The document discusses energy efficiency improvements in the Pali textile cluster in India. It describes how the MSME sector is an important part of the Indian economy but faces challenges in adopting energy efficiency. The Bureau of Energy Efficiency initiated a project to implement energy efficient technologies like air preheaters and economizers in boiler systems in five MSME clusters, including Pali. Air preheaters and economizers allow for waste heat recovery from flue gases which can improve boiler efficiency and reduce fuel consumption. Cost-benefit analyses are provided for installing these technologies in typical textile processing units, finding potential savings of 1% of fuel costs for every 6 degree Celsius rise in feed water temperature from an economizer.
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
The presentation deals with the most complex and fundamental process in a CFBC boiler. i.e., Combustion. Provides an insight into the various features in a CFBC boilers which are incorporated to enhance cpmbustion.
the presentation describes in details about the feed water and condensate heaters used in Thermal Power Stations or elsewhere. The performance parameters of the heaters are also described in details.
Super Critical Technology-Fundamental Concepts about Super Critical Technolog...Raghab Gorain
Nicely describe everything about super critical technology in thermal power plant.This slide is very useful for the freshers.Anybody can get the basic fundamental idea about super critical technology from this slide. In India now we have to think some new technology for power sources as sub critical power plants are less efficient and emit more pollutant to the environment and the alternative is the 'Super Critical Power Plant'.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
Syllabus:
Availability and Irreversibility
Availability Function
Second Law Efficiencies
Work Potential Associated with Internal Energy
Waste Heat Recovery
Heat Losses – Quality vs. Quantity
Principle of Heat Recovery Units
Classification of WHRS on Temperature Range Bases
Commercial Viable Waste Heat Recovery Devices
Benefits of Waste Heat Recovery
Development of a Waste Heat Recovery System
Commercial Waste Heat Recovery Devices
West Heat Recovery Boiler (WHRB)
Recuperators- Regenerative, Ceramic, Regenerative Heat Exchanger
Thermal wheel/ Heat Wheel
Heat Pipe
Economiser
Feed Water
Heat Pump
Shell and Tube Heat Exchanger
Plate Heat Exchanger
Run-around coil
Direct Contact Heat Exchanger
Advantages and Limitations of WHRD’s
Thermo Tech Engineering (TTE) is involved in manufacturing of industrial utility equipments and general fabrication. We offer complete waste heat recovery equipment Custom design fabrication installation and commissioning.
The presentation deals with the most complex and fundamental process in a CFBC boiler. i.e., Combustion. Provides an insight into the various features in a CFBC boilers which are incorporated to enhance cpmbustion.
the presentation describes in details about the feed water and condensate heaters used in Thermal Power Stations or elsewhere. The performance parameters of the heaters are also described in details.
Super Critical Technology-Fundamental Concepts about Super Critical Technolog...Raghab Gorain
Nicely describe everything about super critical technology in thermal power plant.This slide is very useful for the freshers.Anybody can get the basic fundamental idea about super critical technology from this slide. In India now we have to think some new technology for power sources as sub critical power plants are less efficient and emit more pollutant to the environment and the alternative is the 'Super Critical Power Plant'.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
Syllabus:
Availability and Irreversibility
Availability Function
Second Law Efficiencies
Work Potential Associated with Internal Energy
Waste Heat Recovery
Heat Losses – Quality vs. Quantity
Principle of Heat Recovery Units
Classification of WHRS on Temperature Range Bases
Commercial Viable Waste Heat Recovery Devices
Benefits of Waste Heat Recovery
Development of a Waste Heat Recovery System
Commercial Waste Heat Recovery Devices
West Heat Recovery Boiler (WHRB)
Recuperators- Regenerative, Ceramic, Regenerative Heat Exchanger
Thermal wheel/ Heat Wheel
Heat Pipe
Economiser
Feed Water
Heat Pump
Shell and Tube Heat Exchanger
Plate Heat Exchanger
Run-around coil
Direct Contact Heat Exchanger
Advantages and Limitations of WHRD’s
Thermo Tech Engineering (TTE) is involved in manufacturing of industrial utility equipments and general fabrication. We offer complete waste heat recovery equipment Custom design fabrication installation and commissioning.
Thermo Tech Engineering (TTE) is involved in manufacturing of industrial utility equipments and general fabrication. We offer complete waste heat recovery equipment Custom design fabrication installation and commissioning.
WASTE HEAT RECOVERY TO INCREASE BOILER EFFICIENCY USING BAGASSE AS FUEL IAEME Publication
Many industrial heating processes generate waste energy in textile industry; especially exhaust gas from the boiler at the same time reducing global warming. Waste heat found in the
exhaust gas can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Therefore, this article will present a study the way to recovery heat waste from boiler exhaust gas by mean of shell and tube heat exchanger.
Waste heat recovery, co geration and tri-generationAmol Kokare
Diploma in Mechanical Engg.
Babasaheb Phadtare Polytechnic, kalamb-walchandnagar
Sub- Power plant engineering
Unit-Waste heat recovery, co geration and tri-generation.
By- Prof. Kokare Amol Yashwant
We, the fourth-year students of the Dept. of Mechanical Engineering, SUST, vi...Joy Raj Bhowmik
We, the fourth-year students of the Dept. of Mechanical Engineering, SUST, visited the Shahjalal Fertilizer Company Limited (SFCL) along with our two respected teachers Saad Been Mosharof and Tahmidul Haque Ruvo on October 17, 2023. SFCL is an institution of BCIC under the Ministry of Industries to meet the growing demand for urea fertilizer. The visit is a part of our course MEE 482, named Power Plant Engineering Sessional. The focus of that visit was to witness the two-steam generator of that industry capacity of 24MW, 12MW each turbine.
I was lucky enough to learn and watch the working of the Deaerator, Economizer, Boiler, Superheater, Steam turbine - Generator, and Condenser. Also witnessed the Natural Gas supply and Flue gas circulation.
Heat Pump, their types, Classification of airconditioning system, ventilation: its purpose and types, Tunnel and Mine ventilation, All air, All water and Air-water airconditioning system
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
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Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
1. Background
Micro, small and medium enterprises, jointly called
as MSMEs, plays an important role in the Indian
economy. There are around 26 million micro, small
and medium enterprises units in the country, which
provides employment to over 60 million people.
Together, the MSME sector contributes over 45 % of
industrial production and over 40% of exports. The
role of MSME sector is set to grow in the economic
profile of the country. However, the sector has some
inherent issues. The sector is one of the major
consumers of energy. The sector consumed an
estimated 50.5 million tonne of oil equivalent in 2012.
The annual expected growth of energy consumption is
about 6 percent annually. It is estimated that 15-20%
percent of energy consumed by the sector could be
saved. But, due to the small size and traditional nature
of business holding and management, it becomes
difficult for MSME units to adopt energy efficiency
measures, without external supports.
Under this background, the Bureau of Energy
efficiency along with Ministry of MSME and cluster
level associations, initiated a project titled “National
Program on Energy Efficiency and Technology Up-
gradationinSMEs”.FiveMSMEclusterswereidentified
all over India for executing intervention measures. Pali
Textile cluster was one among them. The project here
in Pali, is supported by the Rajasthan Textile and Hand
Processors Association.
Installation of Air-Preheater and
Economizer in Boiler / Thermic
Fluid Heater
Installation of Air-Preheater and
Economizer in Boiler / Thermic
Fluid Heater
A Case Study
2. The Cluster
The Pali textile cluster is one of the biggest MSME
clusters in India having over 250 member industries.
The units in the cluster are mainly located in two
Industrial Areas namely Industrial Area Phase I &
Phase II and Mandia Road Industrial Area. The units
are classified into two segments mainly: 1) Hand
Process Units 2) Power Process Units.
The BEE-SME project aimed to initially implement
energy efficient technologies in selected units in
the cluster. These units will act as demonstration
units for long term and sustainable penetration of
energy efficient technologies in the entire cluster.
Inspire Network for Environment was selected as the
implementing agency for the program.
The Process
ThetypicalflowofthetextileprocessstartswiththeDe-
sizing and Mercerizing of raw material. Subsequently,
the fabric is fed into the Kier Boiler where scouring
operations takes place, then the fabric undergoes
bleaching followed by Air Drying (Adan). The next
step is colouring of the fabric using jigger or jet dyeing
method. This is followed by the finishing process
where the material fabric undergoes pre-shrinking in
a zero-zero machine. Although, this is a typical layout,
other process improvement methods are used, as per
requirement, by different units.
The Fabric is now ready for dispatch. The entire
processing of fabric in a Textile Processing unit
requires steam as the major input. For continuous
supply of steam, a boiler or a thermic fluid heater is
used. The baseline energy audit revealed that boiler is
the major energy guzzler in a typical textile processing
units.
Fig: Process Flow of a Typical Textile Unit
3. The Boiler: Baseline
Scenario
Packaged steam boiler is used to generate wet steam
required for the process in textile units. Steam is used
at a working pressure of 4-5 kg/cm2. Generally pet-
coke is used as the fuel for the steam boiler. The heating
chamber consists of a fluidized bed of coke wherein
air is supplied from bottom. The heat generated by
combustion of coke and air is used to heat water to
form steam. The steam generated is used in various
processes across the unit. The boiler operates for an
average of 12 hours daily.
The steam boiler operating in the unit is a packaged
boiler with water tube design. Steam is the main
agent of energy used in the textile processing unit.
Thus, the boiler is the major energy utilizing source
in these units. Most of the units use conventional
water tube boilers wherein a significant energy is lost
through the flue gas. The baseline energy audits in the
Pali textile units revealed that the flue gas generated
from the heating chamber of a boiler and the thermic
fluid heater is discharged at a significantly high
temperature and not being utilized in these units. A
significant potential for energy saving exists in these
units with implementation of waste heat recovery
system. Accordingly, installation of Air Pre-heater &
Economizer was suggested.
Fig: Typical Boiler Process Flow without Air preheater & Economizer
4. Energy Efficient
Technology
Predominately two technologies were implemented in
the boiler section, under the BEE-SME program i.e.,
Air Pre heater & Economizer.
EE Technology 1: Air Pre Heater for
Boiler / Thermic Fluid Heater
A boiler produces steam which is subsequently used
in different processes in a typical textile processing
unit. Similarly, a Thermic fluid heater utilizes the heat
produced in the system for processing of fabric at
different segments. Energy used to heat the thermic
fluid / water is mostly pet coke. Conventional units do
not have provisions of waste heat recovery to recover
the flue gas. Thus a significant amount of heat is lost
as waste heat.
Air Pre-heaters are basically heat-exchangers installed
in the exit flus gas duct of the boiler. The purpose of
the air preheater is to recover the heat from the boiler
flue gas which increases the thermal efficiency of the
boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to
the flue gas stack (or chimney) at a lower temperature,
allowing simplified design of the conveyance system
and the flue gas stack. It also allows control over the
temperature of gases leaving the stack.
Working Principle
The most common air pre-heaters are tubular
preheaters consisting of straight tube bundles
which pass through the outlet ducting of the
boiler and open at each end outside of the
ducting. Inside the ducting, the hot furnace gases
pass around the preheater tubes, transferring
heat from the exhaust gas to the air inside the
preheater. Ambient air is forced by a fan through
ducting at one end of the preheater tubes and at
other end the heated air from inside of the tubes
emerges into another set of ducting, which
carries it to the boiler furnace for combustion.
Installationofanairpreheatercanleadtorecovery
of heat from the exit of the heating chamber to
pre-heat the air required for combustion. The
pre-heated air can either be utilized in the thermic
fluid heater or the boiler. With an exit waste heat
temperature of 180 0
C ; air pre-heat to the extent
of 100 0
C can be achieved.
5. EE Technology 2: Economizer for
Boiler
Steam is the main agent of energy used in the textile
processing unit. Thus, the boiler is the major energy
utilizing source in a typical textile unit. In conventional
system, the feed water to the boiler is fed at ambient
temperature (35 0
C) while the stack temperature goes
as high as 240 0
C.
The flue gas temperature leaving at 240 0
C from the
boiler can be recovered using an economizer. This can
further be utilized to pre-heat the boiler feed water. A
temperature difference of 1200
C is sufficient to rise
the boiler feed water temperature by 60-650
C. The
increase in boiler feed water temperature can lead to
substantial increase in boiler efficiency thus leading to
reduction in specific fuel consumption.
Economizers are basically tubular heat transfer
surfaces used to preheat boiler feed water before it
enters the steam drum. By recovering the energy from
the flue gas before it is exhausted to the atmosphere
this performs a key function in providing high overall
boiler thermal efficiency.
Working Principle
Boiler stack economizers are simply heat
exchangers with hot flue gas on shell side and
water on tube side with extended heating surface
like Fins or Gills. Economizers must be sized
for the volume of flue gas, its temperature, the
maximum pressure drop allowed through the
stack, what kind of fuel is used in the boiler, and
how much energy needs to be recovered.
The installation of the economizer in the boiler
/ thermic fluid heater and utilizing the same for
pre-heating boiler feed water will lead to following
benefits:
Waste heat recovery
Improvement in boiler efficiency
Reduction in FD/ID fan power usage
Improved environment
Easy to integrate into production cells
Reduced scaling
Fig: Typical Boiler Process Flow with Air preheater & Economizer
6. Cost Benefit Analysis
Cost benefit analysis for installation of a economizer in
a typical unit is tabulated below:
Cost Economic Analysis of proposed
economizer
* Every rise of 6ºC in boiler feed water temperature through
waste heat recovery would offer about 1% fuel savings.
** Cost of fuel taken as Rs 7.5/kg
***Emission factor of coke has been taken as 113.67 tCO2/TJ
Cost benefit analysis for installation of an air-preheater
in a typical unit is tabulated below:
Cost Economic Analysis of proposed
combustion air-preheater
* Every rise of 21o
C in combustion air pre-heat temperature
through waste heat recovery would offer about 1% fuel savings.
** Emission factor of coke taken as 113.67 tCO2/yr
SN Parameter UoM Value
1
Quantity of steam generated
per hr (Q)
kg/hr 3000
2 Quantity of fuel used per hr (q) kg/hr 500
3 Working Pressure (assumed) kg/cm2
10
4 Temperature of feed water 0
C 35
5 Type of fuel Coke
6 Calorific Value of fuel kCal/kg 8200
7 Enthalpy of steam kCal/kg 665
8 Enthalpy of feed water kCal/kg 35
9 Boiler Efficiency % 46
10 Flue gas temperature 0
C 240
11 Steam generation per kg of fuel kg/kg 6
12 Flue gas quantity kg/kg 15
13 Quantity of flue gas kg/hr 7317
14
Quantity of heat available in flue
gas
kCal/hr 201951
15
Rise in feed water temperature
by installation of economizer
0
C 62.6
16
Every rise of 6ºC in boiler feed water temperature
through waste heat recovery would offer about 1%
fuel savings.
17
Savings in terms of fuel for pre-
heated boiler feed water
% 10.43
18 Savings in terms of fuel kg/hr 52.17
19 Annual operating hrs hrs 3600
20 Annual savings of fuel kgs 187800
21 Annual cost savings Rs/yr. 1408500
22 Cost of economizer Rs 184625
23 Pay-back months 1.57
24
Annual Reduction in Energy
Consumption
toe 154.00
25
Annual CO2
emission
reduction
t CO2
/
year
732.40
SN Parameter UoM Value
1 Exit flue gas temperature 0
C 240
2 Stack dew temperature 0
C 120
3
Available temperature for
heat transfer
0
C 120
4
Quanty of steam generated
per hour
kg/hr 3000
5 Quantity of fuel in the boiler kg/hr 500
6 Specific heat of water kCal/ kg 0
C 1
7
Steam generation per Kg
of fuel
kg/kg 6.00
8 Flue gas quantity kg/kg 14.63
9 Quantity of flue gas kg/hr 7317
10
Quantity of heat available in
flue gas
kCal/hr 201951
11
Rise in combustion pre-heat
temperature
0
C 62.6
12
Every rise of 21ºC in combustion air pre-heat
temperature through waste heat recovery would offer
about 1% fuel savings.
13
Savings in terms of fuel fro
pre-heated combustion air
% 2.98
14 Savings in terms of fuel kg/hr 14.90
15 Annual operating hrs hrs 3600
16 Annual savings of fuel kg 53657
17 Annual cost savings Rs/yr 268286
18 Cost of air pre-heater Rs 200000
19 Pay-back months 8.9
20
Annual reduction in energy
consumption
toe 44.00
21
Annual reduction in GHG
emission
tCO2
/yr 209.3
7. Implementation at a Glimpse
Implementation
References
Economizer and air-preheater has been successfully
implemented in the following units in Pali:
M/s Simandhar Fab Tex Pvt. Ltd.
The benefits achieved by the plant has been
summarized in the table below:
Thermic fluid exist with
economizer at Simandhar Fabtex
Energy Efficient Technology
implemented
Investment
(INR Lakhs)
Simple
Payback
period
(months)
Percentage Savings
in specific energy
consumption from
baseline (%)
Annual
Energy
Savings
(TOE)
Annual CO2
emission
reduction
(tCO2
/year)
Economizer in Thermic fluid
exit
1.84 6 10.24 63.97 304.40
Air-preheater (APH) in steam
boiler
2.00 26 2.43 15.20 72.32
Air pre heater installed at
Simandhar Fabtex
8. Bureau of Energy Efficiency
Ministry of Power
Government of India
4th Floor, Sewa Bhawan
R. K. Puram, New Delhi - 110066 (INDIA)
for more information