The area of the heat exchanger comes out to be = 13 m2
Estimated cost of the heat exchanger is about Rs. 70000.
Coal saved per hour is given by 35156.5/4500 = 7.8 Kg.
Coal saved in a year = 7.8 ´ 24 ´ 300 = 56.16 tons
Saving in a year with coal cost of Rs. 1250/- per ton is about Rs. 70200 that gives
a pay back period of about a year.

3.7 USE OF ENERGY EFFICIENT LIGHTS

There were 100 numbers of 40 W fluorescent tubes operating 16 hrs. per day. The
tubes were fitted with conventional chokes which consume about 12 W of power.
Thus for 300 operational days in a year, the annual consumption is given by:
100 ´ 52 ´ 300 ´16 KWh/yr
Annual consumption E1 =
1000

= 24960 KWh/yr
These tubes can be replaced by compact fluorescent lamps (CFL) of 11 W and
electronic chock which consume about 4 W of power. The annual consumption
would be
100 ´ 15 ´ 300 ´ 16 KWh/yr
Annual consumption E2 =
1000
= 7200 KWh/yr
The savings in annual electricity consumption = E1 – E2 = 17760 KWh/yr.
The cost of electricity saved @ Rs. 2/KWh = 17760 ´ 2 = Rs. 35520.
The capital cost for one complete fixture would be about Rs. 300.
The payback period = (300 ´ 100/35520) ´ 12 = 10 months.

3.8 EXCESS DEMAND

During the survey it was found that the total connected load as per the name plate
rating of various devices was 184 KW. In terms of an average PF of 0.75, the
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 Medium and Long Term
corresponding KVA works out to be 245, the contract demand being 132 KVA, Energy Conservation
the scrutiny of electric bills showed exceeding this demand at times leading to Measures in
penalties. Pharmaceutical Industry

The solution lies either in shifting the working hours from peak load hours or
asking for increased contract demand.

3.9 LET US SUM UP

We have discussed energy conservation measures in a pharmaceutical company.

The energy conservation measures are in the area of lighting, power factor
improvement, waste heat recovery, condensate recovery, etc.
The medium term measures are
· Shoring of coal on a concrete floor to avoid carpet losses.
· Management of condensate.
· Installation of power capacitors.
· Replacement of lights by fluorescent tubes.
· The heat recovery device in the form of an air pre-heater.
The long term measures are
· Use of surplus condensate in future expansion plans.
· Replacement of the existing fan of the cooling tower whenever it
needs to be replaced.

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