technologist | 10 May, 2008, 23:15 |
Energy | (6 Reads)
Fuel for energy is generated by the nature. For example, C1 (carbon in the form of CO2) is naturally synthesizes (photosynthesis in presence of natural UV radiation) to molecule Cn (like starch, sugar or cellulose), which are used directly /or indirectly as fuel/ or feed stocks for fuel generation. Consumption of available fuels higher than generation is creating not only fuel shortage but also leaving behind bad consequences to the environment due to exhausted excess carbon dioxide.
Being desired transformations can’t be avoided in the process industries, higher energy wastages in them demands higher input energy. How energy is wasted in the process industry? To understand it, consider following cases:
- Doing more, thus wasting more
- Doing more, but using less
- Wasting more, thus doing more
Doing more, thus wasting more For example, pump filling overhead constant level tank at higher flow rate than required, thus subsequently overflowing excess amount of liquid to ground tank. Being pump is operating at much higher capacity than required, excess energy is wasted.
Doing more, but using less For example, use of higher capacity conveyor for small amount of material transportation. Underutilization of material conveyor wastes more energy for unit production rate.
Wasting more, thus doing more For example, high number of pipe fittings used in the pipe routing leads to high fluid energy wastage in terms of frictional pressure drop, thus more work is to be done by the pump.
Right amount of energy for desired transformations is the ultimate aim of energy conservation. Reduction in energy wastage to minimum reduces the energy demands in the process plants. Following steps for energy conservations are discussed here:
- Good Housekeeping
- Optimization of Plant Operation
- Hardware Modification or Replacement
- Process Modification
Good Housekeeping This is foremost simple step, which any process industry can easily adopt. Arresting steam leakages, stopping idle operating pumps or mixing agitators, etc. are the typical examples falls under this category. Being the simple steps, it absolutely doesn’t require any financial investment and can be implemented at any time. It requires only the energy conscious culture in the process industry. This step itself can save ~5% in energy bills of the industry.
Simply organizations need culture where everyone from shop floor to top management feels himself involved in the process.
Optimization of Plant Operation Excess capacity, provided by the plant designer as safety margin, of the plant hardware provides the scope of using it during actual plant operation. Thus, process plant hardware need to be tuned for energy efficient operation. Liquid transportation with maximum flow capacity of the pump, minimizing reflux ratio for distillation column, etc. are the well known examples for process plant optimization. The optimization exercise require either no or minor financial investment. Though some operational time may be consumed for setting rightful optimum parameters, but often results attained are very positive as far as energy saving is concerned.
Hardware Modification or Replacement Reduced efficiency of existing hardware e.g. scaled or blocked heat exchanger tubes, entry of innovative energy efficient devices in the market like high efficiency distillation column packing, poor selection of hardware at the time of first purchase e.g. lower pipeline size, etc. demands much higher input energy than actually required for desired transformation. Necessary hardware modification or replacement conserves energy in the process plant. Unlike previous two categories, it requires low to medium level financial investment along with process plant stoppage for changeover of the troubling hardware.
Process Modification Many times overall or part of the process is modified for the sake of overall energy savings. Process routes as well as transformation steps are altered to minimize input energy supplies. It requires extensive studies at various levels starting from paperwork to laboratory, pilot plant & semi-commercial levels. Usually such process modifications require high investments as well as higher implementation time for gaining energy benefits. But they are essential at a stage when business need improvement due to tough market competition. Read More......
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technologist | 24 Jan, 2008, 04:48 |
Energy | (191 Reads)
Power transmission equipment e.g. gears or couplings are the most neglected areas where nobody (including good energy auditors also) focuses for energy saving opportunities.
However, a certain approach or simple steps can improve their efficiency by at least 2% which may result in total annual cost saving in power bill by more than 6%. Read More....
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technologist | 25 Dec, 2007, 01:43 |
Energy | (889 Reads)
A building or room gains heat from many sources. Inside occupants, computers, copiers, machinery, and lighting all produce heat. Warm air from outside enters through open doors and windows, or as ‘leakage’ though the structure. However the biggest source of heat is solar radiation from the sun, beating down on the roof and walls, and pouring through the windows, heating internal surfaces. The sum of all these heat sources is know as the heat gain (or heat load) of the building, and is expressed either in BTU (British Thermal Units) or kW (Kilowatts). For an air conditioner to cool a room or building its output must be greater than the heat gain. It is important before purchasing an air conditioner that a heat load calculation is performed to ensure it is big enough for the intended application. Read More....
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technologist | 21 Dec, 2007, 05:08 |
Energy | (246 Reads)
Many of you, especially who are handling projects engineering, may be surprised when & why should I consider bypass for pumps. What is the utility for considering bypasses? Why not only relief valves are sufficient for safeguard against high pressure in the line? The list may be little longer than my expectation…. Here are few things to remember…. Read More.....
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technologist | 13 Oct, 2007, 00:15 |
Energy | (314 Reads)
When multiple pumps operate continuously as part of a parallel pumping system, there can be opportunities for significant energy savings. For example, lead and spare (or lag) pumps are frequently operated together when a single pump could meet process flow rate requirements. This can result from a common misconception—that operating two identical pumps in parallel doubles the flow rate.
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technologist | 12 Oct, 2007, 23:36 |
Energy | (261 Reads)
GE Oil & Gas has received GE ecomagination certification for hot gas expander technology that works with a waste gas recovery system to help refineries significantly reduce their energy costs while also lowering emissions.
The hot gas expander for GE’s Power Recovery Air Train features GE’s latest technology and meets the rigid standards of ecomagination, the GE corporate initiative to address challenges such as the need for cleaner, more efficient sources of energy, reduced emissions and abundant sources of clean water. Read More.....
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technologist | 25 Sep, 2007, 02:36 |
Energy | (587 Reads)
From an energy efficiency perspective, roof technology has not progressed substantially in hundreds of years, but that is changing with the use of active thermal mass components, reflective pigments and coatings, subventing, radiant barriers and other novel techniques being tested by a team led by Bill Miller and Jan Kosny of ORNL's Building Envelopes group. Their prototype roof and attic system works by reducing attic temperatures by about 22 degrees Fahrenheit during a typical summer afternoon and decreasing the amount of heat that gets transferred through the attic floor to the living space. Read More...
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technologist | 01 Aug, 2007, 21:00 |
Energy | (314 Reads)
Are they right for you? Compressors that run on frictionless bearings are an enticing prospect. Dan Foss Turbocor, Inc. is now marketing a line of compressors that use magnetic bearings to provide essentially frictionless operation. These compressors have been on the market for about three years, and now McQuay International is incorporating the compressors into their new line of frictionless chillers. Using innovative technology that levitates the compressor shaft in a magnetic field, the compressors operate without metal-to-metal contact, making them more efficient, and eliminating the need for an oil management system. Turbocor has recently received three prestigious awards for this design: the ASHRAE/AHR Expo "Energy Innovation" Award in 2003, the Natural Resources Canada's Energy Efficiency Award in 2003, and the U.S. Environmental Protection Agency’s Climate Protection Award in 2004. How are they different?Here are some of the features, benefits, and concerns to help you decide whether frictionless compressors (or McQuay’s frictionless chillers) are right for you. Each feature is discussed in more detail below. Read More...
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technologist | 26 Jul, 2007, 05:17 |
Energy | (390 Reads)
This is with reference to my previous log on this topic. BackgroundAlcohol is stored in conventional storage tanks at site, which are non-insulated & low pressure fixed roof tanks. In this kind of storage system, there are three different types of losses of stored liquid. 1. WORKING LOSS Losses due to displacement of inner air space during filling & evacuation. The material is lost each time during filling while fresh air intake results in additional evaporation inside the tank to maintain its partial pressure of liquid in vapor space. 2. BREATHING LOSS Losses due to contraction and expansion of vapor space due to variation in day – night temperature. This also causes similar effect as explained above in item 1. 3. LOSSES DUE TO HEAT GAIN Due to difference in ambient temperature & bulk liquid temperature, the material stored gets energy input through radiative & convective heat transfer from atmosphere. This is significant energy gain by the system compared to other two losses explained above. Read More...
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technologist | 26 Jul, 2007, 05:13 |
Energy | (343 Reads)
Here is my experience based on energy audits of pumping systems in various chemical, metal, textile & petrochemical units. Design systems with lower capacity and total head. Do not assume these requirements are fixed. Calculate flow requirement based on actual mathematical nos without margins in each stage & then add 10-20% straightforward as Normal capacity of the pump. For example if process side heat load in an exchanger is based on normal flow of say 100 M3/hr then do not consider cooling water requirement for peak condition of 120 or say 140 M3/hr. Just calculate it based on normal flow of 100 M3/hr at this stage. Total head requirements can be reduced by: lowering process static gage, pressure, minimizing elevation rise from suction tank to discharge tank, reducing static elevation change by use of siphons, lowering spray nozzle velocities, lowering friction losses through use of larger pipes and low-loss fittings, and eliminating throttle valves. Read More...
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technologist | 06 Jul, 2007, 23:23 |
Energy | (208 Reads)
Perfect tips for the Summer!
Cooling costs can chill your budget in the peak summer months। Here are few tips for chilling out without going broke:
Block out the sun. Using shades and blinds to block sunlight minimizes the amount of energy needed to cool your house. It's also worth noting that dark-colored exterior walls and roof tops can absorb up to 90% of the sun's radiant energy. To keep things cool, try painting your house a brighter color.
Read More......
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technologist | 05 Jul, 2007, 23:22 |
Energy | (157 Reads)
According to Philips Lighting a standard incandescent light bulb costs around €1, and uses €15-worth of electricity a year. A low-energy one costs €5-6 and uses €3-worth. The payback on investing in a compact fluorescent bulb, therefore, is less than a year. Yet low-energy lighting makes up only 30% of Philips's sales. Read More.....
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technologist | 05 Jul, 2007, 01:29 |
Energy | (366 Reads)
Compressed air is an essential part of any manufacturing / processing setup. It is treated as a simple air system without much attention to it, which finally appears as a slow eater of your profit & bottomline.
Compressed air is often overlooked in energy studies also even by experienced energy auditors because many people do not fully understand compressed air equipment, their own system, or what it costs to produce compressed air power. Here is a pie chart representing various cost areas. Some Facts For those who are willing to take a look, and utilize golden opportunity for saving, For More....
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technologist | 04 Jul, 2007, 01:12 |
Energy | (171 Reads)
In many cases you can use lower wattage bulbs and get same amount of light. Look for lumens on the bulb (CFL) & not for watts. Lumen indicates the brightness while power indicates eenrgy required to illuminate the area. Always plan bulb location in such a way that the light is not hindered by any other room fixture. White light is more comfortable than any other light for reading & day to day use. So should consider it in studies, drawing room etc. Other types can be considered for infrequently used areas e.g. toilet, bathroom etc.
Read More........
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technologist | 04 Jul, 2007, 01:09 |
Energy | (176 Reads)
Tips in Day to Day Life Refrigeration / Air Conditioning
"Hibernate or turn off computer while not in use". - Submitted by user 'Almk'. Select proper size AC based on room size, family members, wall & window area etc. Keep your refrigerator & freezers filled to capacity without restricting air circulation. Regularly clean the condenser parts of your refrigerator & AC both to have better efficiency without loosing energy.
Read More........
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technologist | 02 Jul, 2007, 01:16 |
Energy | (200 Reads)
The actual performance of any chemical process plant can be measured by only two terms, energy consumption level and on-stream/reliability factor. These are the two overall indicators of the plant performance out of which reliability factor also contributes to the energy consumption level. Hence, it becomes inevitable in an energy intensive unit like fertilizer industry, to keep a close look on this aspect of plant performance. This in turn will affect the productivity and profitability. The expected annual energy consumption in ammonia production is of the order of 108 gigacalories in India alone that is equivalent to ~11 to 12000 MSm3 of Natural Gas or around 10 million tons of naphtha. Hence, it is most likely today to focus on proper analysis of bottlenecks & deficiencies in an existing plant while absolute analysis of technology at grass root level is also crucial with great care in its selection.
This study has been divided in four major parts, the overall loss structure, brief analysis of sectionwise losses & their remedies, losses through cooling water, and finally the role of catalysts in overall energy efficiency of the plant.
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