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Fan Basics: Air Flow (Q) Static Pressure (PS) Velocity Pressure (PV) Total Pressure (PT)
Fan Basics: Air Flow (Q) Static Pressure (PS) Velocity Pressure (PV) Total Pressure (PT)
Fan Basics: Air Flow (Q) Static Pressure (PS) Velocity Pressure (PV) Total Pressure (PT)
Air Flow (Q) Static Pressure (Ps) Velocity Pressure (Pv) Total Pressure (PT)
FAN EFFICIENCY
FAN EFFICIENCY
H2 = H1 X (N2 / N1)3
H2 = H1 X ( 2 )
( 1)
FAN TECHNOLOGY
Air Foil Design of Blade Structural Design Mechanical Design of Hub Manufacturing Process Validation of Design
FAN
TECHNOLOGY
1. Blade - Fiber Glass Reinforcement Selection - Epoxy based resin to withstand corrosive atmosphere - Quality Checks for Moment Matching & Balancing - Blade Strength determined by Deflection Load Test - Allowable stress and adequate margin of safety. - Adequate thickness to meet all above criteria 2. Hub & Hardware - MS HDG Hub with SS 316 fasteners & CI/Al. Centre Bush - Plate thickness calculated to withstand radial forces generated by the Fan due to self weight and aerodynamic load.
CASE STUDY
Application Location Model Fan Type Measured Flow Measured Power Tip Clearance : Cooling Tower Fan : HCL Cooling Tower : : Metallic : 204832 Cfm : 15.6 KWH : 75 MM
Observations: 1. High Power Consumption 2. Low Fan Output (Flow) 3. Increased Tip Clearance
CASE STUDY
Replacement Fan : FRP Blade Type : Aerodynamic Shaped Measured Flow : 293700 Cfm Measured Power : 12.7 KWH Tip Clearance : 20 MM Power Saving : 18.5% Flow Increase : 43% Observations: Increased Blade Length Minimum Tip Clearance Minimum Air Re-circulation from discharge to Fan Suction
BENEFITS
Enhanced Efficiency More Flow and Better Cooling with same Power Consumption Yearly Saving Rs. 2.75 lacs per fan Payback Period 4 months Increased Expected Fan Life Reduced Vibration & Maintenance Easy Handling due to Light Weight
CONCLUSION
Installed FRP Fan more Efficient than Conventional Metallic Fan All FRP need not be Energy Efficient Efficiency is due to Aerodynamically designed Blade Profile Efficiency not due to MOC or Light Weight
BEE-PRESENTATION
ENERGY CONSERVATION
Initial cost, 2%
Maintenance cost, 8%
Types of pumps
Centrifugal Single Stage Multistage Split Casing Axial Positive Displacement Reciprocating Gear Rotary
Install flow & energy meter for all major pumps. Obverse flow & power consumption pattern hourly, shift and daily basis Identifying pumps having major power consumption.
Wrong selection Over design Improper layout Old inefficient pump Multiple smaller size pump Ad-hoc decision
Accounts for 20 % power consumption in our plant General process industry it consumes 4060% of total power At least 25% energy can be saved
At National level
Pumps Formulae
Energy Parameters
Major parameters are Capacity or flow Head or Pressure Efficiency
Pumps Formulae
If the rpm is reduced say by 10%, what will be happen to the Capacity reduced by 10% Head reduced by 19% Power reduced by 27%
Efficiency Curve
Power Detail
H Total 10 Q 10 7 12.4 10 6.4 Power Savings (kw) 100 89 82 70 45 0 11 18 30 55
Efficiency
S1el
ENERGY MANAGEMENT
ENERGY MANAGEMENT INITIATIVES IN CHLOR-ALKALI INDUSTRY
Presentation By:
M/S H.S.SANDHU, P.P.S.YADAV
S1el
Siel Chemical Complex
Siel chemical complex (SCC), Rajpura, Punjab (A unit of Mawana Sugars Limited. )
Mawana Sugars Limited (Formerly known as Siel Limited) emerged as an independent entity in 1989 out of the restructuring of the erstwhile DCM Group.
Mawana Sugars has been engaged in the business of manufacture and selling of chemicals ,sugar and edible oils.
S1el
ABOUT SCC
One of the oldest business house of India (Formerly DCM Chemical Works) Turn over of SCC Rs. 200 Crore of the unit Integrated Chemical complex, manufacturing wide range of chemicals State- of the - art technology to produce Caustic soda, Bleaching powder and Chlorine Unparalleled standard of commitment to quality and customer satisfaction Presence in international markets
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SIEL CHEMICAL COMPLEX,RAJPURA
Caustic Soda lye Caustic Soda flakes Liquid Chlorine Hydrochloric Acid Bleaching Powder Hydrogen Sodium Hypochlorite
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INPUT COST- CHLOR ALKALI PROCESS
Furnace oil, 9% Others, 6 %
Salt, 15%
Power , 70%
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INITIATIVES AT SCC
CHILLED WATER COMPRESSOR HYDROGEN COOLER VFD COOLING TOWER FAN ENERGY EFFICIENT PUMP CELL REFURBISH MENT CAPACITOR BANK RAIN WATER HARVESTING
S1el
S1el
HYDROGEN COOLER
INSTALLED HYDROGEN COOLER FOR REDUCING LOAD ON HYDROGEN BLOWER Total investment, Rs.:10.85 Lacs Energy saving/Annum, Rs.:1.5 9Lacs Simple payback6.0Year
S1el
VFD FOR CLARIFIED BRINE PUMP
INSTALLED VFD FOR CLRIFIED BRINE PUMP Total investment, Rs.:1. 15Lacs Energy saving/Annum, Rs. :1.36Lacs Simple payback0.8 Year
S1el
COOLING TOWER FAN
REPLACED CONVENTIONAL COOLING TOWER FAN WITH AERODYNAMIC DESIGN FRP FAN Total investment, Rs.:0.20L acs Energy saving/Annum, Rs.:0.4 0Lacs Simple payback-0.5 Year
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CELL REFURBISHMENT
UNDER TAKEN MAJOR CELL REFURBISHMENT FOR IMPROVING CELL HOUSE EFFICIENCY Total investment, Rs.:832La cs Energy savings, Rs.:331Lacs Simple payback2.5years
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CAPACITOR BANK
INSTALLED ADDITIONAL CAPACITOR BANK FOR POWER FACTOR IMPROVEMENT FROM 0.980 TO .997. SAVING:20 LACS/ANNUM INVESTMENT:24 LACS SIMPLE PAYBACK:1.2
S1el
March-08
0.98
POWER FACTOR
1.0
1.0
1.0
0.99 0.99
1.00
0.99
July-07 May-07
1.00
0.99
April-07 March-07
0.99 0.99 0.99
1.00
1.01
1.00
0.99
0.98
0.97
0.96
0.95
S1el
POWER EFFICIENCY
POWER EFFICIENCY
2700
KWH/MT OF CAUSTIC
Yr-2004
YEAR
Yr-2005
Yr-2006
S1el
SAVINGS
SAVING IN LACS(ANNUAL) 500
RS LACS
361
95
Yr-2005 YEAR
Yr-2006
S1el
Certifications
S1el
ISO 9001:2000 certification from DNV for manufacture and supply of SBP. ISO14001:2004 certification from DNV for the Environment Management System of the whole unit ISI certification for grade-1 and grade-2 SBP
Achievements
S1el
Punjab Safety Awards for the year 1999, 2000 and 2002. National Safety Award in 2004 for the year 2003 for outstanding performance in the field of health and safety in chemical and chemical products category by the Ministry of labour and employment, Government of India. Environment Excellence Award from PPCB for the year 2005 for consistence in outstanding performance in the field of Pollution Control. National Energy Conservation Awards-2006 in Chlor-alkali sector by The Ministry of Power, Government of India.
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ENERGY CONSERVATION AWARD
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NATIONAL ENERGY AWARD
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hssandhu@sielchemical.com H.S.SANDHU
Slel