Match industry energy audit report

Che-262 Energy Engineering Match industry audit y 1
Energy Audit Match Industry
ChE-262 Energy Engineering
B Y
Ahmad jan: 15pwche1047
Abdullah: 15pwche1057
Ejaz Afridi: 15pwche1056
Saeed Anwar: 15pwche1070
Ijaz Khalil: 15pwche1072
Submitted to
Dr. Imran Ahmad

Contents
Executive Summary: .........................................................................................3
PROCESS INFORMATION:..................................................................................4
PROCESS FLOW DIAGRAM ............................................................................4
PROCESS EXPLAINATION:..............................................................................4
MATERIAL BALANCE:.........................................................................................7
Total mass balance:.......................................................................................7
X kg wax/kg...............................................................................................8
min............................................................................................................8
CHEMICAL BALANCE: ....................................................................................8
ENERGY BALANCE:............................................................................................8
KINETIC ENERGY:...........................................................................................9
ECM FOR MOTOR............................................................................................10
ANNUAL ENERGY SAVING ...............................................................................11
ELECTRICITY SAVING.......................................................................................11
SAVING (Motor etc) SUGGESTIONS.............................................................12
Appendices: ....................................................................................................13
BILLS: ..............................................................................................................15
ALAM MATCH INDUSTRY LAY OUT (Peshawar) ...............................................16

Executive Summary:
As a part of audit team from University of Engineering and Technology
Peshawar (UET) we visited Industrial state Hayatabad Peshawar on 25-oct-2017
to conduct an energy efficiency audit of a Match sticks industry. The overall
purpose of audit was to assist the plant in identifying low cost or no cost energy
saving opportunities.
To accomplish this, the Audit Team collected data at each plant to make
informed decisions regarding opportunities for improving energy efficiency.
Data were accumulated from several sources, including plant instrumentation,
field measurements, plant records, independent reports, and interviews of
plant operating personnel. Information about the measurements taken during
the audit is included.
After all the calculations and processes the audit team has recommended some
suggestions which should be applied to the industry in order to have an energy
efficient process
1. Some of the motors should be replaced with the new ones of high
efficiency.
2. The fuel used should be changed because we could use a cheaper and
better fuel instead.
By applying these recommended changes the industrial annual profit ratio will
be much high than the previous profit ratios. And the industrial will be more
energy efficient.

PROCESS INFORMATION:
PROCESS FLOW DIAGRAM
Heat
Air
Match Sticks FLOW CHART FOR MATCH INDUSTRY
PROCESS EXPLAINATION:
RAW MATERIALS
Raw materials used for manufacturing of safety Matches include
Wood(Aspheria or Aspin trees), wax, chlorate, sulphur, Bichromate of
potassium, rosin, Manganese (red/black), glass powder, antimony,
phosphorous, carbon black, gelatin, bundle sheet , fuel.
 Wax: Wax is a byproduct from the petroleum refining industry.
Cutting
MachineWood Peeling
Machine
Chopping
Machine
Dry
Chambers
Polish Drum
Blow
er
Blo
wer
Hooper
Blow
er
Simplex
Machine
achine
Blower
Forward for Box Filling and Packing Process
3 4
5
6
1 2

 Chlorate of Potassium: This chemical is a white powder made from
potassium chloride. It is now made in Pakistan and is also imported. The
imported chemical is costlier. The chlorate must be commercially pure
which means that it should not contain more than the slightest quantity
of impurities. It is apt to contain some chloride which is very injurious to
match manufacture. Only the best quality of potash chlorate should be
used.
 Sulphur: This is another important basic raw material for Match
manufacturing process. It can be had from licensed dealers in a finely
powdered form and this is to be used as a match chemical. Sulphur like
potash chlorate, needs license for 155 storing and transport. It is
supplied by both local manufactures and foreign companies chiefly
from Spain.
 Bi-chromate of Potassium: Bi-chromate is used as an oxidizing agent
to produce flame in a trice. It is used to lower the decomposition
temperature of potassium, which a Match needs. It speeds up the
burning reaction.
 Rosin: Rosin is used to control the velocity of propagation of flame in
the Match head.
 Manganese (Red / Black): This raw material is a powerful catalyst. It
is used for the release of oxygen of chlorate. Two types of manganese
are used by the Match industry. The industries that want to produce
Matches of black color flame will use black manganese and the industry
that want to produce red color flame Matches will use red manganese.
 Glue: It is the binding agent, which plays a vital role in Match
production. The glue must be strong enough to bind the powdered
ingredients into a firm bulb, but the amount of glue present must be
enough to permit easy abrasion, which proceeds ignition. The amount

of binder is also limited by its function as fuel. The preparation of its
solution and quality and type of glue used play an important role in
quality determination and the price fixation of Matches.
 Glass powder: Glass powder is used in head composition and side
coating compound. Generally, this is obtained by grinding selected glass
factory wastes or from broken sheet of glass sheet or colourless glass.
This glass powder softens at the burning temperature and acts as a
binder for the other molten head components, giving a compact and
strong ash structure. The sharp edged needles contribute to the friction
properties of both the match head and side coating of Match boxes.
 Antimony: It is used in coating chemical compound on sides. It helps
the Match stick to burn immediately after striking.
 Phosphorus: Phosphorus is one of the fundamental components of
the head composition and the striking surface for the safety Match
stick, namely the surface of the Match box
 Fuel: It is used for preparing glue solution. According to the nature of
raw materials used, the quality and the cost of production vary.

MATERIAL BALANCE:
In the chemical section a mixer is used to make the chemical for the match
head.
Total mass balance:
Mass in = Mass out
𝑚1 + 𝑚2 + 𝑚3 = 𝑚
1.616 kg/min + 2 kg/min +3.5 kg/min = 𝑚̇
𝑚̇ = 7.116kg/min

WAX BALANCE:
3.5 kg wax/min =
𝑚̇ = 7.116 kg/min
X = 0.46 kg wax/min
CHEMICAL BALANCE:
2 kg chemicals/min =
Y = 0.28 kg chemicals/min
ENERGY BALANCE:
We are having an energy balance on a boiler. Wax is being made in the boiler.
𝒎̇
X kg wax/kg
Min
𝒎̇ Y kg chemicals/min
Min

 First of all
Q-Ws=∆𝑯̇ + ∆𝑬 𝑲
̇ + ∆𝑬 𝑷
̇
Ws=0
∆𝑬 𝒑 =̇ 𝟎
Q = ∆𝐻̇ + ∆𝐸 𝑘
̇
 EVALUATE ∆𝐇:
∆𝐻̇ = ∑ 𝑚𝑖𝑜𝑢𝑡 𝐻𝑖 + ∑ 𝑚𝑖 𝐻𝑖𝑖𝑛
= 1.02Kg 2793 Kj -1.6 kg 271kj -0.2kg 125.7kj
Min kg min kg min kg
∆𝐻̇ = 2848.86 - 435.04 - 25.14
∆𝐻̇ = 2388.32 𝑘𝑗/𝑚𝑖𝑛
KINETIC ENERGY:
A= 𝜋𝑟2
= 3.14, 202
𝑐𝑚2
1𝑚2
104
𝑐𝑚2
A = 0.1256 𝑚2
Now,
𝑢 = 𝑣/𝐴̇
= 1.02 kg 1min 0.1166𝑚3
Min 60 s kg 0.1256 𝑚2
v= 0.15 m/s

Thus :
∆𝐸̇ 𝑘 = 𝑚̇ 𝑢2
/2
= 1.02 kg 0.152
𝑚2
1𝑁 1kj
Min 𝑠2
kg.m/ 103
𝑁𝑚
∆𝐸 𝑘 = 22 × 10−3
kj/min
Putting values in equation we get
Q = 22× 10−3
+ 2388.32
Q = 2388.56 kj/min
ECM FOR MOTOR
According to a research we can save energy consumption
in a motor which works a fixed number of hours per year.
For example: 6-20 hp motor should works for 3391 hrs/year .The main motor of
a simplex machine works 3421hrs/year .Having a power of 10 hp and 85 %
efficient.
 ECM CALCULATI0N
If we replace the motor by a NEMA motor of same size and type then
MOTOR POWER: 10 hp
LOAD FACTOR: KWh/KW.days.24 = 78%
ANNUAL OPERATING HOURS: 3421 hrs/year
EXISTING MOTOR EFFICIENCY: 85%
NEW MOTOR EFFICIENCY: 91%

ELECTRICITY LOST: 15 hrs/Kwh
ANNUAL ENERGY SAVING
Annual energy saving = HP× LF × 0.746 KW/hp ×hrs/year
× [100%/𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦1 - 100%/efficiency2] Rs/kwh
=10hp × 0.78 × 0.746 kwh/hp × 3421 hrs/year
× [100/85 – 100/91] × 15 Rs/kwh
Energy saving = 23000Rs/year
ELECTRICITY SAVING
Electricity saving = 0.746 KW/hp [
𝐻𝑃
𝑒𝑓𝑓𝑖1
-
𝐻𝑃
𝑒𝑓𝑓𝑖2
]
=0.746 KW/hp [10/0.85 - 10/0.91]
Electricity saving = 5.7 KW

SAVING (Motor etc) SUGGESTIONS
The industry is using wood as a source of heat. They are using
13295 kg of wood per month is worth 159540 Rs. we have some suggestions
FUEL USED CALORIES Rs/kg
Dry wood
Kj/kg Btu/lb
1216000 6200-7500
Coal (lignite-
Anthracite)
19000 8000-
14000
8.7
If we use coal instead of wood we will have it in less rupees and will give us
higher calorific values. so using coal will be more economical and will take
relatively large time to be fully combusted as compared to wood e.g.( if 1kg
wood gives heat up to half hour 1kg coal will give heat up to 1 hour).

Appendices:
This form may be employed to record data for electrical equipment including
motors, compressors etc.
No. of
motors
Equipment item
Location (near to
which process unit)
Amps
(A)
Volts
(V)
Power
(hp)
Hours
operated/da
y
Days
operated/w
eek
Comm
ents
1 Main motor Cutting machine 15 440 10 3 6
2 Motor Peeling machine 7.5 440 5 7 6
1 Main Motor Peeling machine 15 440 10 9 6
1 Motor Chopping machine 11.25 440 7.5 9 6
1 Gear box Motor Drying chamber 7.5 440 5 9 6
3 3 phase motor Drying chamber 3 440 2 9 6
1 Motor Drying chamber 7.5 440 5 9 6
1 Heat blower Drying chamber 7.5 440 5 9 6
1 Motor Mechanical screening 1.5 440 1 9 6
1 Motor Blower machine 15 440 10 9 6
1 Motor Polish drum 11.25 440 7.5 9 6
2 Screening motor Polish drum 1.5 440 1 10 6
1 Bower motor Polish drum 11.25 440 7.5 10 6
1 Blower motor Hooper 4.5 440 3 10 6
1 Vibrator Hooper 1.5 440 1 10 6
1 Main motor Simplex machine 15 440 10 9 6
1 Tray motor Simplex machine 1.5 440 1 9 6
1 Dust blower Simplex machine 4.5 440 3 9 6
1 Milling machine Simplex machine 3 440 1.5 9 6
1 Table motor Simplex machine 4.5 440 3 9 6
1 Gear box motor Simplex machine 4.5 440 3 9 6
1 Wax conveyer Simplex machine 3 440 1.5 9 6
1 Leveling motor Simplex machine 4.5 440 3 9 6
1 Heater Simplex machine 11.5 440 7 9 6
1 Heat blower Simplex machine 7.5 440 5 9 6
3 Screening motor Chemical section 1.5 440 1.5 10 6
Motor Wax machine 4.5 440 3 10 6
2 Motor Mixer 7.5 440 3 10 6
14 Motors Leveling machine 1.5 440 1 10 6
18 Motors Box making machine 1.5 440 1 10 6
11 Motors Box filling machine 3.5 440 2 10 6

This form may be employed to record data for process streams for material
balance of overall process.
CHEMICALS (Quardz powder+ Sulphur+ china clay + zinc + choric acid +
bichromate + violet color)
3 Gear box motor Dozen machine 1.5 440 1 10 6
2 Gear box motor Grove machine 1.5 440 1 10 6
1 Motor Press machine 11.25 440 7.5 10 6
2 Slip ring motor Dye machine 11.25 440 7.5 10 6
2 Main motor Screen machine 1.5 440 1 10 6
Compressor 11.25 440 7.5 10 6
Design
ation
Location
w.r.t to a
process
unit
Compositio
n
Flow
rate
(kg/
min)
Tem
pera
ture(
c)
Exit
heat
rate
(kj/kg
)
Comments, e.g.
scope for ECM or
O&M
Boiler
Wax
machine
Calcium
carbonate+
Polyvinyl
formal+
C5H5NO2
1.02 150
2388.
32
Mixer
Mixing
unit
Potassium
chlorate(18
kg)+
Chemicals
(17.2kg)+
Wax(5.2kg)
7.11 25

BILLS:
This form may be employed for recording data of utility bills
Months Electricity Natural Gas
kWh Total Rs. Rs./kWh MMBTU Total Rs. Rs./MMBTU
October 2016 16203 251094 15.4 89.335 53601 600
November
2016
19882 304565 15.3 154.116 92470 600
December
2016
19128 301101 15.7 176.001 105601 600
January 2017 22165 336374 15.1 242.29 145374 600
February
2017
25943 434998 16.7 257.674 154604 600
March 2017 27148 441819 16.2 336.957 202174 600
April 2017 30139 487321 16.1 193.662 116173 600
May 2017 21701 293038 13.5 215.703 129044 600
June 2017 20423 321345 15.7 193.706 116350 600
July 2017 13031 215778 16.5 220.568 132341 600
August 2017 29839 456218 15.2 263.112 157873 600
September
2017
31790 478614 15.0 313.902 188341 600

ALAM MATCH INDUSTRY LAY OUT (Peshawar)
Car Parking
GARDEN
Checking
Point
Entrance
Waiting Room
Canteen
Car Parking
Trucks Entrance
Feed
Storage
Process AreaMaintenance Hall
MosqueAccountAndFinanceSection

]
i. Cutting Machine ii.Peeling Machine
iii. Chopping Machine iv. Transport Machine

v. Simplex Machine
MixerPolish Drum
Boiler

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