Energy Efficiency of Industrial

Systems: Part I
SEE705 – Energy Efficiency and Demand
Management

Lecture: Week 5

Unit Chair: Dr. Saman A. Gorji

Lecturer: Jack Connor

Energy Management Handbook- Chapter 5&6

Steps in the Energy Audit of an Industrial
Plant
• Audit plan
• Audit checklist
• Initial visit
• Collecting energy bills
• Preliminary analysis
• Analysing energy bills
• Inventory and measurement of energy use
• Analysing energy use patterns
• Benchmark and comparative energy performance analysis
• Identifying energy efficiency and energy cost reduction
opportunities
Industrial Energy Audit:
Mass and Energy Balance

An energy-mass balance quantifies the flow of mass

and energy through a site or process to determine.
• The amounts of energy used by individual items of
equipment and individual processes or sub-
processes;
• Energy losses from pipes, pumps, ducts and tanks;
• The forms into which energy is converted;
• It also quantifies the material flows through each
processing stage; the physical and chemical changes
that take place; the movement of materials against
friction, gravity or other forces; and the correlation
between energy use and material flows.
Mass And Energy Balance

𝑀𝑎𝑠𝑠 𝐼𝑛 = 𝑀𝑎𝑠𝑠 𝑂𝑢𝑡 + 𝑀𝑎𝑠𝑠 𝑆𝑡𝑜𝑟𝑒𝑑

In other words,
𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 = 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠 + 𝑊𝑎𝑠𝑡𝑒𝑠 + 𝑆𝑡𝑜𝑟𝑒𝑑 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠
𝐸𝑛𝑒𝑟𝑔𝑦 𝐼𝑛 = 𝐸𝑛𝑒𝑟𝑔𝑦 𝑂𝑢𝑡 + 𝐸𝑛𝑒𝑟𝑔𝑦 𝑆𝑡𝑜𝑟𝑒𝑑

෍ 𝐸𝑅 = ෍ 𝐸𝑃 + ෍ 𝐸𝑊 + ෍ 𝐸𝐿 + ෍ 𝐸𝑆

Where:
σ 𝐸𝑅 = Total Energy Entering
σ 𝐸𝑃 = Total Energy Leaving with Products
σ 𝐸𝑊 = Total Energy Leaving with Waste Materials
σ 𝐸𝐿 = Total Energy Lost to Surroundings
σ 𝐸𝑆 = Total Energy Stored

This equation is used to understand how energy flows in the

process and how energy can be saved.
Drink & Syrup Production Process
Drink & Syrup Production Process
Drink & Syrup Production Process
Issues/Opportunities

• A significant proportion of metered gas for the boiler cannot be accounted for from
measurements.

• There is significant unaccounted heat gain to the chilled water system;

• Efficiencies of the high temperature hot water generation (boiler) and heat transfer to syrup
maker seem to offer potential for savings;

• It would be useful to separately meter a number of processes (e.g. cooling tower electricity);

• There are significant heating and cooling applications that could be supplied by heat (and
coldness) recovery from other parts ofthe production process, rather than directly by the boiler
and chiller.
Energy Efficiency Opportunities for Industrial
Systems

Improving efficiency of:

• Process heating systems
• Steam systems
• Electric motors
• Compressed air systems
• Pumping systems
• Fan systems
• Lighting
Electrical demand control
Boilers, Furnaces, Ovens

Boilers and other fired systems, such as furnaces and

ovens combust fuel with air for the purpose of
releasing the chemical heat energy.

Some applications:
• raise the temperature for manufacturing.
• generate high pressure high temperature steam.
• space heating.
Energy Cost of Boilers/Furnaces

Energy consumption is equal to the integral of load

divided by efficiency over a period of time.
Energy cost is equal to the integral of (load divided by
efficiency) multiplied by fuel cost over a period of time. The energy cost of boiler
depends on:
1
𝐸𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑠𝑡 = න(𝑙𝑜𝑎𝑑 ∗ ∗ 𝑓𝑢𝑒𝑙 𝑐𝑜𝑠𝑡) 𝑑𝑡
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
So, Energy cost depends on three factors:
• Load. Load Efficiency Fuel Cost
• Efficiency.
• Fuel Cost.
Load, Time, Load and
The value of load depends on the process; Process
and Weather Process
Efficiency depends on load, weather, and time of the day;
Fuel cost may depend on load and process.
Efficiency of Boilers and Fired Systems

Gross Thermal Efficiency

𝑂𝑢𝑡𝑝𝑢𝑡 𝐻𝑒𝑎𝑡 𝑂𝑢𝑡𝑝𝑢𝑡 𝐻𝑒𝑎𝑡
𝐺𝑇 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = ∗ 100% = ∗ 100%
𝐼𝑛𝑝𝑢𝑡 𝐸𝑛𝑒𝑟𝑔𝑦 𝑂𝑢𝑡𝑝𝑢𝑡 𝐻𝑒𝑎𝑡 + 𝑇𝑜𝑡𝑎𝑙 𝐻𝑒𝑎𝑡 𝐿𝑜𝑠𝑠
Combustion Efficiency
Is a measure of how much is the heat loss through the exhaust gases.
𝑂𝑢𝑡𝑝𝑢𝑡 𝐻𝑒𝑎𝑡
𝐶𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = ∗ 100%
𝑂𝑢𝑡𝑝𝑢𝑡 𝐻𝑒𝑎𝑡 + 𝐻𝑒𝑎𝑡 𝐿𝑜𝑠𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑔𝑎𝑠𝑒𝑠

- Depends on Excess air

Where: Excess air is the amount of air above that level which is theoretically required for complete
combustion.

In other words:
𝐸𝑥𝑐𝑒𝑠𝑠 𝐴𝑖𝑟 = 𝑇𝑜𝑡𝑎𝑙 𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐴𝑖𝑟 − 𝑡ℎ𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑎𝑖𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒 𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛

If there is not sufficient excess air, incomplete combustion begins to occur resulting in the formation of carbon
monoxide and the process becomes inefficient and unsafe. If there is more than sufficient excess air, it results in the
excess air being heated from ambient air temperatures to exhaust gas temperatures resulting in a form of heat loss.
Key Factors That Determine The Combustion
Efficiency

Excess air

Exhaust stack temperature

Waste-heat-steam generation

Load balancing

Boiler blowdown
Reducing Excess Air to Improve Efficiency

Reducing the amount of excess air can improve the combustion efficiency.

Example: Determine the potential energy savings associated with reducing the amount of excess air
to an optimum level for a natural gas-fired steam boiler.

Operation Data.
Current energy consumption: 1,100,000 therms/yr
Boiler rated capacity: 600 boiler horsepower
Operating hours: 8,500 hr/yr
Current stack gas analysis: 9% Oxygen (by volume, dry)
Minimal CO reading
Combustion air inlet temperature: 80°F
Exhaust gas stack temperature: 580°F
Proposed operating condition: 2% Oxygen (by volume, dry)

Therms = 100,000 BTU

Reducing Excess Air to Improve Efficiency

Figure 2: Combustion Excess Air

Figure 1: Combustion Efficiency Chart

Reducing Excess Air to Improve Efficiency
(Solution)
Step 1: Determine the boiler combustion efficiency for the current operation.
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 𝐸𝑥ℎ𝑎𝑢𝑠𝑡 𝑠𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝐼𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 580℉ − 80℉
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 500℉

From Fig. 2, we obtain the % of excess air for the oxygen level of %9
➔ Excess air is 70%

For the 70% excess air, From Fig. 1, obtain the combustion efficiency for stack temperature rise 500 °F.
➔80% efficiency (Current operation)

Step 2: Determine the boiler combustion efficiency for the proposed level of oxygen. From Fig. 2,
obtain the % excess air for oxygen level of 2%.
➔ 10%
For the 10% excess air, From Fig. 1, obtain the combustion efficiency for stack temperature rise 500 °F.
➔ 85.5% efficiency (improved)
Reducing Excess Air to Improve Efficiency
(Solution)

Figure 2: Combustion Excess Air

Figure 1: Combustion Efficiency Chart

Reducing Excess Air to Improve Efficiency
(Solution)
Step 3: Calculate the Fuel savings
𝑛𝑒𝑤 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦−𝑜𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (%) = ∗ 100%
𝑛𝑒𝑤 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
85.5−80
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 % = ∗ 100%
85.5

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 % = 6.43%

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (𝑡ℎ𝑒𝑟𝑚𝑠) = 𝐹𝑢𝑒𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 ∗ 𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (%)

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 𝑡ℎ𝑒𝑟𝑚𝑠 = 1,100,000 ∗ 6.43%
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 𝑡ℎ𝑒𝑟𝑚𝑠 = 70,730 𝑡ℎ𝑒𝑟𝑚𝑠/𝑦𝑒𝑎𝑟
Exhaust Stack Temperature

Increased operating efficiency can be achieved by rejecting exhaust gases at the lowest practical
temperature.

Example: Determine the energy savings associated with installing an economizer on

the boiler from the previous example, with the given data below.

Operation Data.
Current energy consumption: 1,032,460 therms/yr
Boiler rated capacity: 600 boiler horsepower
Operating hours: 8,500 hr/yr
Exhaust stack gas analysis: 2% Oxygen (by volume, dry)
Minimal CO reading
Current Operating Conditions
Combustion air inlet temperature: 80°F
Exhaust gas stack temperature: 580°F

Proposed Operating Condition

Combustion air inlet temperature: 80°F
Exhaust gas stack temperature: 380°F
Exhaust Stack Temperature

Figure 2: Combustion Excess Air

Figure 1: Combustion Efficiency Chart

Exhaust Stack Temperature
(Solution)
Step 1: Determine the boiler combustion efficiency for the current operation.
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 𝐸𝑥ℎ𝑎𝑢𝑠𝑡 𝑠𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝐼𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 580℉ − 80℉
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 500℉

From Fig. 2, we obtain the % of excess air for the oxygen level of %2
➔ Excess air is 10%

For the 10% excess air, From Fig. 1, obtain the combustion efficiency for stack temperature rise 500 °F.
➔ 85.5% efficiency (Current operation)

Step 2: Determine the boiler combustion efficiency for the proposed operating conditions.
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 𝐸𝑥ℎ𝑎𝑢𝑠𝑡 𝑠𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝐼𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 380℉ − 80℉
𝑆𝑡𝑎𝑐𝑘 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 = 300℉

For the 10% excess air, From Fig. 1, obtain the combustion efficiency for stack temperature rise 300 °F.
➔ 89.5% efficiency (Proposed operation)
Exhaust Stack Temperature
(Solution)

Figure 2: Combustion Excess Air

Figure 1: Combustion Efficiency Chart

Reducing Excess Air to Improve Efficiency
(Solution)
Step 3: Calculate the Fuel savings
𝑛𝑒𝑤 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦−𝑜𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (%) = ∗ 100%
𝑛𝑒𝑤 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
89.5−85.5
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 % = ∗ 100%
89.5

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 % = 4.47%

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (𝑡ℎ𝑒𝑟𝑚𝑠) = 𝐹𝑢𝑒𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 ∗ 𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 (%)

𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 𝑡ℎ𝑒𝑟𝑚𝑠 = 1,032,460 ∗ 4.47%
𝐹𝑢𝑒𝑙 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 𝑡ℎ𝑒𝑟𝑚𝑠 = 46,143.46 𝑡ℎ𝑒𝑟𝑚𝑠/𝑦𝑒𝑎𝑟
Energy Efficiency Improvement for Process
Heating

Heat Generation
• Control the air-to-fuel ratio (5 to 25% saving)
• Preheat the combustion air (15 to 30% saving)
• Use the oxygen enriched combustion air (5 to 25% saving)

Heat Transfer
• Improve heat transfer with advanced burners and controls (5 to 10% saving)
• Improve heat transfer within a furnace (5 to 10% saving)

Heat Containment
• Reduce wall heat losses (2 to 5% saving)
• Furnace pressure control (5 to 10% saving)
• Maintain door and tube seals (up to 5% saving)
Energy Efficiency Improvement for Steam and
Condensate Systems
Steam is one of the most abundant, least expensive, and most effective heat-transfer media.

DURING BOILING AND THE CONVERSION OF A LIQUID TO A THE TEMPERATURE IS UNIQUELY

CONDENSATION, IF THE PRESSURE IS VAPOUR ABSORBS LARGE FIXED BY THE PRESSURE, AND HENCE
HELD CONSTANT AND BOTH WATER QUANTITIES OF HEAT. THUS, BY MAINTAINING CONSTANT
AND STEAM ARE PRESENT, THE RELATIVELY SMALL QUANTITIES OF PRESSURE, EXCELLENT CONTROL OF
TEMPERATURE ALSO REMAINS STEAM CAN MOVE LARGE AMOUNTS PROCESS TEMPERATURE CAN ALSO BE
CONSTANT. OF HEAT. MAINTAINED.
Definitions

British Thermal Unit (BTU): One BTU is the amount of heat required to raise 1 pound of water 1
degree Fahrenheit in temperature.

Therms: 100,000 BTU.

Boiling point: The temperature at which water begins to boil at a given pressure.

Absolute pressure: The true force per unit of area.

Gauge pressure: Sensing devices that are exposed to the atmosphere outside, measures the
difference between that force and the force exerted by the outside atmosphere.

Condensate: Liquid produced when steam condenses on a heater surface.

Flash steam: When the steam pressure is suddenly lowered to lower the temperature.
Definitions

Saturated Steam: If water is heated to its boiling point and then the heat is increased in a constant
pressure, then the temperature will be constant at the boiling point while more water will be
evaporated. This steam is called the saturated steam.
Superheated Steam: If the temperature of the steam is increased by applying heating, then this
steam is called the superheated steam.
Sensible heat: Heat that directly changes the temperature.
Latent heat: Heat that goes for a conversion of liquid to vapour.
Enthalpy: The total energy content of a medium in BTU/lb.
Specific volume: the amount of space (e.g., cubic feet) occupied by 1 pound of substance.
Energy Efficiency Improvement for Steam
Systems

Demand Matching
Bigger boilers may not be efficient if the demand is not matching to generation.
Boiler Allocation Control
Automatic controllers determine the incremental costs (change in steam cost/change in load)
for each boiler in the facility, and then shift loads accordingly.
Flue shut-off dampers
A solution to the loss of hot air is to fit fully closing stack dampers, which only operate when the
boiler is not required.
Insulation improvement
Savings of 6-26% can be achieved by combining improved insulation with improved heater
circuit controls.
Energy Savings from Saturated Steam

Example: A 100-ft run of 6-in. steam piping carries saturated steam at 95 psig (gauge pressure).
Tables obtained from an insulation manufacturer indicate that the heat loss from this piping run is
presently 110,000 BTU/hr. With proper insulation, the manufacturer’s tables indicate that this loss
could be reduced to 10500 BTU/hr.
(a) How many pounds per hour of steam savings does this installation represent?
(b) If the boiler is 80% efficient and the condensate temperature is 212 °F, what would be the
resulting fuel savings?
Energy Savings from Saturated Steam
Energy Savings from Saturated Steam
(Solution)
(a) 𝐻𝑒𝑎𝑡 𝑙𝑜𝑠𝑠 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 110,000 − (b) From Table 1, at 212 °F, the condensate has a heat content of
𝐵𝑇𝑈 𝐵𝑇𝑈
10,500 = 99,500 𝐻𝑟 180 𝑙𝑏 .
Heat required to generate 95 psig steam is:
From the table give, at 95 psig pressure,
𝐻𝑒𝑎𝑡 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
the total heat of steam is 1188.4 BTU/lb
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 – ℎ𝑒𝑎𝑡 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 𝑜𝑓 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑎𝑡𝑒
99,500 𝑙𝑏 𝐵𝑇𝑈 𝐵𝑇𝑈
𝑆𝑡𝑒𝑎𝑚 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 = 1188.4 = 83.7 𝐻𝑟 𝐻𝑒𝑎𝑡 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 1188.4 − 180
𝑙𝑏 𝑙𝑏
𝐵𝑇𝑈
𝐻𝑒𝑎𝑡 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 1008.4 𝑙𝑏

The amount of heat present in the boiler fuel:

1008.4
𝐻𝑒𝑎𝑡 𝑃𝑟𝑒𝑠𝑒𝑛𝑡 = 0.80
𝐵𝑇𝑈
𝐻𝑒𝑎𝑡 𝑃𝑟𝑒𝑠𝑒𝑛𝑡 = 1260.5 𝑙𝑏
Fuel savings for the boiler
𝐹𝑢𝑒𝑙 𝑆𝑎𝑣𝑖𝑛𝑔 = 1260.5 ∗ 83.7
𝐵𝑇𝑈
𝐹𝑢𝑒𝑙 𝑆𝑎𝑣𝑖𝑛𝑔 = 105,503.9 𝐻𝑟
Energy Savings from Saturated Steam
(Solution)
Co-Generation Systems

• Coincident or simultaneous generation of

combined heat and power (CHP).

• A significant portion of the generated or

recovered heat is used in a thermal
process as steam, etc.

• The power may be totally used in the

industrial plant that serves as the “host”
of the cogeneration system or may be
partially/totally exported to a utility grid
Energy Efficiency Improvement of Steam
Distribution System

Shutting off excess distribution lines

Prevent under-utilization of steam distribution capacity and extra heat losses.
Proper pipe sizing
Oversizing a steam pipe is not only a cost issue but would also lead to higher heat losses. A pipe
that is too small may lead to erosion and increased pressure drop.
Insulation
Insulation can typically reduce energy losses by 90% and help ensure proper steam pressure at
plant equipment.
Monitoring steam traps
If the steam traps are not maintained for 3 to 5 years, 15-30% of the traps can be
malfunctioning, thus allowing live steam to escape into the condensate return system.
Energy Efficiency Improvement of Fan Systems

Minimizing Pressure
A system with good airflow characteristics (duct velocities and sizes optimized), matched with
the proper control device, pressure monitors, and variable-frequency drives, can help manage
system pressure and reduce cost.
Control Density
Evaporative cooling reduces volume, but the higher-density air requires more power. This may
be more than offset by reduced costs for smaller ducts, control devices, and fans.
Fan Efficiency
The design of the fan and its blade type can affect efficiency and power requirements
significantly. The designer must consider efficiency and pressure curves when selecting the best
fan and operating point to optimize reliability and power usage.
Adjustable Speed Drives
Significant energy savings can be achieved by installing adjustable speed drives on fans.
Case Study for Increasing Boiler
Efficiency: Murray Goulburn Co-
operative, Rochester Branch (Dairy
Processing Sector)
Case Study: Issues Involved in Energy Efficient
Operation

No information on steam requirements available to boiler attendants.

Boilers running at low loads.

Too much time spent on start-up of evaporators and dryers.

Condensate not being used much effectively.

Case Study: Initiative 1: Improving Steam Raising
Efficiency

Increasing the load increases the efficiency.

Improved communication between the main process and boiler operation.

Increase in boiler load from 30% to 60%, contributes to a 4% increase in steam raising
efficiency.

Potential Energy cost savings $180 000 per year and 1536 tonnes potential reduction in
CO2 emission.

Monitoring load profiles for improving efficiency by shutting down standby boilers.
Case Study: Initiative 2: Improving Start-up
Procedure for Evaporator and Dryer

Reducing the start-up time reduces the steam requirements and reduces the gas
requirements for the boiler.

Energy costs will be reduced by $23,000 annually.

Potential reduction in CO2 emission is 195 tonnes.

Case Study: Initiative 3: Improving Condensate
Return

Improving the temperature of the feed tank can lead to efficient use of condensate.

Raising the feedwater tank temperature by 20 degrees C improves the steam raising efficiency of boilers by 3.3%
and reduces the amount of gas required to produce the same amount of steam by 3.3%.

Fixing the leaks in steam pipes leads to reduced energy consumption.

Potential savings in energy cost is $200,000 per year.

Potential reduction in CO2 emission is 1700 tonnes per year

Thank You