Variable Frequency Drive Energy Efficient Motor Thermo Compressor Biogas Plant Diffuser Cogeneration Use Of Boiler’s Flue Gases/Exhaust In Economizer HP Boiler

2. PSSTPSST 4646thth
ANNUALPRESENTATIONANNUALPRESENTATION
RAMZAN
SUGAR MILLS
LIMITED
BY : KAMRAN HASSAN
(ELECTRICAL ENGINEER)

3. AcknowledgementAcknowledgement
 First of all, i would like to thank ALLAH for HIS firmFirst of all, i would like to thank ALLAH for HIS firm
hands in guiding me in the course of completing thishands in guiding me in the course of completing this
paper. It is by HIS grace and mercy that I am able topaper. It is by HIS grace and mercy that I am able to
obtain the research on planning project within such asobtain the research on planning project within such as
limited time. Alhamdulillah.limited time. Alhamdulillah.
 Second, I would like to express my gratitude and thanksSecond, I would like to express my gratitude and thanks
to our project director,to our project director, Mr. Javed IqbalMr. Javed Iqbal,, our HODour HOD
(Electrical)(Electrical) Mr. Abdul LatifMr. Abdul Latif, GM(production), GM(production)
Mr.Waseem GhafoorMr.Waseem Ghafoor,, DGM(mech)DGM(mech) Mr.Ghulam JafarMr.Ghulam Jafar,,
Production ManagerProduction Manager Mr. YaseenMr. Yaseen,, Chief ChemistChief Chemist Mr.Mr.
Ajmal SiddiqueAjmal Siddique, Chief Engineer Mechanical, Chief Engineer Mechanical Mr. NiaziMr. Niazi
Chief Engineer ElecticalChief Engineer Electical Mr. Amjad Ali BhattiMr. Amjad Ali Bhatti and Deputyand Deputy
Chief Engineer ElectricalChief Engineer Electrical Mr. Gulistan AhmedMr. Gulistan Ahmed for hisfor his
professional guidance, wisdom, endurance, advices,professional guidance, wisdom, endurance, advices,
motivation and encouragement during supervision periodmotivation and encouragement during supervision period

4. AcknowledgementAcknowledgement
 Thank you so much for the insights and encouragementThank you so much for the insights and encouragement
they have given to me. Without their patience andthey have given to me. Without their patience and
valuable assistance, the paper would not have been thevaluable assistance, the paper would not have been the
same as presented here.same as presented here.
 Besides that, I would like to convey my thanks to myBesides that, I would like to convey my thanks to my
beloved parents for the advice and give all support to mebeloved parents for the advice and give all support to me
in developing this project.in developing this project.
 My fellow friends should also be recognized for theirMy fellow friends should also be recognized for their
support at various conditions. Their views and tips aresupport at various conditions. Their views and tips are
useful indeed. Unfortunately, it is not possible to list all ofuseful indeed. Unfortunately, it is not possible to list all of
them in this limited space. And last but not least, I amthem in this limited space. And last but not least, I am
grateful to all my subordinates that help me a lot.grateful to all my subordinates that help me a lot.

5. Energy ConservativeEnergy Conservative
TechnologiesTechnologies
1)1) Variable Frequency DriveVariable Frequency Drive
2)2) Energy Efficient MotorEnergy Efficient Motor
3)3) Thermo CompressorThermo Compressor
4)4) Biogas PlantBiogas Plant
5)5) DiffuserDiffuser
6)6) CogenerationCogeneration
7)7) Use Of Boiler’s Flue Gases/Exhaust InUse Of Boiler’s Flue Gases/Exhaust In
EconomizerEconomizer
8)8) HP BoilerHP Boiler

6. Variable Frequency
Variable Frequency
Drive
Drive

7. Variable Frequency DriveVariable Frequency Drive
“Variable Frequency Drive (VFD ) is a system used for
controlling the speed of motor by controlling the frequency
of electric supply”
Principle :Principle :
All electrical motors operate at 50Hz frequency.
Speed of motor depends upon frequency of the
supply. As frequency changes, speed of the motor
also changes.
n =n =

8. How Safe Electrical Energy :How Safe Electrical Energy :
VFD is a energy saving device that can safe up to 30%VFD is a energy saving device that can safe up to 30%
Power consumed by electrical motor is directly proportional
to cube of speed of motor.
If motor runs at 90% speed, power consumed will be only
73% (0.9³ )
If motor runs at 80% speed, power consumed will be only
51% (0.8³ )
If motor runs at 75% speed, power consumed will be only
42% (0.75³)
If motor runs at 50% speed, power consumed will be only
12.5% (0.5³)

9. Advantages of VFD :Advantages of VFD :
 No Need of Soft Starter or Star Delta Starter.No Need of Soft Starter or Star Delta Starter.
 Less Electric Stress on Motor Insulation:Less Electric Stress on Motor Insulation:
VFD initially apply small voltage and gradually rises upVFD initially apply small voltage and gradually rises up
to rated value. If motor is run with soft starter, motor isto rated value. If motor is run with soft starter, motor is
subjected to abrupt high voltage that damages the motorsubjected to abrupt high voltage that damages the motor
insulation.insulation.
 Less Mechanical Stress on Motor’s Bearings :Less Mechanical Stress on Motor’s Bearings :
VFD smoothly rises the speed and torque from zero to desiredVFD smoothly rises the speed and torque from zero to desired
value so less mechanical stress on bearings.value so less mechanical stress on bearings.
 Increases Motor’s Service LifeIncreases Motor’s Service Life
 Reduces the Maintenance By Reducing theReduces the Maintenance By Reducing the
Mechanical Component.Mechanical Component.

10.  Reduces Annual Maintenance Cost Of Motor.Reduces Annual Maintenance Cost Of Motor.
 VFD Improves Power Factor :VFD Improves Power Factor :
Lower the power factor , more will be the cost to run anyLower the power factor , more will be the cost to run any
kind of motor. It safe up to 2% energy.kind of motor. It safe up to 2% energy.
 VFD is Environment Friendly :VFD is Environment Friendly :
Global warmingGlobal warming is the principal effect of excessive carbonis the principal effect of excessive carbon
dioxide in the atmosphere that is harmful to our environmentdioxide in the atmosphere that is harmful to our environment
As VFD consumes less power so less consumption of fuel dueAs VFD consumes less power so less consumption of fuel due
to which less carbon dioxide emission.to which less carbon dioxide emission.
 Reduces Peak Demand Charges :Reduces Peak Demand Charges :
WAPDA charges to company that exceed a preset limit.WAPDA charges to company that exceed a preset limit.
Maximum demand limit crosses when motor starts but VFDMaximum demand limit crosses when motor starts but VFD
reduces the peak demand charges by reducing the startingreduces the peak demand charges by reducing the starting
inrush current and reduces the overall energy cost.inrush current and reduces the overall energy cost.

11.  Optimize the Power Usage In Response To ActualOptimize the Power Usage In Response To Actual
Load :Load :
 VFD provides as much power as need.VFD provides as much power as need.
 We assume a motor , driving a pump, directlyWe assume a motor , driving a pump, directly
connected to supply, always running at full speed .connected to supply, always running at full speed .
The process requirement may change and motor isThe process requirement may change and motor is
not required to operate at full capacity. One possiblenot required to operate at full capacity. One possible
solution is to use throttling value where opening andsolution is to use throttling value where opening and
closing a value controls the flow but motor is stillclosing a value controls the flow but motor is still
running at full power, this is the wastage of powerrunning at full power, this is the wastage of power
and increases maintenance cost. It is just like that youand increases maintenance cost. It is just like that you
are driving your car with brakes on..are driving your car with brakes on..

12. Energy Saving With VFD Speed ControlEnergy Saving With VFD Speed Control

13. Comparison Of Different Speed ControllingComparison Of Different Speed Controlling
MethodsMethods

14. Comparison Between Throttling Value AndComparison Between Throttling Value And
VFD Control With 60% FlowVFD Control With 60% Flow
If flow is controlled with throttle value , motor will consume 100% power.If flow is controlled with throttle value , motor will consume 100% power.
But if flow is controlled with VFD, VFD will reduce the speed of motor toBut if flow is controlled with VFD, VFD will reduce the speed of motor to
60 % so power consumed will only be 0.6³ = 22% so60 % so power consumed will only be 0.6³ = 22% so
Energy Saving = 78%Energy Saving = 78%

15.  Rapid Pay Back :Rapid Pay Back :
Most VFD installations will pay for themselves quickly;Most VFD installations will pay for themselves quickly;
normally payback will occur within 12-18 months.normally payback will occur within 12-18 months.
 Removal of Voltage Sags :Removal of Voltage Sags :
VFD removes voltage sag during motor start up because itVFD removes voltage sag during motor start up because it
politely ramp the motor up to rate speed.politely ramp the motor up to rate speed.
 Less Audible Noise.Less Audible Noise.
 Less Vibration DamagesLess Vibration Damages
 Less Wear And Tear On Motor And PumpLess Wear And Tear On Motor And Pump

16.  Reduces Starting Inrush CurrentReduces Starting Inrush Current ::
 One major problem in sugar industry is thatOne major problem in sugar industry is that
when a heavy motor such as cane cutter motor orwhen a heavy motor such as cane cutter motor or
feed water pump motor it takes high torque loadfeed water pump motor it takes high torque load
that causes shut down or tripping in the powerthat causes shut down or tripping in the power
house. The reason is that motor initially drawshouse. The reason is that motor initially draws
high inrush current (torque load ) that is 6 to 8high inrush current (torque load ) that is 6 to 8
times higher than rated current that producestimes higher than rated current that produces
spike in power consumption. When a VFD starts aspike in power consumption. When a VFD starts a
motor, it initially applies a low frequency andmotor, it initially applies a low frequency and
voltage to the motor. Thus starting at such a lowvoltage to the motor. Thus starting at such a low
frequency avoids the high inrush current andfrequency avoids the high inrush current and
eliminates unnecessary tripping.eliminates unnecessary tripping.

17. Built In Motor Protection :
under voltage, overvoltage, Overcurrent protection, short
circuit protection, over heating protection, motor stall
protection are built in VFD.
“Bypass” is added to bypass
the VFD and to run the
motor on main power line
to avoid the interruption if
VFD get out of order or
require maintenance

18. How It Reduces Current?How It Reduces Current?
As we know the power of three phase motor is given asAs we know the power of three phase motor is given as
Let suppose we have motor with following characteristicsLet suppose we have motor with following characteristics
Power = 100 hp, Speed = 1,785 rpm, Voltage = 460 V, Full loadPower = 100 hp, Speed = 1,785 rpm, Voltage = 460 V, Full load
current = 115 A, Power factor = 0.86current = 115 A, Power factor = 0.86
““A VFD will convert its incoming power, a fixed voltage andA VFD will convert its incoming power, a fixed voltage and
frequency, to a variable voltage and frequency.”frequency, to a variable voltage and frequency.”
Suppose that motor is operating at half of the rated speedSuppose that motor is operating at half of the rated speed
producing full load torque and drawing full load current.producing full load torque and drawing full load current.
Frequency has to be half (30Hz).In order to keep the V/F ratioFrequency has to be half (30Hz).In order to keep the V/F ratio
constant the voltage will also be half (230V) so frequency andconstant the voltage will also be half (230V) so frequency and
voltage at the output of VFD is 30HZ and 230V respectively.voltage at the output of VFD is 30HZ and 230V respectively.
So the power at the output will beSo the power at the output will be
 For ideal VFD deviceFor ideal VFD device

19. Note that the input current is now less than half of the ratedNote that the input current is now less than half of the rated
current.current.
Suppose that motor is operating at rated speed thenSuppose that motor is operating at rated speed then
F=60HzF=60Hz
V=460VV=460V
P.F=0.86P.F=0.86
So power at the output will beSo power at the output will be

21. Side Power
(kW)
Voltage
(V)
Current
(A)
Frequency
(Hz)
Power
Factor
Input 39.4 460 115 60 0.86
Output at
half speed
39.4 230 55.6 30 0.89
Output at
rated speed
39.4 460 111.12 60 0.89
NoteNote
 By VFD we can improve P.FBy VFD we can improve P.F
 Difference in current is more when motor is operating at half orDifference in current is more when motor is operating at half or
lower then rated speedlower then rated speed
 There is a little difference when operating at full speed so beforeThere is a little difference when operating at full speed so before
choosing inverter for a particular application, we have to check thatchoosing inverter for a particular application, we have to check that
either it will be suitable for that particular application or not.either it will be suitable for that particular application or not.

22.  Selection of VFD :Selection of VFD :
When looking to apply VFD control to an existing pump, aWhen looking to apply VFD control to an existing pump, a
basic overview of the application should be investigated. Thebasic overview of the application should be investigated. The
motor drives that do not require to operate at full speed canmotor drives that do not require to operate at full speed can
save energy by using adjustable speed drive energy. Costsave energy by using adjustable speed drive energy. Cost
saving will be more with variable torque. If motor operate atsaving will be more with variable torque. If motor operate at
constant speed, there will be limited save in energy (may beconstant speed, there will be limited save in energy (may be
only 5%).only 5%).
 Where VFD can be used :Where VFD can be used :
Feeder table Primary cane carrier
Clear juice pump Muddy juice pump
ID, FD, Secondary Fans of boiler Sugar elevator
Feed water pump Hot and cold air blowers
A centrifugal drive Raw juice pump

23. Our Practical ExperienceOur Practical Experience::
In Ramzan sugar, we have implemented VFDs onIn Ramzan sugar, we have implemented VFDs on
feed table and ID, FD and Secondary motors offeed table and ID, FD and Secondary motors of
boilers. We avail many tangible advantages suchboilers. We avail many tangible advantages such
as:as:
 Load on boiler has reduced by 30%Load on boiler has reduced by 30%
 It has reduced the maintenance of feed tableIt has reduced the maintenance of feed table
motor that previously requires lot of maintenancemotor that previously requires lot of maintenance
due to frequently stop and start that usuallydue to frequently stop and start that usually
damaged their bearing and weakened motordamaged their bearing and weakened motor
insulation.insulation.
 VFD has reduced the steam consumption.VFD has reduced the steam consumption.
 It removed the torque load of ID, FD andIt removed the torque load of ID, FD and
secondary motors that causes unnecessarysecondary motors that causes unnecessary
tripping and unbudgeted repair cost.tripping and unbudgeted repair cost.

24. M
ultiple M
otor Control
M
ultiple M
otor Control
Using One VFD
Using One VFD

25. Multiple Motor Running With OneMultiple Motor Running With One
VFDVFD

26. One VFD can be used to run multiple motors running parallel atOne VFD can be used to run multiple motors running parallel at
same desired speed at same time.same desired speed at same time.
Where it is used?Where it is used?
 overhead traveling cranes whereoverhead traveling cranes where
two drive wheel motors must runtwo drive wheel motors must run
at the same speedat the same speed
 Exhaust, supply fans or array ofExhaust, supply fans or array of
fans.fans.
How to select VFD ?How to select VFD ?
 All motors must be of same rating (same HP and voltage ).All motors must be of same rating (same HP and voltage ).
 Provide overload protection to each motor.Provide overload protection to each motor.
 Current rating of VFD must be equal to or more than the sumCurrent rating of VFD must be equal to or more than the sum
of all motor current ratingsof all motor current ratings
Current rating of VFD = n × Motor Current RatingCurrent rating of VFD = n × Motor Current Rating
Where n is the number of motors running parallelWhere n is the number of motors running parallel

27.  Total motor lead length must be less than the critical length asTotal motor lead length must be less than the critical length as
specified by the manufacturer.specified by the manufacturer.
 All motors must be started at same time. One of more motorsAll motors must be started at same time. One of more motors
can not be started while one or more motors are alreadycan not be started while one or more motors are already
running unless VFD is sufficiently oversized.running unless VFD is sufficiently oversized.
EXAMPLEEXAMPLE : suppose we have 3 motors of rating: suppose we have 3 motors of rating
5 HP with an FLA 6.2A, 460 volts AC5 HP with an FLA 6.2A, 460 volts AC
5 HP with an FLA 6.2A, 460 volts AC5 HP with an FLA 6.2A, 460 volts AC
10 HP with an FLA 14A, LRA = 86.5, 460 volts AC10 HP with an FLA 14A, LRA = 86.5, 460 volts AC
If all motors are accelerated, decelerated and run in unison, theIf all motors are accelerated, decelerated and run in unison, the
sum of the connected motor FLA allows use of a 20 HP drive.sum of the connected motor FLA allows use of a 20 HP drive.
If it were necessary to accelerate and run the 5 HP motors andIf it were necessary to accelerate and run the 5 HP motors and
then start the 10 HP, the sum of the FLA must be recalculated.then start the 10 HP, the sum of the FLA must be recalculated.
The FLA figures of 5 HP motors would be used, but theThe FLA figures of 5 HP motors would be used, but the
Locked Rotor Amps (LRA) for the 10 HP must be used. AsLocked Rotor Amps (LRA) for the 10 HP must be used. As
this motor would not be accelerated from zero frequency andthis motor would not be accelerated from zero frequency and
voltage to its running condition, it would require its full LRAvoltage to its running condition, it would require its full LRA


28. rating to accelerate to drive’s output frequency. This effect onrating to accelerate to drive’s output frequency. This effect on
sizing is shown below:sizing is shown below:
 6.2 + 6.2 + 86.5 = 98.9 AMPS6.2 + 6.2 + 86.5 = 98.9 AMPS
In this example, a 75 HP drive with 112 Amp continuousIn this example, a 75 HP drive with 112 Amp continuous
rating would be required.rating would be required.
 Advantages of multiple motor drive :Advantages of multiple motor drive :
 Saves moneySaves money
 Reduces maintenance time and costReduces maintenance time and cost
 It requires less spaceIt requires less space
 Reduces control system complexityReduces control system complexity

29. Case StudyCase Study
 Soft start of mechanical vapor compressor with VFD:Soft start of mechanical vapor compressor with VFD:
AL-Khaleej sugar in Dubai, UAE has been using VFD forAL-Khaleej sugar in Dubai, UAE has been using VFD for
mechanical vapor compressor. The installation of mechanicalmechanical vapor compressor. The installation of mechanical
vapor compressor to reuse waste vapor is the latest ongoingvapor compressor to reuse waste vapor is the latest ongoing
innovation project at AL –Khaleej sugar.Two air cooled ACSinnovation project at AL –Khaleej sugar.Two air cooled ACS
1000 MV-VFD are used as soft starting device to avoid high1000 MV-VFD are used as soft starting device to avoid high
inrush current and voltage dips during motor start.inrush current and voltage dips during motor start.
Steps:Steps:
Step 1 :Step 1 : Motor is smoothly accelerated with VFD from standstillMotor is smoothly accelerated with VFD from standstill
up to nominal speed.up to nominal speed.
Step 2 :Step 2 :Motor is synchronized with supply network.Motor is synchronized with supply network.
Step 3 :Step 3 : Motor is then transferred to grid or main supplyMotor is then transferred to grid or main supply

30. VFD Installed at AL-Khaleej sugar industry for mechanical
vapor compressor

31. Energy Efficient Motors
Energy Efficient Motors

33. What is Energy Efficient MotorWhat is Energy Efficient Motor
(EEM)?(EEM)?
 EEM is a specially designed motor having highEEM is a specially designed motor having high
efficiency as compared to standard efficiency motorefficiency as compared to standard efficiency motor
and losses( copper losses, iron losses, core losses,and losses( copper losses, iron losses, core losses,
stray losses) are negligible. EEM have followingstray losses) are negligible. EEM have following
characteristics:characteristics:
 High EfficiencyHigh Efficiency
 Low LossesLow Losses
 Continuous DutyContinuous Duty
 Enclosure Protection IP55Enclosure Protection IP55
 Insulation Class F(155°C)Insulation Class F(155°C)
 Temperature Class B (105°C)Temperature Class B (105°C)

34. Characteristics of EnergyCharacteristics of Energy
Efficient MotorEfficient Motor

35. Why Energy Efficient Motor isWhy Energy Efficient Motor is
So Important ?So Important ?
 Electrical motor consumes 70% of theElectrical motor consumes 70% of the
total electricity produced in industry.total electricity produced in industry.
 Motors are the largest consumer ofMotors are the largest consumer of
electricity in industry and even a smallelectricity in industry and even a small
efficiency improvement can lead toefficiency improvement can lead to
very large saving.very large saving.

36.  Motor initial cost is only 8% of whole life cycleMotor initial cost is only 8% of whole life cycle
cost.cost.
For Example:For Example:
If we have a 30HP motor then:If we have a 30HP motor then:
 Initial Purchase price = Rs. 80,000Initial Purchase price = Rs. 80,000
 Operating hour = 24 x 120 x 15 hr = 43200 hrOperating hour = 24 x 120 x 15 hr = 43200 hr
 KWH = 43200 x 0.746 x 30 = 966816 KWHKWH = 43200 x 0.746 x 30 = 966816 KWH
 Running Cost = 966816 x 10 = Rs. 9,668,160Running Cost = 966816 x 10 = Rs. 9,668,160

38. Motor Efficiency Classes InMotor Efficiency Classes In
Different CountriesDifferent Countries

39. International EfficiencyInternational Efficiency
StandardsStandards
 There are different efficiencyThere are different efficiency
standards. International standard ofstandards. International standard of
efficiency are as followefficiency are as follow
 IE1 (standard efficiency)IE1 (standard efficiency)
 IE2 (high efficiency)IE2 (high efficiency)
 IE3 (premium efficiency)IE3 (premium efficiency)
 IE4 (super premium efficiency)IE4 (super premium efficiency)

40.  IEA (international energy agency) pass laws toIEA (international energy agency) pass laws to
set compulsory energy efficiency standard toset compulsory energy efficiency standard to
protect environment and allow us to reduceprotect environment and allow us to reduce
operating cost.operating cost.

43. Advantages Of Energy EfficientAdvantages Of Energy Efficient
MotorMotor
 Saves energy and moneySaves energy and money
 Short pay back periodShort pay back period
 Substantial saving after pay backSubstantial saving after pay back
periodperiod
 Reduces pollutionReduces pollution
 Enhance motor lifeEnhance motor life
 Increases the plant capacityIncreases the plant capacity
 High power factorHigh power factor
 Low noise and vibrationLow noise and vibration

44. Energy Saving And PaybackEnergy Saving And Payback
CalculationCalculation
 Motor power = 30HPMotor power = 30HP
 Cost of energy efficient motor = Rs 60,000Cost of energy efficient motor = Rs 60,000
 efficiency of old standard motor = 83%efficiency of old standard motor = 83%
 Efficiency of energy efficient motor = 93%Efficiency of energy efficient motor = 93%
 No of operating hours = 24 x 120 = 2880 hrNo of operating hours = 24 x 120 = 2880 hr
 Tariff Rate = C = Rs.10/KWHTariff Rate = C = Rs.10/KWH
 Load factor = L = 0.75Load factor = L = 0.75

 = HP x 0.746 x L x working hours x= HP x 0.746 x L x working hours x

45.  = 30 X 0.746 X 0.75 X 2880 X= 30 X 0.746 X 0.75 X 2880 X
 = 6275/Year= 6275/Year
 Savings = X Tariff RateSavings = X Tariff Rate
= 6275 X 10= 6275 X 10
= Rs. 62,750/Year= Rs. 62,750/Year
Pay Back Period = Investment/SavingPay Back Period = Investment/Saving
= 60,000/62,750= 60,000/62,750
= 0.95 Year = 11 Month= 0.95 Year = 11 Month

46. Misconception About MotorMisconception About Motor
 Oversized motor works efficiently!Oversized motor works efficiently! WhichWhich
is wrong.is wrong.
 Peak efficiency of the motor occursPeak efficiency of the motor occurs
between 75% to 100% loadbetween 75% to 100% load
 Below 50% load, efficiency decreasesBelow 50% load, efficiency decreases
rapidly.rapidly.
 P.F decreases sharply below 75% load.P.F decreases sharply below 75% load.
 Must replace the oversized motor withMust replace the oversized motor with
proper sized motor.proper sized motor.

47. Comparison of Efficiency at FullComparison of Efficiency at Full
Load and at Partial LoadLoad and at Partial Load..

48. Comparison Of Oversize AndComparison Of Oversize And
Proper Size MotorProper Size Motor

49. Make the Motor SystemMake the Motor System
Efficient instead of Only Motor.Efficient instead of Only Motor.
 Motor System includesMotor System includes
Electric motor VFDElectric motor VFD
Cooling fanCooling fan GearGear
Transmission belt.Transmission belt.
Some energy losses occur in motor itself butSome energy losses occur in motor itself but
energy losses are greater in rest of mechanicalenergy losses are greater in rest of mechanical
system to which motor is coupled.system to which motor is coupled.

50. Motor SystemMotor System

51. Note that the efficiency of all components are multipliedNote that the efficiency of all components are multiplied
together to find the system efficiency.together to find the system efficiency.
Note although you have improved the efficiency ofNote although you have improved the efficiency of
motor but still system efficiency is very low due to lowmotor but still system efficiency is very low due to low
efficiency gear system that are still wasting energy. Toefficiency gear system that are still wasting energy. To
improve system efficiency you must improve theimprove system efficiency you must improve the
efficiency of each component involvedefficiency of each component involved

52. So by improving the efficiency of each component,So by improving the efficiency of each component,
you can make the motor system more efficient.you can make the motor system more efficient.

53. What are the barriers?What are the barriers?
 Lack of awarenessLack of awareness
 Limited knowledge of energyLimited knowledge of energy
efficiency optionsefficiency options
 High initial costHigh initial cost
 Short time thinkingShort time thinking
 International trade barriersInternational trade barriers

54. When I should consider buyingWhen I should consider buying
an energy efficient motor?an energy efficient motor?
 For all new installationFor all new installation
 When major modifications are requiredWhen major modifications are required
 Instead of rewinding old standardInstead of rewinding old standard
efficiency motorefficiency motor
 To replace oversized and undersizedTo replace oversized and undersized
motormotor

55. Either I should rewind a failedEither I should rewind a failed
motor?motor?
 Different problems that occur during rewindingDifferent problems that occur during rewinding
• If winding wire is of smaller diameter, increases I²RIf winding wire is of smaller diameter, increases I²R
losseslosses
• Decrease in turn in stator winding reduces windingDecrease in turn in stator winding reduces winding
resistance soresistance so
• Increases stator currentIncreases stator current
• Increases the magnetic fieldIncreases the magnetic field
• Increases starting current by 23%Increases starting current by 23%
• During rewinding due to overheating stator insulationDuring rewinding due to overheating stator insulation
damages that increases the core lossesdamages that increases the core losses
 So rewind only if you have qualified rewindingSo rewind only if you have qualified rewinding
shopshop

56. Therm
ocom
pressor
Therm
ocom
pressor

57. ThermocompressorsThermocompressors

58. Purpose of ThermocompressorPurpose of Thermocompressor
 Steam is a common source of heat inSteam is a common source of heat in
sugar industry. Therefore it is imperativesugar industry. Therefore it is imperative
that sugar industry focus on steamthat sugar industry focus on steam
utilization and take action to minimize orutilization and take action to minimize or
optimize the use of steam. One way is tooptimize the use of steam. One way is to
maximize the use of LP steam withmaximize the use of LP steam with
Thermocompressor.Thermocompressor.
 Thermocompressor increases theThermocompressor increases the
pressure and temperature of LP steam bypressure and temperature of LP steam by
mixing it with HP steam through themixing it with HP steam through the
principle of energy conversion.principle of energy conversion.

59. Construction of ThermocompressorConstruction of Thermocompressor
 Thermocompressor essentially consist of threeThermocompressor essentially consist of three
main parts.main parts.
 NozzleNozzle
 Suction chamberSuction chamber
 DiffuserDiffuser

60. Construction of ThermocompressorConstruction of Thermocompressor

61. Working Principle ofWorking Principle of
ThermocompressorThermocompressor
 Motive steam(High pressure steam) entersMotive steam(High pressure steam) enters
through converging-diverging nozzle.through converging-diverging nozzle.
 Low pressure steam(suction steam) entersLow pressure steam(suction steam) enters
through suction inletthrough suction inlet
 High pressure steam mixes with low pressureHigh pressure steam mixes with low pressure
steam in suction chambersteam in suction chamber
 The resultant steam mixture enters the diffuserThe resultant steam mixture enters the diffuser
where its velocity reduces and its kinetic energywhere its velocity reduces and its kinetic energy
is converted into pressure energy.is converted into pressure energy.
 The resultant steam called discharge steam isThe resultant steam called discharge steam is
then used in process. Discharge steam pressurethen used in process. Discharge steam pressure
is between the pressure of motive and LP suctionis between the pressure of motive and LP suction
steam.steam.

62. Working Principle ofWorking Principle of
ThermocompressorThermocompressor

63. Applications of ThermocompressorApplications of Thermocompressor
1.1. Thermocompressor can be used to compressThermocompressor can be used to compress
or boost the vapours by mixing HP steamor boost the vapours by mixing HP steam
with vapourswith vapours
2.2. Low pressure steam from turbine exhaust canLow pressure steam from turbine exhaust can
be boosted for reuse in the distillerybe boosted for reuse in the distillery
3.3. It can also be used to recover the flash steam.It can also be used to recover the flash steam.

64. Thermocompressor in SugarThermocompressor in Sugar
IndustryIndustry

65. Thermocompressor With BackThermocompressor With Back
Pressure TurbinePressure Turbine

66. Advantages of ThermocompressorAdvantages of Thermocompressor
 Thermo compressor involve no moving part.Thermo compressor involve no moving part.
 No external power supply is requiredNo external power supply is required
 Require very little maintenanceRequire very little maintenance
 Easy installationEasy installation
 Low capital and installation costLow capital and installation cost
 Longer useful operating livesLonger useful operating lives
 Suitable for hazard areasSuitable for hazard areas
 Reduces overall steam consumptionReduces overall steam consumption
 It can improve the thermal efficiency of a factoryIt can improve the thermal efficiency of a factory
by 1-3%by 1-3%
 Vapour recovery from last stage of multi stageVapour recovery from last stage of multi stage
evaporator results in substantial cost saving inevaporator results in substantial cost saving in
sugar plantsugar plant

67. Energy Saving and Pay BackEnergy Saving and Pay Back
CalculationCalculation
 Example :Example :
 Steam vent into atmosphere = 300KG/hr at 0.5Steam vent into atmosphere = 300KG/hr at 0.5
bargbarg
 It is required to compress this steam to 3 bargIt is required to compress this steam to 3 barg
using motive steam of 9 barg.using motive steam of 9 barg.
 Cost of steam per Kg = Rs. 1.5Cost of steam per Kg = Rs. 1.5
 Operating hours = 2880 hrOperating hours = 2880 hr
 Annual saving = 300 x 2880 x 1.5Annual saving = 300 x 2880 x 1.5
= Rs. 1,296,000= Rs. 1,296,000
 Estimated investment = Rs. 3,00,000Estimated investment = Rs. 3,00,000
 Pay back = 91000/144000 = 3 monthsPay back = 91000/144000 = 3 months

68. Biogas plant
Biogas plant

69. IntroductionIntroduction
 Fossil fuel resources are depleting soFossil fuel resources are depleting so
dramatically that we can not relay ondramatically that we can not relay on
them in future Fossil fuel can not fulfill ourthem in future Fossil fuel can not fulfill our
future demands so we should focus ourfuture demands so we should focus our
attention on other energy resources thatattention on other energy resources that
are more reliable and environment friendlyare more reliable and environment friendly
such as biogas plant.such as biogas plant.
 Biogas energy is a very good alternative ofBiogas energy is a very good alternative of
fossil fuel that reduces global warming andfossil fuel that reduces global warming and
green house gases.green house gases.
 Biogas is clean environment friendly fuelBiogas is clean environment friendly fuel
S1.avi
S2.avi

70. Construction of biogas plantConstruction of biogas plant

71. Biogas Generation ProcessBiogas Generation Process
HydrolysisHydrolysis
AcidogenesisAcidogenesis
MethanogenesisMethanogenesis
AcetogenesisAcetogenesis

72. 1 Cubic meter of Biogas Heat Replacement1 Cubic meter of Biogas Heat Replacement
ValueValue
 LPGLPG 0.46Kilogram0.46Kilogram
 GasolineGasoline 0.67Litre0.67Litre
 DieselDiesel 0.60Litre0.60Litre
 HeatingOilHeatingOil 0.55Litre0.55Litre
 FirewoodFirewood 1.50Kilogram1.50Kilogram
 ElectricityElectricity 1.20KW-h1.20KW-h

73. UTILIZATION OF BIOGASUTILIZATION OF BIOGAS
 Cooking:Cooking: Biogas can be used in a speciallyBiogas can be used in a specially
designed burner for cooking purpose.designed burner for cooking purpose.
 Lighting:Lighting: Biogas is used in silk mantle lamps forBiogas is used in silk mantle lamps for
lighting purpose.lighting purpose.
 Power Generation:Power Generation: Biogas can be used toBiogas can be used to
operate a dual fuel engine to replace up to 80 %operate a dual fuel engine to replace up to 80 %
of diesel-oil.of diesel-oil.
 Transport Fuel:Transport Fuel: After removal of COAfter removal of CO22, H, H22S andS and
water vapor, biogas can be converted to naturalwater vapor, biogas can be converted to natural
gas quality for use in vehiclesgas quality for use in vehicles

74. Is biogas safe?Is biogas safe?
 Biogas is not poisonous. The onlyBiogas is not poisonous. The only
danger is from explosion if it isdanger is from explosion if it is
mixed with air and lit by fire.mixed with air and lit by fire.
However, it only explodes if mixedHowever, it only explodes if mixed
with air or oxygen with a lightedwith air or oxygen with a lighted
match or fire very close by.match or fire very close by.

75. Advantages of BIOGASAdvantages of BIOGAS
 Short payback periodShort payback period
 Reduces pollution by replacing fossilReduces pollution by replacing fossil
fuel.fuel.
 Biogas produces excellent fertilizersBiogas produces excellent fertilizers
for use on the farmsfor use on the farms
 Biogas can help in the fight againstBiogas can help in the fight against
global warmingglobal warming
 Biogas reduces green house gasesBiogas reduces green house gases

76. Energy Saving and Pay BackEnergy Saving and Pay Back
CalculationCalculation
 Average dung produced by a cow = 5Kg/dayAverage dung produced by a cow = 5Kg/day
 Average dung produced by 1000 cows =Average dung produced by 1000 cows =
5000Kg/day5000Kg/day
 1 Kg of dung produces biogas = 0.06510 m1 Kg of dung produces biogas = 0.06510 m33
/day/day
 5000 Kg of dung produces biogas = 0.06510 x5000 Kg of dung produces biogas = 0.06510 x
5000 m3 = 325.5 m5000 m3 = 325.5 m33
/day/day
 1m3 of biogas produces = 24.48MJ/day1m3 of biogas produces = 24.48MJ/day
 325.5m3 of biogas produces = 24.48 x325.5m3 of biogas produces = 24.48 x
325.5MJ = 7968.5MJ325.5MJ = 7968.5MJ
 As 1KWh = 3.6 x 10As 1KWh = 3.6 x 1066
J = 3.6MJJ = 3.6MJ
 SoSo 7968.5MJ = 2213.5KWh = 2.2MWh7968.5MJ = 2213.5KWh = 2.2MWh

77. Energy Saving and Pay BackEnergy Saving and Pay Back
CalculationCalculation
 Hence MWh produced in one day = 2.2MWh =Hence MWh produced in one day = 2.2MWh =
2213.5 KWh2213.5 KWh
 Annual saving = Rs. 8 x 2213.5 x 365 =Annual saving = Rs. 8 x 2213.5 x 365 =
= Rs. 64, 63,330= Rs. 64, 63,330
 Investment = 10, 00,000Investment = 10, 00,000
 Pay back period = 5, 00,000/64, 63,330Pay back period = 5, 00,000/64, 63,330
 =2 months=2 months

78. Video Clip Of Biogas PlantVideo Clip Of Biogas Plant

79. Video Clip Of Biogas PlantVideo Clip Of Biogas Plant

80. % Increase In Crop Yield By Using Biogas% Increase In Crop Yield By Using Biogas
As FertilizerAs Fertilizer

81. Characteristics of biogas slurryCharacteristics of biogas slurry
Characteristics Biogas slurry
Moisture content (%) 79
Nitrogen (mg/Kg) 5.88
Phosphorous 2.72
Potassium 1.33
Sulphur 0.79
PH 7.8
Heat value: 24.48MJ/m3

82. ConclusionConclusion
 There are main two purposes of energy conservativeThere are main two purposes of energy conservative
technologies. One is to save environment from hazardtechnologies. One is to save environment from hazard
gases and second is to save energy. Experiencegases and second is to save energy. Experience
obtained from different parts of the world and energyobtained from different parts of the world and energy
auditing programmes show that by installing aboveauditing programmes show that by installing above
mentioned technologies we can save a large amount ofmentioned technologies we can save a large amount of
energy and can contribute positively towardsenergy and can contribute positively towards
environment. Any new technology diffuses very slowlyenvironment. Any new technology diffuses very slowly
in the industry because they don’t have apparentin the industry because they don’t have apparent
advantages but experience of such technologies inadvantages but experience of such technologies in
different industries can help us to explore thedifferent industries can help us to explore the
advantages of such technologies and our sugar industryadvantages of such technologies and our sugar industry
is the example of it that adopt these technologies andis the example of it that adopt these technologies and
save energy and of course lot of money.save energy and of course lot of money.

83. Thank You For YourThank You For Your
Attention !Attention !
Any Question ?Any Question ?