Knowledge about Productivity & Energy Saving

1. KNOWLEDGE MANAGEMENT FOR PRODUCTIVITY
TIPS FOR ENERGY EFFICIENCY
PREM BABOO
SR.MANAGER (PROD)
NATIONAL FERTILIZERS LTD, INDIA,
FIE, INSTITUTION OF ENGINEERS (INDIA)
TECHNICAL ADVISOR AND AN EXPERT FOR
www.ureaknowhow.com
BOILERS:
22ºC REDUCTION IN FLUE GAS TEMPERATURE INCREASES
BOILER EFFICIENCY BY 1%.
5% REDUCTION IN EXCESS AIR INCREASES BOILER
EFFICIENCY BY 1% OR 1% REDUCTION OF RESIDUAL
OXYGEN IN STACK GAS INCREASES BOILER EFFICIENCY BY
1%.
A 1 MM THICK SCALE (DEPOSIT) ON THE WATERSIDE
COULD INCREASE FUEL CONSUMPTION BY 5 TO 8%.

2. A 3 MM THICK SOOT DEPOSITION ON THE HEAT TRANSFER
SURFACE CAN CAUSE AN INCREASE IN FUEL CONSUMPTION
TO THE TUNE OF 2.5%.
STEAM SYSTEM:
A 3 MM DIAMETER HOLE ON A PIPE LINE
COMPRESSED AIR LEAK FROM 1 MM HOLE DIA SIZE AT 7
KG/CM2 PRESSURE WOULD RESULT MEAN POWER LOSS
EQUIVALENT TO 0.5 KW.
EVERY 50 C REDUCTION IN INTAKE AIR TEMPERATURE
WOULD RESULT IN 1% REDUCTION IN COMPRESSOR
POWER CONSUMPTION.
CHILLERS:
CARRYING 7 KG/CM2 STEAM WOULD WASTE 33 KILO
LITRES OF FUEL OIL PER YEAR.
6ºC RISE IN FEED WATER TEMPERATURE BY ECONOMIZER
/ CONDENSATE RECOVERY CORRESPONDS TO A 1%
SAVING IN FUEL CONSUMPTION, IN BOILER.
0.25 MM THICK AIR FILM OFFERS THE SAME RESISTANCE
TO HEAT TRANSFER AS A 330 MM THICK COPPER
WALL……..!

3. INSULATION:
A BARE STEAM PIPE OF 150 MM DIAMETER & 100-METER
LENGTH, CARRYING SATURATED STEAM AT 8 KG/CM2
WOULD WASTE 25000 LITERS FURNACE OIL IN A YEAR…..!
70% HEAT LOSSES CAN BE REDUCED BY FLOATING A
LAYER OF 45 MM DIAMETER POLYPROPYLENE (PLASTIC)
BALLS ON THE SURFACE OF 900 HOT LIQUID /
CONDENSATE.
MOTORS:
HIGH EFFICIENCY MOTORS OFFER 4-5% HIGHER
EFFICIENCY THAN STANDARD MOTORS.
FOR EVERY 100 C INCREASE IN MOTOR OPERATING
TEMPERATURE OVER RECOMMENDED PEAK, THE MOTOR
LIFE IS ESTIMATED TO BE HALVES.
IF REWINDING IS NOT DONE PROPERLY, THE EFFICIENCY
CAN BE REDUCED BY 5-8%.
COMPRESSED AIR:

4. REDUCTION OF 1 KG/CM2 AIR PRESSURE (8KG/CM2 TO 7
KG/CM2) WOULD RESULT IN 9% INPUT POWER SAVINGS.
THIS WILL REDUCE COMPRESSED AIR LEAKAGE RATES BY
10%.
REDUCING CONDENSING TEMPERATURE BY 5.50 C
RESULTS IN 20-25% DECREASE IN COMPRESSOR POWER
CONSUMPTION.
5.50 C INCREASE IN EVAPORATOR TEMPERATURE
REDUCES COMPRESSOR POWER CONSUMPTION BY 20-
25%.
1 MM SCALE BUILD UP ON CONDENSER TUBES CAN
INCREASE ENERGY CONSUMPTION BY 40%.
COST OF ENERGY
AVERAGE COST--- ` 2400/G.CAL
Do you know?
A mature tree absorbs between 54.43 to 108.86 kg/year of particles
and gases like CO2, which are released in to air by automobiles and
industrial facilities.
A single tree can store an average of 5.9kg of Carbon annually. A
Community forest can store 2.6 tons of carbon per acre per year.

5. A single tree produces nearly three quarters of Oxygen required for one
person and a mature tree produces as much as Oxygen in a season as 10
people in a year. Making cans from recycled aluminum cuts related
water pollution by 97%.
Recycling one aluminum can saves enough energy to run a television
for three hours.
Manufacturing new aluminum can from used bewa rage containers
uses 95% less energy than producing them from virgin materials; an
energy saving equivalent to tens of millions of barrels of oil each year.
The average motor vehicle battery contains between 18-22 pounds of
recoverable lead, a gallon sulfuric acid and about three pounds of
polypropylene casting.
Every tone of recycled paper saves 17 trees, 7000 gallons of water and
4100kWh of electricity.
All steel products contains at least 25% of recycled content. One
recycled glass product would save energy to power a computer for 25
minutes.
70% less energy is required to recycle paper compared with making it
from raw materials. Glass is 100% recyclable and it can be used again
and again. It takes 24 trees to make one tone of newspaper. One
recycled plastic bottle would save enough energy to power a 60W bulb
for 3 Hours.
Plastic can takes up to 500 years to decompose. £36000000 worth of
aluminum is thrown away each year. Aluminum cans can recycle and
ready to use in just 6weeks. It takes half a barrel of crude oil to produce
the rubber in just one tire.
1 Gca1of NG can produce 0.240 te of CO2 1 Gcal of Naphtha can produce
0.30 te of CO2 1SM³ NG when used as fuel produces approx. 2kg of CO2
1kg Naphtha when used as fuel produces approx. 3.10kg of CO2 .