Energy conversion is the process r Energy conversion is the process . It is an essential part of our daily life and industrial systems. Energy exists in many forms like mechanical energy, heat energy, electrical energy, chemical energy, nuclear energy, and light energy. Energy conversion helps in using energy effectively for different purposes. For example, in a generator, mechanical energy is changed into electrical energy. When a windmill rotates due to wind, it turns the blades of a turbine which then produces electricity. This is an example of mechanical energy converting into electrical energy. In a candle or a fuel-based engine, chemical energy changes into heat and light energy. When fuel like petrol or diesel burns in a car engine, the chemical energy of the fuel is converted into thermal energy and mechanical movement. Another example is thermal energy converting into mechanical energy. In steam engines, coal or gas is burned to produce heat. This heat turns water into steam. The steam then moves the piston or turbine, converting heat energy into mechanical energy. In electric fans and mixers, electrical energy is converted into mechanical energy. The current from the plug gives power to the motor inside the device, which creates motion. Solar panels work by converting solar energy into electrical energy. The sunlight hits the solar cells and generates electricity, which can be used to run household devices. Batteries are a good example of chemical energy being converted into electrical energy. The chemicals inside the battery react and produce an electric current that powers electronic devices. Energy conversion is very important. In our daily life, we use many machines and devices that rely on different forms of energy conversion. In industries, large machines work using the same principles. In renewable energy systems like solar power or wind energy, natural sources are converted into useful electrical power. However, no energy conversion is perfect. Some energy is always lost, mostly in the form of heat. This is why engineers and scientists work on improving the efficiency of energy conversion. Efficient systems save energy, reduce costs, and help protect the environment. Understanding energy conversion helps us design better machines and use natural resources wisely. It also plays a key role in building a cleaner and more sustainable future. In short, energy conversion is the backbone of modern life and technology. Whether it is a light bulb, a motor, or a solar panel, all these work because of the conversion of one form of energy into another.

1. LOGO
➢ Submitted By:
Ram Dayal
Reg. No.: 21102109013
➢ Submitted To:
Prof. Abhinas Sir
Dept. of ME
Modules 3 & 4: Thermal Systems & Utility Efficiency in
Industries

2. Page 2
LOGO CONTENTS
❑ Boilers, Furnaces & Thermic Fluid Heaters
❑ Efficiency Computation & Energy Conservation
❑ Steam Distribution & Usage
❑ Steam Traps, Condensate Recovery, Flash Steam
❑ Insulation & Refractories
❑ Pumps, Fans, Blowers
❑ Compressed Air Systems
❑ Refrigeration & Air Conditioning (RAC)
❑ Cooling Towers
❑ Diesel Generator (DG) Sets

3. Page 3
LOGO INTRODUCTION
Energy conservation plays a crucial role in improving efficiency, reducing
operational costs, and minimizing environmental impact in industrial settings.
This presentation focuses on energy-saving opportunities in thermal systems
such as boilers, furnaces, and steam systems, as well as major utility
equipment including pumps, fans, air compressors, refrigeration systems,
cooling towers, and DG sets.
Understanding these systems and implementing conservation measures can
lead to significant energy and cost savings.

4. Page 4
LOGO Boilers, Furnaces & Thermic Fluid Heaters
Boilers
▪ Used to generate steam for industrial processes.
▪ Key losses: flue gases, blowdown, radiation.
▪ Efficiency improvement: excess air control, heat recovery, insulation.
Furnaces
▪ Used for heating materials (e.g., metal melting, annealing).
▪ Energy losses: flue gases, openings, wall losses.
▪ Conservation: proper burner design, preheating, automation.
Thermic Fluid Heaters
▪ Provide indirect heating using thermic oil.
▪ Safer for high-temperature operations without high pressure.
▪ Efficiency tips: regular maintenance, correct fuel-air ratio, insulation.

5. Page 5
LOGO Efficiency Computation & Energy Conservation
Efficiency Computation
▪ Boiler Efficiency (%) = (Heat Output / Heat Input )×100
▪ Methods:
1. Direct Method (Input-Output)
2. Indirect Method (Heat Losses Analysis)
▪ Used to assess and monitor system performance.
Energy Conservation Techniques
▪ Reduce excess air in combustion.
▪ Recover heat from flue gases using economizers.
▪ Insulate steam lines and equipment.
▪ Schedule preventive maintenance.
▪ Automate controls for optimized operation.
▪ Use energy-efficient motors and drives.

6. Page 6
LOGO Steam Distribution & Usage
Steam Distribution
▪ Transports steam from boilers to process areas.
▪ Common losses: leakage, poor insulation, pressure drops.
▪ Conservation tips: insulate steam pipes, avoid long routing, maintain traps.
Steam Usage
▪ Steam used for heating, power generation, drying, sterilization, etc.
▪ Match steam pressure and quantity to process needs.
▪ Use condensate and flash steam recovery systems.

7. Page 7
LOGO Steam Traps, Condensate Recovery & Flash Steam
Steam Traps
▪ Devices that discharge condensate without steam loss.
▪ Types: Thermodynamic, Float & Thermostatic, Inverted Bucket.
▪ Regular testing prevents energy loss.
Condensate Recovery
▪ Reuses hot condensate to reduce fuel and water usage.
▪ Benefits: saves energy, reduces boiler blowdown, improves efficiency.
Flash Steam Utilization
High-pressure condensate releases steam when pressure drops.
▪ Use in low-pressure applications (e.g., heating, drying).
▪ Saves fuel by reducing fresh steam demand.

8. Page 8
LOGO Steam Traps, Condensate Recovery & Flash Steam
Steam Traps
▪ Devices that discharge condensate without steam loss.
▪ Types: Thermodynamic, Float & Thermostatic, Inverted Bucket.
▪ Regular testing prevents energy loss.
Condensate Recovery
▪ Reuses hot condensate to reduce fuel and water usage.
▪ Benefits: saves energy, reduces boiler blowdown, improves efficiency.
Flash Steam Utilization
▪ High-pressure condensate releases steam when pressure drops.
▪ Use in low-pressure applications (e.g., heating, drying).
▪ Saves fuel by reducing fresh steam demand.

9. Page 9
LOGO Insulation & Refractories
Insulation
▪ Prevents heat loss in pipes, boilers, tanks, and ducts.
▪ Materials: Glass wool, Rock wool, Calcium silicate, etc.
▪ Benefits: energy saving, temperature control, safety improvement.
Refractories
▪ Heat-resistant materials used in furnaces, boilers, and heaters.
▪ Withstand high temperatures and harsh conditions.
▪ Good refractory = reduced heat loss + extended equipment life.

10. Page 10
LOGO Pumps, Fans & Blowers
Pumps
▪ Used to move fluids in industrial systems.
▪ Energy losses due to throttling, leakages, and oversizing.
▪ Conservation tips: use variable frequency drives (VFDs), proper sizing, regular
maintenance.
Fans & Blowers
▪ Move air/gas for ventilation, cooling, or combustion.
▪ Efficiency depends on design, control systems, and duct layout.
▪ Energy-saving measures: optimize impeller design, reduce resistance, use
VFDs.

11. Page 11
LOGO Compressed Air Systems
Overview
▪ Used in tools, machines, and processes.
▪ Least efficient utility — only ~10% of input energy becomes useful work.
➢ Common Losses
• Leakages (up to 30%)
• pressure drops
• improper use of compressed air
❑ Energy Conservation Measures
▪ Fix air leaks and avoid artificial demand.
▪ Operate at optimal pressure (no overpressurizing ).
▪ Use energy-efficient compressors and heat recovery systems.
▪ Schedule maintenance for filters, dryers, and drains.

12. Page 12
LOGO Refrigeration & Air Conditioning Systems (RAC)
Overview
▪ Used for cooling processes, storage, and comfort.
▪ Major energy consumers in many industries.
❑ Energy Losses
• Poor insulation
• refrigerant leaks
• inefficient compressors
• Overcooling
❑ Energy Conservation Tips
▪ Maintain proper temperature settings.
▪ Ensure regular cleaning of coils and filters.
▪ Use energy-efficient compressors and controls.
▪ Recover waste heat where possible.
▪ Replace old systems with star-rated or modern high-efficiency units.

13. Page 13
LOGO Cooling Towers
❑ Function
Remove heat from water used in industrial processes or HVAC systems.
Operate by evaporative cooling.
❖ Common Inefficiencies
• Poor airflow,
• scale buildup,
• excessive drift,
• water loss.
❑ Energy Conservation Tips
• Maintain optimal airflow and water flow rates.
• Regularly clean nozzles, fill media, and drift eliminators.
• Use energy-efficient fans and motors with VFDs.
• Monitor approach temperature and water quality.
• Reduce blowdown by recycling and treating water.

14. Page 14
LOGO Diesel Generator (DG) Sets
Function
▪ Provide backup or primary power in industries.
▪ Operate on diesel fuel to generate electricity.
❖ Common Inefficiencies
• Low load operation
• poor maintenance
• fuel wastage
❑ Energy Conservation Tips
▪ Operate DG sets near rated load for better efficiency.
▪ Regularly maintain fuel injectors, filters, and cooling systems.
▪ Monitor load factor and avoid idle running.
▪ Use electronic controllers for better load management.
▪ Consider hybrid systems or energy storage integration.

15. THANK
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