Industrial Energy Conservation, Volumes 1-2

858 Pages·2018·4.487 MB·English

by  S. C. Bhatia, Puneet Mangla

Industrial Energy Conservation
Volume I-II

Contents iii
Industrial Energy Conservation
Volume I-II
S C Bhatia
BE (Chemical), BITS Pilani & MBA
Puneet Mangla (Co-Author)
B.E. (Industrial Production), M.Tech. (Engineering Systems)
Head and Associate Professor - Department of Mechanical Engineering,
Hindustan College of Science and Technology, (Mathura)
Edited by
Sarvesh Devraj
B.Tech (Mechanical), UPTU
M.Tech (Renewable Energy Engineering and Management), TERI University,
(Research Associate – TERI, New Delhi)
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Contents v
Contents
Volume I
Preface xv
Section I: General concepts and engineering considerations 1
1. Industrial energy conservation: A review 3
1.1 Introduction 3
1.2 Industrial sector energy efficiency 3
1.3 Energy consumption and energy related
carbon dioxide emissions trends 5
1.4 Industrial energy efficiency 6
1.5 Causes of the energy crisis 10
1.6 Non-conventional renewable energy sources 12
1.7 Energy conservation 13
1.8 Need of energy conservation 15
2. Energy efficiency technologies and benefits 21
2.1 Introduction 21
2.2 Benefits of increased energy efficiency 23
2.3 Importance of energy efficiency 25
2.4 Target sectors in energy efficiency 28
2.5 Energy efficiency actions 31
2.6 Barriers to implementation of energy efficiency measures 34
2.7 Combining renewables and energy efficiency to
improve sustainability of energy development 38
3. Energy audit 41
3.1 Introduction 41
3.2 Types of energy audits 42
3.3 Steps for conducting energy audit 42
3.4 Data collection hints 46
3.5 Tips for energy audit 50
vi Industrial energy conservation
4. Efficient steam distribution system 53
4.1 Introduction 53
4.2 Energy conservation 54
4.3 Improving efficiency of steam systems 61
5. Energy efficiency in boilers 67
5.1 Introduction 67
5.2 Heating surfaces in a boiler 67
5.3 Classification of boilers 68
5.4 Performance evaluation of boilers 70
5.5 Boiler water treatment 71
5.6 Energy conservation opportunities in boilers 78
5.7 Improving boiler efficiency 83
5.8 Factors affecting boiler efficiency 88
5.9 Practical standard operating practices for
improving boiler efficiency 89
5.10 Case study Atul limited—Ankleshwar (Gujrat) 90
6. Industrial waste heat recovery 97
6.1 Introduction 97
6.2 Basic heat recovery 97
6.3 Process heating 99
6.4 Industrial process heat recovery 100
6.5 Heat recovery methods 102
6.6 Cost considerations 118
Section II: Energy conservation in electrical and
telecom industries 123
7. Energy conservation in electrical industries 125
7.1 Introduction 125
7.2 Energy conservation in electrical systems 125
7.3 Energy conservation techniques 126
7.4 Diesel generator (DG) 132
8. Energy efficiency technologies for thermal power plants 141
8.1 Introduction 141
8.2 Combined cycle gas turbine (CCGT) 145
Contents vii
8.3 Mechanism of CCGT 146
8.4 Typical size and configuration of CCGT plants 149
8.5 Integrated gasification combined cycle (IGCC) 151
8.6 Performance without CO capture 153
2
8.7 Major IGCC blocks and components 164
8.8 IGCC system issues 178
9. Energy efficient motors, compressors and
refrigeration systems 185
9.1 Introduction 185
9.2 Salient aspects of motor performance 185
9.3 Energy efficiency in fans 191
9.4 Energy efficiency in compressed air systems 197
9.5 Refrigeration systems 204
10. Energy conservation in telecom sector 213
10.1 Introduction 213
10.2 Importance of green and energy efficient
telecom equipments 213
10.3 Global initiatives in energy efficient technologies 214
10.4 Corporate social responsibility and community service 218
10.5 Telecom industry and green energy 218
10.6 Drivers for energy efficiency in telecommunications 220
10.7 Energy efficiency in telecom optical networks 226
Section III: Energy conservation in mechanical industries 229
11. Energy efficiency in machining and gears 231
11.1 Introduction 231
11.2 Optimised automation in machine operations 232
11.3 Cutting power analysis in machining operations 233
11.4 Concepts of energy efficiency in utilisation of
machine tools 234
11.5 Gear efficiency 236
11.6 Hydraulic presses 242
12. Energy conservation in forging industry 245
12.1 Introduction 245
12.2 Energy conservation in forging industry 245
viii Industrial energy conservation
12.3 Rational use of energy in induction heaters for
forging industry 250
Section IV: Energy conservation in cement, ceramic and
glass industries 259
13. Energy conservation in cement industry 261
13.1 Introduction 261
13.2 Major process equipments 261
13.3 Energy efficiency opportunities 263
13.4 Promotion of energy conservation techniques 266
13.5 Energy efficiency opportunities in individual
sections in a cement plant 269
13.6 Cogeneration of power utilising waste heat in
cement manufacture: technological perspectives 271
13.7 Technical consideration for cogeneration schemes 272
13.8 Availability of waste heat 274
13.9 Energy efficiency technologies and measures for the
U.S. cement industry 277
14. Energy conservation in ceramic industry 297
14.1 Introduction 297
14.2 Ceramic manufacturing process 297
14.3 Energy consumption in ceramic manufacturing 298
14.4 Energy conservation measures in ceramic cluster 302
14.5 Tips for energy saving in various operation of
ceramic industries 317
15. Energy conservation in glass industry 325
15.1 Introduction 325
15.2 Manufacture of glass 325
15.3 Energy consumption in glass industry 328
Section V: Energy conservation in metallurgical and
mining industries 343
16. Energy conservation in iron and steel industry 345
16.1 Introduction 345
16.2 Iron and steel making processes 345
16.3 Energy conservation technologies 350