Some Examples:

An industry has a -inch-thick uninsulated mild steel tank storing a hot fluid. The fluid is heated
to 200oF, while ambient air is 70oF. The tank is 10 ft in diameter and 10 ft tall. The thermal
conductivity of mild steel is 314.4 Btu.in/ft2.h.oF and of glass wool is 0.25 Btu.in/ft2.h.oF.
i)

What is the heat loss for the uninsulated tank?

ii)

If the tank surface is insulated with 1-inch-thick aluminum-jacketed fiberglass, how

much heat we can save?

Ans: Heat loss takes place through two way: 1) heat loss through the wall, and 2) heat loss
through the roof.
Total heat resistance
Rtotal = Rtank + R surface coefficient
Rtank = d/K =0.5/314.4 = 0.0016 h.ft2.oF/Btu
Assuming that the surface is dull metal and the surface temperature is around 120 oF
Then R surface coefficient = 0.50 h.ft2.oF/Btu
U = 1/ (Rsurface + Rtank) = 1/0.5016 = 1.99 Btu/ft2.oF.h, where U = conductance
A = area = DH + r2 = (10ft)(10ft) +(5 ft2) = 392.7 ft2
Qtotal = UAt = (1.99 Btu/ ft2.oF.h) x(392.7 ft2)(200o-70oF)
= 101,591 Btu/h

Ans: If surface is insulated with 1-inch thick aluminum-jacketed fiberglass, the

Rinsulation = d/K = 1/0.25 = 4 h.ft2.oF/Btu (K is found at average temperature of around 140
o

F)
U = 1/ (Rsurface + Rtank + Rinsulation ) = 1/(0.0016 + 4 + 0.88) = 0.205 Btu/ft2.oF.h
Qtotal = UAt = (0.205 Btu/ ft2.oF.h) x(392.7 ft2)(130 oF)
= 10,465 Btu/h
Savings = 101,796 10,465 = 91,331Btu/h
%Savings = 91,331/101,796 x 100 = 89.7%

What are the causes of electric power loss in the transmission line and how can we
reduce the losses?
As electricity travels over miles of transmission lines to get to our homes, it experiences
resistance and as a result, some of its energy is lost - usually as heat. The further the electricity
has
to
travel,
the
more
electricity
is
lost.
When consider the high end of the scale, this means that for every 10 tons of coal burned for
electricity generation; up to one ton is lost just through the line loss issue.
Transmitting electricity at high voltage reduces the fraction of energy lost to resistance.
In an alternating current circuit, the inductance and capacitance of the phase conductors can be
significant. The currents that flow in these components of the circuit impedance constitute
reactive power, which transmits no energy to the load. Reactive current causes extra losses in
the transmission circuit. The ratio of real power (transmitted to the load) to apparent power is
the power factor. As reactive current increases, the reactive power increases and the power
factor decreases. For systems with low power factors, losses are higher than for systems with
high power factors. Utilities add capacitor banks and other components (such as phase-shifting
transformers; static VAR compensators; physical transposition of the phase conductors; and
flexible AC transmission systems, FACTS) throughout the system to control reactive power flow
for reduction of losses and stabilization of system voltage.

In any industry a fraction of energy can be saved by proper management. Demonstrate

the ways of saving energy in the industry by proper management.
Proper management and reduction of waste energy can keep energy consumption and costs at
a controlled minimum. However, this needs to establish an energy management program as
follows:
Program Organization
Four basic elements are essential to any energy management program: 1) top management
commitment, (2) clearly designated program responsibility, (3) defined realistic goals, and (4)
program planning and implementation.

(1) Top Management Commitment: Top management must be dedicated

and committed to an energy conservation program. It must be willing to provide resources as
required, both personnel and financial. Employees will apply their best efforts to the program.
(2) Program Responsibility: The planning and implementation of an energy management
program must be the clearly defined responsibility of an energy program committee. This
committee is appointed by management and headed by a coordinator, who reports to
management. The committee consists of representatives from each department. Figure 1 is a
typical energy management organization chart.

(3) Program Goals: An energy saving goal should be set initially in order to provide a later
be revised following a more thorough analysis of potential energy savings. How large the
initial and revised goals should be, or how they should be expressed, will depend on
individual circumstances. In all cases, goals should be specific, measurable, and should
offer sufficient incentive to all employees to make achievement a challenge.

(4) Program Planning: The first technical step in an energy management program is to
conduct an energy audit. An audit is made from a series of surveys that show where and
how energy is being used and /or wasted. For effective planning, it is essential to know
how much energy each major area uses. An ideal audit lists each process step, the
theoretical energy required for each step, the actual energy used, and the variance
between theoretical and actual use.
The audit will reveal where energy flow measurement is needed and whether its
installation can be justified economically.
Goals may be shown on an energy budget using the format illustrated by the following Figure 2.

Energy use
by
consumptio
n
area and
process
steps
Buildings &
grounds
Heating
Shipping
Lighting
Receiving
Shop
Assembly
Combustion

Actual
energy
used

Theoretical
energy
requiremen
t

Variance between
theory and
practice
Amount
%
of
energy

Goal

Change
from
previous
month

An energy audit should be organized in three phases.

Phase I-Data Gathering
Phase 11-Energy Balances
Phase 111- Analysis

Figure 3. Energy management equipment inventory record (gas/electric)

Location

Description

Quantity

Rated input,
Btu/h or kW

Annual use
MBtu or kWh

Remarks

Program Implementation: The obvious wastes found in the initial survey should have been
corrected immediately, and the corrective action recorded. Most of these wastes can be
eliminated by procedural changes requiring little capital investment, and can result in savings of
5 to 20 percent. An analysis of the energy audits will reveal which energy services (steam, gas,
electricity) show the most potential for immediate improvement. A cost/benefit analysis (based, if
possible, on future energy costs) will reveal the merit of each potential improvement project and
enable priorities to be set. Selected projects should be implemented when approved.
By this way any industry can save a potential amount of energy.
Management officer

Plant energy management coordinator

Consultant

Energy management committee

Engineering

Production

Department representative

Purchasing

Maintenance

Maintenance representative

Example
A kiln has two complete operating cycles per week and runs for 48 weeks per year; the existing
gas consumption is 150 therm/cycle. It has been decided to reline the inside brickwork with
ceramic fiber with a cost of 1400 in order to save some energy and it would be benefited if the
pay-back period is less than 2 years. Assuming the price of gas 32/therm, calculate the
percentage saving in gas required to achieve the required pay-back period.

The initial annual gas consumption is

150 x 2 x 48 = 14400 therm
i.e. the annual fuel cost is
14400 x 32 /100 = 4068
The annual fuel saving due to the relining for a pay-back period of two years is given by
4068/2 = 700
i.e. Percentage annual fuel savings required = 700 x 100/4608 = 15.2%
This order of reduction is well within that expected for ceramic fiber relining.