Energy Efficiency Case Studies in Industry

Shashibhushan Subhash Agrawal, BE(MECH), Chartered Engineer (BEE Certified Energy Auidtor EA-1090)
Email :- shashi@charteredvaluer.com; Mobile Number :- 09422161638
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Innovative Technologies Implemented / Under Active Implement ation for Energy Conservation During 2010-2012 Innovative Technology 1 :- Replacement of Asynchronous Frequency
Converter with Variable Frequency Drive.
Measure Heading = Replacement of Rotating Type Asynchronous Frequency Converter with Variable Frequency Drive (VFD) Energy Saving by Replacing Rotating Type Asynchronous Frequency Converter (NC type) (Slip ring Motor based driven by squirrel cage induction motor) for Ball pen tip making (PM20) machine with VFD.
Brief Details of Measure
Brief Details of Existing System
Currently a synchronous Rotating Type (slip ring type) converter of 2.5 kVA output capacity provided.
Specification of Existing Rating of Rotating Asynchronous Rotating Frequency Converter is as given below
Address :- AEEE Consultancy Services, 'Kapil' Building, Opposite Dr. Naik's X-ray Clinic, New Bhagwat Plots, Akola (Maharashtra) 444005; Web Site : www.aeeec.com
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Input to Asynchronous Converter Voltage 220/380 Volts Amps 4.2/2.4 Amp Hz 50 Hz
Kva Volts Amps Hz
Output Required by Load 2.5 125/94/79/39 11.6 Amp 400/300/225/125
Other Parameters for Driving Motor :Cos 0.8
RPM
1470/2890
The asynchronous frequency converter is an electric rotating machine consisting of an asynchronous motor with cage rotor and by an asynchronous generator with wound rotor co-axial coupled. Converts transform the electric energy at mains frequency in energy with higher frequency and they used to feed high frequency motors. In NC series converter, the excitation is supplied on generator stator terminals and output voltage at the desired higher frequency on slip ring terminals. The energy balance will be as given below If going by claims of Manufacturer under normal & Ideal condition is as given belowIn Asynchronous rotating frequency converter the energy loss as specified by manufacturer is 25% of output power of 2.5 kVA. Thus total loss of rotating type converter is 0.625 kw against 6% loss of VFD of same rating i.e 0.15 kW. Thus saving of 0.475 kw per converter. During actual field results the actual saving achieved is 0.7 to 0.9 kW per converter due to variable actual loading, lower efficiency of existing system on account of rewinding, maintenance issue etc. (Feedback with trial details from client attached) After successful trial of the retrofit, it is replicated for other 22 machines and considerable savings in electricity achieved. Special Remark about the measure :- The retrofit of VFD is not for usual reason. I hope the measure will help lot of other industries utilizing rotating asynchronous frequency converter to rethink on entire energy consumption and may help to save lot of energy. Name & Address of Industry where Implementation :- One Engineering Industry in Gujarat. Current Status :- Implemented in Majority of similar machines (about 22 nos). Working successfully.
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Innovative Technology 2 :-Low Loss & Compact (Phase Change

Material Based) Thermal Storage System in place of Higher Loss, Bulky Thermal Storage System (Ice Bank) in Dairy Industry.
Measure Heading = Low Loss & Compact (Phase Change Material Based) Thermal Storage System in place of Higher Loss, Bulky Thermal Storage System (Ice Bank) in Dairy Industry. Existing Thermal Storage System used by Dairy industry have higher thermal losses & is Bulky. The same can be replaced by compact phase change material (PCM) based thermal storage system to save energy on four counts i.e. Thermal loss minimization, avoiding heat induced by mechanical stirrer in existing thermal storage system, better working load condition for compressor & by TOD benefits.
Brief Details of Measure
Brief Details of Existing System
The existing thermal storage system in dairy industry is, conventional IBT (Ice Bank Tank) System is provided in all the milk chilling center and dairies. The conventional IBT Tank is civil constructed tank provided with all civil constructed wall (except bottom side) thermal insulation. While top face of tank is open and covered by wooden planks supported on MS angle fabricated support structure. The IBT tank is not air tight and top portion of tank covered with wooden planks have many gaps and thin spaces where out side atmospheric air comes directly in the contact of chilled water inside the IBT Tank. These leakages are one of the major components of loss of IBT tank. Individual standing on top of IBT tank feels the air conditioning effect in surrounding. Mechanical stirrers (agitator) are provided (one in each section of IBT tank) for creating forced circulation inside IBT tank for uniform cooling of water inside IBT Tank. These stirrers also induce heat inside the IBT tank proportional to BHP of shaft of stirrer at motor end.
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The existing thermal storage system is resulting in considerable thermal energy loss & thus loss of electrical energy. Proposed Low Loss & Compact (Phase Change Material Based) Thermal Storage System is as mentioned belowThe Proposed Low loss compact thermal Storage System is composed of a tank filled with "nodules". The tank has upper manholes to allow the filling with nodules. A lower manhole allows emptying. Inside the tank two diffusers (inlet and outlet) spread the heat transfer fluid along the tank. The pressure drop through the tank is 2.5 mWG.
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The inlet in charge mode must be via the lower diffuser in order to ensure the natural stratification. The tanks are manufactured in black steel (test pressure between 4.5 to 10 bar), are delivered empty and positioned on site or, if the access to site is impossible, constructed on site. The nodules are spherical with a diameter of 77 mm, 78 mm or 98 mm (depending on the nodule type). The nodules contain the Phase Change Material (PCM). The mechanical and chemical characteristics of the nodule shell (manufactured in polyolefin) are well adapted to the conditions encountered in Air Conditioning or Refrigeration systems. Once filled with PCM the nodule plugs are sealed by ultrasonics to ensure perfect water tightness.The nodules are delivered in 22 kg bags. Tanks are filled on site. The filling is regular and homogeneous. A standard globule filling procedures are followed. The tank shape is usually cylindrical in order to withstand service pressure higher than 3 bar. The test pressure varies between 4.5 to 10 bar. The spherical shape allows an easy filling.The nodule diameter has been calculated to meet economical and technical requirements. The size allows high exchanges until the end of the cycle.
Special Remark about the measure :- The retrofit of Low Loss & Compact (Phase Change Material Based) Thermal Storage System not only saves energy, the space required is lesser as compared to conventional one. Name & Address of Industry where Implementation :- Under Active Implementation in Dairy Industries. Current Status :- The measure under active implementation in one of the Dairy Cluster
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Innovative Technology 3 :-Integrating MCDT (Machine Conditioning &

Diagnostic Techniques) as Integral Part of Energy Audit to save Energy
Measure Heading Utilization of MCDT (Machine Conditioning & Diagnostic Techniques) for Energy Conservation. Brief Details of Measure = Utilization of MCDT (Machine Conditioning & Diagnostic Techniques) like Thermal Imaging for Thermal insulation survey, steam trap survey, phase imbalance study to save energy. Integrating the MCDT Techniques in regular energy audit will result in substantial energy savings. Areas of Energy Audit = 1) Thermal Insulation Survey to detect latent thermal where Thermal Imaging leakages. can be useful 2) Thermal leakages in Air condition system. 3) Steam Trap Survey. 4) Waste Heat Recovery opportunity exploration. 5) Misalignments and related problems detection. I received special training for MCDT from JICA Japan under "Energy Conservation Techniques for India". Post training, I purchased thermal imaging camera (FLIR E-50) for integrating MCDT with energy conservation. Thermal Imaging is Integral Part of all my current energy Audits. Electrical System Imbalance Detection :=
Steam Trap Survey Using Thermal Imaging :-
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Thermal Insulation Leak Detection :-
Special Remark about the measure :- MCDT and in particular Thermal Imaging is integral part of all energy audits for both electrical & thermal system. The results are satisfactory one. In my opinion no energy audit in future will be completed without thermal imaging. Name & Address of Industry where Implementation :- Many Industries where we have carried energy audit have implemented findings of Thermal Imaging for energy savings. Current Status :- The energy saving measures related to thermal imaging are already successfully implemented by many clients.
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Innovative Technology 4 :- GPRS operated, cloud computing based

Street Light operation SCADA System.
Measure Heading Brief Details of Measure = GPRS operated, cloud computing based Street Light operation SCADA System. = SCADA system operating with Microprocessor base timer (operating based on location such as longitude, latitude), with late night staggering feature, GPRS Based data acquisition system provided for Akola Municipal Corporation. = GPRS Based data acquisition system with data storage in cloud is unique feature of system. The system was conceptualized by me and currently working in many feeders at Akola Municipal Corporation Street Lighting system.
Brief Details of System
The advantages of GPRS based SCADA with data storage in clod are enormous. Multi users can access data from various locations, even using mobile applications. The microprocessor based timer working on exact location of system, results in energy saving, operation of street light based on sun set & sun rise timing. The total operations becomes based on "Day of Year". Also features such as staggering (late night hours & avoiding dark spots) result in additional energy saving. With dimming enabled system, dimming in late hours results in additional energy saving. The project is under implementation at Akola Municipal Corporation in Maharashtra. Few systems have already been installed and their working has resulted in energy savings. Special Remark about the measure :- GPRS Based SCADA with data storage in cloud is new concept and better than GSM type system. Though the SCADA for street light is not so common, GPRS based SCADA with data storage in cloud may be probably first case in India. Name & Address of Industry where Implementation :- Akola Municipal Council, Street Light Energy Saving Project under finance from MEDA. Current Status :- Implemented successfully by client working successfully.
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Renewable Energy Utilization :1) Fuel Switching from Coal to Bio-mass (Renewable Energy).
Measure Heading Brief Details of Measure = = Fuel Switching from Coal to Bio-mass. The FBC Boiler utilizing pulverized coal has been tried with biomass pallets resulting in cost saving along with reduction in carbon emission.
By shifting from conventional coal with 4000 kca/kg calorific value to bio-mass briquets (finer size) of calorific value 3500 kcal/kg, Cost can be saved along with reduction in carbon emission. At Gajanan Paper Mills Pvt Ltd., Malkapur (Dist:- Buldhana) in Maharashtra, Trials were conducted for pallet type bio-mass for fuel switching from conventional coal. The results are encouraging and fuel switching is possible. The fuel switching from fossils fuel to renewable energy is most desired in current Indian atmosphere. Special Remark about the measure :- Utilization of biomass in FBC Boiler in pallet form is not so common in India. Utilization of bio-mass will lead to collection of agro waste which is currently mostly burnt at farm site as waste. Name & Address of Industry where Implementation One of the Medium Scale Paper Mill in Maharashtra. I am currently exploring the option of utilization of renewal energy in all energy audits. Current Status :- Successful trials conducted & further arrangement of regular supply and regular utilization under being stream lined.
2) Solar Water Heater for Industrial Process :Measure Heading = Solar Water Heater for Industrial Process water heating. = The solar water heater can be provided in various industrial process for water heating requirement.
Brief Details of Measure Brief Details of System
= I have recommended solar water heater to many industries for process hot water requirement. In Gujarat dairy cluster the solar water heating for milk chilling center have been implemented. The details of the milk chilling center are as given in schematic diagram. The solar water heaters have been recommended to majority of energy audit carried by me.
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Special Remark about the measure :- The utilization of solar water heating can eliminate the need of thermal energy for almost major months in year. I explore the measure in all the energy audits carried by me. Name & Address of Industry where Implementation :- Under Active Implementation in Dairy Industries. Current Status :- The measure under active implementation in one of the Dairy Cluster
10
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3) Methane Capture By Anaerobic Effluent Treatment Technology in Dairy Industry

Measure Heading Brief Details of Measure = Methane Capture By Anaerobic Effluent Treatment Technology in Dairy Industry. = The COD & BOD of effluent of Dairy Industry are suitable methane capture by Anaerobic Effluent Treatment Technology in Dairy Industry. By capturing the methane from the effluent both purpose of environment protection and energy saving can be achieved. = Currently in many industries mechanical and chemical effluent treatment is provided which itself consumes energy. By methane capture by anaerobic effluent treatment energy can be harnessed from methane and energy for treatment can be saved upto certain extent.
FLOW CHART FOR BIODIGESTOR SYSTEM
1000 m3/day
11
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The methane captured is used for boiler firing in dairy industry. The project is under active implementation in BEE Sponsored Gujarat Dairy Cluster Project. Special Remark about the measure :- Methane capture saves energy & benefits environment also. Name & Address of Industry where Implementation :- Under Active Implementation in Dairy Industries. Current Status :- The measure already implemented in one of the dairy in area of Dairy Cluster
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Energy Efficiency Case Studies in Industry

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Shashibhushan Subhash Agrawal, BE(MECH), Chartered Engineer (BEE Certified Energy Auidtor EA-1090)

Email :- shashi@charteredvaluer.com; Mobile Number :- 09422161638

Brief Details of Measure

Brief Details of Existing System

Input to Asynchronous Converter Voltage 220/380 Volts Amps 4.2/2.4 Amp Hz 50 Hz

Kva Volts Amps Hz

Output Required by Load 2.5 125/94/79/39 11.6 Amp 400/300/225/125

Other Parameters for Driving Motor :Cos 0.8

Innovative Technology 2 :-Low Loss & Compact (Phase Change

Brief Details of Measure

Brief Details of Existing System

Innovative Technology 3 :-Integrating MCDT (Machine Conditioning &

Steam Trap Survey Using Thermal Imaging :-

Thermal Insulation Leak Detection :-

Innovative Technology 4 :- GPRS operated, cloud computing based

Brief Details of System

Brief Details of System

Brief Details of Measure Brief Details of System

3) Methane Capture By Anaerobic Effluent Treatment Technology in Dairy Industry

Brief Details of System

FLOW CHART FOR BIODIGESTOR SYSTEM

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