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One-day workshop on Industrial Heating

Heating consists of the majority of the energy demand in Industries. Around 123 Gwh of energy is consumed every year.
The workshop was conducted to give an understanding of the various ways to sustainably provide heat for processes.

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One-day workshop on Industrial Heating

  1. 1. Leader in Industry scale solar thermal plants with over 2 MW installation and industrial heat pump with over 500 kW Rooftop solar installation for 40-120o C industrial processes Industry’s first 90/95 °C Heat pump Replace fossil fuel and reduce carbon emission with clean green solar energy Technical expertise for hybridization Unique PPA model for solar industrial heating Proud Pioneers About Aspiration Energy
  2. 2. Solar Heating For Industries Industrial Processes suitable for Solar / Heat pump Drying Electroplating Bleaching Cleaning Cooking Pickling Degreasing Steaming Evaporating Phosphating Preheating Washing
  3. 3. Solar Power Active Solar PV Solar Thermal Passive Heat Pump Solar Power: Classification
  4. 4. Solar Heating For Industries Active Solar Solar Thermal System Passive Solar Heat Pump System
  5. 5. Ambient Heat Primary power (Electricity) Heat Pump USABLE ENERGY Renewable Energy Conventional Energy Heat Pump
  6. 6. AC vs Heat Pump
  7. 7. COP WHAT IS MEANT BY EFFICIENCY? Efficiency = 𝑶𝒖𝒕𝒑𝒖𝒕 𝑰𝒏𝒑𝒖𝒕
  8. 8. WHAT IS THE EFFICIENCY OF A NORMAL INDUCTION MOTOR? Example: For 7.5 kW IE1 = 84 - 86% IE2 = 87 - 88% IE3 = 89 - 90% COP
  9. 9. COP WHAT IS THE EFFICIENCY OF FAN? CENTRIFUGAL/AXIAL FAN = 60-70%
  10. 10. COP WHAT IS THE EFFICIENCY OF BOILER? Typical efficiency of boilers = 70-90%
  11. 11. 10 kW Useful energy (compressed air) 1 kW Efficiency of Air Compressor = 10% 9 kW – as waste heat Efficiency of Air Compressor
  12. 12. COP WHAT IS THE EFFICIENCY OF A CAR? IF YOU FILL 10 LITRES OF FUEL IN A CAR, HOW MUCH ENERGY IS USED TO MOVE IT ON THE ROAD? 10 lts 1.5 lts Fuel Efficiency = 15%
  13. 13. COP
  14. 14. 1 kW 900 W 90% How Efficient Is Electric Heater ?
  15. 15. COP DO YOU KNOW ANY MACHINE WHICH CAN HAVE 100% EFFICIENCY ? IS IT POSSIBLE?
  16. 16. COP WHAT IS THE EFFICIENCY OF AN AIR CONDITIONER? EG. 1.5 TR AC Power consumption = 2 kW 1 Ton of Refrigeration= 3512 W Energy output = 3512 X 1.5 TR = 5268 W = 5.268 kW EFFICIENCY or COP = Output / Input = 5.268/2 = 2.634 WHAT IT MEANS? IF YOU GIVE 1 KW OF ENERGY IT WILL GENERATE 2.6 kW OF ENERGY. HOW?
  17. 17. TYPES OF HEAT PUMP BY SOURCE AIR SOURCE HEAT PUMP WATER SOURCE HEAT PUMP BY TEMPERATURE 55/60 DEG C HEAT PUMP 75/80 DEG C HEAT PUMP 90/95 DEG C HEAT PUMP
  18. 18. Ambient Heat Primary power (Electricity) Heat Pump USABLE ENERGY Renewable Energy Conventional Energy Heat Pump
  19. 19. 1 kW1 - 2 kW 2- 3 kW+ = Heatistakeninfromtheambient The system pumps heat from a low temperature reservoir to a high temperature Heat Pump - Principle
  20. 20. COP WHAT IS THE EFFICIENCY OF A HEAT PUMP? 300% TO 500% WITH COP OF 3 TO 4 WHAT IT MEANS? IF YOU GIVE 1 KW OF ENERGY IT WILL GENERATE 3 kW TO 5 KW OF ENERGY.
  21. 21. Free Cooling DO YOU NEED LIFE LONG FREE AC? HEAT PUMP GIVES YOU FREE COLD WATER UPTO 7 DEG C WHILE SIMULTANEOUSLY PRODUCING HOT WATER AROUND 55 DEG C 7 DEG C 55 DEG C
  22. 22. Water Source Heat Pump Hot Water Tank Air Conditioner Water source heat pump 50℃ 8℃ 55℃ 13℃
  23. 23. Air Source Heat Pump
  24. 24. Expansion Valve Evaporator: Helps transfer heat from atmosphere to the refrigerant Condenser: refrigerant loses the heat to the water Compressor: compresses refrigerant to high temperature and pressure Heat Pump: Components
  25. 25. Industrial Application of Heat Pump
  26. 26. Steam @ 2000C 250C 250C Steam @ 2000C900C Boiler Feed Assisted Boiler Feed
  27. 27. Component Washing Industrial Washing Machine Pre-treatment Plants
  28. 28. Dish Wash
  29. 29. Bathing & Hand Wash
  30. 30. Boiler Efficiency & Calorific Value
  31. 31. FUEL IN (100 Litres) COLD WATER IN STEAM / HOT WATER OUT (70%) FLUE GAS OUT + OTHER LOSSES (30%) BOILER EFFICIENCY BOILER EFFICIENCY = 70% Boiler Efficiency
  32. 32. Through Fuel Consumption Energy required = Fuel Consumption x Calorific Value x Boiler Efficiency Energy required for Process Fuel Consumption Boiler Efficiency Fuel Calorific Value = 20 x 9422 x 70% = 1,31,908 kcal/hr = 131908/860 Energy required = 154 kW 20 litres/hr 9422 kcal/l 70%
  33. 33. Calorific Values Liquid Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Specific Gravity kcal/litres Diesel 44,800 10707.2 0.88 9422.3 SKO 46,200 11041.8 0.8 8833.4 FO 43,000 10277 0.92 9454.8 Gaseous Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Propane 50,350 12033.65 LPG 46,100 11017.9 Solid Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Coal 15,000 3585 Coke 28,000 6692
  34. 34. Fuel Calorific Value Litre/kg Boiler Efficiency kW Litre/kg Fuel Price Cost of Energy Spent per kW (Rs) kcal kW Furnace oil 9454.84 11.00 per litre 60% 6.6 per litre 36 5.45 HSD 9422.3 11.00 per litre 60% 6.6 per litre 63 9.55 SKO 8833.3 10.30 per litre 60% 6.18 per litre 50 8.09 LPG 11017.9 13.00 per kg 60% 7.8 per kg 43 5.51 Propane 12033.7 14.00 per kg 60% 8.4 per kg 42 5.00 Coal/Coke 5250 6.00 per kg 60% 3.6 per kg 8 2.22 Briquette (Sugarcane husk) 3996 4.65 per kg 60% 2.79 per kg 4.5 1.61 Electricity 860 1 per unit 95% 0.95 per unit 8 8.42 Calorific Values
  35. 35. Boiler Efficiency The maximum rated efficiency of the boiler can be, Liquid Fuel : 80 – 85% Gaseous Fuel : 90 – 95% Solid Fuel : 75 – 80% Boiler Efficiency
  36. 36. Boiler Losses
  37. 37. Did you know….? Volume of water for the production of normal food stuffs.. Food Stuff Quantity Water consumption (liters) Rice 1 kg 2,497 Chicken 1 kg 4,325 Mutton 1 kg 10,412 Beef 1 kg 15,415 Chocolates 1 kg 17,196 Pizza 1 unit 1,239 Apple 1 kg 822 Banana 1 kg 790
  38. 38. LOAD CALCULATIONS - BASICS
  39. 39. Load Calculation CALCULATION TYPES: Through litres per day of water • Canteen & Boiler Feed water application Through Fuel Consumption • Process heating & washing machine applications
  40. 40. Through Litres per day of Water Q = m x Cp x ΔT Canteen & Boiler feed application Q = Energy required (kW) m = Mass flow of water in LPD Cp = Specific heat of water (kcal/kg K) ΔT = Temperature difference (deg C) Example: 10000 LPD has to be raised from ambient to 80 deg C Q = 10000 x 1 x (80 – 30) = 500000 kcal = 500000/860 = 581 kWh per day
  41. 41. Through Litres per day of Water LOAD ESTIMATION FOR HEAT PUMP SYSTEM Effective working hours = 16 - 18 hours per Day Heat Pump Capacity = 𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲 𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐇𝐨𝐮𝐫𝐬 = 581/16 = 36 kW
  42. 42. TYPE - 2 Thru Fuel Consumption Amount of Fuel consumed by the Boiler? Boiler Efficiency? Example: Average Fuel consumed by the boiler per hour = 10 Litres of Diesel Calorific value of Diesel = 11 kW per litre Total energy = 110 kWh of Energy With Boiler efficiency of 70%, the effective Output per hour = 110*0.7 = 77 kW
  43. 43. TYPE-2: THRU FUEL CONSUMPTION FUEL IN (10 Litres) or 110 kWh COLD WATER IN HOT WATER OUT (70%) or 77 kWh FLUE GAS OUT (30%) BOILER EFFICIENCY BOILER EFFICIENCY = 70%
  44. 44. Solar Capacity Actual Energy required for Process Pipe Heat Loss Pipe Heat Loss will normally be 10% to 20%
  45. 45. Did you know….? Carbon negative……….Has anyone heard?
  46. 46. Canteen Cooking / PLATE WASH / HAND WASH / BOILER FEED
  47. 47. Heat Pump schematic
  48. 48. Features of Indirect Heating Constant Hot water 24/7 Suitable for raw water application Water transfer to secondary tank happens automatically Microprocessor controlled Less maintenance
  49. 49. Component Washing Industrial Washing Machine Pre-treatment Plants
  50. 50. Indirect Heating – Immersed coil
  51. 51. Indirect Heating – 2 PHEs
  52. 52. HEAT PUMP INTEGRATION
  53. 53. Process heating application Temperature required Fuel Consumed Hours of operation Fuel used Boiler Efficiency Fuel Cost
  54. 54. Sample data 65 Deg C Temperature 60 kg/shift of LPG Fuel Consumed 70% Boiler efficiency 8 hrs Operation Hours 6, 8, 7.5, 9, 9, 8.5, 6, 6 Hourly Load pattern/shift (kg/hr) LPG Fuel Used Rs. 55/kg Cost of Fuel
  55. 55. Load Estimation Fuel Consumed per hour = 9 kg/hr (during peak load) Calorific value of LPG = 12.8 kW/kg Boiler Efficiency = 70% Energy required for process = Fuel Consumption * Calorific value * Boiler efficiency = 9 * 12.8 * 0.70 = 80.64 kW Total Energy required for one hour = 80.64 kW
  56. 56. Did you know….? How much energy from the sun reaching earth is equivalent to Annual human usage…?
  57. 57. Sizing of Pipes
  58. 58. • Flow Rate • Pressure drop • Pressure Drop ∝ to Flow rate • More the flow rate, more the pressure drop and vice versa Pipe Selection Criteria
  59. 59. Which size to be selected??
  60. 60. 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 PressureDropinm(for100mtrofpipelinelength) Flow Rate (LPH) Pressure Loss in Pipe line for 100 mtr of Length - Pump Head Calculation 1.5" Pipe Pressure Drop 2" Pressure Drop 2.5" Pressure Drop 3" Pressure Loss Pressure Loss
  61. 61. 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 PipeSize(Inches) Flow Rate (LPH) 1.5 Inch Pipe from 0 LPH to 3750 LPH 2 Inch Pipe From 3750 LPH to 6250 LPH 2.5 Inch Pipe From 6250 LPH to 8750 LPH 3 Inch Pipe From 8750 LPH to 13750 LPH 3.5Inch Pipe From 137500 LPH to 18300 LPH 4 Inch Pipe From 18300 LPH to 23500 LPH Pipe Sizing
  62. 62. Maintenance
  63. 63. Strainer Maintenance
  64. 64. Piping Maintenance
  65. 65. Tank maintenance
  66. 66. Did you know….? How much CO2 is produced on burning a litre of diesel or Petrol..? 1 litre of Diesel = 2.6 kg of CO2 1 litre of Petrol = 2.3 kg of CO2
  67. 67. Water Quality
  68. 68. Parameter Unit LPD Specifications Process Specifications Colour Colourless Colourless Odour Unobjectionable Unobjectionable Turbidity NTU 5 5 pH 6.5 to 8.5 6.5 to 8.5 Total Dissolved Solids mg/L 300 50 Total Alkalinity mg/L 120 20 Total Hardness mg/L 180 30 Calcium mg/L 45 7.5 Magnesium mg/L 18 3 Chloride mg/L 150 25 Sulphate mg/L 120 20 Iron mg/L 0.018 0.003 Nitrate mg/L 27 4.5 Fluoride mg/L 0.6 1 Water quality
  69. 69. pH is a numeric scale used to specify the acidity or alkalinity of an aqueous solution Effects of pH Acidity Alkalinity Neutral • pH below 6.5 causes erosion of material which results in leakage • pH above 8.5 causes scale formation inside tube.
  70. 70. Case Study @ Brakes India,Padi Existing Process Conventional Heat Source Electrical Heater Application Component washing Temperature Range 50-60 ⁰C Electricity Consumption 24 kWh per hour After Heat Pump Project size 28 kW Present Consumption 12 kWh per hour Units saved per year 86,400 kWh Annual Carbon Abatement 73, 440 kg
  71. 71. Case Study @ Lucas TVS Project Size 160 kW Conventional Heat Source SKO Application Pre-Treatment Temperature Range 70 - 90 ⁰C ZERO Investment from Customer Rs. 8 per MCal Present Cost Rs. 5.5 per MCal Offered Cost Unique PPA Model
  72. 72. Execution Credibility Aspiration Energy provides comprehensive EPC solutions for solar projects. We design, integrate, install and commission with our in- house design and development team. From concept to commissioning to operation and maintenance we take care of complete lifespan of the plant. Over the years, we have developed expertise in engineering and technology.
  73. 73. Same founders • Rs. 300 Cr, 1500 people • A Deloitte and Touche Fast 500 Asia Company Award winner for consecutive 4 years Profitable IT firm • Fast Forward to the Solar Future. Vision • 7 Years in Solar • 3 Years in Industrial Heating • Pioneers of RESCO model - Capex to Opex in Solar Thermal Our Experience Promoter Background
  74. 74. 20+ years experienced entrepreneur Co-founder, Aspire Systems Chairman, Energy Committee, South Indian Chamber of Commerce Mechanical Engineer from Pondicherry University MBA from Kellogg School of Management, Northwestern University, USA Certified PV Designer from Solar Energy International (SEI) Bhoovarahan Thirumalai, Founder and CEO Management
  75. 75. Satyanarayanan S, CTO Faculty at IIT Madras, Co-ordinator of Industrial Assessment Centre Formerly head of exploratory R&D at Forbes Marshall, US$250 company in the domain of industrial process heating and control instrumentation Research experience with General Electric – Global Research Centre in the area of Aero Thermal and Mechanical Systems PhD, Mechanical Engineering from Texas A&M University, College Station Gowri Subramaniam, Director and Co Founder 20+ years experienced entrepreneur Co-founder and CEO of Aspire Systems, Mechanical Engineer from Pondicherry University MS - Industrial Engineering from Texas A&M, USA Management
  76. 76. Photo : Bhoovarahan Thirumalai, CEO and Manoharan Head Solar Thermal, receiving the award from The Honurable Union Minister Shri Prakash Javedakar. CLIMATE SOLVER AWARD: WWF
  77. 77. PARIVARTAN SUSTAINABILITY AWARD
  78. 78. Bhoovarahan Thirumalai of Aspiration Energy was awarded by MNRE for successful development of ESCO projects under UNDP/GEF Global water heating market transformation and strengthening initiative India country program. MNRE AWARD
  79. 79. TESTIMONIALS The crowning glory of the UNDP GSWH Program… an undisputed example of a win-win situation for client and the ESCO…marks the beginning of a new chapter in energy savings by industries through the ESCO route.. would help the industries in fulfilling their renewable purchase obligation and reduce the consumption of an expensive fossil fuel. I expect all forwarding looking companies would embrace what Aspiration Energy has demonstrated. ~Sandeep Tandon, UNDP
  80. 80. ASPIRATION ENERGY IN THE NEWS
  81. 81. Be the proud pioneer and save the future… >> Fast Forward to the Solar Future!! >> Contact us @ info@aspirationenergy.com/044-42185301

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Heating consists of the majority of the energy demand in Industries. Around 123 Gwh of energy is consumed every year. The workshop was conducted to give an understanding of the various ways to sustainably provide heat for processes.

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