The various ways through which sustainable industrial heating is possible.

1. Approaches to Sustainable
Process Heating
From demand management to alternative heating
Prof. Satyanarayanan

2. 1: Boiler efficiency
27 LPH Kerosene oil
Can supply 182 kW heat
(1,57,122 kCal/hr)
87 % Efficiency
Only if your boiler is designed for 2 to 4
lakh kcal/hr
• A high capacity boiler in this case will supply at efficiencies lower
than 60%
• The cost of delivered energy increases
• Boiler is frequently fluctuating

3. 1: Boiler efficiency – how to manage low loads and fluctuations?
Manage with load accumulators Arrangement for steam systems
Reduce fuel consumption by up to 45%
In the previous example, fuel cost can reduce by upto Rs. 38.8 lakhs

4. 1: Load balancing with solar boilers
Thermal storage allows efficient integration of
renewable heat with process

5. Tank Name
Volume of
the tank
Temperature to be
maintained
Dimension (L x B x H) &
Liquid depth (m)
Minimum ambient
temperature
RH% Component mass
Hot water 7900 Litres 55 - 65 ⁰C
2.5 x 1.875 x 2
(1.8 m of Liquid depth)
20 ⁰C 40% 700 kg
KOD 7900 Litres 55 - 65 ⁰C
2.5 x 1.875 x 2
(1.8 m of Liquid depth)
20 ⁰C 40% 700 kg
Degreaser 7900 Litres 55 - 65 ⁰C
2.5 x 1.875 x 2
(1.8 m of Liquid depth)
20 ⁰C 40% 700 kg
Phosphating 7900 Litres 48 - 52 ⁰C
2.5 x 1.875 x 2
(1.8 m of Liquid depth)
20 ⁰C 40% 700 kg
Arriving at load – Case study at Auto component* PT shop, in Pune
2: Understanding process lossess
Configuration Heat load/tank (kW)
Heat uptake by
component (kW)
Open top W/O Insulation 45.3 5.8
Open top W/ Insulation 38.3 5.8
Closed top 11.8 5.8
Heat losses from open top contributes significantly process heating

6. 3: Monitoring thermal system performance
Electrical energy is standard – easily measured!
What about thermal energy?

7. 4: Why should you monitor?
Product Electricity
Required KJ/kg
Thermal Energy
required KJ/kg
Thermal/Electrical
energy
Fluid Milk 272 388 1.43
Cottage cheese 100 137 1.37
Creamery Butter 835 449 0.54
Cheese 828 449 0.56
Powdered dry Milk 476 236 0.5
Example: Dairy
If heat is not monitored, ~ 40% of plant energy consumption is unmonitored
Without monitoring, no control is possible and energy efficiency gains are not visible!!
One of the reasons why many energy audit recommendations, esp. with regards to thermal systems are not implemented!

8. 5: Consider utilization efficiency of heat sources…
• Consider downsizing your boiler
• Economizers can add up to 10% on efficiency
• Upgrading to Combined Heat and Power can
reduce your overall energy cost by up to 50%
6TPH boiler, supplying 4 TPH @ 8 bar steam to process
Replace with 4 TPH @ 24 bar to a BPT and supply @ 8
bar to process (a tea factory)
Simple payback: 1.9 years!
~ 10 % reduction in annual energy bills!

9. 6: Consider cost of energy

10. Cost assumptions: HFO – 23Rs/L
: HSD – 44 Rs/L
: LPG – 40 Rs/kg
Cost assumptions: Coal – 5 Rs/kg
: Biomass – 5 Rs/kg
6: Consider cost of energy @ operational load

11. • Load your boilers optimally
• Consider accumulators
• Understand the process needs
• Sustainability can come in from simply reducing losses
• Don’t squander your efficiency gains
• Monitor thermal energy consumption
• Consider utilization efficiency of heat sources (EXERGY!!)
• Switch to alternatives
• Sustainable heating is cheaper than you think!!
Tenets….

13. A Negawatt is better
than the Megawatt!!
Leaders in sustainable industrial heating
Contact us @ info@aspirationenergy.com/044-42185301