Project: Energy Analysis of an Industrial Furnace/Kiln/Oven
Project is to be carried out in groups of 5 students. The allocation of industrial units is as follows.
Group No. Industrial Unit Group No. Industrial Unit
1 Cement Kiln 9 Lime Kiln
2 Steel Reheating Furnace 10 Blast Furnace
3 Glass Melting Furnace 11 Annealing Furnace
4 Aluminum Smelting Furnace 12 Calciner
5 Ceramic Kiln 13 Powder Coating Oven
6 Heat Treatment Furnace 14 Drying Oven
7 Foundry Furnace 15 Bakery Oven
8 Brick Kiln 16 Curing Oven
There are three phases in the project with specific deadlines to submit group reports (60 marks). There will
be an individual viva at the end (40 marks). Datasets for phase 2 will be provided at the end of phase 1. In
the following activity descriptions and rubrics, whenever the terminology ‘furnace’ is used, it is applicable
to other similar industrial units such as kilns and ovens as well.
Phase 1: Understanding furnace operation and measurement requirements (Deadline: 25th July)
1. Provide an overview of the furnace’s purpose, relevant inputs and outputs, and operational details
based on literature.
2. Identify and explain key parameters that affect furnace efficiency.
3. List specific measurements that need to be taken during an energy audit of the furnace.
4. Specify types of equipment required to take these measurements.
5. Clarify the purpose of each measurement and how it contributes to the audit.
Phase 2: Data analysis and efficiency evaluation (Deadline: 8th August)
1. Analyze provided datasets to calculate furnace efficiency.
2. Quantify energy losses and illustrate the furnace energy balance using Sankey diagram.
3. Identify potential areas for improvement and propose practical measures.
4. Estimate potential energy savings from the proposed measures.
Phase 3: Feasibility and implementation planning (Deadline: 15th August)
1. Evaluate the technical feasibility and discuss potential environmental benefits of the proposed
measures.
2. Conduct a cost-benefit analysis of the proposed measures.
3. Offer recommendations for implementing energy-saving measures.
Phase 1: Understanding furnace operation and measurement requirements (18 marks)
Criteria Exemplary (A+, A, A- > 70) Competent (70 > B+, B, B- Developing (55 > C+, C, Beginning (35 > F)
> 55) C-, D > 35)
Overview of Provides a thorough and Provides a comprehensive Provides a basic overview Overview is
furnace insightful overview of the overview of the furnace's of the furnace's purpose, incomplete or
(3 marks) furnace's purpose, inputs, outputs, purpose, inputs, outputs, and inputs, outputs, and unclear, lacking
and operational details based on operational details. Integrates operational details. Lacks depth and
literature. Integrates theoretical some theoretical concepts. integration of theoretical integration.
concepts effectively. concepts.
Key parameters Identifies and explains key Identifies and explains key Identifies key parameters Identification of
influencing parameters influencing furnace parameters influencing influencing furnace key parameters is
efficiency efficiency comprehensively and furnace efficiency with efficiency but lacks clarity unclear or incorrect.
(4 marks) with clear examples or case clarity and some examples. or examples. Limited
studies. Demonstrates a deep Demonstrates understanding understanding of impact on
understanding of impact on of impact on efficiency. efficiency.
efficiency.
List of specific Lists all necessary measurements Lists necessary Lists some measurements List of
measurements for the energy audit accurately measurements for the energy for the energy audit but measurements is
(4 marks) and clearly relates each to furnace audit with clarity, showing lacks clarity or incomplete or
performance and energy relevance to furnace completeness. Relevance to irrelevant to the
efficiency assessment. performance and energy furnace performance and audit.
efficiency assessment. energy efficiency is
unclear.
Specifying Specifies types of equipment Specifies types of equipment Specifies types of Equipment
equipment needed for measurements needed for measurements equipment needed but lacks specification is
(4 marks) accurately, justifying choices with some justification based justification or accuracy. incorrect or
based on furnace type and on furnace type and irrelevant.
measurement needs. measurement needs.
Purpose and Clearly explains the purpose of Explains the purpose of each Explains the purpose of Purpose of
contribution of each measurement in the context measurement in the context each measurement but measurements and
measurements of the energy audit and its of the energy audit and its lacks depth or clarity in their contribution
(3 marks) significant contribution to contribution to evaluating explaining contribution to are unclear or
evaluating furnace efficiency. furnace efficiency. Provides the audit. Discussion is incorrect.
Provides insightful discussion. adequate discussion. limited.
Phase 2: Data analysis and efficiency evaluation (24 marks)
Criteria Exemplary (A+, A, A- > 70) Competent (70 > B+, B, Developing (55 > C+, C, Beginning (35 > F)
B- > 55) C-, D > 35)
Analysis of Conducts thorough analysis of Conducts analysis of Conducts basic analysis of Analysis of datasets is
datasets provided datasets to calculate provided datasets to provided datasets to incomplete or incorrect.
(7 marks) furnace efficiency accurately calculate furnace calculate furnace
using appropriate formulas. efficiency accurately. efficiency. Explanations
Provides clear explanations. Explanations are mostly lack clarity or
clear. thoroughness.
Energy losses Quantifies energy losses within Quantifies energy losses Quantifies energy losses Energy losses are not
and Sankey the furnace system within the furnace system. within the furnace system quantified or incorrectly
diagram comprehensively. Creates a clear Creates a clear Sankey but lacks clarity in quantified. Sankey
(7 marks) and accurate Sankey diagram diagram illustrating energy explanation or diagram. diagram is missing or
illustrating energy flows and flows and losses. Sankey diagram is incorrect.
losses effectively. incomplete or unclear.
Identification of Thoughtfully identifies potential Identifies potential areas Identifies areas for Identification of
improvement areas for improvement in furnace for improvement in improvement in furnace improvement areas is
areas efficiency based on data analysis. furnace efficiency. efficiency but lacks depth superficial or incorrect.
(5 marks) Proposes practical measures that Proposes practical or clarity in proposals. Measures proposed are
are relevant and feasible. measures, though some Some measures proposed not feasible or relevant.
may lack detail or are impractical.
feasibility.
Estimation of Estimates potential energy Estimates potential energy Provides a basic estimate of Estimation of energy
energy savings savings achievable through savings achievable through potential energy savings savings is incorrect or
(5 marks) proposed measures with proposed measures. but lacks clarity or incomplete. Calculation
reasonable accuracy. Clearly Explains calculation accuracy in calculations. methods are unclear or
explains calculation methods and methods adequately. Explanation of methods is incorrect.
assumptions. limited.
Phase 3: Feasibility and implementation planning (18 marks)
Criteria Exemplary (A+, A, A- > 70) Competent (70 > B+, B, B- Developing (55 > C+, C, Beginning (35 > F)
> 55) C-, D > 35)
Technical Critically evaluates the Evaluates the technical Evaluates the technical Evaluation of technical
feasibility and technical feasibility of feasibility of proposed feasibility of proposed feasibility is superficial
environmental proposed efficiency measures efficiency measures with efficiency measures but or incorrect. Discussion
benefits with thorough analysis. clear analysis. Discusses lacks depth or of environmental
(6 marks) Discusses potential potential environmental thoroughness in analysis. benefits is missing or
environmental benefits benefits adequately. Discussion of incorrect.
comprehensively. environmental benefits is
limited.
Cost-benefit Conducts a comprehensive Conducts a cost-benefit Provides a basic cost- Cost-benefit analysis is
analysis cost-benefit analysis of analysis of proposed benefit analysis but lacks incorrect or incomplete.
(6 marks) proposed measures, measures with consideration depth or clarity in Evaluation of economic
considering initial costs, of initial costs, operational considering economic viability is missing or
operational savings, and savings, and payback period. factors. Evaluation of incorrect.
payback period effectively. Provides adequate economic viability is
Provides well-supported evaluation of economic limited.
evaluation of economic viability.
viability.
Implementation Offers detailed and Provides recommendations Provides basic Implementation
recommendations actionable recommendations for implementing energy- recommendations for recommendations are
(6 marks) for implementing energy- saving measures, though implementing energy- superficial or incorrect.
saving measures. some may lack detail or saving measures but lacks Recommendations lack
Recommendations feasibility. Addresses detail or feasibility. Some feasibility or relevance.
encompass operational operational adjustments, aspects of
adjustments, equipment equipment upgrades, and implementation are
upgrades, and maintenance maintenance strategies unclear.
strategies effectively. adequately.
Individual viva (40 marks)
Criteria Exemplary (A+, A, A- > 70) Competent (70 > B+, B, B- > Developing (55 > C+, C, C-, Beginning (35 > F)
55) D > 35)
Viva Demonstrates thorough Shows good understanding, Basic understanding, some Incomplete understanding,
knowledge, clear and insightful adequate analysis with minor analysis evident, but lacks significant gaps in analysis
analysis, well-supported gaps, feasible depth or clarity in or recommendations, or
recommendations, and strong recommendations, and recommendations, and difficulty in communication.
communication skills. effective communication. communication is adequate.