The document discusses a study of 10 asphalt plants that found average energy savings of 68% by replacing damper control of induced draft fans with variable frequency drives (VFDs). VFDs provided average paybacks of 3-5 years. Extrapolating the savings to the 3,600 asphalt plants in the US could result in almost 200,000 MWh of annual energy savings. The methodology section describes how pre-retrofit fan energy use was measured and post-retrofit energy was calculated using fan laws and curve fitting. Results showed that fan energy comprised 18% of total plant energy on average prior to retrofits.
This document discusses optimizing the design of a heat pump system using fuzzy logic and genetic algorithms. It first provides background on heat pumps and their operation. It then describes using fuzzy logic to determine thermodynamic properties of refrigerants, which are important for heat pump performance simulation and optimization. Next, it outlines using a genetic algorithm to optimize parameters of an air-source heat pump system with R-404a refrigerant. Fuzzy logic was employed to predict refrigerant properties for use in the genetic algorithm optimization of the heat pump system design. The approach showed potential for simplifying heat pump system optimization.
The document discusses technologies for improving gas turbine efficiency through higher operating temperatures. It covers new high-temperature materials like superalloys and ceramics that allow increasing the combustion temperature. It also discusses manufacturing techniques like directional solidification and single crystal growth that enhance material properties. Combined cycle power plants are highlighted as a way to further increase efficiency by capturing waste heat. Challenges of using syngas from gasification as a fuel are also summarized.
Improved efficiency of gas turbine by Razin Sazzad MollaRazin Sazzad Molla
This document discusses ways to improve the efficiency of gas turbine engines through various design modifications and upgrades. It describes how increasing turbine inlet temperatures, improving compressor and turbine components, adding modifications like intercooling and regeneration, and utilizing advanced cooling techniques can boost efficiency. Other methods covered include inlet air cooling systems, compressor and turbine coatings, supercharging, and comprehensive component replacements. The goal of ongoing research is to enhance power output while reducing emissions and fuel consumption.
Turbine Inlet Air Cooling (TIAC) - Case Studies - Economics - Performance - C...Salman Haider
Efficiency Enhancement of a Gas Turbine in Hot climate conditions. Design strategies and technology varieties. Detailed Case Studies of TIAC equipped power plants, economic and performance analysis. Study of Climate effect on GT Performance in three different locations.
Power plant engineering unit 3 notes by Varun Pratap SinghVarun Pratap Singh
Download Link: https://sites.google.com/view/varunpratapsingh/teaching-engagements (Copy URL)
Unit-3
Diesel power plant
General layout, performance of diesel engine, fuel system, lubrication system, air intake and admission system, supercharging system, exhaust system, diesel plant operation and efficiency, heat balance.
Gas turbine power plant
Elements of gas turbine power plants, Gas turbine fuels, cogeneration, auxiliary systems such as fuel, controls and lubrication, operation and maintenance, Combined cycle power plants.
Options for optimizing combined cycle plantsHossam Zein
This document discusses several options for optimizing the efficiency of combined cycle power plants, including:
1. Improving compressor cleanliness by using HEPA filters, which can increase power output by 6% and extend time between cleanings.
2. Making operational adjustments such as optimizing low load setpoints and reducing heat loss.
3. Installing aftermarket systems like ECOMAX automated combustion tuning to improve heat rate by 0.2-0.25% and boost output up to 11 MW.
4. A technology called TurboPHASE that uses a reciprocating engine to add compressed air to combustion turbines, allowing 10-20% faster response time and up to 7% improved heat rate.
Power plant engineering unit 2 notes by Varun Pratap SinghVarun Pratap Singh
Download Link: https://sites.google.com/view/varunpratapsingh/teaching-engagements (Copy URL)
SYLLABUS
Unit-II
Steam power plant
Power plant boilers including critical and super critical boilers. Fluidized bed boilers, boilers
mountings and accessories.
General layout of steam power plant. Different systems such as fuel handling system,
pulverizes and coal burners, combustion system, draft, ash handling system, feed water
treatment and condenser and cooling system, turbine auxiliary systems such as governing, feed
heating, reheating, flange heating and gland leakage.
Operation and maintenance of steam power plant, heat balance and efficiency.
This document discusses optimizing the design of a heat pump system using fuzzy logic and genetic algorithms. It first provides background on heat pumps and their operation. It then describes using fuzzy logic to determine thermodynamic properties of refrigerants, which are important for heat pump performance simulation and optimization. Next, it outlines using a genetic algorithm to optimize parameters of an air-source heat pump system with R-404a refrigerant. Fuzzy logic was employed to predict refrigerant properties for use in the genetic algorithm optimization of the heat pump system design. The approach showed potential for simplifying heat pump system optimization.
The document discusses technologies for improving gas turbine efficiency through higher operating temperatures. It covers new high-temperature materials like superalloys and ceramics that allow increasing the combustion temperature. It also discusses manufacturing techniques like directional solidification and single crystal growth that enhance material properties. Combined cycle power plants are highlighted as a way to further increase efficiency by capturing waste heat. Challenges of using syngas from gasification as a fuel are also summarized.
Improved efficiency of gas turbine by Razin Sazzad MollaRazin Sazzad Molla
This document discusses ways to improve the efficiency of gas turbine engines through various design modifications and upgrades. It describes how increasing turbine inlet temperatures, improving compressor and turbine components, adding modifications like intercooling and regeneration, and utilizing advanced cooling techniques can boost efficiency. Other methods covered include inlet air cooling systems, compressor and turbine coatings, supercharging, and comprehensive component replacements. The goal of ongoing research is to enhance power output while reducing emissions and fuel consumption.
Turbine Inlet Air Cooling (TIAC) - Case Studies - Economics - Performance - C...Salman Haider
Efficiency Enhancement of a Gas Turbine in Hot climate conditions. Design strategies and technology varieties. Detailed Case Studies of TIAC equipped power plants, economic and performance analysis. Study of Climate effect on GT Performance in three different locations.
Power plant engineering unit 3 notes by Varun Pratap SinghVarun Pratap Singh
Download Link: https://sites.google.com/view/varunpratapsingh/teaching-engagements (Copy URL)
Unit-3
Diesel power plant
General layout, performance of diesel engine, fuel system, lubrication system, air intake and admission system, supercharging system, exhaust system, diesel plant operation and efficiency, heat balance.
Gas turbine power plant
Elements of gas turbine power plants, Gas turbine fuels, cogeneration, auxiliary systems such as fuel, controls and lubrication, operation and maintenance, Combined cycle power plants.
Options for optimizing combined cycle plantsHossam Zein
This document discusses several options for optimizing the efficiency of combined cycle power plants, including:
1. Improving compressor cleanliness by using HEPA filters, which can increase power output by 6% and extend time between cleanings.
2. Making operational adjustments such as optimizing low load setpoints and reducing heat loss.
3. Installing aftermarket systems like ECOMAX automated combustion tuning to improve heat rate by 0.2-0.25% and boost output up to 11 MW.
4. A technology called TurboPHASE that uses a reciprocating engine to add compressed air to combustion turbines, allowing 10-20% faster response time and up to 7% improved heat rate.
Power plant engineering unit 2 notes by Varun Pratap SinghVarun Pratap Singh
Download Link: https://sites.google.com/view/varunpratapsingh/teaching-engagements (Copy URL)
SYLLABUS
Unit-II
Steam power plant
Power plant boilers including critical and super critical boilers. Fluidized bed boilers, boilers
mountings and accessories.
General layout of steam power plant. Different systems such as fuel handling system,
pulverizes and coal burners, combustion system, draft, ash handling system, feed water
treatment and condenser and cooling system, turbine auxiliary systems such as governing, feed
heating, reheating, flange heating and gland leakage.
Operation and maintenance of steam power plant, heat balance and efficiency.
TIAC Is a group of technologies and techniques consisting of cooling down the intake air of thegas turbine. The direct consequence of cooling the turbine inlet air ispower output augmentation.
Thermal power plants generate electricity through combustion of fuels like coal and gas. The key components are the boiler, steam turbine, and electric generator. Control systems regulate critical functions like fuel and air management, steam temperatures, feedwater levels, and turbine speed. Supercritical plants operate at higher pressures and temperatures for greater efficiency. Combined cycle plants further improve efficiency by capturing waste heat from gas turbines to power additional steam turbines.
Combined Cycle Gas Turbine Power Plant Part 1Anurak Atthasit
Introduction to Combined Cycle Gas Turbine Power Plant. Describing the advantage and design limit of the CCGT. Overview of Brayton Cycle and Rankine Cycle - showing some basic thermodynamic to explain some background of CCGT.
The document discusses the potential of solar boosted heat pumps (SB-HPWH) for domestic hot water heating. It notes that SB-HPWH can improve heat pump performance and reduce collector area needs compared to solar thermal or heat pump only systems. New approaches being researched include dual-mode vented collectors and PV/thermal panels, which could maximize solar and ambient heat collection. Successfully integrating PV/thermal, heat pumps, and controls remains a challenge but could provide high solar conversion efficiencies and leverage electricity generation to boost thermal output.
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
Use of Biogas Energy in Poultry Farming Heatingtheijes
Energy shortage is a global issue that is more severe in Jordan. One of the solutions to this problem in rural areas is the use of biogas energy either in heating applications or for electricity generation. The paper discusses the feasibility of using biogas produced from the fermentation of cow dung for the purpose of heating a standard poultry house, located around Queen Alia airport in the middle of Jordan. This work includes gathering information of a real poultry house and approximating some of its specifications; to calculate the required heating load of it throughout a whole year, which reached a maximum of (62.39 kW) in January. The next step is to find how much local traditional type of fuels, LPG and Diesel, are needed for the heating of this house. After that, through some calculations, the amount of biogas required and the amount of cow dung needed for its production is found. Finally, a financial analysis is applied to confirm the feasibility of this approach, which showed a payback period of about 15 months for the biogas system compared traditional heating fuel systems.
Improve energy efficiency for distillate hydrotreaters retrofit options hyd...Bhavesh kanani
This document discusses options for improving the energy efficiency of retrofitting distillate hydrotreaters. It examines increasing the surface area of feed preheat exchangers and installing a hot separator. Installing additional surface area in exchangers E-1 and E-3 through projects like adding twisted tubes recovers some heat but has a payback period of 4-14 years. Installing a hot separator that sends liquid directly to the stripper eliminates the need for exchanger E-3 and has better energy savings and payback around 3 years.
An exhaust heat recovery system turns waste heat energy in exhaust gases into electric energy for batteries or mechanical energy put on the crankshaft.
The technology is of increasing interest as car and heavy-duty vehicle manufacturers continue to increase efficiency, saving fuel and reducing emissions.
While technological improvements have greatly reduced the fuel consumption of internal combustion engines, the peak thermal efficiency of a 4-stroke Otto cycle engine is around 35%, which means that 65% of the energy released from the fuel is lost as heat.
This document summarizes an energy modeling analysis that compared the energy performance of seven common gas-fired heating systems for warehouses. The analysis found that direct-fired, high temperature rise blow-thru space heaters used 35-38% less natural gas and 92-93% less fan electricity than the ASHRAE 90.1 baseline system. Using any other type of heater increased energy use by 24-59% compared to the blow-thru heaters. Blow-thru heaters were determined to use the least amount of total energy to heat and ventilate large warehouses based on their design advantages of higher burner efficiency, more efficient controls, and higher discharge air temperatures.
The document discusses cogeneration and waste heat recovery. Cogeneration, or combined heat and power (CHP), simultaneously generates electricity and useful heat. Trigeneration adds cooling to CHP. Cogeneration improves efficiency and reduces emissions and costs. Waste heat recovery units transfer heat from high-temperature processes to improve efficiency. Common applications of waste heat recovery include preheating, steam generation, and power generation. Cogeneration offers economic and environmental benefits over conventional power generation.
Energy Audit & Energy Conservation Opportunities in Electrical Equipments ...Manohar Tatwawadi
The discussion is for the Energy Conservation drive in the thermal power plants in the Auxilliary Consumption of the Electrical Auxilliaries in the Plant and thereby identify the steps to be taken for the reduction in Auxilliary Consumption
Electric Compressor Selection & Integration dccmarketing
Follow T/CCI Manufacturing on LinkedIn.
T/CCI's Advanced Engineering Director, Erik Huyghe, outlines electric compressor selection and integration for heavy-duty and offroad vehicles.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
Syllabus:
Introduction
Need of Cogeneration
Principle and Advantages of Cogeneration
Technical Options for Cogeneration
Gas turbine Cogeneration Systems
Reciprocating Engine Cogeneration Systems
Classification of Cogeneration Systems
Topping Cycle
Bottoming Cycle
Factors Influencing Cogeneration Choice
Important Technical Parameters for Cogeneration
Typical Cogeneration Performance Parameters
Relative Merits of Cogeneration Systems
Case Study
Analytics Project - Combined Cycle Power PlantJyothi Lakshmi
The document describes a dataset containing measurements collected from a combined cycle power plant over 6 years. The dataset contains 9568 hourly records of 4 ambient variables (temperature, exhaust vacuum, ambient pressure, relative humidity) and the corresponding electrical energy output. The records are split into training and test datasets. Exploratory data analysis finds strong correlations between the energy output and temperature, vacuum, and pressure. A multiple linear regression model will be used to predict the energy output based on the 4 ambient variables.
The document presents a preliminary design of a turbofan engine aimed at achieving over 25,000 N of thrust with a thrust specific fuel consumption of less than 0.025 kg/s/kN. A MATLAB code was used to generate carpet plots of specific thrust and thrust specific fuel consumption for different bypass ratios, compressor pressure ratios, and bypass pressure ratios. The final optimal design parameters chosen were: a turbine inlet temperature of 1300 K, compressor pressure ratio of 30, bypass ratio of 6, bypass pressure ratio of 1.35, inlet diameter of 0.738 m, thrust of 25,050.9 N, and thrust specific fuel consumption of 0.0187 in order to meet mission requirements with high fuel efficiency.
The document summarizes a practical training seminar on the Dholpur Combined Cycle Power Project. It describes the project's setup in 2007 near Dholpur, Rajasthan to generate 330 MW of electricity using a combined cycle technique. This technique uses both a gas turbine and a steam turbine for improved efficiency. It also discusses the various components involved - the gas turbine, heat recovery steam generator, and steam turbine - and explains how combined cycle power generation provides benefits like high efficiency, low pollution, and low costs.
To Improve Thermal Efficiency of 27mw Coal Fired Power PlantIJMER
Booming demand for electricity, especially in the developing countries, has raised power generation technologies in the headlines. At the same time the discussion about causes of global warming has focused on emissions originating from power generation and on CO2 reduction technologies such as:
(1) Alternative primary energy sources,
(2) Capture and storage of CO2,
(3) Increasing the efficiency of converting primary energy content into electricity.
In the dissertation, the thermal efficiency of the power plant is improved when Control of furnace draft (nearer to balanced draft). Oxygen level decreases percentage of flue gases. Above this level heat losses are increases & below this carbon mono-oxide is formed. Steam power plant is using fuel to generate electrical power. The used of the fuel must be efficient so the boiler can generate for the maximum electrical power. By the time the steam cycle in the boiler, it also had heat losses through some parts and it effect on the efficiency of the boiler. This project will analyze about the parts of losses and boiler efficiency. to find excess air which effect heat losses in boiler. By using the 27 MW coal fired thermal power plant of Birla Corporation Limited, Satna (M.P.) the data is collect by using types of Combustion & heat flow in boiler. Result of the analysis show that the efficiency of boiler depends on mass of coal burnt & type of combustion .This study is fulfilling the objective of analysis to find the boiler efficiency and heat losses in boiler for 27 MW thermal power plant of Birla Corporation Limited, Satna (M.P.)
Cogeneration systems produce both electricity and useful thermal energy in a single integrated system to improve efficiency. This document discusses cogeneration systems that use steam turbines, gas turbines, or reciprocating engines as the prime mover. Steam turbine cogeneration systems can be backpressure or extraction condensing configurations. Gas turbine cogeneration systems operate on the Brayton cycle of compressing, heating, and expanding air. Cogeneration provides benefits like increased efficiency, lower emissions, and cost savings compared to separate thermal and electrical systems.
Hindalco Industries Limited operates an integrated aluminum manufacturing facility located in Renukoot, India. The facility includes a cogeneration plant that produces steam and electricity. The cogeneration plant has several large boilers that fire coal to produce steam, which is used to drive steam turbines that generate electricity. The steam is also used for other processes at the aluminum facility. The cogeneration plant provides efficient combined heat and power to meet the needs of the aluminum production processes on site.
Energy Efficiency and Performance Analysis of Industrial (Textile Sector) Fan...inventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Enhancement of Specific Power Output of a Gas Turbine Using Filtered Chilled AirIOSR Journals
Conventionally the specific power output of the gas turbine can be increased using reheating and
intercooling. The thermal efficiency can be improved by adding a regenerating at lower pressure ratios. In the
present work the emphasis is given to enhance the specific power output by other means like reduction in the air
temperature at the inlet duct. The power output of the gas turbine has been estimated by allowing air at reduced
temperatures, step wise. The experiment is conducted till STP conditions are attained. The chiller coils are used
for inlet air cooling. The variation of power output with respect to temperature is also studied.
TIAC Is a group of technologies and techniques consisting of cooling down the intake air of thegas turbine. The direct consequence of cooling the turbine inlet air ispower output augmentation.
Thermal power plants generate electricity through combustion of fuels like coal and gas. The key components are the boiler, steam turbine, and electric generator. Control systems regulate critical functions like fuel and air management, steam temperatures, feedwater levels, and turbine speed. Supercritical plants operate at higher pressures and temperatures for greater efficiency. Combined cycle plants further improve efficiency by capturing waste heat from gas turbines to power additional steam turbines.
Combined Cycle Gas Turbine Power Plant Part 1Anurak Atthasit
Introduction to Combined Cycle Gas Turbine Power Plant. Describing the advantage and design limit of the CCGT. Overview of Brayton Cycle and Rankine Cycle - showing some basic thermodynamic to explain some background of CCGT.
The document discusses the potential of solar boosted heat pumps (SB-HPWH) for domestic hot water heating. It notes that SB-HPWH can improve heat pump performance and reduce collector area needs compared to solar thermal or heat pump only systems. New approaches being researched include dual-mode vented collectors and PV/thermal panels, which could maximize solar and ambient heat collection. Successfully integrating PV/thermal, heat pumps, and controls remains a challenge but could provide high solar conversion efficiencies and leverage electricity generation to boost thermal output.
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
Use of Biogas Energy in Poultry Farming Heatingtheijes
Energy shortage is a global issue that is more severe in Jordan. One of the solutions to this problem in rural areas is the use of biogas energy either in heating applications or for electricity generation. The paper discusses the feasibility of using biogas produced from the fermentation of cow dung for the purpose of heating a standard poultry house, located around Queen Alia airport in the middle of Jordan. This work includes gathering information of a real poultry house and approximating some of its specifications; to calculate the required heating load of it throughout a whole year, which reached a maximum of (62.39 kW) in January. The next step is to find how much local traditional type of fuels, LPG and Diesel, are needed for the heating of this house. After that, through some calculations, the amount of biogas required and the amount of cow dung needed for its production is found. Finally, a financial analysis is applied to confirm the feasibility of this approach, which showed a payback period of about 15 months for the biogas system compared traditional heating fuel systems.
Improve energy efficiency for distillate hydrotreaters retrofit options hyd...Bhavesh kanani
This document discusses options for improving the energy efficiency of retrofitting distillate hydrotreaters. It examines increasing the surface area of feed preheat exchangers and installing a hot separator. Installing additional surface area in exchangers E-1 and E-3 through projects like adding twisted tubes recovers some heat but has a payback period of 4-14 years. Installing a hot separator that sends liquid directly to the stripper eliminates the need for exchanger E-3 and has better energy savings and payback around 3 years.
An exhaust heat recovery system turns waste heat energy in exhaust gases into electric energy for batteries or mechanical energy put on the crankshaft.
The technology is of increasing interest as car and heavy-duty vehicle manufacturers continue to increase efficiency, saving fuel and reducing emissions.
While technological improvements have greatly reduced the fuel consumption of internal combustion engines, the peak thermal efficiency of a 4-stroke Otto cycle engine is around 35%, which means that 65% of the energy released from the fuel is lost as heat.
This document summarizes an energy modeling analysis that compared the energy performance of seven common gas-fired heating systems for warehouses. The analysis found that direct-fired, high temperature rise blow-thru space heaters used 35-38% less natural gas and 92-93% less fan electricity than the ASHRAE 90.1 baseline system. Using any other type of heater increased energy use by 24-59% compared to the blow-thru heaters. Blow-thru heaters were determined to use the least amount of total energy to heat and ventilate large warehouses based on their design advantages of higher burner efficiency, more efficient controls, and higher discharge air temperatures.
The document discusses cogeneration and waste heat recovery. Cogeneration, or combined heat and power (CHP), simultaneously generates electricity and useful heat. Trigeneration adds cooling to CHP. Cogeneration improves efficiency and reduces emissions and costs. Waste heat recovery units transfer heat from high-temperature processes to improve efficiency. Common applications of waste heat recovery include preheating, steam generation, and power generation. Cogeneration offers economic and environmental benefits over conventional power generation.
Energy Audit & Energy Conservation Opportunities in Electrical Equipments ...Manohar Tatwawadi
The discussion is for the Energy Conservation drive in the thermal power plants in the Auxilliary Consumption of the Electrical Auxilliaries in the Plant and thereby identify the steps to be taken for the reduction in Auxilliary Consumption
Electric Compressor Selection & Integration dccmarketing
Follow T/CCI Manufacturing on LinkedIn.
T/CCI's Advanced Engineering Director, Erik Huyghe, outlines electric compressor selection and integration for heavy-duty and offroad vehicles.
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
Syllabus:
Introduction
Need of Cogeneration
Principle and Advantages of Cogeneration
Technical Options for Cogeneration
Gas turbine Cogeneration Systems
Reciprocating Engine Cogeneration Systems
Classification of Cogeneration Systems
Topping Cycle
Bottoming Cycle
Factors Influencing Cogeneration Choice
Important Technical Parameters for Cogeneration
Typical Cogeneration Performance Parameters
Relative Merits of Cogeneration Systems
Case Study
Analytics Project - Combined Cycle Power PlantJyothi Lakshmi
The document describes a dataset containing measurements collected from a combined cycle power plant over 6 years. The dataset contains 9568 hourly records of 4 ambient variables (temperature, exhaust vacuum, ambient pressure, relative humidity) and the corresponding electrical energy output. The records are split into training and test datasets. Exploratory data analysis finds strong correlations between the energy output and temperature, vacuum, and pressure. A multiple linear regression model will be used to predict the energy output based on the 4 ambient variables.
The document presents a preliminary design of a turbofan engine aimed at achieving over 25,000 N of thrust with a thrust specific fuel consumption of less than 0.025 kg/s/kN. A MATLAB code was used to generate carpet plots of specific thrust and thrust specific fuel consumption for different bypass ratios, compressor pressure ratios, and bypass pressure ratios. The final optimal design parameters chosen were: a turbine inlet temperature of 1300 K, compressor pressure ratio of 30, bypass ratio of 6, bypass pressure ratio of 1.35, inlet diameter of 0.738 m, thrust of 25,050.9 N, and thrust specific fuel consumption of 0.0187 in order to meet mission requirements with high fuel efficiency.
The document summarizes a practical training seminar on the Dholpur Combined Cycle Power Project. It describes the project's setup in 2007 near Dholpur, Rajasthan to generate 330 MW of electricity using a combined cycle technique. This technique uses both a gas turbine and a steam turbine for improved efficiency. It also discusses the various components involved - the gas turbine, heat recovery steam generator, and steam turbine - and explains how combined cycle power generation provides benefits like high efficiency, low pollution, and low costs.
To Improve Thermal Efficiency of 27mw Coal Fired Power PlantIJMER
Booming demand for electricity, especially in the developing countries, has raised power generation technologies in the headlines. At the same time the discussion about causes of global warming has focused on emissions originating from power generation and on CO2 reduction technologies such as:
(1) Alternative primary energy sources,
(2) Capture and storage of CO2,
(3) Increasing the efficiency of converting primary energy content into electricity.
In the dissertation, the thermal efficiency of the power plant is improved when Control of furnace draft (nearer to balanced draft). Oxygen level decreases percentage of flue gases. Above this level heat losses are increases & below this carbon mono-oxide is formed. Steam power plant is using fuel to generate electrical power. The used of the fuel must be efficient so the boiler can generate for the maximum electrical power. By the time the steam cycle in the boiler, it also had heat losses through some parts and it effect on the efficiency of the boiler. This project will analyze about the parts of losses and boiler efficiency. to find excess air which effect heat losses in boiler. By using the 27 MW coal fired thermal power plant of Birla Corporation Limited, Satna (M.P.) the data is collect by using types of Combustion & heat flow in boiler. Result of the analysis show that the efficiency of boiler depends on mass of coal burnt & type of combustion .This study is fulfilling the objective of analysis to find the boiler efficiency and heat losses in boiler for 27 MW thermal power plant of Birla Corporation Limited, Satna (M.P.)
Cogeneration systems produce both electricity and useful thermal energy in a single integrated system to improve efficiency. This document discusses cogeneration systems that use steam turbines, gas turbines, or reciprocating engines as the prime mover. Steam turbine cogeneration systems can be backpressure or extraction condensing configurations. Gas turbine cogeneration systems operate on the Brayton cycle of compressing, heating, and expanding air. Cogeneration provides benefits like increased efficiency, lower emissions, and cost savings compared to separate thermal and electrical systems.
Hindalco Industries Limited operates an integrated aluminum manufacturing facility located in Renukoot, India. The facility includes a cogeneration plant that produces steam and electricity. The cogeneration plant has several large boilers that fire coal to produce steam, which is used to drive steam turbines that generate electricity. The steam is also used for other processes at the aluminum facility. The cogeneration plant provides efficient combined heat and power to meet the needs of the aluminum production processes on site.
Energy Efficiency and Performance Analysis of Industrial (Textile Sector) Fan...inventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Enhancement of Specific Power Output of a Gas Turbine Using Filtered Chilled AirIOSR Journals
Conventionally the specific power output of the gas turbine can be increased using reheating and
intercooling. The thermal efficiency can be improved by adding a regenerating at lower pressure ratios. In the
present work the emphasis is given to enhance the specific power output by other means like reduction in the air
temperature at the inlet duct. The power output of the gas turbine has been estimated by allowing air at reduced
temperatures, step wise. The experiment is conducted till STP conditions are attained. The chiller coils are used
for inlet air cooling. The variation of power output with respect to temperature is also studied.
An Algorithm of a Convectional Factory Electric Tray Dryertheijes
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.
Development of a Measuring Apparatus for Aerodynamic Properties of Granular M...CrimsonpublishersMCDA
In handling and processing of agricultural products, air or water is often used as a transport medium for separating the desirable product from unwanted materials. When an air stream is used for separating a product from its associated foreign materials, such as straw and chaff, knowledge of aerodynamic characteristics of all the particles involved is necessary. This helps to define the range of air velocities for effective separation of the grain from foreign materials. For this reason, the terminal velocity (Vt) has been used as an important aerodynamic characteristic of materials in such applications as pneumatic conveying and their separation from foreign materials.
For more open access journals in Crimson Publishers please click on link: https://crimsonpublishers.com
For more articles on journal of agronomy and crop science please click on below link: https://crimsonpublishers.com/mcda/
This document summarizes research on modeling and experimentally analyzing a generator for a vapor absorption refrigeration system. The researchers designed a prototype system using heat from exhaust gases to vaporize an ammonia-water working fluid in a plate heat exchanger generator, replacing a heating coil generator typically used. They analyzed the available heat in exhaust gases from an internal combustion engine and modeled the plate heat exchanger. The document describes the components and working of an ammonia-water vapor absorption refrigeration system, specifications of the internal combustion engine used, design calculations for the plate generator, and presents conclusions on utilizing exhaust heat and further modeling needed.
This document summarizes research on modeling and experimentally analyzing a generator for a vapor absorption refrigeration system. The researchers designed a prototype system using heat from exhaust gases to vaporize an ammonia-water working fluid in a plate heat exchanger generator, replacing a heating coil generator typically used. They analyzed the available heat in exhaust gases from an internal combustion engine and modeled the plate heat exchanger. The document describes the components and working of an ammonia-water vapor absorption refrigeration system, specifications of the internal combustion engine used, design calculations for the plate generator, and presents conclusions on utilizing exhaust heat and further modeling needed.
Reducing ac power consumption by compressor downsizing on a sportArun Prakash
This document discusses reducing air conditioning (AC) power consumption in vehicles by downsizing the AC compressor. It describes testing conducted on a sports utility vehicle (SUV) originally equipped with a 170 cc/rev reciprocating piston compressor. The study involved experimentally evaluating three compressors: 1) the original 170 cc compressor, 2) a 130 cc reciprocating compressor, and 3) a 90 cc rotary scroll compressor. The compressors were tested at the component, system, and vehicle levels. Results showed the 130 cc compressor reduced power consumption by 5-18% compared to the 170 cc compressor at the component level. At the system level, the 130 cc compressor maintained equivalent cooling to the 170 cc compressor after optimizing other system components
Variable Speed Drives for Gas compressor OperationsVijay Sarathy
To understand the effects of Variable Speed Drive (VSD) and Fixed Speed Drive (FSD) mode of operation on gas compressor start-up, a case study is made.
Turning Waste Into Revenue Through BioTransformationnjcnews777
The City of Waco Wastewater Treatment Plant operates a sludge pelleting process that converts wastewater sludge into a marketable pellet used as a soil conditioner and nutrient. This process generates about $275,000 in annual revenue. The plant also uses methane from anaerobic digestion to generate electricity, offsetting $17,380 in monthly electricity costs. Future plans include expanding electricity generation and adding composting and methane co-generation to further reduce costs and diversify biotransformation options.
The increasingly worldwide problem regarding rapid economy development and a relative shortage of
energy. Out of the total heat supplied to the engine in the form of fuel, approximately, 30 to 40% is converted
into useful mechanical work. With the rapid changing environment and atmospheric effect, the air conditioning
of the moving vehicle has become a necessity. In the same time consumers are incapable to bear the increasing
operating cost of the vehicles due to continuous raise in fuel prices, component costs and maintenance costs
associated with vehicles. Keep in mind in this paper, an exploration has been done to research the possibility of
waste heat recovery and its subsequent utilization in air conditioning system of a vehicle without increasing the
component cost, weight, number of component and bring improvement in vehicle by making luxurious. In this
system the Shell and Tube HE type will be used, designed and developed along with vapour absorption
refrigeration system and is tested for performance.
Keywords — Eefficiency, Exhaust Gas, Waste Heat & Shell Tube HE.
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The document discusses gas turbines and their components. It provides details about BHEL, an Indian company that manufactures gas turbine components including rotors. It describes the working of gas turbines, the Brayton cycle, components like compressors and turbines. It also discusses factors that affect gas turbine performance such as ambient temperature, pressure and humidity as well as technical parameters like pressure ratio, turbine inlet temperature and isentropic efficiency.
Use of Process Analyzers in Fossil Fuel PlantsIves Equipment
In spite of all efforts concerning energy savings and efficiency, the growing world population and the aspired higher 'standard of living' will lead to a further in- crease of world energy demand. In this context, almost half of the primary energy demand will continue to be covered by solid fuels, particularly by coal, until 2020 and many years beyond.
This document summarizes the findings of an energy audit conducted at a textile mill in Tirupur, India. It identifies areas of high energy consumption and provides recommendations for improving energy efficiency. The major energy consuming systems identified are humidification plants, air compressors, and the motors used in carding, simplex, spinning, and auto coner departments. Recommendations include replacing old motors with high efficiency models, improving maintenance of humidification and air distribution systems to reduce leaks, and optimizing fan and pump operations. Implementing the recommendations could save over 200,000 units of electricity annually, reducing energy costs.
Integrated Air Conditioning Unit for AutomobilesIJARTES
This document summarizes several research papers on using waste heat from vehicle exhaust to power an absorption refrigeration system for automotive air conditioning. The key points are:
1) Absorption refrigeration systems can utilize low-grade waste heat from exhaust to run the air conditioning, unlike vapor compression which increases fuel use. Measured COP of a proposed system is 0.85 to 1.04.
2) A study designed a generator heat exchanger to transfer exhaust heat to the refrigerant in the generator. Experimental results showed exhaust is a viable alternative heating source.
3) Other studies analyzed using exhaust heat to power ammonia-water and lithium bromide absorption systems for vehicle air conditioning. Re
IRJET- Performance and Evaluation of Aqua Ammonia Air Conditioner System ...IRJET Journal
This document discusses the performance evaluation of an aqua-ammonia air conditioning system for automobiles that uses waste exhaust heat from the vehicle engine. The study examines how the generator and absorption refrigeration system can utilize the available waste heat. Results found that the cooling capacity was affected by the ammonia concentration and provided acceptable cooling between 1-1.5 tons. The coefficient of performance was highest at higher generator and evaporator temperatures but decreased with increasing condenser and absorber temperatures. Overall, the study shows that an aqua-ammonia vapor absorption system has the potential to provide air conditioning for vehicles using only waste exhaust heat from the engine.
Solar Air Heater Integrated with Different Shaped Turbulators A Reviewijtsrd
The thermo hydraulic efficiency of any device is determined by the flow route arrangement and the fluids interaction with the heated surfaces inside the crossing. The effectiveness of a solar air heating system is mostly determined by the absorber design and the fluid through duct. Many scientists have studied the various aspects of SAHs, particularly the absorber plate and duct containing various rib or turbulator shapes, such as circular and square ribbon cross sections, tapered recto cross sections, different configurations of V shaped ribs, wavelength delta wings, anchor shaped inserts, and perforated vortex winglets. The current study provides an in depth examination of experimental and numerical investigations on solar air heater integrated with different shaped turbulators. Prof. Pushparaj Singh | Shailendra Tiwari "Solar Air Heater Integrated with Different Shaped Turbulators: A Review" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-6 | Issue-5 , August 2022, URL: https://www.ijtsrd.com/papers/ijtsrd50296.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/50296/solar-air-heater-integrated-with-different-shaped-turbulators-a-review/prof-pushparaj-singh
This document summarizes a research paper published in the International Journal of Advanced Research in Engineering and Technology. The paper discusses installing a shrouded wind turbine at the outlet of a cooling tower to harness wasted exhaust air and generate electricity. A shroud works by concentrating and accelerating wind flow, increasing velocity and available wind power by up to 66.99% compared to an unshrouded turbine. Prior studies show cooling tower exhaust air can reach 18 m/s, sufficient for wind power generation. The shrouded turbine design captures more wind through reduced pressure inside the shroud and increased velocity entering the turbine blades.
1. USE OF VFDS ON ASPHALT PLANT INDUCED DRAFT FANS
Glen R Anderson - Senior Energy Analyst - etc Group, Inc - Salt Lake City, UT
Patti L Case – Principal – etc Group, Inc – Salt Lake City, UT
Justin Lowery – Accounting/Utilities - Staker Parson Companies – Ogden, UT
ABSTRACT
Studies of 10 asphalt plants in the Intermountain
Region have identified average ID fan energy savings
of 68% by controlling airflow using Variable
Frequency Drives (VFDs) on the fan motors in place
of damper control (inlet or outlet). Average paybacks
were 3 -5 years before utility incentives.
In the 10 plants evaluated, the ID fans accounted
for as much as 30% of the total plant electrical
consumption. In the majority of these plants the
outlet dampers were typically 50%-60% closed. Fan
motors ranged from 200 Hp to 500 Hp.
With approximately 3,600 existing asphalt plants
in operation across the United States, a large
opportunity for retrofits exists. Working with
manufacturers and owners, a new standard can be
established for installing VFDs on all plants.
INTRODUCTION
As with many industrial processes,
manufacturers build asphalt plants designed to insure
equipment is sized to meet maximum production
needs under the worst operating conditions. This can
create the perfect storm when induced draft fans are
sized for an asphalt plant’s exhaust system.
Typically the exhaust system is sized for maximum
output, wet aggregate, and cold, humid air.
A huge opportunity exists to transfer standard
HVAC technologies to the industrial market. One
such opportunity is the use of VFDs on variable flow
fans in the asphalt industry. Plants typically operate
at less than 80% capacity under less demanding
weather conditions (dry aggregate, fairly dry and hot
air, and at less than full capacity.) Most asphalt
plants modulate airflow with an outlet damper to
meet exhaust requirements through the bag-house.
There are 3,600 hot mix asphalt plants in the
United States, producing almost 500 million tons of
asphalt paving material. About 1,300 of these plants
are of the drum mixing variety, as studied in this
paper (1).
Extrapolating savings achieved with 10 asphalt
plants in the Intermountain West, almost 200,000
MWh of annual energy savings could be achieved in
the United States through the installation of VFDs on
the induced draft fan motors.
ASPHALT PLANT OPERATION
Asphalt plants produce hot mix asphalt for
paving application. The paving aggregates are dried
and heated, then mixed and coated with asphalt
cement and briefly stored in heated silos. Trucks are
loaded from the silos and material is delivered to the
paving site. The hot mix is typically produced at
about 350°F and laid at 225°F or higher so it has a
fairly short “shelf life”.
Continuous mix asphalt plants operate by
feeding aggregate into a mixing drum where a burner
heats and dries the aggregate. Liquid asphalt cement
is added to the aggregate before the hot mix is
transferred from the drum to holding silos. Most
plants use some recycled pavement which is loaded,
screened and fed to the drum mixer.
Asphalt plant exhaust systems are designed to
use an induced draft fan to maintain a constant drum
vacuum pressure by drawing exhaust air from the
mixing drum through an air cleaner (baghouse or wet
scrubber). Standard design practice entails outlet
dampers on the fan to operate the plant at part flow
conditions.
Continuous mix asphalt plants either operate as
parallel flow or counter flow. In a parallel flow
mixing drum, the aggregate enters the drum at the
burner and both the hot mix and air exit at the
opposite end of the drum. In a counter flow mixing
drum, the aggregate enters at the opposite end from
the burner and the hot mix exits at the burner.
Test Platform
Burner
Hot
Mix
out
Aggragate in
Recycle Larger
Particles Dust out
Cyclone
Clean Gas out
Exhaust
Stack
Bag House
Induced
Draft Fan
Drum
Discharge
Damper
Burner Fan
Air
in
Dust out
Figure 1 Counter Flow Mixing Drum
The aggregate is heated and dried as it moves
down the drum toward the burner. Asphalt cement is
added to the aggregate and the hot mix is transferred
out of the drum to holding silos. Air is drawn into
the drum mixer at the burner end and flows across the
aggregate as it moves toward the burner. The hot air
2. is exhausted from the mixer through a cyclone and
bag-house by an induced draft (ID) fan. There is a
discharge damper right at the fan exit.
The drum mixer typically operates around 325°F
and 0.25 inches negative water gauge pressure. The
burner is controlled by the drum bed temperature.
The ID fan discharge damper is controlled to
maintain the drum pressure. The picture below
shows an exhaust fan setup with an outlet damper.
Figure 2 Asphalt Plant Exhaust
PROJECT DEVELOPMENT
Utah Power FinAnswer Program
Utah Power operates an aggressive demand side
management program, called FinAnswer, that pays
up to 50% of the project cost based on 12¢ /kWh and
$50/average monthly kW for the first year of savings.
Utah Power hires consultants to identify and evaluate
energy saving opportunities for their customers.
Utah Power initiated a site visit with a consultant
(etc Group, Inc.) in December, 2002 at Staker Parson
Company’s (a wholly owned subsidiary of
OldCastle) Beck Street asphalt plant which identified
an opportunity for replacing the existing damper
control on the induced draft fan with a VFD. This
fan was powered by two 250 Hp motors.
Following the initial opportunity identification,
etc Group, Inc performed a detailed analysis (paid for
by Utah Power) to quantify the cost and savings
potential. Staker approved the project and completed
work in March 2003. Utah Power provided a
$22,540 incentive check to Staker in June, 2003 that
covered 50% of the project costs.
Measure Repeatability
The success of the first retrofit provided the
justification for Utah Power to fund studies at 4
additional Staker plants. Staker retrofit all of these
plants by the spring of 2004. OldCastle is
completing retrofits on 2 additional plants in Idaho
and is making preparations for the analysis of 3
plants in Spokane, Washington, while scoping
opportunities in Montana, Wyoming, Oregon, New
Mexico, Colorado, and South Dakota. They are
working with all of the local utilities to identify and
capture incentive opportunities.
Utah Power has transferred success with Staker’s
projects to other Utah Power served asphalt plant
operators. Two customers completed projects last
year with one possibly completing another retrofit
this winter and the other planning to analyze another
site this coming year.
METHODOLOGY
The energy savings estimates were based on
measured pre-retrofit baselines, production records
and fan system analysis. Actual savings were
verified with post retrofit fan power measurements.
Power was first logged on the fan motors for 2
to 3 weeks. Daily tons produced and logged fan
power was used to calculate hours of fan operation
and production rates. Normal annual production
(tons) and average production rates (ton/hr)
determine annual hours of operation. The logged
power data was extrapolated for a full year of
production by assuming the logged frequency
distribution remains constant throughout the year.
Figure 3 provides a histogram of the annual
distribution of fan energy.
-
100
200
300
400
500
600
50 100 140 150 160 170 180 190 200 210 220 230
kW
AnnualHours
Figure 3 Baseline Fan Energy
This data was used with flow measurements to
estimate the fan-flow load-duty cycle.
1. The fan motor energy was spot measured
simultaneously with airflow at multiple
operating points.
2. The measured data (corrected for
temperature and humidity) was used to
create a fan curve equation relating fan
power to flow.
3. This equation was used to calculate airflow
from the logged power.
Once the air-flow duty cycle was estimated, the
retrofit energy use for the variable speed fan was
calculated.
3. 4. One of the measurements in step 1 above
was made with the outlet damper wide open.
The airflow and power at this operating
point defines the system curve. According
to the fan affinity laws, the fan power
changes by the cube of the ratio change in
airflow.
kWnew = kWbase * (CFMnew/CFMbase) ^3.
5. The retrofit energy use is based on the fan
following the system curve to deliver the
same airflow distribution as in Step 3.
Figure 4 compares the measured power vs
airflow curve to the manufacturer provided curve.
0
50
100
150
200
250
300
0 20,000 40,000 60,000 80,000
ACFM
FanPower(Hp)
Measured
Fan Curve
Figure 4 Fan Curve - Published vs Measured
Figure 5 shows the curve fit equation used to
calculate airflow (CFM) based on the logged power.
y = 4.0525x1.7272
R2
= 0.9973
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
0 50 100 150 200 250 300
Fan Power
ACFM
225
Power (225)
Figure 5 Fan Curve Equation
Table 1 demonstrates the airflow and retrofit
energy calculations.
Hours CFM kW kWh
104 14,000 2 184
133 14,000 2 236
118 25,000 10 1,195
35 29,000 16 544
30 32,000 21 626
49 36,000 30 1,487
49 39,000 38 1,890
133 43,000 51 6,840
498 48,000 71 35,591
187 52,000 91 17,025
335 56,000 114 38,052
20 61,000 147 2,893
1,691 106,563
Table 1 Retrofit Fan Energy
RESULTS
Overview of All Plants
At 8 of the plants studied, the induced draft fans
initially accounted for 18% of the total plant energy.
Table 2 and Table 3 list energy characteristics of the
8 sites where pre and post measurements were taken.
Two of the plants analyzed only included post retrofit
measurements
Name Damper Plant kWh Fan kWh Fan %
Staker West Haven Outlet 1,021,040 304,681 30%
Ogden Plant Outlet 548,640 171,257 31%
POM Plant Outlet 1,284,480 318,618 25%
Orem Plant Inlet 890,250 96,731 11%
Staker Cedar City Outlet 502,320 115,949 23%
Staker Beck Street Outlet 2,374,500 471,804 20%
Staker Idaho Fed Way* Outlet 1,561,760 98,808 6%
Staker Idaho Ten Lane* Outlet 1,124,720 97,465 9%
9,307,710 1,675,313 18%
* Plant has electrically heated storage tanks
Table 2 Baseline Plant Energy Use
Verified savings range from 24% to 84% with
aggregated savings for all of the plants at 68%.
Name Pre-kWh Post-kWh % saved
Staker West Haven 304,681 108,227 64%
Ogden Plant 171,257 27,008 84%
POM Plant 318,618 87,706 72%
Orem Plant 96,731 33,726 65%
Staker Cedar City 115,949 42,586 63%
Staker Beck Street 471,804 106,157 77%
Staker Idaho Fed Way 98,808 52,456 47%
Staker Idaho Ten Lane 97,465 74,270 24%
1,675,313 532,136 68%
Table 3 Retrofit Fan Energy Use
Energy Use Details of a Single Plant
Eight of the fans have been re-measured after
VFD installation. The retrofit energy was within
15% of the predicted energy for all of the plants.
4. Figure 6 shows the energy use distribution for
the baseline, prediction, and actual retrofit
measurements for Staker’s Westhaven Asphalt plant.
-
100
200
300
400
500
600
700
800
900
50 100 140 150 160 170 180 190 200 210 220 230
kW
AnnualHours
Baseline Predicted Measured
Figure 6 Staker Ogden Results
Figure 7 shows the impact on monthly demand
following the installation of a VFD between 2003
and 2004.
0
100
200
300
400
500
600
700
800
Dec Nov Oct Sep Aug Jul Jun May Apr Mar Feb Jan
Demand(kW)
2003 2004
Figure 7 Staker Ogden Monthly kW
Project Financials
Several factors affect the payback of potential
projects. These include:
• Operating Hours
• Utility Rates
• Available Incentives
The projects analyzed in the Intermountain West
proved successful even with low operating hours
(typically around 1,200 hours annually) and low
utility rates (around 3¢/kWh). Utility incentives and
engineering expertise definitely pushed all of the
customers to complete projects. Asphalt plants
around the country will find attractive paybacks even
without incentives.
Table 4 shows the financials for the projects
analyzed.
Name Savings Cost Incentive Payback
Staker West Haven 15,025$ 31,997$ 15,999$ 1.1
Ogden Plant 17,865$ 62,531$ 20,288$ 2.4
POM Plant 10,509$ 45,211$ 22,606$ 2.2
Orem Plant 5,765$ 48,026$ 8,940$ 6.8
Staker Cedar City 7,785$ 16,338$ 8,169$ 1.0
Staker Beck Street 12,878$ 45,080$ 22,540$ 1.8
Staker Idaho Fed Way 3,565$ 28,766$ 5,246$ 6.6
Staker Idaho Ten Lane 4,598$ 22,749$ 7,427$ 3.3
77,990$ 300,698$ 111,215$ 2.4
Table 4 Project Financials
ADDITIONAL ITEMS OF CONSIDERATION
Inlet Vanes
Some manufacturers have followed the HVAC
industry by installing inlet vanes between the
baghouse and the exhaust fan. While the vanes do
provide savings as compared to outlet dampers, they
do not provide the same savings as HVAC inlet
vanes. Inlet vanes provide savings by creating a
swirl to the air as it enters the fan and correct
placement is important. The further the vanes are
from the inlet, the less benefit they provide. At the
plant studied, the inlet vane appears to be located too
far from the fan intake.
Figure 8 Fan With Inlet Damper
Figure 9 shows expected impact of the inlet
vanes as compared to an outlet damper, and to
variable speed control (VFD in this case).
Fan Power
0
50
100
150
200
250
300
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000
ACFM
Hp
Inlet Vanes
Outlet Damper
VFD
Figure 9 Effect of Fan Control Mechanism
5. Burner Forced Draft Fans
All of the asphalt plants visited also operate with
forced draft fans on the burners. These fans present
additional savings opportunities, although the savings
potential is smaller and the costs will be greater.
Issues which have limited the use of variable speed
control on the burner FD fans include:
• Many of the plant manufacturers are
hesitant to use VFDs in burner controls.
The existing operation uses a common
linkage to control airflow and fuel flow
and they are concerned about breaking
this linkage. Existing plants whose
manufacturers will support VFDs
almost all need a control upgrade to
provide analog output signals to a VFD.
• As the fuel modulates from 0 to 50%,
the airflow varies from 0 to 100%. The
air flow stays at 100% above 50% load,
reducing the savings potential.
• The blower fan motors are only 30% to
50% the size of the exhaust fan motors.
CONCLUSION
Asphalt plant owners can benefit greatly by
installing VFDs on the induced draft fan motors of
the exhaust systems. Manufacturers typically size
fans to ensure proper operation under the most
extreme conditions. These conditions are seldom
realized so fans require damper control, wasting the
majority of the energy consumed by these fans.
VFDs have provided 68% savings of baseline
fan energy on 10 plants analyzed. 10 plants in the
Intermountain West are saving a combined
1,143,177 kWh. This measure can be duplicated in
the vast majority of the 1,300 drum mixing plants
nationwide.
REFERENCES
1. Baghouse Fines – Material Description, March 14,
2005, Recycled Materials Resource Center at the
University of New Hampshire.
http://www.rmrc.unh.edu/partners/userguide/bd.htm