Calculation of Unutilised Heat and Heat Utilisation of Blower (SBO10) in Pet 300 BPM Line

Hindustan Coca -Cola Beverages Pvt. Ltd.
, Raninagar

1

Project on:
Calculation of unutilised heat and heat utilisation of
blower (SBO10) in pet 300 bpm line
Prepared by:
Kushagra Abhishek
Haldia Institute of Technology

Hindustan Coca -Cola Beverages Pvt. Ltd., Raninagar

2

PREFACE
Summer training at Raninagar was a very wonderful learning experience. It enables me to
know the functioning of industry, which we are used to study in theory. All theory norms
were applied here to have glimpse of practical situation. Carried out a project here was yet
another new and different experience.

In this report there is a detailed situation prevailing in technical unit of industry and their
working is discussed in detail.


3

Acknowledgement
I would like to thank Mr. Joydeep Roy , Production Manager at HCCBPL Raninagar for
giving me a very challenging and interesting project on Calculation of unutilised heat and
heat utilisation of blower (sbo10) in pet 300 bpm line . His proper guidance and instruction
throughout the project work keeps me energetic and enthusiastic. I would like to thank him
again for giving me a wonderful opportunity to have a firsthand industry experience. I would
also like to thank Mr. Arindam Nath Roy and Mr. Argha Sarkar , both production executive
for their valuable assistance throughout the project As and when required.
At last but not the least I would also like to thank Sujit Dhar and Amit Roy, operator at
blower room for their knowledge sharing on machine related issues.


4

S.no. Content Page no.
1 Abstract 5
2 Introduction 6
3 What is PET 7
4 Why PET 7
5 Preforms 8
6 PET blowing basics 8
7 PET blowing process 8
8 Blow molding operation 9
9 Bottle manufacturing process 9
10 How blowing is done 13
11 Compressor 13
12 R- back system 13
13 Preforms and bottle classification 14
14 Parameters of blowing 15
15 Oven heating and lamp setup 15
16 Heat loss calculation 17
17 Benefits of waste heat recovery 20
18 Methods and equipments for recovery of waste heat 23
19 Conclusion 25
20 References 26


5

Abstract
Heat loss from any system is highly undesirable for any industry, as huge potential of energy is
wasted continuously from the stack or chimney of boiler, oven or furnace. So every industry is
searching a way to utilise this waste heat to meet other energy requirement. By reducing the waste
heat loss and utilising them, industry can save their capital. Industries are trying their level best in
recovering Waste heat. During one month training at HCCBPL Raninagar, I have calculated amount
waste heat which is escaping out to atmosphere from blower of SBO 10 in PET 300 BPM line. These
heat loss can be minimised by installing a waste heat recovery unit having various type of direct and
indirect contact heat exchanger. These waste heats have sufficient amount of energy, which can be
used for heating of water, drying bottles and also can be used in RGB line in bottle washing .


6

Introduction
Hindustan coca cola beverage private limited, Raninagar is a company owned bottling unit.
In India there are total 24 HCCBPL plant situated throughout the nation.HCCBPL Raninagar plant was
set up in the year 2002in siliguri, west Bengal. Plant initially has only one production line of 100 bpm
(bottles per minute).With passage of years it set up consecutively two more lines of production
RGB(returnable glass bottle ) line and pet (Ploy Ethylene Terepthalic )300 bpm line.
HCCBPL

100 bpm 300 pet bpm
RGB
Raninagar plant is producing different coke flavour such as Sprite, Thums up, coke, Fanta, Limca,
kinley (all 600, 1250 and 2000ml) and except kinley 600 ml.
FLAVOUR

600 ml 1250 ml 2000 ml
(SPT, KO, TU, KIN,FANTA, LIMCA) (Except kinley all flavour) (except kinley all flavour)
With a capacity of producing 1.5 lac bottles per day, its main consumption supply is in most districts
of Bihar, North Bengal, and North Eastern states like Sikkim and Assam.
Bottles are made from performs which is a polymer of ethylene glycol (EG) and Terepthalic acid
(PTA). Plant get the supply of performs from Sikkim, Kolkata, and up.
Perform manufacturer Location
Canpet Kolkata
Epitome petrochemical ltd. Sikkim
AMD U.P.
Chemco Kolkata

This plant has various unit such as quality and its accessories, quality checking and laboratory,
production having 100bpm,300 BPM and RGB line. There is also effluent treatment plant (ETP) and
water treatment plant (WTP) which have capacity of treating effluent and water at 100 liter per day.
During one month training at HCCBPL Raninagar plant, carried out a project on calculation of
unutilised heat from sbo10 blower in pet 300 bpm line. In this report there is a detailed content on
blow moulding equipment, operation and various its aspects.


7

WHAT I S PET
Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly
abbreviated PET, PETE, or the obsolete PETP or PET-P, is a thermoplastic polymer resin of the
polyester family and is used in synthetic fibers; beverage, food and other liquid containers;
thermoforming applications; and engineering resins often in combination with glass fiber. The term
polyethylene terephthalate is a source of confusion because this substance, PET, does not contain
polyethylene. Depending on its processing and thermal history, polyethylene terephthalate may
exist both as an amorphous (transparent) and as a semi crystalline polymer. The semi crystalline
material might appear transparent (particle size < 500 nm) or opaque and white (particle size up to a
few microns) depending on its crystal structure and particle size. Its monomer (bis--
hydroxyterephthalate) can be synthesized by the esterification reaction between terepthalic acid
and ethylene glycol with water as a byproduct, or by transestrification reaction between ethylene
glycol and dimethyl terephthalate with methanol as a byproduct. The majority of the world's PET
production is for synthetic fibers (in excess of 60%), with bottle production accounting for around
30% of global demand. In the context of textile applications, PET is referred to by its common name,
"polyester," whereas the acronym "PET" is generally used in relation to packaging. Polyester makes
up about 18% of world polymer production and is the third-most-produced polymer; polyethylene
(PE) and polypropylene (PP) are first and second, respectively.PET consists of polymerized units of
the monomer ethylene terephthalate, with repeating C
10
H
8
O
4
units. PET is commonly recycled, and
has the number "1" as its recycling symbol.

OH + OOHC COOH heat
OH acid
(EG)
(PTA)

PET
WHY PET?
There are many reasons for using pet for manufacturing of preforms some of them are listed below
Good barrier property for co2 and o2
Minimal sensory impact
Safety and easy to handle
High mechanical property when it is stretched biaxial
Light weight and clarity and 100% recyclable

8

Some PET properties are:
The production process of the preforms results in an amorphous structure of the PET, which is
characterized by transparency, hardness, and fragility, at low temperature and high deformability at
moderate temperature (about 100 C). In this condition the material presents a Density of 1,370
g/cm3, a Heat Capacity at constant pressure of 1000 J/(kgK) and a Thermal Conductivity of 0.15
W/(mK). These values can vary depending on the characteristic of the materials production
process; consequently this study had been conducted by using literature values that can be relevant
as a qualitative reference for the industrial practice.

Preforms used as a raw material for blowing operation it is made up of PET.
Some preform details are :
100% pet
Reliance/aspet resin supplier
Central procurement of resin cocacola
Approved perform suppliers will convert resin into perform
Perform supplier /resin supplier follows coca cola standard

Performs requirement are: preforms
Differences in dimension in neck causes co2 losses and torque problems
In HCCBPL 28 mm PCO(plastic closure only) 1810 for CSD(Carburetted soft drinks) and 30/25
mm 3 start for water for neck are being used
PET Blowing basics:
Stretch blowing occurs in four steps:
Preform heating
Mechanical stretching axial(vertical)
Radial stretching using compressed air (horizontal) first pre blow at 5 to15 bar and then
blow at 32 to 40 bar
Air recovery about 20 to 30% @ 10 bar
Exhaust

Types of blow moulding process:
Raw material (generally resin) blown to bottle in a single machine. Ex are jars,20/25 l water
bulk container. This is done single stage moulding process.
Two stage (used by HCCBPL): raw materials are converted perform in one machine and then
performs are blown to bottle in other machine. Examples are all pet product.

9

Pet blowing process
Perform heating mechanical stretching radial stretching
(Axial and vertical) a) pre blow (7 bar)
b) Blow (40 bar)

outlet air recovery at 10 bar
(20 to 30%)

Blow moulding operation:
For blowing performs into bottles HCCBPL Raninagar plant is using Sidel blow moulding machine
which is called as sbo10 for heating of performs and SBO universal for molding operation .These
machines are very highly efficient and consume, 45% less power than traditional blowing
machines.
Bottle manufacturing process:
There are various steps involved in bottle making .preforms goes to different stages via different
equipment. These are discussed below:

Hopper:
Preforms are dumped in large hopper having capacity up to 500 kg.

Elevators
Performs are elevated to a certain height through elevator.
These elevators are inclined 60 to70 with hopper base level.
Preforms are then allowed to fall down in unscramble roller.

Unscramble roller
These are somewhat complicated machines having two cylindrical
rollers rotating axially in counter direction .There is a gap of about 2
cm between the roller so that due to continuous vibration preforms
align themselves between roller having neck tucked in gap.
Preforms which dont align in gap are allowed to move back to
hopper via recycling pipe.

10

In feed rail:
After coming from roller, performs arranges themselves in feed
rail which are inclined at certain angle and then enter in SBO 10
machine. Before entering in oven zone of SBO10 performs
follows some path profile, which is depicted in adjacent figure

Infeed wheel:
Preforms from infeed rail are moved to infeed wheel which
rotates and hence preforms are made to travel in horizontal
line . From here preforms are moved to spindle chain.

Spindle chain:
Spindles are cylindrical rod and which rotates on its axis .
performs are fixed in the spindle head .As spindle chain
moves preforms also moves parallel to oven so that
performs get heated up and it is easy to blow heated
perform as it is flexible than hard and dry preforms. In one
chain there are 196 spindles. There is a cooling ramp having
circulation of cold water. This is necessary as to keep neck of
preform cool, because in blowing process there is no any
need of altering neck of preforms as it is same for all types of
bottle.

Spindle wheel:
These wheel are just to the reverse the direction of
performs. So that preform again passes through another set
of oven. From distribution oven to another of oven i.e.
penetration oven.


11

Oven
In SBO 10 machine there are two set of oven which is
located on opposite side of machine. Its SBO 10 because
there are total 10 number of oven. First five set of oven
is called distribution oven and second five set is called
penetration oven. Each oven contain 9 infrared lamps
which are fitted in oven one above other. First lamps
from bottom of each oven have power rated of 3000
watt while rest of the lamps are 2500 watt.

Temperature of oven is set manually considering weight of
performs in spindle chain, external or atmospheric temperature
etc. oven temperature is controlled or set through by keeping ON
different numbers of lamp at a time and also setting different zone
heating percentage. Its quite common to keep the temperature of
oven below the melting point of preform.

Infrared lamp
These lamps have power rated 2500 watt and 3000
watt. These lamps are ceramic coated which gives more
radiations intense luminous Technical Data : Volts 400
Colour Temp Watts 3000 and 2500 watt, Life 5000 hr.
Lumen/Watt 4-6 Burning Position Horizontal Finish
Clear/refl ect coat.


12

Above figure clearly depicts preform movement in oven zone also hoe preforms are heated can be
easily understand by above figure. There is continuous reflection of IR rays from metallic shining
surface which heat up the preforms.

Blower
After getting heated, performs enter the blower machine and get fitted itself in mould of blower.
In Raninagar plant SBO blower in 300 pet line have 10 mould .rotates at a rate of 300 bpm.

Mold
Generally performs are fitted in mould and are given
preblow pressure and then final blow pressure. There is
continuous circulation of chilled water to keep the
different parts like neck and base panel cool during blow
so that bottles cant burst. In HCCBPL there are different
mould for 600 ml, 1250 ml and 2000 ml of bottle.
Preforms get the shape in mould as final blowing
pressure is applied.


13

How blowing is done?

For blowing preforms into bottle there is application of 7bar to 10 bar pressure in heated preforms.
This initial blowing process is called preblow. This is done to make performs more flexible so that it
can bear later high blow pressure of 40 bar. If directly 40 bar pressure is applied in the preforms
then bottle will burst frequently. For generating such high pressure of 40 bar plant have installed a
40 bar Ateliers Francois air compressor manufactured by Siemens, Belgium

Compressor
These compressor generate 40 bar pressure in three
stage at first stage 3.5 to 5 bar pressure is generated
then 7 to 10 bar pressure is generated and finally 40
bar pressure at third stage is achieved.

3.5 kg/cm2 3
rd
stage
1
st
stage T=30-40c T=3-4C
40

2
nd
stage(10 bar)

Return back
System Air recovery Main blow pressure 40 bar

Regulator
Pre blow 15 bar

Mould

Before 7 bar
(To atmosphere, air not recovered) Atomizer
(for base spray) For bottle rejection

40 bar air
Compressor
40 bar
air tank
Air dryer
Air recovery
tank
3.5 kg/cm2
Air
tank
Exhaust
silencer


14

Raninagar plant is currently using kaizen formula of air recovery system in 40 bar air compressor.
When bottle is blown then there is exhaust air coming out of mould having pressure up to
3.5kg/cm
2
. Plant is collecting these pressurised air in air receiver tank .this enables compressor to
move directly to second stage as first stage of attaining 3.5 bar pressure is already happened by air
recovery system. By this company is claiming that they are saving rs.1875 per day at the same time
reducing 2.5 tonnes of co
2
emission annually

After blowing of bottle it is ejected from blower
having high temperature of about 80 to 100c so
water is sprayed in the base of bottle and then
allowed to enter in the air conveyer which have air
blower at fixed distance over it which blows dry air
at very high velocity and pushes the bottles forward.
Through air conveyer bottles are sent to filler section
for filling up of beverages into the bottle. From there
bottles are conveyed to labeller for labelling purpose
through belt conveyer.

Coca cola Raninagar plan classifies preforms according to their weight and so that they can be
molded and blowed in 600ml, 1.25lt and 2 lt bottle.
Weight of preform volume flavour
27gm 600 ml Spt,kin,tu,ko,limca
25gm 600ml fanta
39gm 1250 ml Spt,kin,tu,ko,limca
48 gm 2000ml Spt,kin,tu,ko,limca

Bottles are classified as dimple, contour and splash.

Bottles

dimple coke generic splash


15

Different parameters and operating temperature and pressure for various flavour of coke bottle are
given below:
Perform
weight
Flavour Temperat
ure of
oven
Feeding
temperatur
e
Output % Output
setpoint
Preform
temperatur
e
27 gm Dimple/sprite 106c 85c 80 20000b/h 99c
27 gm Kin /TU 120c 85c 85 20000b/h 99c
27gm Coke 120c 85c 80 20000b/h 98c
27gm Fanta /limca 120c 85c 80 20000b/h 99c
39gm Coke 210c 135c 90 18000b/h 93c
39gm generic 205c 140c 80 18000b/h 96c
48gm coke 210c 160c 85 14000b/h 95c

Oven heating and lamp setup for preform heating is also given below:

For 600 ml dimple

For 600 ml coke
Lamp setup

48gm generic 220c 190c 95 14000b/h 110c
Penetration oven Distribution oven**
Zone
no.
1 2 3 4 5 6 7 8 9 10
9
8
7
6
5
4
3
2
1
Zone
no.
1 2 3 4 5 6 7 8 9 10
9
8
7
6
5
4
3
2
1


16

For 600 ml splash Lamp setup

For 1250 ml generic clear Lamp setup

.

For 1250 ml coke Lamp setup

Zone
no.
1 2 3 4 5 6 7 8 9 10
9
8
7
6
5
4
3
2
1
Zone
no.
1 2 3 4 5 6 7 8 9 10
9
8
7
6
5
4
3
2
1
Zone
no.
1 2 3 4 5 6 7 8 9 10
9
8
7
6
5
4
3
2
1

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PET blow molding machines are the most popular technology employed to produce bottles and
flagons. The process starts with the production of the PET, which is then used to make preforms that
will be finally transformed into bottles. This paper will focus on the heating process of the preforms
that leads to the final blow-molding transformation. The heating process is controlled through a
series of panels, mounting Infra Red lamps, and the cooling airflow generated by dedicated fans. In
fact one of the main issues in this transformation process is the temperature distribution along the
preform length and the radial thickness, which should ideally vary according to the shape of the
preform and the mechanical stresses introduced by the stretching action. Consequently the main
objective of this development was to design an oven which gave the possibility of a fine regulation of
the temperature in the PET section with a particular attention for the critical regions. The deep level
of knowledge reached with this simulation work will lead to the production of better quality bottles,
thanks to a higher level of reliability of the process, whilst also savings on production waste.
Heat generated by oven is calculated by taking account no. of lamps ON and its overall zone heating
percentage individually for each zone and then the heat coming from each zone is summed to get
the total heating of oven.
Also the heat acquired by preforms is calculated by very famous equation Q = mc
p
dT where Q is heat
gained by one preform, m is mass of preform, c
p
is specific heat capacity of preform (c
p
for pet
preform is 1KJ/Kgc) dT is change in temperature of performs i.e. Preform temperature after coming
from all set of ovens- perform external or normal temperature. Then for getting heat gained by
performs in one hour, Q value is multiplied by no. of preform passing through oven in hour.
Heat loss from blower is calculated by taking out the difference between total heat generated by
oven and total heat gained by preforms in one hour.

(i)For 600 ml sprite bottle, heat loss calculation is done as follows:
Total heat given by all oven = sum of heat given by each zone
For zone 1 i.e. for 3000 watt lamp, heat given= power X (no. of lamps ON) X overall heating %
= 3000 X 8 X 0.64 considering 8 no. of on lamps
64% of overall heating of zone 1

= 15360 J/S
For zone 2 to 9 i.e. for 2500 watt lamp, heat given = power X (no. of lamps ON) X overall heating %
= 2500 X (6X.45+4X.29+4X.296+3X.53+6X.36)
= 20192 J/S
Total Heat given by oven = (15360+20192) J/S
=127987.2 KJ/hr

18

Heat gained by preform in one hour = m X c
p
X dT X (input rate of preform)
=0.027 X 1X (99-25) X 16000 Cp of preform is 1kj/kgc
= 31968 KJ/hr and dT= (preform temperature
external temperature)

Heat loss or unutilised heat = total heat given by oven heat gained by preform in one hour
= (127987.2 31968) KJ/hr
=96019.2 KJ/hr
NOW heat required to raise the temperature of 100 litre of water from 20 to 50c is computed as:
Q=mc
p
dT, c
p
for water is 4.2 kj/kgc
= 100 X 4.2 X (50-20) KJ
=12600 KJ only
So we can utilise the waste heat coming out as exhaust to warm the water and use it in various other
processing unit in the plant.

(ii)For 1250 ml sprite bottle, heat loss calculation is done as follows:
= 3000 X 6 X 0.436 considering 6 no. of on lamps

= 7848 J/S
= 2500 X(7X.523+3X.243+4X.337+3X.268+4X1.09)
= 27305 J/S
Total Heat given by oven = (7848 + 27305) J/S
=126550 KJ/hr
p
=0.039 X 1X (105-25) X 14000 Cp of preform is 1kj/kgc


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= (126550 43680) KJ/hr
=82870 KJ/hr
(iii)For 2000 ml sprite bottle, heat loss calculation is done as follows:
= 3000 X 6 X 0..436 considering 6 no. of on lamps

= 28252KJ/S
= 2500 X (6X.44+3X.24+5X.40+3X.26+4X.1.07)
= 94968 J/S
Total Heat given by oven = (15360+20192) J/S
=123220.2 KJ/hr
p
=0.047 X 1X (110-25) X12000 Cp of preform is 1kj/kgc

= (123220 47940) KJ/hr
=27300 KJ/hr
From above three heat loss calculation, we find that heat loss is not always constant it varies with
the type of bottle in the production line. Also heat loss is more in case of small size bottle where as
heat loss decreases when larger volume of bottles are made. Also heat emission is not continuous
from oven because when there is any blockage in infeed rail or when preforms dont undergo
heating process then lamps get switched off thus saving power and cost. Also there is limited no. of
lamps are kept ON so that optimum heating is achieved at low power. Sufficient Metallic reflector is
placed in spindle line and also on both side of preform incoming line during its motion in oven zone
to minimise the heat loss. Inspite of highly efficient designing of blower machine there is always
some heat loss in the form of waste heat. Quality and quantity of such waste heat loss have been
studied minutely and their further utilisation in other process have been investigated.

20

Heat Losses Quality Depending upon the type of process, waste heat can be rejected at virtually
any temperature from that of chilled cooling water to high temperature waste gases from an
industrial furnace or kiln. Usually higher the temperature, higher the quality and more cost effective
is the heat recovery. In any study of waste heat recovery, it is absolutely necessary that there should
be some use for the recovered heat. Typical examples of use would be preheating of combustion air,
space heating, or pre-heating boiler feed water or process water. With high temperature heat
recovery, a cascade system of waste heat recovery may be practiced to ensure that the maximum
amount of heat is recovered at the highest potential. An example of this technique of waste heat
recovery would be where the high temperature stage was used for air pre-heating and the low
temperature stage used for process feed water heating or steam raising.
Heat Losses Quantity In any heat recovery situation it is essential to know the amount of heat
recoverable and also how it can be used. An example of the availability of waste heat is given below:
Heat recovery from heat treatment furnace In a heat treatment furnace, the exhaust gases are
leaving the furnace at 900oC at the rate of 2100 m3/hour. The total heat recoverable at 180oC final
exhaust can be calculated as
Q = V x x Cp x T
Q is the heat content in kCal V is the flow rate of the substance in m3/hr
Bureau of Energy Efficiency 1
8. Waste Heat Recovery
is density of the flue gas in kg/m3 Cp is the specific heat of the substance in kCal/kg oC T is the
temperature difference in oC Cp (Specific heat of flue gas) = 0.24 kCal/kg/oC
Heat available (Q) = 2100 x 1.19 x 0.24 x (900-180) = 4,31,827 kCal/hr By installing a recuperator,
this heat can be recovered to pre-heat the combustion air. The fuel savings would be 33% (@ 1%
fuel reduction for every 22C reduction in temperature of flue gas.
Benefits of Waste Heat Recovery
Benefits of waste heat recovery can be broadly classified in two categories:
Direct Benefits:
Recovery of waste heat has a direct effect on the efficiency of the process. This is reflected by
reduction in the utility consumption & costs, and process cost.
Indirect Benefits:
a) Reduction in pollution: A number of toxic combustible wastes such as carbon monoxide gas, sour
gas, carbon black off gases, oil sludge, Acrylonitrile and other plastic chemicals etc, releasing to
atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers heat and reduces the
environmental pollution levels.

21

b) Reduction in equipment sizes: Waste heat recovery reduces the fuel consumption, which leads to
reduction in the flue gas produced. This results in reduction in equipment sizes of all flue gas
handling equipments such as fans, stacks, ducts, burners, etc.
c) Reduction in auxiliary energy consumption: Reduction in equipment sizes gives additional benefits
in the form of reduction in auxiliary energy consumption like electricity for fans, pumps etc.
comparative study of waste heat in cocacola with other large industry such as steel or coal
industry.

Coca cola other industry (steel, coal, cement etc.)

Blower machine running in coca cola is very heat efficient there is only little loss of heat as compared
to other processing industries. Temperature of exhaust gas in metallurgical industries is some times
as high as 1500C and quantity of exhaust gas is 10 times more than plastic related industry. In coca
cola plant exhaust heat has temperature of about 120C to 140C only during peak running
condition. The heat coming from is in the form of infrared radiation while other industries have flue
gas which is produced by burning fuels or during combustion process.

Heat is needed for blowing preforms
purpose mainly , drying, warming water etc.
Heat is needed for melting solid, boiling etc.
All above process requires moderate
amount of heat
Above process requires very large quantity of heat at
every processing stage.
Maximum temperature of heat
requirement is up to 160C , because 220C
is the melting point of preforms and in
cocacola all blowing operation is performed
below the melting point.
No any fixed maximum limit of temperature of heat
requirement it may be around 2000C t0 2500C

Temperature of exhaust is about 120C on
an average.
Temperature of exhaust gas is about 1500C

Quality of waste heat is of low grade as it
have low temperature
Exhaust gases or flue gas have sufficient heat
capacity to be used in other process easily and
efficiently high grade of exhaust gas is available

if collected may be used for space heating
or air preheats.
Exhaust gas have large potential to be reused in
boilers or furnace by recirculating it .
Most of the heat is lost in transportation of
waste heat hence reducing its potential and
usefulness

Minimum heat is lost during transportation

22

Stack of blower machine through which hot radiation and air escape to atmosphere.
Temperature at stack inlet is about 120 c and at stack outlet is about 50c. to recover the waste
heat which are escaping through stack , it is necessary to determine the area these waste if collected
can find some use.

(i) It has been found that there is requirement of warm water of about 35c for spraying on
bottles to carry out condensation on bottle surface because bottles which are coming
out of filler is very cool and surface of bottle is chilled .

(ii) Before labelling of bottle starts it is necessary to dry the surface of bottle so that
labelling is done effectively, so there in labelling section there is provision of spraying
hot air which has temperature of about 50c if waste heat is collected then it can be used
to generate hot air by intermixing atmospheric air with exhaust gas.

(iii) Space heating can also be achieved by this waste heat.


23

Methods and equipment for recovering waste heat
These waste heat can be recovered by using heat exchanger, heat pipe , shell and tube , recuperator,
heat wheel etc.

Heat pipe:
A heat pipe can transfer up to 100 times more thermal energy than copper, the best known
conductor. In other words, heat pipe is a thermal energy absorbing and transferring system
and have no moving parts and hence require minimum maintenance.

The Heat Pipe comprises of three elements a sealed container, a capillary wick structure and a
working fluid. The capillary wick structure is integrally fabricated into the interior surface of the
container tube and sealed under vacuum. Thermal energy applied to the external surface of the
heat pipe is in equilibrium with its own vapour as the container tube is sealed under vacuum.
Thermal energy applied to the external surface of the heat pipe causes the working fluid near the
surface to evaporate instantaneously. Vapour thus formed absorbs the latent heat of vapourisation
and this part of the heat pipe becomes an evaporator region. The vapour then travels to the other
end the pipe where the thermal energy is removed causing the vapour to condense into liquid again,
thereby giving up the latent heat of the condensation. This part of the heat pipe works as the
condenser region. The condensed liquid then flows back to the evaporated region.


24

Shell and tube heat exchanger:

When the medium containing waste heat is a liquid or a vapor which heats another liquid, then the
shell and tube heat exchanger must be used since both paths must be sealed to contain the
pressures of their respective fluid. The shell contains the tube bundle, and usually internal baffles, to
direct the fluid in the shell over the tubes in multiple passes. The shell is inherently weaker than the
tube, so that the higher-pressure fluid is circulated in the tubes while the lower pressure fluid flows
through the shell. When a vapor contains the waste heat, it usually condenses, giving up its latent
heat to the liquid being heated. In this application, the vapor is almost invariably contained within
the shell. If the reverse is attempted, the condensation of vapors within small diameter parallel
tubes causes flow instabilities. Tube and shell heat exchangers are available in a wide range of
standard sizes with many combinations of materials for the tubes and shells.

Convective recuperator

A common configuration for recuperators is called the tube type or convective recuperator. As seen
in the figure above, the hot gases are carried through a number of parallel small diameter tubes,
while the incoming air to be heated enters a shell surrounding the tubes and passes over the hot
tubes one or more times in the direction normal to their axes.
If the tubes are baffled to allow the gas to pass over them twice, the heat exchanger is termed a
two-pass recuperator; if two baffles are used, a three-pass recuperator, etc. Although baffling
increases both the cost of the exchanger and the pressure drop in the combustion air path, it
increases the effectiveness of heat exchange. Shell and tube type recuperators are generally more
compact and have a higher effectiveness than radiation recuperators, because of the larger heat
transfer area made possible through the use of multiple tubes and multiple passes of the gases.


25

Heat wheel

A heat wheel is finding increasing applications in low to medium temperature waste heat recovery
systems. It is a sizable porous disk, fabricated with material having a fairly high heat capacity, which
rotates between two side-by-side ducts: one is a cold gas duct, the other a hot gas duct. The axis of
the disk is located parallel and on the partition between the two ducts. As the disk slowly rotates,
sensible heat (moisture that contains latent heat) is transferred to the disk by the hot air and, as the
disk rotates, from the disk to the cold air. The overall efficiency of sensible heat transfer for this kind
of regenerator can be as high as 85 per cent.
A variation of the heat wheel is the rotary regenerator where the matrix is in a cylinder rotating
across the waste gas and air streams. The heat or energy recovery wheel is a rotary gas heat
regenerator, which can transfer heat from exhaust to incoming gases.
Its main area of application is where heat is exchanged between large masses of air having small
temperature differences. Heating and ventilation systems and recovery of heat from dryer exhaust
air are typical applications.

Waste heat recovery from blower will enable sharp reduction of power consumption along with
limiting the emission of harmful gas into the atmosphere thus reducing global warming.

Conclusion:
Utilisation of waste heat from stack is very much cost effective and can boost the power
requirement of company to a large scale. So heat utilisation of exhaust from blower can be used to
meet the energy requirement of the industry. Plant should work on heat utilisation, as maximum
portion of energy input is wasted. Only small portion of heat input is converted into useful work and
rest are allowed to escape into atmosphere which ultimately results in increase in pollution level.
During one month training at coca cola plant, heat loss calculation is carried out and found that
these waste heats have large potential of heating water, space heating and can be useful at many
other processing units. Some methods of heat recovery have been also suggested, herewith.


26

Refrences:

(i) Sidel training manual on blow molding machine
(ii) Thermal Energy Equipment: Waste Heat Recovery by A.k. ghosh
(iii) Best Practices and Industry Standards in PET Plastic Recycling by David J. Hurd, Associate
Director BRONX 2000 ASSOCIATES, INC
(iv) Sidel.com/blowing colution.pdf
(v) Principles of Heat Transfer Supplement to Heat Transfer Product Reviews March 2008
Version 1.1
(vi) Wikipedia.com/polyethylene terepthalate

Calculation of Unutilised Heat and Heat Utilisation of Blower (SBO10) in Pet 300 BPM Line

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