2. PI and Co-PI details
PI:
Engr. Asif Sultan, Shift Engineer Utilities
Renewable energy and Alternative fuel energy expert
Electrical engineer from PAF KIET
Plot No. 55: road No. I, Phase III, Industrial State, Hattar Haripur, KPK, Pakistan
Email: asif.sultan@cfl.com.pk
Phone: 0995-617551-2 (173)
Cell: +923333874940
I did my engineering from Karachi institute of Economics & Technology after completing my engineering
I joined R.A Engineering Company as Electrical/Power engineer and now I am in Coronet Foods as
engineer utilities. My areas of interest are R&D on energy, renewable energy, thermal energy and
Electrical Energy Systems.
Co-PI:
Dr. Saim Saher, Assistant Professor and Energy Expert
Materials for Energy Storage and Conversion
U.S.-Pakistan Center for Advanced Studies in Energy (USPCAS-E)
University of Engineering and Technology (UET), Peshawar
New Academic Block, 2nd Floor, University of Engineering and Technology, Peshawar, Khyber
Pakhtunkhwa, Pakistan.
Email: s.saher@uetpeshawar
Phone: +92-91-9222089, 9222104
Fax: +92-91-5611159
Recently, Dr. Saim Saher has joined USPCAS-E as Assistant Professor after completing PhD studies in the
field of Membrane Engineering. His areas of are renewable energy, energy conservation, innovative
solutions for sustainable energy and smart energy systems.
Co-PI:
Engr. Khalid Mehmood, Mechanical Engineer
Coronet Foods (Pvt.) Ltd.
Plot No. 55: road No. I, Phase III, Industrial State, Hattar Haripur, KPK, Pakistan
Email: khalid.mehmood@cfl.com.pk
3. Phone: 0995-617551-2 (183)
Cell: +923325323640
He has done bachelors in mechanical Engineering from Mirpur University of Science & Technology. His
areas of interest are mechanical design, fabrication and analysis.
Executive Summary
Waste heat is heat generated in a process by way of fuel combustion or chemical reaction, which is then
“dumped” into the environment and not reused for useful and economic purposes. The essential fact is
not the amount of heat, but rather its “value”. The mechanism to recover the unused heat depends on
the temperature of the waste heat gases and the economics involved.
This proposal report involved the design and construction of an exhaust flue heat recovery system. The
primary aim of the task is to design and construct a system which will recover 70% of natural gas furnace
ovens waste heat energy and make it useable for water heating purpose. Right now we are wasting this
energy into environment.
Coronet Foods operation depends almost 80% on natural gas and 20% on electricity energy. Food sector
is vital to the state’s economy and striving to keep low operating costs while maintaining clean
environment and energy-efficient operations.
Coronet foods is one of the largest biscuit industries in Pakistan and our production is mainly depends on
Gas. Due to limited resources and low gas pressure of natural gas we are using LPG-natural gas
combination in our plants to fulfill our industrial requirement of plants.
There are various exhaust flue gas stacks in our ovens and the temperature of exhaust is around 200C°-
250C°. We can recover this heat by implementing comprehensive flue gas heat recovery system (FGHRS)
for producing hot water used in production process, washing areas and kitchens. Currently we are
performing this operation from gas geezers.
The heat recovery system is essential to the industry and viable for country economy. The efficiently
recovering of wasted heat in exhaust gases from the furnaces and converting it to useable energy can save
more than 20% of the Pakistan energy resources.
Aim
To investigate the possibility of decreasing the gas consumption of the Coronet foods (Pvt.) Ltd. by
suitably utilizing the waste heat of exhaust gasses produced by natural gas baking ovens, which is at
present directly released to the environment.
4. Objectives
To analyze the waste flue gases from oven’s exhaust.
To recover maximum exhaust waste heat and make it useable energy.
To implement heat recovery system for water heating.
Background
Coronet foods is one of the largest biscuit industries in Pakistan and our production is mainly depends on
Gas. Our company’s operation depends almost 80% on natural gas and 20% on electricity energy. We have
6 biscuits plants and key part of our plant is gas oven. The share of gas section in our utility bill is 80% in
terms of monetary value. Due to limited resources and low gas pressure of natural gas we are using natural
gas in combination with LPG to fulfil plant requirement. Our average monthly consumption of gas is
around 27, 33,72m³ in which 70% is LPG and 30% is natural gas. On the other hand we required huge
amount of hot water in our different areas of production process like mixing areas, washing areas and
kitchens. Our hot water requirement is around 200 gallons/hour and we are using gas geezers for this
operation. These gas geezers is adding the huge amount in our utility bill.
Average natural gas consumption in m³ is around = 156,728 m³ / month
Natural gas per unit cost = 18 / m³ PKR
Average natural gas consumption cost = 282,110,4 PKR / month
Average LPG consumption in Kg is around = 81,150 KG / month
Average LPG consumption in m³ is around = 116,644 m³ / month
LPG per unit cost = 52 / m³ PKR
Average LPG consumption cost = 608,625,0 PKR /month
Total Average Gas consumption in m³ (Natural gas + LPG) = 273,372 m³ / month
Gas consumption per unit cost (LPG + NG) = 33 PKR / m³
Total cost of gas (LPG + NG) = 890,735,4 PKR / month
Importance and application of the project
Waste flue gas heat recovery project is very useful for industrial sector. This system can save more than
20% of gas consumption in most of the industries according to exhaust flew gas temperature and flow
rate. There are many applications of heat recovery project like
Steam generation for stirling power engines
Water pre heating for boilers
Combustion air pre heating for ovens
Water distillation
5. The objective of project is to recycle the exhaust waste flue gases and using recycling heat for heating
water used in production processes. The utilization of wasted heat will lower 10% to 25% of production
cost.
Technical details
Fuel composition – The initial fuel composition directly affects the ultimate composition of combustion
products and the amount of heat released into heating system. In general, with all other conditions
remaining the same, flues containing higher carbon monoxide and hydrogen would have lower available
heat, most fossil fuels are combusted with ambient air (as differentiated from combustion with pure
oxygen).
Since ambient air contains about 76% volume gaseous nitrogen (N2), which is essentially non-
combustible, the largest part of the flue gas from most fossil-fuel combustion is un-combusted nitrogen
and the least part of Carbon dioxide (CO2). The next largest part of flue gas can be as much as 10−25%
volume.
Flue Gas Losses
Waste heat losses means energy is emitted in unused form into the atmosphere. And this loss is greater
and the hotter the flue gas leaves the heat generator. The stack temperature should be as low as possible.
However, it should not be so low that water vapor in the exhaust condenses on the stack walls. This is
important in fuels containing significant Sulphur and low temperature can lead to Sulphur dew point
corrosion. Stack temperatures greater than 150°C indicates potential for recovery of waste heat. We can
use flue gas heat for preheating of ovens that will cause temperature drop in flue gas exhaust. If
temperature of exhaust is above to 150°C we can use this flue heat for water heating.
1 m3 natural gas needs about 10 m3 air (Stoichiometric Combustion)
6. So for every m3 natural gas we produce 11 m3 flue gas
Natural Gas contains = 31.56 MJ / m³
More air, more loss
One m³ of natural gas = 3500 BTU
One KG of LPG = 0.54 m³
1 BTU = 1055 joule
Heat: m. Cp. ∆T
Where: m = mass, Cp = Specific heat and ∆T = temperature difference
Exhaust flue temperature of oven = 250 C°
Fuel temperature = 30 C°
Cp =1
- Flue heat losses per m³ of natural gas = 11 * 1 * (250 – 30) = 2530 kJ
- Our total gas consumption = 273,372 m³ / month
- Average flue gas losses in a month = 691,631 MJ / month
- Average flue gas losses in a month = 655.5 mmbtu / month
- Average flue gas losses in an hour = 900,000 btu / hour
- Average flue gas losses in one minute = 15,000 btu / min
Line losses, air mixture in LPG losses and LPG re-filling pump losses are not considered in all above
calculations.
Flue gas heat Recovery
A Btu is defined as the amount of heat required to raise the temperature of one pound of water one
degree Fahrenheit.
If we change the temperature 1 gallon of water from 12C°or 55°F to to 40C°or 105°F then
The amount of heat required = Water Volume (lb) x Temperature rise (°F) x 1 Btu/lb°F
Water Volume (lb) = 1 gal/min x 1 min x 8.34 lb/gal = 8.34 lb
Temperature rise from 50°F to 105°F = 55°F
-The amount of heat required = 8.34 lb x 55°F = 458btu (BTU required to raise 1 gallon of 12C° water up
to 40C° in one minute)
- Our flue gas losses is 15000 btu / min, and the required btu to raise 1 gallon of 12C° water up to 40C°
in one minute is 458 btu /min.
7. - So we can recover this flue loses to heating water = 15000 btu / 458 btu = 32.7 gallon / min and 1962
gallons / hour.
We are wasting 655.5 mmbtu flue gases in a month into environment which is equal to 18,728m³ ideally
Savings
Our hot water requirement is 200 gallon / hour, for this purpose we are using gas geezers.
The amount of heat required = Water Volume (lb) x Temperature rise (°F) x 1 Btu/lb°F
Water Volume (lb) = 3.3 gal/min x 60 min x 8.34 lb/gal = 1651.3 lb
Temperature rise from 50°F to 105°F = 55°F
The amount of heat required = 1651.3 lb x 55°F = 90821.5 (BTU required to raise 3.3 gallons of
12C° water up to 40C° in one hour)
- If the gas water geezers efficiency is 50%, then there would (90821.5 /.50) = 181,643 btus required
- Water geezers gas consumption per hour = 181643btu / 3500btu = 51m³ / hour
- Water geezer gas consumption per month = 36,720m³ / month
- One m³ cost of gas (LPG + NG) = 33 PKR / m³.
- Gas consumption cost per month = 36720 * 33 = 121, 176,0 PKR / month
Currently we are investing this amount only for water heating. After installation of heat recovery system
we would save every month.
Heat Exchanger for waste flue gases heat
The 130 °C limit for economizers makes sense even though the complete thermal energy is not utilized in
this way. In this case the flue gas does not cool down on the way to the top of the stack to such an extent
that the temperature drops below the dew point and the water vapor in the flue gas condenses. This
would have fatal consequences, i.e. corrosion in the entire flue gas system. Things are different with
stainless steel. This material is resistant to corrosion. If the economizer and the flue gas system are made
of stainless steel, the flue gas temperature can therefore be substantially further reduced. This is referred
to as “condensing appliance technology”. The condensing appliance technology is of particular interest if
a great deal of fresh water or process water has to be heated up. In other words, the lower the flue gas
temperature can be reduced, the more efficient the condensing appliance technology. The function of the
condensing heat exchanger corresponds to that of the economizer, the big difference being that here the
flue gas can be cooled down much more. This technology is advantageous especially with fuels that
contain a great deal of hydrogen (e.g. natural gas) because the water vapour in the flue gas begins to
condense at higher temperatures (in the case of natural gas, for example, at 58 °C) and thus releases its
energy at an early stage.
8. Construction
A heat pipe is a metal tube, sealed at both ends with a vacuum inside, filled with a small quantity of fluid.
The fluid used depends upon the required working temperature range of the heat pipe. The working
temperature range with a water fill is 80ºC to 320ºC which will meet over 90% of application
requirements.
The metal used for the heat pipe construction depends upon the application and most common materials
are:
• Copper
• Carbon steel
• Stainless steel (AISI 304 and AISI 316)
• Aluminum
Potential for commercialization
Food processing industry of Pakistan will be the beneficial of our heat recovery system. At first stage the
Coronet Foods, a biscuit manufacturing company will be the end user of heat recovery project. Expert
machinery is a company which will implement this heat recovery project in Coronet Foods with the help
of research team.
The cost of this heat recovery project is 239, 850,0 PKR.
For maximum heat recovery from the flue
gases use condensing appliance technology.
9. This heat recovery project will save 121,1760 PKR / month ideally and system cost will be recovered in
60 working days.
This heat recovery project will save 969,408 PKR / month at 80% efficiency and system cost will be
recovered in 72 working days.
This heat recovery project will save 484,704 PKR / month at 40% efficiency and system cost will be
recovered in 147 working days.
Research plan:
Work packages (WP), Tasks (T), Milestone (M) and Deliverables (D)
Work Packages & Related Tasks Milestones & Deliverables
1st Year
Q1 Q2 Q3 Q4
WP1: Design and material procurement
T1.1: Design of equipment
M1.1: Fluid flow analysis
M1.2: Structure design and analysis
M1.3: Material procurement
D1.1. Report on equipment designT1.2: Procurement of material
WP2: Material processing
T2.1: Bending, drawing and
machining of parts
M2.1: Material processing, for
example: bending, drawing and
machining of parts
M2.2: Initial fitting check of parts
D2.1: Report on material processingT2.2: Fitting check of parts
WP3: Assembly and installation of equipment
T3.1: Assembly of equipment
M3.1: Assembly of heat recovery
system at workshop
M3.2: Installation of heat recovery
system in plant
D6.1: Internal dissemination of
knowledge
D6.2: Dissemination through papers
in
specialized high impact scientific
journals
D6.3: Participation in knowledge
transfer
events (national and international
conferences, seminars)
D6.4: Master Theses
D6.5: International patent applications
(if any)
T3.2: Installation of equipment in
plant
T3.3: Training and education of
young researchers
T3.4: Dissemination of knowledge
through scientific publications,
conference presentations and IPR
protection (international patent
application)
10. Budget allocation:
Cost Categories Total Allocation
Remuneration to PI (Coronet) [12 month] Rs. 30,000/month
Remuneration to Co-PI #1 (Coronet) [12 month] Rs. 30,000/month
Remuneration to Co-PI #2 (USPCAS-E UET Peshawar) [12 month] Rs. 30,000/month
Studentships: MS/M. Phil. Student (01) [12 month] Rs. 20,000/month
Design cost
Heat exchanger fluid flow analysis
Heat exchanger structure design and analysis
Rs. 200,000/-
Material cost
Consumables:
Metal pipes, metal sheets, welding rods, soldering metal, sealing material,
fasteners
Rs. 450,000/-
Equipment, Lab. Supplies
Operational hours of metal drawing, bending, machining.
Ultrasonic testing of welded and soldered pipes for monitoring of welded
and soldering joints.
Rs. 500,000/-
Installation cost of equipment Rs. 300,000/-
Labor cost (matching funds from industry)
Labor of Machining shop, process unit, welding and soldering unit,
assembly shop
Rs. 300,000/-
Salary of engineers and project team (matching funds from industry)
Process engineer (01), 20% of the full salary/month/year
Machine shop engineer (01), 20% of the full salary/month/year
Account and finance manager (01), 10% of the full salary/month/year
Office boy (01), 20% of the full salary/month/year
Rs. 600,000/-
Office and other supplies (matching funds from industry) Rs. 150,000/-
Training of USPCAS-E UET students (matching funds from industry) Rs. 100,000/-
Journals and Conference feeds Rs. 80,000/-
Secretariat staff of CAS-EP and
Research Directorate staff
involved in the project
Rs. 30,000/-
Supplies Rs. 20,000/-
Audit/Accounts Rs. 30,000/-
Travel (in Pakistan) Rs. 50,000/-
Consultancy charges Rs. 20,000/-
Cost under the budget head of USPCAS-E project proposal
Matching funds from Coronet Industry
Total cost under the budget head of USPCAS-E + Coronet Industry
Rs. 300,000/-
Rs. 115,0000/-
Rs. 415,0000/-
11. References
[1] Agriculture and Agri-Food Canada, Departmental Electronic Publications. Heat Recovery for Canadian
Food and Beverage Industries. 2001. www.agr.gc.ca/cal/epub/5181e/images/5181e_pic85.gif and
www.agr.gc.ca/cal/epub/5181e/5181-0007_e.html
[2] Department of Coal, Government of India. Coal and Industrial Furnaces – Efficient Utilization. 1985
[3] Hardtech Group. www.hardtech.es/hgg_tt_hrt.0.html
[4] King Fahad University of Petroleum & Minerals. 2003.
http://faculty.kfupm.edu.sa/me/antar/Shell_Tube/classes/Shell-and-tube.jpg
[5] Petroleum Conservation Research Association (PCRA), Ministry of Petroluem. Fuel Economy in
Furnaces and Waste heat recovery. Industrial Booklet 5. 1998. www.pcra.org Reay, D.A. and Span, F.N.
Heat Recovery Systems.1979.
[6] Reay, D.A. Low Temperature Waste Heat Recovery in the Process Industry. Good Practice Guide No.
141. 1996.
[7] SADC Energy Sector. Module 15. Heat Recovery Systems. Developed as part of the SADC Industrial
Energy Management Project for the Canadian International Development Agency.
www.siemp.co.zw/manuals/htm 1999.
[8] Sustainable Energy Authority of Victoria (SEAV), Australia. Best Practice Design, Technology and
Management, Module 5. 2004.
www.seav.vic.gov.au/ftp/advice/business/info_sheets/HeatRecoveryInfo_0_a.pdf
12. COVER LETTER
December 15, 2015
Asif Sultan, Engineer
Coronet Foods
PLOT NO. 55: ROAD NO. I, PHASE III, INDUSTRIAL STATE, HATTAR HARIPOR, KPK, Pakistan
Dear Deputy Director Projects USPCAS-E UET Peshawar:
I am pleased to submit to you this research proposal for my project, tentatively titled ‘Heat Recovery
from Exhaust Flue Gases.’ This is the joined project of Coronet Foods and Xpert Machinery companies.
The purpose for this research proposal is to request funding from the USPCAS-E UET Peshawar to
complete the project."
If you have any questions or need further assistance, please contact me at 0995-617551-2 (173) or
asif.sultan@cfl.com.pk
Sincerely,
Asif Sultan, Engineer, Coronet Foods, Principal Investigator
Dr. Saim, Assistant Professor, USPCAS-E UET Peshawar, Co-Principal Investigator
Khalid Mehmood, Engineer, Coronet Foods, Co-Principal Investigator
