Documente Academic
Documente Profesional
Documente Cultură
1.1 Introduction
Performance of the boiler, like efficiency and evaporation ratio reduces with time, due to
poor combustion, heat transfer fouling and poor operation and maintenance. Deterioration
of fuel quality and water quality also leads to poor performance of boiler. Efficiency test-
ing helps us to find out how far the boiler efficiency drifts away from the best efficiency.
Any observed abnormal deviations could therefore be investigated to pinpoint the problem
area for necessary corrective action. Hence it is necessary to find out the current level of
efficiency for performance evaluation, which is a pre requisite for energy conservation
action in industry.
1.4 Scope
The procedure describes routine test for both oil fired and solid fuel fired boilers using coal,
agro residues etc. Only those observations and measurements need to be made which can be
readily applied and is necessary to attain the purpose of the test.
ASME Standard: PTC-4-1 Power Test Code for Steam Generating Units
This consists of
• Part One: Direct method (also called as Input -output method)
• Part Two: Indirect method (also called as Heat loss method)
x 100
Heat output
There are several methods, which can be used for measuring heat output. With steam boilers,
an installed steam meter can be used to measure flow rate, but this must be corrected for tem-
perature and pressure. In earlier years, this approach was not favoured due to the change in
accuracy of orifice or venturi meters with flow rate. It is now more viable with modern flow
meters of the variable-orifice or vortex-shedding types.
The alternative with small boilers is to measure feed water, and this can be done by previ-
ously calibrating the feed tank and noting down the levels of water during the beginning and
end of the trial. Care should be taken not to pump water during this period. Heat addition for
conversion of feed water at inlet temperature to steam, is considered for heat output.
In case of boilers with intermittent blowdown, blowdown should be avoided during the trial
period. In case of boilers with continuous blowdown, the heat loss due to blowdown should be
calculated and added to the heat in steam.
1.6.3 Boiler Efficiency by Direct Method: Calculation and Example
Test Data and Calculation
Water consumption and coal consumption were measured in a coal-fired boiler at hourly inter-
vals. Weighed quantities of coal were fed to the boiler during the trial period. Simultaneously
water level difference was noted to calculate steam generation during the trial period. Blow
down was avoided during the test. The measured data is given below.
The following losses are applicable to liquid, gas and solid fired boiler
L1– Loss due to dry flue gas (sensible heat)
L2– Loss due to hydrogen in fuel (H2)
L3– Loss due to moisture in fuel (H2O)
L4– Loss due to moisture in air (H2O)
L5– Loss due to carbon monoxide (CO)
L6– Loss due to surface radiation, convection and other unaccounted*.
*Losses which are insignificant and are difficult to measure.
The following losses are applicable to solid fuel fired boiler in addition to above
L7– Unburnt losses in fly ash (Carbon)
L8– Unburnt losses in bottom ash (Carbon)
Boiler Efficiency by indirect method = 100 – (L1 + L2 + L3 + L4 + L5 + L6 + L7 + L8)
e) Water condition
1. Total dissolved solids (TDS)
2. pH
3. Blow down rate and quantity
The various parameters that were discussed above can be measured with the instruments
that are given in Table 1.1.
However it is suggested to get a ultimate analysis of the fuel fired periodically from a
reputed laboratory.
Theoretical (stoichiometric) air fuel ratio and excess air supplied are to be determined first
for computing the boiler losses. The formula is given below for the same.
The various losses associated with the operation of a boiler are discussed below with
required formula.
Note–1:
For Quick and simple calculation of boiler efficiency use the following.
A: Simple method can be used for determining the dry flue gas loss as given below.
m x Cp x (Tf – Ta) x 100
a) Percentage heat loss due to dry flue gas =
GCV of fuel
Total mass of flue gas (m)/kg of fuel = mass of actual air supplied/kg of fuel + 1 kg of fuel
Note-2: Water vapour is produced from Hydrogen in fuel, moisture present in fuel and air dur-
ing the combustion. The losses due to these components have not been included in the dry flue
gas loss since they are separately calculated as a wet flue gas loss.
9 x H2 x {584 + Cp (Tf – Ta )}
L2 = x 100
GCV of fuel
Where
H2 = kg of hydrogen present in fuel on 1 kg basis
Cp = Specific heat of superheated steam in kCal/kg°C
Tf = Flue gas temperature in °C
Ta = Ambient temperature in °C
584 = Latent heat corresponding to partial pressure of water vapour
where
M = kg moisture in fuel on 1 kg basis
Cp = Specific heat of superheated steam in kCal/kg°C
Tf = Flue gas temperature in °C
Ta = Ambient temperature in °C
584 = Latent heat corresponding to partial pressure of water vapour
where
AAS = Actual mass of air supplied per kg of fuel
Humidity factor = kg of water/kg of dry air
Cp = Specific heat of superheated steam in kCal/kg°C
Tf = Flue gas temperature in °C
Ta = Ambient temperature in °C (dry bulb)
%CO x C 5744
L5 = x x 100
% CO + % CO2 GCV of fuel
Normally surface loss and other unaccounted losses is assumed based on the type and size
of the boiler as given below
However it can be calculated if the surface area of boiler and its surface temperature are
known as given below :
Heat loss due to unburned carbon in fly ash and bottom ash:
Small amounts of carbon will be left in the ash and this constitutes a loss of potential heat in
the fuel. To assess these heat losses, samples of ash must be analyzed for carbon content. The
quantity of ash produced per unit of fuel must also be known.
Total ash collected per kg of fuel burnt x G.C.V of bottom ash x 100
L8 =
GCV of fuel
Heat Balance:
Having established the magnitude of all the losses mentioned above, a simple heat balance
would give the efficiency of the boiler. The efficiency is the difference between the energy
input to the boiler and the heat losses calculated.
Theoretical air required for = [(11.6 x C) + {34.8 x (H2 – O2/8)} + (4.35 x S)] /100
complete combustion kg/kg of coal
= 4.91 kg / kg of coal
7900 x [20.37 – 14 ]
=
14a x [100 – 20.37]
= 45.17 %
Mass of dry flue gas = Mass of CO2 + Mass of N2 content in the fuel +
Mass of N2 in the combustion air supplied + Mass of
oxygen in flue gas
= 7.54 kg / kg of coal
m x Cp x (Tf – Ta)
1. % Heat loss in dry flue gas (L1) = x 100
GCV of fuel
L1 = 7.88 %
L2 = 3.44 %
M x {584 + Cp ( Tf – Ta )}
3. % Heat loss due to moisture in = X 100
fuel (L3) GCV of fuel
L3 = 5.91 %
L4 = 0.29 %
%CO x C 5744
5. % Heat loss due to partial = x x 100
conversion of C to CO (L5) % CO + (% CO2)a GCV of fuel
L5 = 2.58 %
49017.6 x 100
% radiation and convection loss =
3501 x 5599.17
L6 = 0.25 %
a) Theoretical air required = [(11.6 x C) + [{34.8 x (H2 – O2/8)} + (4.35 x S)] /100
kg/kg of fuel. [from fuel analysis]
= [(11.6 x 84) + [{34.8 x (12 – 1.5/8)}
+ (4.35 x 1.5)] / 100
= 13.92 kg/kg of oil
b) Excess Air supplied (EA) = (O2 x 100) / (21 – O2)
= (7.4 x 100) / (21 – 7.4)
= 54.4 %
c) Actual mass of air supplied/ kg = {1 + EA/100} x theoretical air
of fuel (AAS)
= {1 + 54.4/100} x 13.92
= 21.49 kg / kg of fuel
Mass of dry flue gas = Mass of (CO2 + SO2 + N2 + O2) in flue gas + N2
in air we are supplying
0.84 x 44 0.015 x 64 7.4x23 21.49 x 77
= + + 0.005 + +
12 32 100 100
= 21.36 kg / kg of oil
m x Cp x (Tf – Ta)
% Heat loss in dry flue gas = x 100
GCV of fuel
21.36 x 0.23 x (190 – 30)
= x 100
10000
L1 = 7.86 %
9 x H2 x{584 + Cp (Tf – Ta )}
Heat loss due to evaporation of = x 100
water due to H2 in fuel (%) GCV of fuel
L2 = 7.08 %
M x {584 + Cp ( Tf - Ta )}
% Heat loss due to moisture = X 100
in fuel GCV of fuel
0.005 x {584 + 0.45 (190 – 30)}
= x 100
10000
L3 = 0.033%
L4 = 0.38 %
Radiation and convection loss = 0.548 x [ (Ts / 55.55)4 – (Ta / 55.55)4] + 1.957
(L6) x (Ts – Ta)1.25 x sq.rt of [(196.85 Vm + 68.9) / 68.9]
= 0.548 x [ (353 / 55.55)4 – (303 / 55.55)4] + 1.957
x (353 – 303)1.25 x sq.rt of [(196.85 x 3.8 + 68.9)/ 68.9]
= 1303 W/m2
= 1303 x 0.86
= 1120.58 kCal / m2
Total radiation and convection = 1120 .58 x 90 m2
loss per hour = 100852.2 kCal
% Radiation and convection loss = 100852.2 x 100
10000 x 2648.125
L6 = 0.38 %
Normally it is assumed as 0.5 to 1 % for simplicity
Note:
For quick and simple calculation of boiler efficiency use the following.
A: Simple method can be used for determining the dry flue gas loss as given below.
m x Cp x (Tf – Ta ) x 100
a) Percentage heat loss due to dry flue gas =
GCV of fuel
Total mass of flue gas (m) = mass of actual air supplied (ASS)+ mass of fuel supplied
= 21.49 + 1=22.49
All these factors individually/combined, contribute to the performance of the boiler and
reflected either in boiler efficiency or evaporation ratio. Based on the results obtained from the
testing further improvements have to be carried out for maximizing the performance. The test
can be repeated after modification or rectification of the problems and compared with standard
norms. Energy auditor should carry out this test as a routine manner once in six months and
report to the management for necessary action.
Fuel Fired
GCV of fuel
Specific gravity of fuel (Liquid)
Bulk density of fuel (Solid)
4 Nitrogen %
5 Ash %
6 Moisture %
7 Oxygen %
Boiler Rating
Conventionally, boilers are specified by their capacity to hold water and the steam generation
rate. Often, the capacity to generate steam is specified in terms of equivalent evaporation (kg
of steam / hour at 100°C). Equivalent evaporation- "from and at" 100°C. The equivalent of the
evaporation of 1 kg of water at 100°C to steam at 100°C.
Efficiency : In the boiler industry there are four common definitions of efficiency:
a. Combustion efficiency
Combustion efficiency is the effectiveness of the burner only and relates to its ability to completely burn
the fuel. The boiler has little bearing on combustion efficiency. A well-designed burner will operate
with as little as 15 to 20% excess air, while converting all combustibles in the fuel to useful energy.
b. Thermal efficiency
Thermal efficiency is the effectiveness of the heat transfer in a boiler. It does not take into account
boiler radiation and convection losses - for example from the boiler shell water column piping etc.
c. Boiler efficiency
The term boiler efficiency is often substituted for combustion or thermal efficiency. True boil-
er efficiency is the measure of fuel to steam efficiency.
Boiler turndown
Boiler turndown is the ratio between full boiler output and the boiler output when operating at
low fire. Typical boiler turndown is 4:1. The ability of the boiler to turndown reduces frequent
on and off cycling. Fully modulating burners are typically designed to operate down to 25% of
rated capacity. At a load that is 20% of the load capacity, the boiler will turn off and cycle fre-
quently.
A boiler operating at low load conditions can cycle as frequently as 12 times per hour or 288
times per day. With each cycle, pre and post purge airflow removes heat from the boiler and
sends it out the stack. Keeping the boiler on at low firing rates can eliminate the energy loss.
Every time the boiler cycles off, it must go through a specific start-up sequence for safety assur-
ance. It requires about a minute or two to place the boiler back on line. And if there is a sud-
den load demand the start up sequence cannot be accelerated. Keeping the boiler on line assures
the quickest response to load changes. Frequent cycling also accelerates wear of boiler com-
ponents. Maintenance increases and more importantly, the chance of component failure
increases.
Boiler(s) capacity requirement is determined by many different type of load variations in
the system. Boiler over sizing occurs when future expansion and safety factors are added to
assure that the boiler is large enough for the application. If the boiler is oversized the ability of
the boiler to handle minimum loads without cycling is reduced. Therefore capacity and turn-
down should be considered together for proper boiler selection to meet overall system load
requirements.
Primary air: That part of the air supply to a combustion system which the fuel first encoun-
ters.
Secondary air: The second stage of admission of air to a combustion system, generally to
complete combustion initiated by the primary air. It can be injected into the furnace of a boil-
er under relatively high pressure when firing solid fuels in order to create turbulence above the
burning fuel to ensure good mixing with the gases produced in the combustion process and
thereby complete combustion
Tertiary air: A third stage of admission of air to a combustion system, the reactions of which
have largely been completed by secondary air. Tertiary air is rarely needed.
Balanced draught: The condition achieved when the pressure of the gas in a furnace is the
same as or slightly below that of the atmosphere in the enclosure or building housing it.
Gross calorific value (GCV): The amount of heat liberated by the complete combustion,
under specified conditions, by a unit volume of a gas or of a unit mass of a solid or liquid fuel,
in the determination of which the water produced by combustion of the fuel is assumed to be
completely condensed and its latent and sensible heat made available.
Net calorific value (NCV): The amount of heat generated by the complete combustion, under
specified conditions, by a unit volume of a gas or of a unit mass of a solid or liquid fuel, in the
determination of which the water produced by the combustion of the fuel is assumed to remain
as vapour.
Absolute pressure The sum of the gauge and the atmospheric pressure. For instance, if the
steam gauge on the boiler shows 9 kg/cm2g the absolute pressure of the steam is 10 kg/cm2(a).
Atmospheric pressure The pressure due to the weight of the atmosphere. It is expressed in
pounds per sq. in. or inches of mercury column or kg/cm2. Atmospheric pressure at sea level is
14.7 lbs./ sq. inch. or 30 inch mercury column or 760mm of mercury (mm Hg) or 101.325 kilo
Pascal (kPa).
Carbon monoxide (CO): Produced from any source that burns fuel with incomplete com-
bustion, causes chest pain in heart patients, headaches and reduced mental alertness.
Blow down: The removal of some quantity of water from the boiler in order to achieve an
acceptable concentration of dissolved and suspended solids in the boiler water.
Perfect combustion: The complete oxidation of the fuel, with the exact theoretical (stoi-
chiometric) amount of oxygen (air) required.
Saturated steam: It is the steam, whose temperature is equal to the boiling point corre-
sponding to that pressure.
Superheated Steam Steam heated to a temperature above the boiling point or saturation tem-
perature corresponding to its pressure
Oxygen trim sensor measures flue gas oxygen and a closed loop controller compares the
actual oxygen level to the desired oxygen level. The air (or fuel) flow is trimmed by
the controller until the oxygen level is corrected. The desired oxygen level for each firing
rate must be entered into a characterized set point curve generator. Oxygen Trim maintains
the lowest possible burner excess air level from low to high fire. Burners that don't have
Oxygen Trim must run with Extra Excess Air to allow safe operation during variations in
weather, fuel, and linkage.
Thermic Fluid
Thermic Fluid is used as a heat transfer mechanism in some industrial process and heating
applications. Thermic Fluid may be a vegetable or mineral based oil and the oil may be raised
to a high temperature without the need for any pressurization. The relatively high flow and
return temperatures may limit the potential for flue gas heat recovery unless some other system
can absorb this heat usefully. Careful design and selection is required to achieve best energy
efficiency.
Hot water
Water is a fluid with medium density, high specific heat capacity, low viscosity and relatively
low thermal conductivity. At relatively low temperature e.g. 70°C – 90°C, hot water is useful
for smaller heating installations.
Steam
When water is heated its temperature will rise. The heat added is called sensible heat and the
heat content of the water is termed its enthalpy. The usual datum point used to calculate
enthalpy is 0°C.
When the water reaches its boiling point, any further heat input will result in some propor-
tion of the water changing from the liquid to the vapour state, i.e. changing to steam. The heat
required for this change of state is termed the 'latent heat of evaporation' and is expressed in
terms of a fixed mass of water. Where no change in temperature occurs during the change of
state, the steam will exist in equilibrium with the water. This equilibrium state is termed 'satu-
ration conditions'. Saturation conditions can occur at any pressure, although at each pressure
there is only one discrete temperature at which saturation can occur.
If further heat is applied to the saturated steam the temperature will rise and the steam will
become 'superheated'. Any increase in temperature above saturated conditions will be accom-
panied by a further rise in enthalpy.
Steam is useful heat transfer medium because, as a gas, it is compressible. At high pressure
and consequently density, steam can carry large quantities of heat with relatively small volume.
QUESTIONS
1) Define boiler efficiency.
2) Why boiler efficiency by indirect method is more useful than direct method?
3) What instruments are required for indirect efficiency testing?
4) What is the difference between dry flue gas loss and wet flue gas loss?
5) Which is the best location for sampling flue gas analysis?
6) Find out the efficiency by direct method from the data given below.
An oil fired package boiler was tested for 2 hours duration at steady state condition.
The fuel and water consumption were 250 litres and 3500 litres respectively. The
specific gravity of oil is 0.92. The saturated steam generation pressure is
7 kg/cm2(g). The boiler feed water temperature is 30°C. Determine the boiler effi-
ciency and evaporation ratio.
7) What is excess air? How to determine excess air if oxygen / carbon dioxide percent-
age is measured in the flue gas?
8) As a means of performance evaluation, explain the difference between efficiency and
evaporation ratio.
9) Testing coal-fired boiler is more difficult than oil-fired boiler. Give reasons.
10) What is controllable and uncontrollable losses in a boiler?
REFERENCES
1. Energy audit Reports of National Productivity Council
2. Energy Hand book, Second edition, Von Nostrand Reinhold Company - Robert
L.Loftness
3. Industrial boilers, Longman Scientific Technical 1999
www.boiler.com
www.eng-tips.com
www.worldenergy.org
Figure 2.1: Pusher-Type 3-Zone Reheating Furnace Figure 2.2: Walking Beam-Type Reheating Furnace
The purpose of the performance test is to determine efficiency of the furnace and specific
energy consumption for comparing with design values or best practice norms. There are many
factors affecting furnace performance such as capacity utilization of furnaces, excess air ratio,
final heating temperature etc. It is the key for assessing current level of performances and find-
ing the scope for improvements and productivity.
Heat output
1. Furnace Efficiency, η = x 100
Heat Input
Furnace Efficiency
The efficiency of a furnace is
the ratio of useful output to heat
input. The furnace efficiency can
be determined by both direct and
indirect method.
Figure 2.4 Factor for Determining the Equivalent of Heat Release from Openings to the Quality of Heat
Release from Perfect Black Body
TOTAL BLACK BODY RADIATION (kCal/cm2/hr)
Temperature (°C)
Figure 2.5 Graph for Determining Black Body Radiation at a Particular Temperature
The reheating furnace in example has 460mm thick wall (X) on the billet extraction outlet
side, which is 1m high (D) and 1m wide. With furnace temperature of 1340°C, the quantity (Q)
of radiation heat loss from the opening is calculated as follows:
Total heat loss = Black body radiation x area of opening x factor of radiation x emissivity
The quantity of heat loss from surface of furnace body is the sum of natural convection and
thermal radiation. This quantity can be calculated from surface temperatures of furnace. The
temperatures on furnace surface should be measured at as many points as possible, and their
average should be used. If the number of measuring points is too small, the error becomes
large.
The quantity (Q) of heat release from a reheating furnace is calculated with the following
formula:
where
Q : Quantity of heat release in kCal / W / m2
a : factor regarding direction of the surface of natural convection ceiling = 2.8,
side walls = 2.2, hearth = 1.5
tl : temperature of external wall surface of the furnace (°C)
t2 : temperature of air around the furnace (°C)
E : emissivity of external wall surface of the furnace
The first term of the formula above represents the quantity of heat release by natural con-
vection, and the second term represents the quantity of heat release by radiation.
From the Figure 2.6, the quantities of heat release from ceiling, sidewalls and hearth per unit
area can be found.
Stock
Charged amount in Charging Discharging Discharge
furnace temperature temperature material
Tons/hr °C °C kg/ton
Fuel Analysis
Cooling water
The Table 2.1 can be used to construct a heat balance for a typical heat treatment furnace
In practical terms this means the radiation losses from an open furnace door at 1500°C are
11 times greater than the same furnace at 700°C. A good incentive for the iron and steel melters
is to keep the furnace lid closed at all times and maintaining a continuous feed of cold charge
onto the molten bath.
Standby Losses
Energy is lost from the charge or its enclosure in the way of heat: (a) conduction, (b) convec-
tion; or/and (c) radiation
Furnace Draft Control
Furnace pressure control has a major effect on fuel fired furnace efficiency. Running a furnace
at a slight positive pressure reduces air ingress and can increase the efficiency.
Theoretical Heat
Example of melting one tonne of steel from an ambient temperature of 20°C . Specific heat of
steel = 0.186 Wh/kg/°C, latent heat for melting of steel = 40 Wh/kg/°C. Melting point of steel
= 1600°C.
Theoretical Total heat = Sensible heat + Latent heat
Sensible Heat = 1000 kg x 0.186 Wh /kg °C x (1600-20)°C = 294 kWh/T
Latent heat = 40 Wh/ kg x 1000 kg = 40 kWh/T
Total Heat = 294 + 40 = 334 kWh/T
So the theoretical energy needed to melt one tonne of steel from 20°C = 334 kWh.
Actual Energy used to melt to 1600°C is 700 kWh
Efficiency = 334 kWh x 100 = 48%
700 kwh
Typical furnace efficiency for reheating and forging furnaces (As observed in few trials
undertaken by an Energy Auditing Agency on such furnaces)
Note: These are the trial figures and cannot be presumed as standards for the furnaces
in question.
QUESTIONS
1) What is a heating Furnace and give two examples?
2) Define furnace efficiency.
3) How do you determine the furnace efficiency by direct method?
4) How do you determine the furnace efficiency by Indirect method?
5) Between efficiency and specific energy consumption, which is a better mean of com-
paring furnaces?
6) List down the various heat losses taking place in oil-fired furnace.
7) What are the major factors affecting the furnace performance?
8) Apart from the furnace operating parameters, energy auditor needs certain data from
reference book/manual for assessing furnace. Name few of them
9) What will be the difference in approach for conducting efficiency testing of batch
and continuous type furnace?
10) How will you measure the temperature of the stock inside the furnace?
REFERENCES
1. Handbook of Energy Conservation for Industrial Furnaces, Japan Industrial Furnace
Association.
2. Energy audit reports of National Productivity Council
3. Industrial Furnace, Volume 1 and Volume 2, John Wiley & Sons - Trinks
4. Improving furnace efficiency, Energy Management Journal
3.1 Introduction
Cogeneration systems can be broadly classified as those using steam turbines, Gas turbines and
DG sets. Steam turbine cogeneration systems involve different types of configurations with
respect to mode of power generation such as extraction, back pressure or a combination of back-
pressure, extraction and condensing.
Gas turbines with heat recovery steam generators is another mode of cogeneration.
Depending on power and steam load variations in the plant the entire system is dynamic. A per-
formance assessment would yield valuable insights into cogeneration system performance and
need for further optimisation.
kCal/kg
kCal/kg
outlined in the following section for the measurement of heat rate and efficiency of a
co-generation plant. This part provides performance-testing procedure for a coal fired steam
based co-generation plant, which is common in Indian industries.
3.5.1 Test Duration
The test duration is site specific and in a continuous process industry, 8-hour test data should
give reasonably reliable data. In case of an industry with fluctuating electrical/steam load pro-
file a set 24-hour data sampling for a representative period.
3.5.2 Measurements and Data Collection
The suggested instrumentation (online/ field instruments) for the performance measurement is
as under:
Steam flow measurement : Orifice flow meters
Fuel flow measurements : Volumetric measurements / Mass flow meters
Air flow / Flue gas flow : Venturi / Orifice flow meter / Ion gun / Pitot tubes
Flue gas Analysis : Zirconium Probe Oxygen analyser
Unburnt Analysis : Gravimetric Analysis
Temperature : Thermocouple
Cooling water flow : Orifice flow meter / weir /channel flow/
non-contact flow meters
Pressure : Bourdon Pressure Gauges
Power : Trivector meter / Energy meter
Condensate : Orifice flow meter
It is essential to ensure that the data is collected during steady state plant running conditions.
Among others the following are essential details to be collected for cogeneration plant perfor-
mance evaluation.
1. Total power generation for the trial period from individual turbines.
2. Hourly average power generation
3. Quantity of power import from utility ( Grid )*
4. Quantity of power generation from DG sets.*
5. Auxiliaries power consumption
* Necessary only when overall cogeneration plant adequacy and system optimization / upgra-
dation are the objectives of the study.
Step 1 :
Calculate the actual heat extraction in turbine at each stage,
* Due to wetness of steam in the condensing stage, the enthalpy of steam cannot be considered
as equivalent to saturated steam. Typical dryness value is 0.88 – 0.92. This dryness value can be
used as first approximation to estimate heat drop in the last stage. However it is suggested to cal-
culate the last stage efficiency from the overall turbine efficiency and other stage efficiencies.
Step 3 :
Step 4 :
Calculate plant heat rate*
M x (h1 – h11)
Heat rate, kCal / kWh =
P
3.6 Example
Calculations :
Step 1 :
Total heat of steam at turbine inlet conditions at 15kg / cm2 and 250°C, h1 =698 kCal/kg
Step 2 :
Total heat of steam at turbine outlet conditions at 2 kg/cm2 and 130°C, h2 = 648 kCal/kg
Step 3 :
Heat energy input to turbine per kg of inlet steam (h1– h2) = (698-648) = 50 kCal/kg
Step 4 :
Step 5 :
Energy input to the turbine = 5100 x 50 = 2,55,000 kCal/hr.
Step 6 :
Energy output
Power generation efficiency of the turbo alternator = --------------------- x 100
Energy Input
86,000
= ------------- x 100 = 34%
2,55,000
Step 7 :
Efficiency of the turbo alternator = 34%
Efficiency of Alternator = 92 %
Efficiency of gear transmission = 98 %
Step 8 :
Quantity of steam bypassing the turbine = Nil
Step 9 :
Coal consumption of the boiler = 1550 kg/hr.
Step 10:
Overall plant heat rate, kCal/kWh
= Mass flow rate of steam x ((Enthalpy of steam, kCal/kg – Enthalpy of feed water, kCal/kg)
Power output, kW
= 5100 x (698 – 30)
100
= 34068 kCal/kWh*
*Note: The plant heat rate is in the order of 34000 kCal/kWh because of the use of backpres-
sure turbine. This value will be around 3000 kcal/kWh while operating on fully condensing
mode. However with backpressure turbine, the energy in the steam is not wasted, as it is utilised
in the process.
Analysis of Results:
The efficiency of the turbine generator set is as per manufacturer design specification. There is
no steam bypass indicating that the power generation potential of process steam is fully utilized.
At present the power generation from the process steam completely meets the process electri-
cal demand or in other words, the system is balanced.
Remarks: Similar steps can be followed for the evaluation of performance of gas turbine
based cogeneration system.
QUESTIONS
1. What is meant by plant heat rate? What is its significance?
2. What is meant by turbine cylinder efficiency? How is it different from turbo-genera-
tor efficiency?
3. What parameters should be monitored for evaluating the efficiency of the turbine?
4. What is the need for performance assessment of a cogeneration plant?
5. The parameters for back pressure steam turbine cogeneration plant is given below
Inlet Steam: P =16 kg/cm2, T = 310°C, Q = 9000kg/hr
Outlet Steam: P = 5.0 kg/cm2, T = 235°C, Q = 9000kg/hr
Find out the turbine cylinder efficiency?
6. Explain why heat rate for back pressure turbine is greater than condensing turbine.
7. Explain the methodology of evaluating performance of a gas turbine with a heat
recovery steam generator.
REFERENCES
1. NPC report on 'Assessing cogeneration potential in Indian Industries'
2. Energy Cogeneration Handbook, George Polimeros, Industrial Press Inc.
4.1 Introduction
Heat exchangers are equipment that transfer heat from one medium to another. The proper
design, operation and maintenance of heat exchangers will make the process energy efficient
and minimize energy losses. Heat exchanger performance can deteriorate with time, off
design operations and other interferences such as fouling, scaling etc. It is necessary to
assess periodically the heat exchanger performance in order to maintain them at a high effi-
ciency level. This section comprises certain proven techniques of monitoring the perfor-
mance of heat exchangers, coolers and condensers from observed operating data of the
equipment.
When the hot and cold stream flows and inlet temperatures are constant, the heat transfer
coefficient may be evaluated using the above formula. It may be observed that the heat pick up
by the cold fluid starts reducing with time.
Nomenclature
A typical heat exchanger is shown in figure 4.1 with nomenclature.
Heat duty of the exchanger can be calculated either on the hot side fluid or cold side fluid
as given below.
Heat Duty for Hot fluid, Qh = Wx Cph x (Ti–To) ………..Eqn–1,
Heat Duty for Cold fluid, Qc = wx Cpc x ( to–ti) ………...Eqn–2
If the operating heat duty is less than design heat duty, it may be due to heat losses, fouling
in tubes, reduced flow rate (hot or cold) etc. Hence, for simple performance monitoring of
exchanger, efficiency may be considered as factor of performance irrespective of other para-
meter. However, in industrial practice, fouling factor method is more predominantly used.
Density and viscosity can be determined by analysis of the samples taken from the flow
stream at the recorded temperature in the plant laboratory. Thermal conductivity and specific
heat capacity if not determined from the samples can be collected from handbooks.
4.4.2 Examples
a. Liquid - Liquid Exchanger
A shell and tube exchanger of following configuration is considered being used for oil cool-
er with oil at the shell side and cooling water at the tube side.
Tube Side
• 460 Nos x 25.4mmOD x 2.11mm thick x 7211mm long
• Pitch - 31.75mm 30° triangular
• 2 Pass
Shell Side
• 787 mm ID
• Baffle space - 787 mm
• 1 Pass
Bureau of Energy Efficiency 59
4. Energy Performance Assessment Of Heat Exchangers
Heat Duty: Actual duty differences will be practically negligible as these duty differences
could be because of the specific heat capacity deviation with the temperature. Also, there could
be some heat loss due to radiation from the hot shell side.
Pressure drop: Also, the pressure drop in the shell side of the hot fluid is reported normal
(only slightly less than the design figure). This is attributed with the increased average bulk
temperature of the hot side due to decreased performance of the exchanger.
Temperature range: As seen from the data the deviation in the temperature ranges could be
due to the increased fouling in the tubes (cold stream), since a higher pressure drop is noticed.
Heat Transfer coefficient: The estimated value has decreased due to increased fouling that has
resulted in minimized active area of heat transfer.
Physical properties: If available from the data or Lab analysis can be used for verification
with the design data sheet as a cross check towards design considerations.
b. Surface Condenser
A shell and tube exchanger of following configuration is considered being used for Condensing
turbine exhaust steam with cooling water at the tube side.
Tube Side
20648 Nos x 25.4mmOD x 1.22mm thk x 18300mm long
Pitch - 31.75mm 60° triangular
1 Pass
The monitored parameters are as below:
9. Corrected LMTD
MTD = F x LMTD = 1.0 x 11.8 = 11.8 deg C.
10. Heat Transfer Co-efficient
Overall HTC, U = Q/ A ∆T = 576990/ (27871 x 11.8) = 1.75 kW/m2. K
Heat Duty: Actual duty differences will be practically negligible as these duty differences
could be because of the specific heat capacity deviation with the temperature. Also, there could
be some heat loss due to radiation from the hot shell side.
Pressure drop: The condensing side operating pressure raised due to the backpressure
caused by the non-condensable. This has resulted in increased pressure drop across the steam
side
Temperature range: With reference to cooling waterside there is no difference in the range
however, the terminal temperature differences has increased indicating lack of proper heat
transfer.
Heat Transfer coefficient: Heat transfer coefficient has decreased due to increased amount of
non-condensable with the steam.
Trouble shooting: Operations may be checked for tightness of the circuit and ensure
proper venting of the system. The vacuum source might be verified for proper
functioning.
C. Vaporizer
A shell and tube exchanger of following configuration is considered being used for vaporizing
chlorine with steam at the shell side.
Tube Side
200 Nos x 25.4mmOD x 1.22mm thick x 6000mm long
Pitch - 31.75mm 30° triangular
2 Pass
Area = 95.7.m2
1. Duty:
Q = qS + qL
Hot fluid, Q = 3130 kW
Cold Fluid, Q = qS + qL = 180.3 kW + 2948 kW = 3128.3 kW
2. Hot Fluid Pressure Drop
Pressure Drop = Pi – Po = 0.4 – 0.3 = 0.1 bar
3. Cold Fluid Pressure Drop
Pressure Drop = pi – po = 9 – 8.8 = 0.2 bar.
4. Temperature range hot fluid
Temperature Range ∆T = Ti – To = 0 °C
5. Temperature Range Cold Fluid
Temperature Range ∆t = ti – to = 34 – 30 = 4 °C.
6. Capacity Ratio
Capacity ratio, R = Not significant in evaluation here.
7. Effectiveness
Effectiveness, S = (to – ti) / (Ti – ti) = Not significant in evaluation here.
8. LMTD
Calculated considering condensing part only
a). LMTD, Counter Flow =((108 – 30)–(108–34))/ ln ((108–30)/(108–34)) = 76 °C.
b). Correction Factor to account for Cross flow
F = 1.0.
9. Corrected LMTD
MTD = F x LMTD = 1.0 x 76 = 76 °C.
10. Heat Transfer Co-efficient
Overall HTC, U = Q/ A ∆T = 3130/ (95.7 x 76) = 0.43 kW/m2. K
Heat Duty: There is no difference inferred from the duty as the exchanger is performing as per
the requirement
Pressure drop: The steam side pressure drop has increased in spite of condensation at the
steam side. Indication of non-condensable presence in steam side
Trouble shooting: Operations may be checked for presence of chlorine at the shell side
through tube leakages. Observing the steam side vent could do this. Alternately condensate pH
could be tested for presence of acidity.
d. Air heater
A finned tube exchanger of following configuration is considered being used for heating air
with steam in the tube side.
The monitored parameters are as below:
Heat Duty: The difference inferred from the duty as the exchanger is under performing than
required
Pressure drop: The airside pressure drop has increased in spite of condensation at the steam
side. Indication of choking and dirt blocking at the airside.
Heat Transfer coefficient: Decreased because of decreased fin efficiency due to choking on
air side.
Trouble shooting: Operations may be checked to perform pulsejet cleaning with steam / blow
air jet on air side if the facility is available. Mechanical cleaning may have to be planned dur-
ing any down time in the immediate future.
QUESTIONS
1. What is meant by LMTD ?
2. Distinguish between heat exchanger efficiency and effectiveness.
3. Explain the terms heat duty and capacity ratio.
4. What is meant by fouling?
5. List five heat exchangers used in industrial practice.
6. What are the parameters, which are to be monitored for the performance assessment
of heat exchangers?
7. In a heat exchanger the hot stream enters at 70°C and leaves at 55°C. On the other
side the cold stream enters at 30°C and leaves at 55°C. Find out the LMTD of the
heat exchanger.
8. In a condenser what type of heats are considered in estimating the heat duty?
a) Latent Heat b) Sensible heat c) Specific heat d) Latent heat and sensible heat
9. What is the need for performance assessment of a heat exchanger?
10. The unit of overall coefficient of heat transfer is
a) kCal/hr/m2 °C b) kCal/kg °C c) kCal/m2 hr d) kCal/hg m2
REFERENCES
1. "Process Heat Transfer" by D.Q.Kern, Edn. 1965.
2. "Modern Power Station Practice" - British Electricity International- Volume - G;
Chapter - 7 - " Plant performance and performance monitoring.
3. Coulsons & Richardson's CHEMICAL ENGINEERING Volume 3 third edition
4. Scimod " Scientific Modeling Software", techno software International, India
5. Ganapathy. V, "Fouling factor estimated quickly", O&G Journal, Aug 1992.
6. Liberman, Norman P, Trouble shooting Process Operations, Penwell Books, Tulsa,
Oklahoma
5.1 Introduction
The two parameters of importance in a motor are effi-
ciency and power factor. The efficiencies of induction
motors remain almost constant between 50% to 100%
loading (Refer figure 5.1). With motors designed to
perform this function efficiently; the opportunity for
savings with motors rests primarily in their selection
and use. When a motor has a higher rating than that
required by the equipment, motor operates at part load.
In this state, the efficiency of the motor is reduced.
Replacement of under loaded motors with smaller
motors will allow a fully loaded smaller motor to oper-
ate at a higher efficiency. This arrangement is general- Figure 5.1 Efficiency vs. Loading
ly most economical for larger motors, and only when
they are operating at less than one-third to one-half
capacity, depending on their size.
Efficiency :
The efficiency of the motor is given by
Pout Ploss
η = —— = 1 – ——
Pin Pin
R2 235 + t2
—– = ———– , where, t1 = ambient temperature, °C & t2 = operating temperature, °C.
R1 235 + t1
The rotor resistance can be determined from locked rotor test at reduced frequency, but rotor
I2R losses are measured from measurement of rotor slip.
Rotor I2R losses = Slip x (Stator Input - Stator I2R Losses - Core Loss)
Accurate measurement of slip is possible by stroboscope or non-contact type tachometer. Slip
also must be corrected to operating temperature.
output. It must be remarked that actual value of stray losses is likely to be more. IEEE - 112 spec-
ifies values from 0.9 % to 1.8 %.
Solution
a) Let Iron plus friction and windage loss, Pi + fw
No load power, Pnl = 1063.74 Watts
Stator Copper loss, P st-30°C (Pst.cu)
= 3 x (16.1 / √3)2 x 0.264
= 68.43 Watts
Pi + fw = Pnl - Pst.cu
= 1063.74 – 68.43
= 995.3 W
b) Stator Resistance at 120°C,
120 + 235
R120°C = 0.264 x —————
30 + 235
= 0.354 ohms per phase
c) Stator copper losses at full load, Pst.cu 120°C
= 3 x (57 / √3)2 x 0.354
= 1150.1 Watts
d) Full load slip
S = (1500 – 1475) / 1500
= 0.0167
Rotor input, Pr = Poutput/ (1-S)
= 34000 / (1-0.0167)
= 34577.4 Watts
e) Motor full load input power, P input
= Pr + Pst.cu 120°C + (Pi + fw) + Pstray
= 34577.4 + 1150.1 + 995.3 + (0.005* x 34000)
= 36892.8 Watts
*
where, stray losses = 0.5% of rated output (assumed)
f) Motor efficiency at full load
Poutput
Efficiency = ——– x 100
Pinput
34000
= ——–
36892.8
= 92.2%
= Pinput
Full Load PF = —————–
= √3 x V x Ifl
= 36892.8
= ——————–
= √3 x 415 x 57
= 0.90
Comments :
a) The measurement of stray load losses is very difficult and not practical even on test beds.
b) The actual value of stray loss of motors up to 200 HP is likely to be 1 % to 3 % compared
to 0.5 % assumed by standards.
c) The value of full load slip taken from the nameplate data is not accurate. Actual measure-
ment under full load conditions will give better results.
d) The friction and windage losses really are part of the shaft output; however, in the above
calculation, it is not added to the rated shaft output, before calculating the rotor input
power. The error however is minor.
e) When a motor is rewound, there is a fair chance that the resistance per phase would
increase due to winding material quality and the losses would be higher. It would be inter-
esting to assess the effect of a nominal 10 % increase in resistance per phase.
• First measure input power Pi with a hand held or in-line power meter
Pi = Three-phase power in kW
• Note the rated kW and efficiency from the motor name plate
Example
The nameplate details of a motor are given as power = 15 kW, efficiency η = 0.9. Using a power
meter the actual three phase power drawn is found to be 8 kW. Find out the loading of the motor.
Input power at full-rated power in kW, Pir = 15 /0.9
= 16.7 kW
Percentage loading = 8/16.7
= 48 %
3. Slip Method
In the absence of a power meter, the slip method can be used which requires a tachometer. This
method also does not give the exact loading on the motors.
Slip
Load = —— *100%
Ss–Sr
Where:
Load = Output power as a % of rated power
Slip = Synchronous speed - Measured speed in rpm
Ss = Synchronous speed in rpm at the operating frequency
Sr = Nameplate full-load speed
Example: Slip Load Calculation
Given: Synchronous speed in rpm = 1500 at 50 HZ operating frequency.
(Synchronous speed = 120f/P) f: frequency, P: Number of poles
Nameplate full load speed = 1450
Measured speed in rpm = 1480
Nameplate rated power = 7.5 kW
Determine actual output power.
1500 – 1480
Load = ————— *100% = 40%
1500 – 1450
From the above equation, actual output power would be 40% x 7.5 kW = 3 kW
The speed/slip method of determining motor part-load is often favored due to its simplicity
and safety advantages. Most motors are constructed such that the shaft is accessible to a
tachometer or a strobe light.
The accuracy of the slip method, however, is limited. The largest uncertainty relates to
the accuracy with which manufacturers report the nameplate full-load speed. Manufacturers
generally round their reported full-load speed values to some multiple of 5 rpm. While 5 rpm is
but a small percent of the full-load speed and may be considered as insignificant, the slip
method relies on the difference between full-load nameplate and synchronous speeds. Given a
40 rpm "correct" slip, a seemingly minor 5 rpm disparity causes a 12% change in calculated
load.
Slip also varies inversely with respect to the motor terminal voltage squared. A voltage cor-
rection factor can, also, be inserted into the slip load equation. The voltage compensated load
can be calculated as shown
Slip
Load = ———————– x 100%
(Ss – Sr) x (Vr/V)2
Where:
Load = Output power as a % of rated power
Slip = Synchronous speed - Measured speed in rpm
Ss = Synchronous speed in rpm
Sr = Nameplate full-load speed
V = RMS voltage, mean line to line of 3 phases
Vr = Nameplate rated voltage
General Data
Driven Equipment__________________ Motor Operating Profile:
Motor Name Plate Data No of hours of operation
Manufacturer ______________________ I Shift _____________
Model ___________________________ II Shift _____________
Serial Number _____________________ III Shift _____________
Type :Squirrel cage/Slp ring__________
Size (hp/kW)______________________ Annual Operating Time ______ hours/year
Synchronous Speed (RPM) ___________
Full-Load Speed (RPM) _____________ Type of load
Voltage Rating _____________________ 1.Load is quite steady, motor "On" during shift
Full-Load Amperage ________________ 2.Load starts, stops, but is constant when "On"
Full-Load Power Factor (%) __________ 3.Load starts, stops, and fluctuates when "On"
Full-Load Efficiency (%) ____________
Temperature Rise __________________ Measured Data
Insulation Class ____________________ Supply Voltage
By Voltmeter
VRY ________
From Test Certificate VYB ________ V avg ______
Load 100% 75% 25% No Load VBR ________
Input Amps
Current By Ammeter
PF A a __________
A b __________ A avg ______
Efficiency
A c __________
Power Factor (PF) _____________________
Stator resistance per phase = Input Power (kW) ______________________
The speed of an induction motor is proportional to the frequency of the AC voltage applied to
it, as well as the number of poles in the motor stator. This is expressed by the equation:
RPM = (f x 120) / p
Where f is the frequency in Hz, and p is the number of poles in any multiple of 2.
Therefore, if the frequency applied to the motor is changed, the motor speed changes in
direct proportion to the frequency change. The control of frequency applied to the motor is the
job given to the VSD.
The VSD's basic principle of operation is to convert the electrical system frequency and volt-
age to the frequency and voltage required to drive a motor at a speed other than its rated speed.
The two most basic functions of a VSD are to provide power conversion from one frequency to
another, and to enable control of the output frequency.
DC bus energizes the inverter, which converts it back to AC voltage again. The inverter can
be controlled to produce an output frequency of the proper value for the desired motor shaft
speed.
b) Motor Information
The following motor information will be needed to select the proper variable frequency drive:
Full Load Amperage Rating. Using a motor's horsepower is an inaccurate way to size vari-
able frequency drives.
Speed Range. Generally, a motor should not be run at any speed less than 20% of its specified
maximum speed allowed. If it is run at a speed less than this without auxiliary motor cooling,
the motor will overheat. Auxiliary motor cooling should be used if the motor must be operated
at very slow speeds.
Multiple Motors. To size a variable frequency drive that will control more than one motor, add
together the full-load amp ratings of each of the motors. All motors controlled by a single drive
must have an equal voltage rating.
Additional Protection: Over and under voltage, over temperature, ground fault, control or
microprocessor fault. These protective circuits should provide an orderly shutdown of the VFD,
provide indication of the fault condition, and require a manual reset (except under voltage)
before restart. Under voltage from a power loss shall be set to automatically restart after return
to normal. The history of the previous three faults shall remain in memory for future review.
If a built-up system is required, there should also be externally-operated short circuit protec-
tion, door-interlocked fused disconnect and circuit breaker or motor circuit protector (MCP)
To determine if the equipment under consideration is the right choice for a variable speed
drive:
The load patterns should be thoroughly studied before exercising the option of VSD. In effect
the load should be of a varying nature to demand a VSD ( refer figure 5.3 & 5.4).
Figure 5.3 Example of an excellent variable Figure 5.4 Example of a poor variable speed
speed drive candidate drive candidate
The first step is to identify the number of operating hours of the equipment at various load
conditions. This can be done by using a Power analyzer with continuous data storage or by a
simple energy meter with periodic reading being taken.
5.7.3 Information needed to Evaluate Energy Savings for Variable Speed Application
1. Method of flow control to which adjustable speed is compared:
o output throttling (pump) or dampers (fan)
o recirculation (pump) or unrestrained flow (fan)
o adjustable-speed coupling (eddy current coupling)
o inlet guide vanes or inlet dampers (fan only)
o two-speed motor.
2. Pump or fan data:
o head v's flow curve for every different type of liquid (pump) or gas (fan) that is
handled
o Pump efficiency curves.
3. Process information:
o specific gravity (for pumps) or specific density of products (for fans)
o system resistance head/flow curve
o equipment duty cycle, i.e. flow levels and time duration.
4. Efficiency information on all relevant electrical system apparatus:
o motors, constant and variable speed
o variable speed drives
o gears
o transformers.
If we do not have precise information for all of the above, we can make reasonable assump-
tions for points 2 and 4.
QUESTIONS
1) Define motor efficiency.
2) Why it is difficult to measure motor efficiency at site?
3) Describe the various methods by which you calculate motor loading.
4) If no instrument other than tachometer is available, what method you would suggest
for measuring the motor load?
5) A 20 kW rated motor is drawing actual measured power of 14 kW. If the rated effi-
ciency is 92%, determine the motor loading?
6) What are the limitations of slip method in determining motor loading?
7) A 4 pole motor is operating at a frequency of 50 Hz. Find the RPM of the motor?
8) What are the two factors influencing the speed of induction motor?
9) A fan's operating hours and loading are given below:
15 hours at 100% load
8 hours at 95% load
1 hour at 40% load
Is the application suitable candidate for application of VSD?
11) The losses in a variable speed drive is a) 12% b) 8% c) <5% d) no losses at all
REFERENCES
1. Motor challenge: Office of Industrial Technologies, Department of Energy, USA
2. Energy audit Reports of National Productivity Council
6.1 Introduction
This section describes the method of testing a fan installed on site in order to determine the
performance of the fan in conjunction with the system to which it is connected.
Static Pressure: The absolute pressure at a point minus the reference atmospheric pressure.
Dynamic Pressure: The rise in static pressure which occurs when air moving with specified
velocity at a point is bought to rest without loss of mechanical energy. It is also known as veloc-
ity pressure.
Total Pressure: The sum of static pressures and dynamic pressures at a point.
Fan Shaft Power: The mechanical power supplied to the fan shaft
Motor Input Power: The electrical power supplied to the terminals of an electric motor
drive.
6.4 Scope
The procedure describes field testing of centrifugal fans and blowers for assessing performance
and efficiency.
General: The flow measurement plane shall be located in any suitable straight length,
(preferably on the inlet side of the fan) where the airflow conditions are substantially axial,
symmetrical and free from turbulence. Leakage of air from or into the air duct shall be negligi-
ble between the flow measuring plane and the fan. Bends and obstructions in an air duct can
disturb the airflow for a considerable distance downstream, and should be avoided for the pur-
poses of the test.
Test length: That part of the duct in which the flow measurement plane is located, is termed
the 'test length' and shall be straight, of uniform cross section and free from any obstructions
which may modify the airflow. It shall have a length equal to not less than twice the equiva-
lent diameter of the air duct (i.e. 2De). For rectangular duct, equivalent diameter, De is given by
2 LW/(L + W) where L, W is the length and width of the duct. For circular ducts De is the same
as diameter of the duct.
Inlet side of the fan: Where the 'test length' is on the inlet side of the fan, its downstream end
shall be at a distance from the fan inlet equal to atleast 0.75De. See figure 6.1. In the case of a
fan having an inlet box , the downstream end of the test length shall be at a distance from the
nearest part of the inlet cone of the fan equal to at least 0.75De.
Outlet side of the fan: Where the 'test length' is on the outlet side of the fan, the upstream
end of the 'test length' shall be at a distance from the fan outlet of at least 3De. See figure 6.2.
For this purpose, the fan outlet shall be considered as being the outlet of any expander on the
outlet side of the fan.
Location of the Flow Measurement Plane within the 'Test Length': The flow measure-
ment plane shall be located within the 'test length' at a distance from the downstream end of the
'test length' equal to at least 1.25De.
Location of Pressure Measurement Plane: For the purpose of determining the pressure rise
produced by the fan, the static pressure shall be measured at planes on the inlet and/or the out-
let side of the fan sufficiently close to it to ensure that the pressure losses between the measur-
ing planes and the fan are calculable in accordance with available friction factor data without
adding excessively to the uncertainty of fan pressure determination.
If conveniently close to the fan, the 'test length' selected for air flow measurement should
also be used to pressure measurement. Other planes used for pressure measurement should be
no closer than 0.25De from the fan inlet and no closer than 4De from the fan outlet. The plane
of pressure measurement should be selected at least 4De downstream of any bend, expander or
obstruction which are likely to cause separated flow or otherwise interfere with uniformity of
pressure distribution.
Pitot Tube: In Figure 6.4, note that separate static connections (A) and total pressure con-
nections (B) can be connected simultaneously across a manometer (C). Since the static pressure
is applied to both sides of the manometer, its effect is canceled out and the manometer indicates
only the velocity pressure.
In practice this type of measurement is usually made with a Pitot tube which incorporates both
static and total pressure sensors in a single unit. Essentially, a Pitot tube consists of an impact tube
(which receives total pressure input) fastened concentrically inside a second tube of slightly larger
diameter which receives static pressure input from radial sensing holes around the tip. The air space
between inner and outer tubes permits transfer of pressure from the sensing holes to the static pres-
sure connection at the opposite end of the Pitot and then, through connecting tubing, to the low or
negative pressure side of a manometer. When the total pressure tube is connected to the high pres-
sure side of the manometer, velocity pressure is indicated directly. See Figure 6.5.
To ensure accurate velocity pressure readings, the Pitot tube tip must be pointed directly into
(parallel with) the air stream. As the Pitot tube tip is parallel with the static pressure outlet tube,
the latter can be used as a pointer to align the tip properly. When the Pitot tube is correctly
aligned, the pressure indication will be maximum.
Figure 6.5 Pitot tube senses total and static pressure. Manometer measures
velocity pressure (Difference between total and static pressures)
Traverse readings: In practical situations, the velocity of the air stream is not uniform across
the cross section of a duct. Friction slows the air moving close to the walls, so the velocity is
greater in the center of the duct.
To obtain the average total velocity in ducts of 100 mm diameter or larger, a series of
velocity pressure readings must be taken at points of equal area. A formal pattern of sensing
points across the duct cross section is recommended. These are known as traverse readings.
Figure 6.6 shows recommended Pitot tube locations for traversing round and rectangular
ducts.
In round ducts, velocity pressure readings should be taken at centers of equal concentric areas.
At least 20 readings should be taken along two diameters. In rectangular ducts, a minimum of 16
and a maximum of 64 readings are taken at centers of equal rectangular areas. Actual velocities for
each area are calculated from individual velocity pressure readings. This allows the readings and
velocities to be inspected for errors or inconsistencies. The velocities are then averaged.
By taking Pitot tube readings with extreme care, air velocity can be determined within an
accuracy of ± 2%. For maximum accuracy, the following precautions should be observed:
Anemometer: The indicated velocity shall be measured at each traverse point in the cross
section by holding the anemometer stationary at each point for a period of time of not less than
1 minute. Each reading shall be converted to velocity in m/s and individually corrected in accor-
dance with the anemometer calibration. The arithmetic mean of the corrected point velocities
gives the average velocity in the air duct and the volume flow rate is obtained by multiplying
the area of the air duct by the average velocity.
Other Prime Movers: When the fan forms one unit with a non-electric prime mover it is rec-
ommended that the fuel consumption (oil, steam, compressed air etc.) should be specified and
determined in place of the overall power.
A. Design Parameters:
Volume = 292 m3/sec.
Static Pressure = 609.6 mmwc
B. Measurements:
Temperature = 32°C
Speed = 740 RPM
C. Performance calculations:
a) Gas Density = 273 x 1.293
(Corrected to NTP) 273 + T°C (at site condition)
= 273 x 1.293
273 + 32°C (at site condition)
= 1.15 kg/m3
QUESTIONS
1) What is the relationship between static pressure, dynamic pressure and total pres-
sure?
2) For determining fan efficiency, why static pressure readings should be taken as close
to fan as possible?
3) What is the significance of having traverse points in velocity measurement?
4) What is fan efficiency?
5) Determine various traverse points for a round duct of 0.5 m diameter.
6) Why flow should not be measured very close to inlet and outlet of fan?
7) Calculate the flow rate for the following data:
Diameter of duct: 0.5 m, differential pressure: 100mmWC,
Density of air at 0°C: 1.293, Temperature of air in the duct: 100°C, pitot coefficient:
0.85
8) How many traverse points you would propose for a rectangular duct of 1 m x 1 m
dimensions?
9) What are the various ways of measuring the flow?
10) What are the various factors, which can affect fan performance?
REFERENCES
1. British Standard: BS 848 : Part 1 : 1980
2. Energy and Environmental Audit Reports of National Productivity Council
7.1 Introduction
Pumping is the process of addition of kinetic and potential energy to a liquid for the
purpose of moving it from one point to another. This energy will cause the liquid to do work
such as flow through a pipe or rise to a higher level. A centrifugal pump transforms mechan-
ical energy from a rotating impeller into a kinetic and potential energy required by the
system.
The most critical aspect of energy efficiency in a pumping system is matching of pumps to
loads. Hence even if an efficient pump is selected, but if it is a mismatch to the system then the
pump will operate at very poor efficiencies. In addition efficiency drop can also be expected
over time due to deposits in the impellers. Performance assessment of pumps would reveal the
existing operating efficiencies in order to take corrective action.
Pump Capacity, Q = Volume of liquid delivered by pump per unit time,m3/hr or m3/sec
Q is proportional to N, where N- rotational speed of the pump
The pump head represents the net work done on unit weights of a liquid in passing from
inlet of the pump to the discharge of the pump.
There are three heads in common use in pumps namely
(i) Static head
(ii) Velocity head
(iii) Friction head.
The frictional head in a system of pipes, valves and fittings varies as a function (roughly as
the square) of the capacity flow through the system.
System resistance: The sum of frictional head in resistance & total static head.
Pump Efficiency: Fluid power and useful work done by the pump divided by the power input
in the pump shaft.
Tracer Method
The Tracer method is particularly suitable for cooling water flow measurement because of their
sensitivity and accuracy.
This method is based on injecting a tracer into the cooling water for a few minutes at an
accurately measured constant rate. A series of samples is extracted from the system at a point
where the tracer has become completely mixed with the cooling water. The mass flow rate is
calculated from:
qcw = q1 x C1/C2
ηPump = Ph
Ps
Measured Data
curve changes from normal / design. The example following from the earlier example outlines
the method of constructing a system curve.
Example:
Location of equipments
The Refrigeration plant is located at +0.00 level and the Process plant condensers are located at
+15 M level. One cooler having a design pressure drop of 1.9 kg/cm2 is located at the 0.00 level
(ground level). Other relevant data can be inferred from the earlier section. See schematic in
Figure 7.1.
It can be noted that at full load the condenser and cooler circuits offer the maximum resis-
tance to flow.
Choose the condenser loop as it offers maximum resistance and is also having a static head
component
Static head: 15 M
Dynamic head at full load; 39 M
Compute system resistance at different flow rates
Step 4 - Plot the system resistance against flow in the pump efficiency curves (see Figure 7.2)
provided by the vendor and compare actual operating duty point and see whether it operates at
maximum efficiency. In the example provided it is found that the pump system efficiency is
lower by 4 % due to change in operating conditions.
QUESTIONS
1) How would you measure the flow by using tracer method?
2) What are the various ways of measuring flow?
3) A pump motor draws 75 A current. The voltage is 415 V. Assuming a power factor of
0.9. Calculate the power drawn?
4) The suction head is 1m below the pump centerline. The discharge pressure shows 3
kg/cm2. The flow is calculated to be 100 m3/hr. Find out the pump efficiency.
5) The pump efficiency is 70%. The hydraulic power is calculated to be 22 kW. Find
out the motor power required to drive the pump.
REFERENCES
1. Pump handbook by Karassik
2. Energy Audit Reports of National Productivity Council
8.1 Introduction
The compressed air system is not only an energy intensive utility but also one of the least ener-
gy efficient. Over a period of time, both performance of compressors and compressed air sys-
tem reduces drastically. The causes are many such as poor maintenance, wear and tear etc. All
these lead to additional compressors installations leading to more inefficiencies. A periodic per-
formance assessment is essential to minimize the cost of compressed air.
ratio of upstream pressure (receiver) to the downstream pressure (atmospheric) i.e. Mach num-
ber equals one.
When the pressure in the receiver is kept constant for a reasonable intervals of time, the air-
flow output of the compressor is equal to that of the nozzle and can be calculated from the
known characteristic of the nozzle.
• Thermometers or Thermocouple
• Pressure gauges or Manometers
• Differential pressure gauges or Manometers
• Standard Nozzle
• Psychrometer
• Tachometer/stroboscope
• Electrical demand analyser
8.6 Example
In the above example the measured flow is 1407.6 m3/hr and actual power consumption is
100 kW.
Another way of determining the Free Air Delivery of the compressor is by Pump Up
Method - also known as receiver filling method. Although this is less accurate, this can be
adopted where the elaborate nozzle method is difficult to be deployed.
• Isolate the compressor along with its individual receiver being taken for test from main
compressed air system by tightly closing the isolation valve or blanking it, thus closing
the receiver outlet.
• Open water drain valve and drain out water fully and empty the receiver and the pipeline.
Make sure that water trap line is tightly closed once again to start the test.
• Start the compressor and activate the stopwatch.
• Note the time taken to attain the normal operational pressure P2 (in the receiver) from ini-
tial pressure P1.
• Calculate the capacity as per the formulae given below:
Where
P2 = Final pressure after filling (kg/cm2 a)
P1 = Initial pressure (kg/cm2a) after bleeding
P0 = Atmospheric Pressure (kg/cm2 a)
V = Storage volume in m3 which includes receiver,
after cooler, and delivery piping
T = Time take to build up pressure to P2 in minutes
The above equation is relevant where the compressed air temperature is same as the ambi-
ent air temperature, i.e., perfect isothermal compression. In case the actual compressed air tem-
perature at discharge, say t2°C is higher than ambient air temperature say t1°C (as is usual case),
the FAD is to be corrected by a factor (273 + t1) / (273 + t2).
EXAMPLE
An instrument air compressor capacity test gave the following results (assume the final com-
pressed air temperature is same as the ambient temperature) - Comment?
Capacity shortfall with respect to 14.75 m3/minute rating is 1.577 m3/minute i.e.,
10.69 %, which indicates compressor performance needs to be investigated further.
QUESTIONS
1) What is meant by Free Air Delivery?
2) Describe the method of estimating flow by nozzle method.
3) Describe the method of estimating flow by pump up method.
4) Define the term isothermal efficiency and explain its significance.
5) Define the term volumetric efficiency and explain its significance.
6) How is specific power requirement calculated?
REFERENCES
1. IS 10431:1994: Measurement of airflow of compressors and exhausters by nozzles.
2. IS 5456:1985 code of practice for testing of positive displacement type air compressors
and exhausters
3. Compressor performance – Aerodynamics for the user by M Theodore Gresh-
Butterworth Heinemann.
9.1 Introduction
Air conditioning and refrigeration consume significant amount of energy in buildings and in
process industries. The energy consumed in air conditioning and refrigeration systems is sensi-
tive to load changes, seasonal variations, operation and maintenance, ambient conditions etc.
Hence the performance evaluation will have to take into account to the extent possible all these
factors.
Net Refrigerating Capacity. A quantity defined as the mass flow rate of the evaporator water
multiplied by the difference in enthalpy of water entering and leaving the cooler, expressed in
kCal/h, tons of Refrigeration.
kW/ton rating: Commonly referred to as efficiency, but actually power input to compressor
motor divided by tons of cooling produced, or kilowatts per ton (kW/ton). Lower kW/ton indi-
cates higher efficiency.
Coefficient of Performance (COP): Chiller efficiency measured in Btu output (cooling) divid-
ed by Btu input (electric power).
Energy Efficiency Ratio (EER): Performance of smaller chillers and rooftop units is fre-
quently measured in EER rather than kW/ton. EER is calculated by dividing a chiller's cooling
capacity (in Btu/h) by its power input (in watts) at full-load conditions. The higher the EER, the
more efficient the unit.
9.5 Procedure
9.5.1 To determine the net refrigeration capacity
The test shall include a measurement of the net heat removed from the water as it passes
through the evaporator by determination of the following:
a. Water flow rate
b. Temperature difference between entering and leaving water
The heat removed from the chilled water is equal to the product of the chilled water flow
rate, the water temperature difference, and the specific heat of the water is defined as
follows
The net refrigeration capacity in tons shall be obtained by the following equation:
The accurate temperature measurement is very vital in refrigeration and air conditioning and
least count should be at least one decimal.
Use this data to calculate other energy efficiency parameters with the following
relations
Heat load can also be calculated theoretically by estimating the various heat loads, both sen-
sible and latent, in the air-conditioned room (refer standard air conditioning handbooks). The
difference between these two indicates the losses by way of leakages, unwanted loads, heat
ingress etc.
Evaporator
a. Temperature of water entering evaporator
b. Temperature of water leaving evaporator
c. Chilled water flow rates
d. Evaporator water pressure drop (inlet to outlet)
Compressor
e. Power input to compressor electrical power, kW
9.7 Example
In a brewery chilling system, ethylene glycol is used a secondary refrigerant. The designed
capacity is 40 TR. A test was conducted to find out the operating capacity and energy perfor-
mance ratios. The flow was measured by switching off the secondary pump and measuring the
tank level difference in hot well.
Measurements data:
QUESTIONS
1) What is meant by a ton of refrigeration?
2) Define the terms net refrigeration capacity, COP, energy efficiency ratio.
3) What is the relation between COP and kW/ton of refrigeration?
4) How would you calculate the heat load for a room to be air-conditioned?
5) If the power consumed by a refrigerating unit / ton of refrigeration is 2 kW then find
energy efficiency ratio?
REFERENCES
1. Refrigeration and Air Conditioning by Richard C.Jordan & Gayle B.Priester - Prentice
Hall of India pvt.ltd.
2. Modern Air Conditioning Practice by Norman C.Harris - McGraw-Hill International
Edition.
10.1 Introduction
Lighting is provided in industries, commercial buildings, indoor and outdoor for
providing comfortable working environment. The primary objective is to provide the
required lighting effect for the lowest installed load i.e highest lighting at lowest power
consumption.
tal working plane with general lighting of an interior. Unit: watts per square metre per 100 lux
(W/m²/100 lux)
100
Installed power density (W/m²/100 lux) = —————————————–
Installed load efficacy (lux/W/m²)
Average maintained illuminance is the average of lux levels measured at various points in a
defined area.
Color Rendering Index (CRI) is a measure of the effect of light on the perceived color of objects.
To determine the CRI of a lamp, the color appearances of a set of standard color chips are measured
with special equipment under a reference light source with the same correlated color temperature as
the lamp being evaluated. If the lamp renders the color of the chips identical to the reference light
source, its CRI is 100. If the color rendering differs from the reference light source, the CRI is less
than 100. A low CRI indicates that some colors may appear unnatural when illuminated by the lamp.
To obtain an approximately "square array", i.e. the spacing between the points on
each axis to be approximately the same, it may be necessary to increase the number of
points.
Length = 9m, Width = 5m, Height of luminaires above working plane (Hm) = 2m
Calculate RI = 9 x 5 = 1.607
2(9 + 5)
Therefore in this example the spacing between points along rows along the length of the
interior = 9 ÷ 6 = 1.5m and the distance of the 'end' points from the wall = 1.5 ÷ 2 = 0.75m.
Similarly the distance between points across the width of the interior = 5 ÷ 3 = 1.67m with
half this value, 0.83m, between the 'end' points and the walls.
If the grid of the measurement points coincides with that of the lighting fittings, large errors
are possible and the number of measurement points should be increased to avoid such an
occurrence.
10.5.2 Calculation of the Installed Load Efficacy and Installed Load Efficacy Ratio of a
General Lighting Installation in an Interior
The principal difference between the targets for Commercial and Industrial Ra: 40-85
(Cols.2 & 3) of Table 10.2 is the provision for a slightly lower maintenance factor for the lat-
ter. The targets for very clean industrial applications, with Ra: of 40 -85, are as column 2.
ILER Assessment
0.75 or over Satisfactory to Good
0.51 – 0.74 Review suggested
0.5 or less Urgent action required
Having derived the ILER for an existing lighting installation, then the difference between
the actual ILER and the best possible (1.0) can be used to estimate the energy wastage. For a
given installation:
Annual energy wastage (in kWh)
= (1.0 - ILER) x Total load (kW) x annual operating hours (h)
This process of comparing the installed load efficacy (ILE) with the target value for the
Room Index and type of application can also be used to assess the efficiency of designs for new
or replacement general lighting installations. If, when doing so, the calculated ILE (lux/W/m²)
is less than the target value then it is advisable to ascertain the reasons. It may be that the
requirements dictate a type of luminaire that is not as efficient as the best, or the surface
reflectances are less than the normal maxima, or the environment is dirty, etc., Whatever the
reasons, they should be checked to see if a more efficient solution is possible.
Referring to table 3, ILER of 0.7 means that there is scope for review of the lighting system.
Annual energy wastage = (1 - ILER) x watts x no. of operating hours
= (1 - 0.7) x 990 x 8 hrs/day x 300 days
= 712 kWh/annum
• Look for natural lighting opportunities through windows and other openings
• In the case of industrial lighting, explore the scope for introducing translucent sheets
• Assess scope for more energy efficient lamps and luminaries
• Assess the scope for rearrangement of lighting fixtures
TABLE 10.4 IES ILLUMINANCE CATEGORIES AND VALUES - FOR GENERIC INDOOR
ACTIVITIES
Step 2: More detailed task descriptions are given in the recommended illuminance level tables
in the IES Handbook. (For an intensive lighting survey) Under the task category "Libraries,"
subheading "Card files," the illuminance category is E.
Step 3: From the IES Illuminance Category and Ranges table, find category E and choose 500-750-
1000 lux for the range of illuminance recommended. The first column in the table is illuminance
values in units of lux, the metric version of footcandle. Notice that categories A through C are for
general illumination throughout the area, but D through I are for illuminance on the task. Categories
G through I would require a combination of general lighting and task lighting.
Step 4: Use the weighting factors to decide which of the values in the illuminance range to use.
Since libraries are public facilities, there may be many individuals over 55 years of age so select
the category 'Over 55' for a weighting factor of +1.
Next, decide whether the demand for speed and accuracy is not important, important or crit-
ical. Filing of cards correctly is not a critical activity, so the weighting factor of zero (0) is
selected. An example of critical might be drafting work. The task background reflectance for
black type on a white page is 85%. So choose "greater than 70 percent" for a weighting factor
of -1. The total weighting factor is 0. So use the middle recommended illuminance, or 750 lux.
For more detailed information on this the IES handbook may be referred.
Super 20000
HPSV 600 --- --- --- --- --- ---
Super
HPMV 80 3400 43 9 4000 - 0.6 - 0.69 8
5000
HPMV 125 6300 50 12 4000 - 0.6 - 0.69 10
5000
HPMV 250 13000 52 16 4000 - 0.6 - 0.69 18
5000
HPMV 400 22000 55 25 4000 - 0.6 - 0.69 18
5000
Metal 70 4200 84 26 10000 0.9 - 0.93 ---
Halide
Metal 150 10500 70 20 10000 0.9 - 0.93 ---
Halide
Metal 250 19000 76 25 10000 0.9 - 0.93 ---
Halide
Metal 400 31000 76 60 10000 0.9 - 0.93 ---
Halide
Metal 1000 80000 80 65 10000 0.9 - 0.93 ---
Halide
FTL 40 2400 60 15 4400 0.8 - 0.89 3.2 - 3.8
FTL 36 3250 90 5 14000 0.8 - 0.89 3.2 - 3.8
Super
QUESTIONS
1) What is circuit watts?
2) Define ILER and its significance.
3) Distinguish between lux and lumens.
4) What do you understand by the term colour rendering index?
5) Define room index?
6) For a room of length 10 m and width 20 m, calculate room index?
7) For a room of 9 x 6 m, determine the appropriate number of measuring points for lux
levels?
8) What possible improvement measures you would look for in a general lighting sys-
tem?
9) Which of the following lamps has the maximum lamp efficiency?
(lumes/Watt) a) Metal Hallide b) Fluorescent c) Incandescent d) HPSV
REFERENCES
1. Illumination engineering for energy efficient luminous environments by Ronald N.
Helms, Prentice-Hall, Inc.
2. The 'LIGHTSWITCH' programme, Energy Saving Trust, UK
11.1 Introduction
When planning an energy efficiency or energy management project, the costs involved
should always be considered. Therefore, as with any other type of investment, energy man-
agement proposals should show the likely return on any capital that is invested. Consider the
case of an energy auditor who advises the senior management of an organisation that capi-
tal should be invested in new boiler plant. Inevitably, the management of the organisation
would ask:
• How much will the proposal cost?
• How much money will be saved by the proposal?
These are, of course, not unreasonable questions, since within any organisation there are
many worthy causes, each of which requires funding and it is the job of senior management to
invest in capital where it is going to obtain the greatest return. In order to make a decision about
any course of action, management needs to be able to appraise all the costs involved in a pro-
ject and determine the potential returns.
This however, is not quite as simple as it might first appear. The capital value of plant
or equipment usually decreases with time and it often requires more maintenance as it gets
older. If money is borrowed from a bank to finance a project, then interest will have to be
paid on the loan. Inflation too will influence the value of any future energy savings that
might be achieved. It is therefore important that the cost appraisal process allows for all
these factors, with the aim of determining which investments should be undertaken, and of
optimising the benefits achieved. To this end a number of accounting and financial appraisal
techniques have been developed which help energy managers and auditors make correct and
objective decisions.
The financial issues associated with capital investment in energy saving projects are inves-
tigated in this chapter. In particular, the discounted cash flow techniques of net present value
and internal rate of return are discussed in detail.
Example 1
The capital cost of the DG set is Rs.9,00,000, the annual output is 219 MWh, and the mainte-
nance cost is Rs.30,000 per annum. The cost of producing each unit of electricity is 3.50
Rs./kWh. The total cost of a diesel generator operating over a 5-year period, taking into con-
sideration both fixed and variable cost is:
From Example 1, it can be seen that the fixed costs represent 21.5% of the total cost. In fact,
the annual electricity output of 219 MWh assumes that the plant is operating with an average
output of 50 kW. If this output were increased to an average of 70 kW, then the fuel cost would
become Rs. 53,65,500, with the result that the fixed costs would drop to 16.37% of the total.
Thus the average unit cost of production decreases as output increases.
The concept of fixed and variable costs can be used to determine the break-even point
for a proposed project. The break-even point can be determined by using the following
equation.
Example 2
If the electricity bought from a utility company costs an average of Rs.4.5/kWh, the break-
even point for the generator described in Example 1, when the average output is 50 kW is
given by:
4.5 x 50 x n = (9,00,000 + 150000) + (3.5 x 50 x n)
n = 21000 hours
If the average output is 70 kW, the break-even point is given by:
4.5 x 70 x n = (9,00,000 + 150000) + (3.50 x 70 x n)
n = 15000 hours
Thus, increasing the average output of the generator significantly reduces the break-even
time for the project. This is because the capital investment (i.e. the generator) is being better
utilised.
(i) Simple interest: If simple interest is applied, then charges are calculated as a fixed per-
centage of the capital that is borrowed. A fixed interest percentage is applied to each year of
the loan and repayments are calculated using the equation.
(ii) Compound interest: Compound interest is usually calculated annually (although this is
not necessarily the case). The interest charged is calculated as a percentage of the outstanding
loan at the end of each time period. It is termed 'compound' because the outstanding loan is
the sum of the unpaid capital and the interest charges up to that point. The value of the total
repayment can be calculated using the equation.
Example 3
A company borrows Rs.3,00,00,00 to finance a new boiler installation. If the interest rate is
10% per annum and the repayment period is 5 years, let us calculate the value of the total
repayment and the monthly repayment value, assuming (i) simple interest and (ii) compound
interest.
Alternatively, the following equation can be used to determine the compound interest repay-
ment value.
It can be seen that by using compound interest, the lender recoups an additional Rs.33,1530.
It is not surprisingly lenders usually charge compound interest on loans.
The annual net cost saving (AS) is the least savings achieved after all the operational costs have
been met. Simple payback period is illustrated in Example 4.
Example 4
A new small cogeneration plant installation is expected to reduce a company's annual energy
bill by Rs.4,86,000. If the capital cost of the new boiler installation is Rs.22,20,000 and the
annual maintenance and operating costs are Rs. 42,000, the expected payback period for the
project can be worked out as.
Solution
• The payback method does not consider savings that are accrued after the payback period
has finished.
• The payback method does not consider the fact that money, which is invested, should
accrue interest as time passes. In simple terms there is a 'time value' component to cash
flows. Thus Rs.1000 today is more valuable than Rs.1000 in 10 years' time.
In order to overcome these weaknesses a number of discounted cash flow techniques have
been developed, which are based on the fact that money invested in a bank will accrue annual
interest. The two most commonly used techniques are the 'net present value' and the 'internal
rate of return' methods.
The value of the sum at the end of year 1 = 22,20,000 + (0.08 x 22,20,000) = Rs.23,97,600
The value of the sum at the end of year 2 = 23,97,600 + (0.08 x 23,97,600) = Rs.25,89,408
The value of the investment would grow as compound interest is added, until after n years
the value of the sum would be:
Example :
The future value of the investment made at present, after 5 years will be:
So in 5 years the initial investment of 22,20,000 will accrue Rs.10,41,908.4 in interest and will
be worth Rs.32,61,908.4. Alternatively, it could equally be said that Rs.32,61908.4 in 5 years
time is worth Rs.22,20,000 now (assuming an annual interest rate of 8%). In other words the
present value of Rs.32,61,908.40 in 5 years time is Rs.22,00,000 now.
The present value of an amount of money at any specified time in the future can be deter-
mined by the following equation.
The net present value method calculates the present value of all the yearly cash flows (i.e.
capital costs and net savings) incurred or accrued throughout the life of a project, and summates
them. Costs are represented as a negative value and savings as a positive value. The sum of all
the present values is known as the net present value (NPV). The higher the net present value,
the more attractive the proposed project.
The present value of a future cash flow can be determined using the equation above.
However, it is common practice to use a discount factor (DF) when calculating present value.
The discount factor is based on an assumed discount rate (i.e. interest rate) and can be deter-
mined by using equation.
DF = (1 + IR/100)–n
The product of a particular cash flow and the discount factor is the present value.
PV = S x DF
The values of various discount factors computed for a range of discount rates (i.e. interest rates)
are shown in Table 11.1. The Example 5 illustrates the process involved in a net present value
analysis.
Example 5
Using the net present value analysis technique, let us evaluate the financial merits of the proposed
projects shown in the Table below. Assume an annual discount rate of 8% for each project.
Project – 1 Project – 2
Capital cost (Rs.) 30 000.00 30 000.00
Year Net annual saving (Rs.) Net annual saving (Rs.)
1 +6 000.00 +6 600.00
2 +6 000.00 +6 600.00
3 +6 000.00 +6 300.00
4 +6 000.00 +6 300.00
5 +6 000.00 +6 000.00
6 +6 000.00 +6 000.00
7 +6 000.00 +5 700.00
8 +6 000.00 +5 700.00
9 +6 000.00 +5 400.00
10 +6 000.00 +5 400.00
Total net saving at +60 000.00 + 60 000.00
end of year 10
Solution
The annual cash flows should be multiplied by the annual discount factors for a rate of 8% to
determine the annual present values, as shown in the Table below:
It can be seen that over a 10 year life-span the net present value for Project 1 is
Rs.10,254.00, while for Project 2 it is Rs.10,867.80. Therefore Project 2 is the preferential
proposal.
The whole credibility of the net present value method depends on a realistic prediction of
future interest rates, which can often be unpredictable. It is prudent therefore to set the discount
rate slightly above the interest rate at which the capital for the project is borrowed. This will
ensure that the overall analysis is slightly pessimistic, thus acting against the inherent uncertain
ties in predicting future savings.
Example 6
A proposed project requires an initial capital investment of Rs.20 000. The cash flows generat-
ed by the project are shown in the table below:
Given the above cash flow data, let us find out the internal rate of return for the project.
Solution
It can clearly be seen that the discount rate which results in the net present value being zero
lies somewhere between 12% and 16%.
For12% discount rate, NPV is positive; for 16% discount rate, NPV is negative. Thus
for some discount rate between 12 and 16 percent, present value benefits are equated to
present value costs. To find the value exactly, one can interpolate between the two rates
as follows:
459.5
Internal rate of return = 0.12 + (0.16 – 0.12) x x 100
(459.5 – (–1508.5))
459.5
Internal rate of return = 0.12 + (0.16 – 0.12) x x 100 = 12.93%
(459.5 + 1508.5)
Thus the internal rate of return for the project is 12.93 %. At first sight both the net present
value and internal rate of return methods look very similar, and in some respects are. Yet there
is an important difference between the two. The net present value method is essentially a com-
parison tool, which enables a number of projects to be compared, while the internal rate of
return method is designed to assess whether or not a single project will achieve a target rate of
return.
Profitability index
Another technique, which can be used to evaluate the financial viability of projects, is the prof-
itability index. The profitability index can be defined as:
Example 7
Determine the profitability index for the projects outlined in Example 5
10254
For Project 1: Profitability index = = 0.342
30,000
10867
For Project 2: Profitability index = = 0.362
30,000
• The capital value of plant and equipment generally depreciates over time
• General inflation reduces the value of savings as time progresses. For example, Rs.1000
saved in 1 year's time will be worth more than Rs.1000 saved in 10 years time.
The capital depreciation of an item of equipment can be considered in terms of its salvage
value at the end of the analysis period. The Example 8 illustrates the point.
Example 8
It is proposed to install a heat recovery equipment in a factory. The capital cost of installing the
equipment is Rs.20,000 and after 5 years its salvage value is Rs.1500. If the savings accrued by
the heat recovery device are as shown below, we have to find out the net present value after
5 years. Discount rate is assumed to be 8%.
Data
Year 1 2 3 4 5
7000 6000 6000 5000 5000
Solution
It is evident that over a 5-year life span the net present value of the project is Rs.4489.50.
Had the salvage value of the equipment not been considered, the net present value of the pro-
ject would have been only Rs.3468.00.
Real value
Inflation can be defined as the rate of increase in the average price of goods and services. In
some countries, inflation is expressed in terms of the retail price index (RPI), which is deter-
mined centrally and reflects average inflation over a range of commodities. Because of infla-
tion, the real value of cash flow decreases with time. The real value of sum of money (S)
realised in n years time can be determined using the equation.
RV = S x (1 + R/100)–n
Where RV is the real value of S realized in n years time. S is the value of cash flow in n
years time and R is the inflation rate (%).
As with the discount factor it is common practice to use an inflation factor when assessing
the impact of inflation on a project. The inflation factor can be determined using the equation.
IF = (1 + R/100)–n
The product of a particular cash flow and inflation factor is the real value of the cash flow.
RV = S x IF
Example 9
Recalculate the net present value of the energy recovery scheme in Example 8, assuming the
discount rate remains at 8% and that the rate of inflation is 5%.
Solution
Because of inflation; Real interest rate = Discount rate – Rate of inflation
Therefore Real interest rate = 8 – 5 = 3%
NPV = +4397.88
The Example 9 shows that when inflation is assumed to be 5%, the net present value of the
project reduces from Rs.4489.50 to Rs.4397.88. This is to be expected, because general infla-
tion will always erode the value of future 'profits' accrued by a project.
QUESTIONS
1. Why fresh investments are needed for energy conservation in industry ?
2. Cost of an heat exchanger is Rs.1.00 lakhs. Calculate simple pay back period consid-
ering annual saving potential of Rs.60,000/- and annual operating cost of
Rs.15,000/-.
3. What is the main draw back of simple pay back method?
4. Calculate simple pay back period for a boiler that cost Rs.75.00 lakhs to purchase
and Rs.5 lakhs per year on an average to operate and maintain and is expected to
save Rs.30 lakhs.
5. What are the advantages of simple pay back method?
6. What do you understand by the term " present value of money"?
7. Define ROI.
8. What is the objective of carrying out sensitivity analysis?
9. You are investing Rs.100 in a bank. The bank gives 10% interest per year for two
years. What is the present value and what is the future value?
REFERENCES
1. Energy Management, Supply and Conservation, Dr. Clive Beggs, .Butterworth
Heinemann
Solar Cooker
Solar cooker is a device, which uses solar energy for cooking, and thus saving fossil fuels, fuel
wood and electrical energy to a large extent. However, it can only supplement the cooking fuel,
and not replace it totally. It is a simple cooking unit, ideal for domestic cooking during most of
the year except during the monsoon season, cloudy days and winter months
Box type solar cookers: The box type solar cookers with a
single reflecting mirror are the most popular in India.
These cookers have proved immensely popular in rural
areas where women spend considerable time for collecting
firewood. A family size solar cooker is sufficient for 4 to
5 members and saves about 3 to 4 cylinders of LPG every
year. The life of this cooker is upto 15 years. This cooker
costs around Rs.1000 after allowing for subsidy. Solar
cookers.(Figure 12.2) are widely available in the market. Figure 12.2 Box Type Solar Collector
Parabolic concentrating solar cooker:
A parabolic solar concentrator comprises of sturdy Fibre
Reinforced Plastic (FRP) shell lined with Stainless Steel
(SS) reflector foil or aluminised polyester film. It can accom-
modate a cooking vessel at its focal point. This cooker is
designed to direct the solar heat to a secondary reflector
inside the kitchen, which focuses the heat to the bottom of a
cooking pot. It is also possible to actually fry, bake and roast
food. This system generates 500 kg of steam, which is
enough to cook two meals for 500 people (see Figure 12.3).
This cooker costs upward of Rs.50,000.
Positioning of solar panels or collectors can greatly
influence the system output, efficiency and payback. Tilting
mechanisms provided to the collectors need to be adjusted
according to seasons (summer and winter) to maximise the
collector efficiency.
The period four to five hours in late morning and early
Figure 12.3 Parabolic Collector
afternoon (between 9 am to 3pm) is commonly called the
"Solar Window". During this time, 80% of the total collectable energy for the day falls on
a solar collector. Therefore, the collector should be free from shade during this solar win-
dow throughout the year - Shading, may arise from buildings or trees to the south of the
location.
Solar Electricity Generation
Solar Photovoltaic (PV): Photovoltaic is the technical
term for solar electric. Photo means "light" and voltaic
means "electric". PV cells are usually made of silicon,
an element that naturally releases electrons when
exposed to light. Amount of electrons released from
silicon cells depend upon intensity of light incident
on it. The silicon cell is covered with a grid of
metal that directs the electrons to flow in a path
to create an electric current. This current is guided
into a wire that is connected to a battery or DC appli-
ance. Typically, one cell produces about 1.5 watts of
power. Individual cells are connected together to form a Figure 12.4 Solar Photovoltaic Array
solar panel or module, capable of producing 3 to 110 Watts power. Panels can be connected
together in series and parallel to make a solar array (see Figure 12.4), which can produce
any amount of Wattage as space will allow. Modules are usually designed to supply
electricity at 12 Volts. PV modules are rated by their peak Watt output at solar noon on a
clear day.
Some applications for PV systems are lighting for commercial buildings, outdoor (street)
lighting (see Figure 12.5),
rural and village lighting
etc. Solar electric power
systems can offer indepen-
dence from the utility grid
and offer protection during
extended power failures.
Solar PV systems are
found to be economical
especially in the hilly and Figure 12.5 Photovoltaic Domestic and Streetlights
far flung areas where con-
ventional grid power supply will be expensive to reach.
Back-up systems are necessary since PV systems only generate electricity when the sun is
shining. The two most common methods of backing up solar electric systems are connecting the
system to the utility grid or storing excess electricity in batteries for use at night or on cloudy
days.
Performance
The performance of a solar cell is measured in terms of its efficiency at converting sunlight into
electricity. Only sunlight of certain energy will work efficiently to create electricity, and much
of it is reflected or absorbed by the material that make up the cell. Because of this, a typical
commercial solar cell has an efficiency of 15%—only about one-sixth of the sunlight striking
the cell generates electricity. Low efficiencies mean that larger arrays are needed, and higher
investment costs. It should be noted that the first solar cells, built in the 1950s, had efficiencies
of less than 4%.
Case Example:
Under the Solar Photovolatic
Water Pumping Programme
of the Ministry of Non-
conventional Energy Sources
during 2000-01 the Punjab
Energy Development Agency
(PEDA) has completed
installation of 500 solar
pumps in Punjab for agricul-
tural uses.
Under this project, 1800
watt PV array was coupled
with a 2 HP DC motor pump Figure 12.6 Photovoltaic Water Pumping
set. The system is capable of
delivering about 140,000 litres water every day from a depth of about 6 – 7 metres. This quan-
tity of water is considered adequate for irrigating about 5 – 8 acres land holding for most of the
crops. Refer Figure 12.6.
The Figure 12.7 illustrates the two types of turbines and typical subsystems for an electric-
ity generation application. The subsystems include a blade or rotor, which converts the energy
in the wind to rotational shaft energy; a drive train, usually including a gearbox and a genera-
tor, a tower that supports the rotor and drive train, and other equipment, including controls, elec-
trical cables, ground support equipment, and interconnection equipment.
Wind Potential
In order for a wind energy system to be feasible there must be an adequate wind supply. A wind
energy system usually requires an average annual wind speed of at least 15 km/h. The following
table represents a guideline of different wind speeds and their potential in producing electricity.
A wind generator will produce lesser power in summer than in winter at the same wind
speed as air has lower density in summer than in winter.
Similarly, a wind generator will produce lesser power in higher altitudes - as air pressure as
well as density is lower -than at lower altitudes.
The wind speed is the most important factor influencing the amount of energy a wind tur-
bine can produce. Increasing wind velocity increases the amount of air passing the rotor, which
increases the output of the wind system.
In order for a wind system to be effective, a relatively consistent wind flow is required.
Obstructions such as trees or hills can interfere with the wind supply to the rotors. To avoid
this, rotors are placed on top of towers to take advantage of the strong winds available
high above the ground. The towers are generally placed 100 metres away from the nearest
obstacle. The middle of the rotor is placed 10 metres above any obstacle that is within
100 metres.
Applications
• Utility interconnected wind turbines generate power which is synchronous with the grid and
are used to reduce utility bills by displacing the utility power used in the household and by
selling the excess power back to the electric company.
• Wind turbines for remote homes (off the grid) generate DC current for battery charging.
• Wind turbines for remote water pumping generate 3 phase AC current suitable for driving
an electrical submersible pump directly. Wind turbines suitable for residential or village
scale wind power range from 500 Watts to 50 kilowatts.
Application
Biogas Plants
Biogas is a clean and efficient fuel, generated from cow-dung,
human waste or any kind of biological materials derived through
anaerobic fermentation process. The biogas consists of 60%
methane with rest mainly carbon-di-oxide. Biogas is a safe fuel
for cooking and lighting. By-product is usable as high-grade
manure.
A typical biogas plant has the following components: A digester in which the slurry (dung
mixed with water) is fermented, an inlet tank - for mixing the feed and letting it into the
digester, gas holder/dome in which the generated gas is collected, outlet tank to remove the
spent slurry, distribution pipeline(s) to transport the gas into the kitchen, and a manure pit,
where the spent slurry is stored.
Biomass fuels account for about one-third of the total fuel used in the country. It is the most
important fuel used in over 90% of the rural households and about 15% of the urban households.
Using only local resources, namely cattle waste and other organic wastes, energy and manure are
derived. Thus the biogas plants are the cheap sources of energy in rural areas. The types of biogas
plant designs popular are: floating drum type, fixed dome-type and bag-type portable digester.
Biomass Briquetting
The process of densifying loose agro-waste into a
solidified biomass of high density, which can be
conveniently used as a fuel, is called Biomass
Briquetting (see Figure 12.8). Briquette is also
termed as "Bio-coal". It is pollution free and eco-
friendly. Some of the agricultural and forestry
residues can be briquetted after suitable pre-treat-
ment. A list of commonly used biomass materials
that can be briquetted are given below:
CornCob, JuteStick, Sawdust, PineNeedle,
Bagasse, CoffeeSpent, Tamarind, CoffeeHusk,
AlmondShell, Groundnutshells, CoirPith, Figure 12.8 Biomass Briquetting
BagaseePith, Barleystraw, Tobaccodust, RiceHusk, Deoiled Bran
Advantages
Some of advantages of biomass briquetting are high calorific value with low ash content,
absence of polluting gases like sulphur, phosphorus fumes and fly ash- which eliminate the need
for pollution control equipment, complete combustion, ease of handling, transportation & stor-
age - because of uniform size and convenient lengths.
Application
Biomass briquettes can replace almost all conventional fuels like coal, firewood and lignite in
almost all general applications like heating, steam generation etc. It can be used directly as fuel
instead of coal in the traditional chulhas and furnaces or in the gasifier. Gasifier converts solid
fuel into a more convenient-to-use gaseous form of fuel called producer gas.
Biomass Gasifiers
Biomass gasifiers (see Figure 12.9) convert the
solid biomass (basically wood waste, agricul-
tural residues etc.) into a combustible gas mix-
ture normally called as producer gas. The con-
version efficiency of the gasification process is
in the range of 60%–70%. The producer gas
consists of mainly carbon-monoxide, hydro-
gen, nitrogen gas and methane, and has a lower
calorific value (1000–1200 kcal/Nm3). Figure 12.9 Biomass Gasifiers
Gasification of biomass and using it in place of conventional direct burning devices will
result in savings of atleast 50% in fuel consumption. The gas has been found suitable for com-
bustion in the internal combustion engines for the production of power.
Applications:
Water pumping and Electricity generation: Using biomass gas, it possible to operate a diesel
engine on dual fuel mode-part diesel and part biomass gas. Diesel substitution of the order of
75 to 80% can be obtained at nominal loads. The mechanical energy thus derived can be used
either for energizing a water pump set for irrigational purpose or for coupling with an alterna-
tor for electrical power generation - 3.5 KW - 10 MW
Heat generation: A few of the devices, to which gasifier could be retrofitted, are dryers- for
drying tea, flower, spices, kilns for baking tiles or potteries, furnaces for melting non-ferrous
metals, boilers for process steam, etc.
Direct combustion of biomass has been recognized as an important route for generation of
power by utilization of vast amounts of agricultural residues, agro-industrial residues and for-
est wastes. Gasifiers can be used for power generation and available up to a capacity 500 kW.
The Government of India through MNES and IREDA is implementing power-generating sys-
tem based on biomass combustion as well as biomass gasification
Bio fuels
Unlike other renewable energy sources, biomass can be converted
directly into liquid fuels— biofuels— for our transportation needs
(cars, trucks, buses, airplanes, and trains). The two most common
types of biofuels are ethanol and biodiesel. See Figure 12.10.
Ethanol is an alcohol, similar to that used in beer and wine. It
is made by fermenting any biomass high in carbohydrates (starch-
es, sugars, or celluloses) through a process similar to brewing beer.
Ethanol is mostly used as a fuel additive to cut down a vehicle's
carbon monoxide and other smog-causing emissions. Flexible-fuel
Figure 12.10 Biodiesel
vehicles, which run on mixtures of gasoline and up to 85% Driven Bus
ethanol, are now available.
Biodiesel, produced by plants such as rapeseed (canola), sunflowers and soybeans, can be
extracted and refined into fuel, which can be burned in diesel engines and buses. Biodiesel can
also made by combining alcohol with vegetable oil, or recycled cooking greases. It can be used
as an additive to reduce vehicle emissions (typically 20%) or in its pure form as a renewable
alternative fuel for diesel engines.
Biopower
Biopower, or biomass power, is the use of biomass to generate electricity. There are six
major types of biopower systems: direct-fired, cofiring, gasification, anaerobic digestion,
pyrolysis, and small - modular.
Most of the biopower plants in the world use direct-fired systems. They burn bioenergy
feedstocks directly in boiler to produce steam. This steam drives the turbo-generator. In some
industries, the steam is also used in manufacturing processes or to heat buildings. These are
known as combined heat and power facilities. For example, wood waste is often used to pro-
duce both electricity and steam at paper mills.
Many coal-fired power plants use cofiring systems to significantly reduce emissions, espe-
cially sulfur dioxide emissions. Cofiring involves using bio energy feedstock as a supplemen-
tary fuel source in high efficiency boilers.
Gasification systems use high temperatures and an oxygen-starved environment to convert
biomass into a gas (a mixture of hydrogen, carbon monoxide, and methane). The gas fuels a gas
turbine, which runs an electric generator for producing power.
The decay of biomass produces methane gas, which can be used as an energy source.
Methane can be produced from biomass through a process called anaerobic digestion.
Anaerobic digestion involves using bacteria to decompose organic matter in the absence of oxy-
gen. In landfills -scientific waste disposal site - wells can be drilled to release the methane from
the decaying organic matter. The pipes from each well carry the gas to a central point where it
is filtered and cleaned before burning. Methane can be used as an energy source in many ways.
Most facilities burn it in a boiler to produce steam for electricity generation or for industrial
processes. Two new ways include the use of microturbines and fuel cells. Microturbines have
outputs of 25 to 500 kilowatts. About the size of a refrigerator, they can be used where there are
space limitations for power production. Methane can also be used as the "fuel" in a fuel cell.
Fuel cells work much like batteries, but never need recharging, producing electricity as long as
there is fuel.
In addition to gas, liquid fuels can be produced from biomass through a process called
pyrolysis. Pyrolysis occurs when biomass is heated in the absence of oxygen. The biomass then
turns into liquid called pyrolysis oil, which can be burned like petroleum to generate electrici-
ty. A biopower system that uses pyrolysis oil is being commercialized.
Several biopower technologies can be used in small, modular systems. A small, modular
system generates electricity at a capacity of 5 megawatts or less. This system is designed
for use at the small town level or even at the consumer level. For example, some farmers
use the waste from their livestock to provide their farms with electricity. Not only do
these systems provide renewable energy, they also help farmers meet environmental
regulations.
Biomass Cogeneration
Cogeneration improves viability and profitability of sugar industries. Indian sugar mills are
rapidly turning to bagasse, the leftover of cane after it is crushed and its juice extracted, to gen-
erate electricity. This is mainly being done to clean up the environment, cut down power costs
and earn additional revenue. According to current estimates, about 3500 MW of power can be
generated from bagasse in the existing 430 sugar mills in the country. Around 270 MW of
power has already been commissioned and more is under construction.
Small Hydro
Small Hydro Power is a reliable, mature and proven technology. It
is non-polluting, and does not involve setting up of large dams or
problems of deforestation, submergence and rehabilitation. India
has an estimated potential of 10,000 MW
Micro Hydel
Hilly regions of India, particularly the Himalayan belts, are endowed with
rich hydel resources with tremendous potential. The MNES has launched
a promotional scheme for portable micro hydel sets for these areas. These
sets are small, compact and light weight. They have almost zero mainte-
nance cost and can provide electricity/power to small cluster of villages.
They are ideal substitutes for diesel sets run in those areas at high genera-
tion cost.
Micro (upto 100kW) mini hydro (101-1000 kW) schemes can
provide power for farms, hotels, schools and rural communities, and help create local
industry.
Ocean Energy
Oceans cover more than 70% of Earth's surface, making them the world's largest solar collec-
tors. Ocean energy draws on the energy of ocean waves, tides, or on the thermal energy (heat)
stored in the ocean. The sun warms the surface water a lot more than the deep ocean water, and
this temperature difference stores thermal energy.
The ocean contains two types of energy: thermal energy from the sun's heat, and mechan-
ical energy from the tides and waves.
Ocean thermal energy is used for many applications, including electricity generation. There
are three types of electricity conversion systems: closed-cycle, open cycle, and hybrid. Closed
cycle systems use the ocean's warm surface water to vaporize a working fluid, which has a low
boiling point, such as ammonia. The vapour expands and turns a turbine. The turbine then acti-
vates a generator to produce electricity. Open-cycle systems actually boil the seawater by oper-
ating at low pressures. This produces steam that passes through a turbine / generator. The hybrid
systems combine both closed-cycle and open-cycle systems.
Ocean mechanical energy is quite different from ocean thermal energy. Even though
the sun affects all ocean activity, tides are driven primarily by the gravitational pull of the
moon, and waves are driven primarily by the winds. A barrage (dam) is typically used
to convert tidal energy into electricity by forcing the water through turbines, activating a
generator.
India has the World's largest programmes for renewable energy. Several renewable energy
technologies have been developed and deployed in villages and cities of India. A Ministry of
Non-Conventional Energy Sources (MNES) created in 1992 for all matters relating to Non-
Conventional / Renewable Energy. Government of India also created Renewable Energy
Development Agency Limited (IREDA) to assist and provide financial assistance in the form
of subsidy and low interest loan for renewable energy projects.
IREDA covers a wide spectrum of financing activities including those that are connected to
energy conservation and energy efficiency. At present, IREDA's lending is mainly in the fol-
lowing areas: -
• Solar energy technologies, utilization of solar thermal and solar photo voltaic systems
• Wind energy setting up grid connected Wind farm projects
• Small hydro setting up small, mini and micro hydel projects
• Bio-energy technologies, biomass based co-generation projects, biomass gasification, ener-
gy from waste and briquetting projects
• Hybrid systems
• Energy efficiency and conservation
The estimated potential of various Renewable Energy technologies in India by IREDA are
given below.
QUESTIONS
1 What do you mean by renewable energy
2 Why is solar energy potential high in India?
3. Explain working of solar water heater?
4. List few applications of low temperature water heaters in domestic and industrial use
5. What are the two methods by which energy can be recovered from solar radiation
6. How can the performance of solar collectors be improved?
7. Explain any two applications of concentrated solar energy?
8. What do you mean by photovoltaic?
9. Explain the terms cell, module and array as applicable to photovoltaic.
10. What are the typical applications of photovoltaic power?
11. Name the few states with high wind energy potential in India.
12. What are the criteria for selection of wind mill installation?
13. What ere the incentives available for wind mill installation?
14. Explain the bio-energy potential in India and its applications.
15. What are the various methods by which power can be generated from biomass?
16. What is the role of IREDA in renewable energy sector
17. India has recorded good growth in wind energy sector. Do you agree? What are the
factors responsible for such a high growth?
REFERENCES
1. Alternate Energy Sources by T H Taylor.Adam Hilger Ltd, Bristol
2. Renewable Energy Sources for rural areas in Asia and Pacific, APO, Tokyo, 2000
3. www.ireda.org
4. www.windenergy.com
13.1 Introduction
Traditionally, waste is viewed as an unnecessary element arising from the activities of any
industry. In reality, waste is a misplaced resource, existing at a wrong place at a wrong time.
Waste is also the inefficient use of utilities such as electricity, water, and fuel, which are
often considered unavoidable overheads. The costs of these wastes are generally underestimat-
ed by managers. It is important to realise that the cost of waste is not only the cost of waste dis-
posal, but also other costs such as:
Disposal cost
Inefficient energy use cost
Purchase cost of wasted raw material
Production cost for the waste material
Management time spent on waste material
Lost revenue for what could have been a product instead of waste
Potential liabilities due to waste.
What is waste minimisation?
Waste minimisation can be defined as "systematically reducing waste at source". It means:
• Prevention and/or reduction of waste generated
• Efficient use of raw materials and packaging
• Efficient use of fuel, electricity and water
• Improving the quality of waste generated to facilitate recycling and/or reduce hazard
• Encouraging re-use, recycling and recovery.
Waste minimisation is also known by other terms such as waste reduction, pollution preven-
tion, source reduction and cleaner technology. It makes use of managerial and/or technical inter-
ventions to make industrial operations inherently pollution free
It should be also clearly understood that waste minimization, however attractive, is not a
panacea for all environmental problems and may have to be supported by conventional treat-
ment/disposal solutions.
Waste minimization is best practiced by reducing the generation of waste at the source itself.
After exhausting the source reduction opportunities, attempts should be made to recycle the
Wastes Resources
Fly ash from power plant Raw material for cement or brick
manufacture
Bagasse wastes from sugar manufacture Fuel for boiler
CO2 release from ammonia plant Raw material for Urea manufacture
Source Reduction
Under this category, four techniques of WM are briefly discussed below:
a) Good Housekeeping- Systems to prevent leakages & spillages through preventive main-
tenance schedules and routine equipment inspections. Also, well-written working instructions,
supervision, awareness and regular training of workforce would facilitate good housekeeping.
c) Recycling
i) On-site Recovery and Reuse - Reuse of wasted materials in the same process or
for another useful application within the industry.
d) Product Modification
Characteristics of the product can be modified to minimise the environmental impacts
of its production or those of the product itself during or after its use (disposal).
It is not advisable to spent more time and money to make a perfect material balance. Even
a rough / preliminary material balance throws open Waste Minimization opportunities which
can be profitably exploited.
On the other hand, the precision of analytical data and flow measurements is important as
it is not possible to obtain a reliable estimate of the waste stream by subtracting the materials
in the product from those in the raw materials. In such cases, a direct monitoring and analysis
of waste streams should be carried out.
Based on this, for each waste stream, total cost per unit of waste (Rs/KL or Rs/Kg)
should be worked out. This figure would be useful in working out the feasibility of the waste
minimization measures. The result can also be used to categorize the waste streams for
priority action.
Review of Process
Through the material and energy balances, it is possible to carry out a cause analysis to locate
and pinpoint the causes of waste generation. These causes would subsequently become the tools
for evolving Waste Minisation measures. There could be a wide variety of causes for waste
generation ranging from simple lapses of housekeeping to complex technological reasons as
indicated below.
Poor layout
Bad technology
Employee Demotivation
Lack of recognition
Absence of reward
Emphasis only on production, not on people
Lack of commitment and attention by top management
The selection of a Waste Minimization solution for implementation requires that it should not
only be techno-economically viable, but also environmentally desirable.
Availability of equipment
Availability of operating skills
Space availability
Effect on production
Effect on product quality
Safety aspects
Maintenance requirements
Effect on operational flexibility
Shut down requirements for implementation
The work done so far should be documented. Apart from becoming a reference document
for seeking approvals in implementation, the document would also be useful in obtaining
finances from external finance institutions, reporting status to other agencies, and establishing
base levels for performance evaluation and review.
Implement Solutions
The task comprises layout and drawing preparation equipment fabrication / procurement, trans-
portation to site, installation and commissioning. Whenever required, simultaneous training of
manpower should be taken up as many excellent measures have failed miserably because of
non-availability of adequately trained people.
The biggest challenges in Waste Minimization lies in sustaining Waste Minimization. The
enthusiasm of the Waste Minimization team wanes off with time. Such tragic ends should be
avoided. Backing out from commitment, predominance of production at any cost, absence of
rewards and appreciation, and shifting of priorities are some of the commonly encountered rea-
sons, which one should check and avoid.
Also monitoring and review of the implemented measures should be communicated to all
employees in the industry so that it fans the desires for minimizing wastes. Involvement of as
large a number of employees as possible and rewarding the deserving ones, will help long term
sustenance of Waste Minimization.
Having implemented Waste Minimization solutions in the area under study, the Waste
Minimization team should go back to Step-2 i.e. analysing the process steps and identifying
and selecting the next wasteful area. In this way, the cycle continues, till all the steps are
exhausted.
In a nutshell, a philosophy of minimizing waste must be developed within the compa-
ny. This means that Waste Minimization should become an integral part of company's
activities. All successful Waste Minimization programmes, till date, have been founded on
this philosophy.
QUESTIONS
1. Explain the concept of waste minimization with suitable examples.
2. "Waste is a misplaced resource" Explain.
3. What are the 3R's in waste minimization techniques?
4. Which would you prefer between recycling and source reduction? Justify.
5. List down few housekeeping measures by which wastes can be reduced.
6. Explain how modifying a product can help minimize the wastes with few examples.
7. For a coal-fired boiler, draw a block diagram and indicate various material and ener-
gy inputs, outputs and wastes.
8. Can employee be a factor in reducing wastes? Explain.
REFERENCES
1. From Waste to Profits, Guidelines for Waste Minimization by National Productivity
Council, New Delhi
2. Waste Minimization Manual for Textile Processing by National Productivity Council,
Chennai.