FAN BASICS

Air Flow (Q) Static Pressure (Ps) Velocity Pressure (Pv) Total Pressure (PT)

FAN EFFICIENCY

Total Efficiency ( T) = PT x Q x 9.81 1000 x Input Power (Kw)

Static Efficiency ( S) = PS x Q x 9.81 1000 x Input Power (Kw)

FAN EFFICIENCY

Induced Draft Cross Flow Cooling Tower

COOLING TOWER FAN OPERATION

FACTORS AFFECTING FAN PERFORMANCE Aero Foil Design

FACTORS AFFECTING FAN PERFORMANCE Effect of Blade Profile

FACTORS AFFECTING FAN PERFORMANCE Obstacles in the Flow Path

FACTORS AFFECTING FAN PERFORMANCE Tip Clearance

FACTORS AFFECTING FAN PERFORMANCE

Blade Pitch Angle

Optimum Pitch Angle Maximum Permissible angle Stall Condition

FACTORS AFFECTING FAN PERFORMANCE Seal Disc

FACTORS AFFECTING FAN PERFORMANCE

Effect of Fan Speed

1. Fan Air Flow Rate Varies Directly with Fan Speed Ratio
Q2 = Q1 X (N2 / N1) 2. Fan Pressure Varies with the Square of Fan Speed Ratio P2 = P1 X (N2 / N1 )2 3. Fan Input Power Varies with Cube of Fan Speed Ratio

H2 = H1 X (N2 / N1)3

FACTORS AFFECTING FAN PERFORMANCE

Altitude & Temperature Effect of Air density

1. Air Flow Rate Remains The Same With a Change in Air Density 2. Pressure Varies in Proportion to The Air Density P2 = P1 X ( 2 ) ( 1) 3. Fan Input Power Varies in Proportion to the Air Density

H2 = H1 X ( 2 )
( 1)

FACTORS AFFECTING FAN PERFORMANCE

Blade Leveling

FAN TECHNOLOGY

Air Foil Design of Blade Structural Design Mechanical Design of Hub Manufacturing Process Validation of Design

FAN

TECHNOLOGY

Structural Design Consideration

1. Blade - Fiber Glass Reinforcement Selection - Epoxy based resin to withstand corrosive atmosphere - Quality Checks for Moment Matching & Balancing - Blade Strength determined by Deflection Load Test - Allowable stress and adequate margin of safety. - Adequate thickness to meet all above criteria 2. Hub & Hardware - MS HDG Hub with SS 316 fasteners & CI/Al. Centre Bush - Plate thickness calculated to withstand radial forces generated by the Fan due to self weight and aerodynamic load.

CASE STUDY
Application Location Model Fan Type Measured Flow Measured Power Tip Clearance : Cooling Tower Fan : HCL Cooling Tower : : Metallic : 204832 Cfm : 15.6 KWH : 75 MM

Observations: 1. High Power Consumption 2. Low Fan Output (Flow) 3. Increased Tip Clearance

CASE STUDY

Replacement Fan : FRP Blade Type : Aerodynamic Shaped Measured Flow : 293700 Cfm Measured Power : 12.7 KWH Tip Clearance : 20 MM Power Saving : 18.5% Flow Increase : 43% Observations: Increased Blade Length Minimum Tip Clearance Minimum Air Re-circulation from discharge to Fan Suction

BENEFITS

Enhanced Efficiency More Flow and Better Cooling with same Power Consumption Yearly Saving Rs. 2.75 lacs per fan Payback Period 4 months Increased Expected Fan Life Reduced Vibration & Maintenance Easy Handling due to Light Weight

CONCLUSION

Installed FRP Fan more Efficient than Conventional Metallic Fan All FRP need not be Energy Efficient Efficiency is due to Aerodynamically designed Blade Profile Efficiency not due to MOC or Light Weight

BEE-PRESENTATION

ENERGY CONSERVATION

ENERGY SAVING IN PUMPS

LIFE CYCLE COST

Initial cost, 2%

Maintenance cost, 8%

Initial cost Maintenance cost Energy cost

Energy cost, 90%

Pumps- Simple Definition

Machines designed to Transport fluid Add energy

Types of pumps

Centrifugal Single Stage Multistage Split Casing Axial Positive Displacement Reciprocating Gear Rotary

Approach to energy conservation in pumps..

Install flow & energy meter for all major pumps. Obverse flow & power consumption pattern hourly, shift and daily basis Identifying pumps having major power consumption.

Explore energy saving possibilities.

Reason for excess power consumption

Wrong selection Over design Improper layout Old inefficient pump Multiple smaller size pump Ad-hoc decision

Energy Saving in Pumps

Accounts for 20 % power consumption in our plant General process industry it consumes 4060% of total power At least 25% energy can be saved

At National level

Annual savings potential in industrial pumps Rs 4250 Million

Pumps Formulae

Capacity Head Power -

(RPM) (RPM)2 (Capacity*Head) (RPM)3

Energy Parameters
Major parameters are Capacity or flow Head or Pressure Efficiency

Pumps Formulae

If the rpm is reduced say by 10%, what will be happen to the Capacity reduced by 10% Head reduced by 19% Power reduced by 27%

Efficiency Curve

Power with different control methods

Power Detail
H Total 10 Q 10 7 12.4 10 6.4 Power Savings (kw) 100 89 82 70 45 0 11 18 30 55

Throttle control 12.7 By passing On-off(70%) VFD 6.5 10 7

Efficiency

S1el
ENERGY MANAGEMENT
ENERGY MANAGEMENT INITIATIVES IN CHLOR-ALKALI INDUSTRY
Presentation By:
M/S H.S.SANDHU, P.P.S.YADAV

SIEL CHEMICAL COMPLEX ,RAJPURA PUNJAB

S1el
Siel Chemical Complex
Siel chemical complex (SCC), Rajpura, Punjab (A unit of Mawana Sugars Limited. )
Mawana Sugars Limited (Formerly known as Siel Limited) emerged as an independent entity in 1989 out of the restructuring of the erstwhile DCM Group.

Mawana Sugars has been engaged in the business of manufacture and selling of chemicals ,sugar and edible oils.

S1el
ABOUT SCC
One of the oldest business house of India (Formerly DCM Chemical Works) Turn over of SCC Rs. 200 Crore of the unit Integrated Chemical complex, manufacturing wide range of chemicals State- of the - art technology to produce Caustic soda, Bleaching powder and Chlorine Unparalleled standard of commitment to quality and customer satisfaction Presence in international markets

S1el
SIEL CHEMICAL COMPLEX,RAJPURA
Caustic Soda lye Caustic Soda flakes Liquid Chlorine Hydrochloric Acid Bleaching Powder Hydrogen Sodium Hypochlorite

S1el
INPUT COST- CHLOR ALKALI PROCESS
Furnace oil, 9% Others, 6 %

Salt, 15%

Power Salt Furnace oil Others

Power , 70%

S1el
INITIATIVES AT SCC
CHILLED WATER COMPRESSOR HYDROGEN COOLER VFD COOLING TOWER FAN ENERGY EFFICIENT PUMP CELL REFURBISH MENT CAPACITOR BANK RAIN WATER HARVESTING

SCREW COMPRESSOR CHILLED WATER

REPLACED OLD CENTRIFUGAL CHILLED WATER COMPRESSOR OF 600TR(CARRIER MAKE) REPLACED WITH ENERGY EFFICIENT COMPRESSOR. SUPPLIED BY M/S VOLTAS (MAKE:DANHAM BUSH Malaysia) INITIAL POWER -300KW PRESENT POWER-200KW INVESTMENT-66 LACS SAVING ANNUAL-35LACS

S1el

S1el
HYDROGEN COOLER
INSTALLED HYDROGEN COOLER FOR REDUCING LOAD ON HYDROGEN BLOWER Total investment, Rs.:10.85 Lacs Energy saving/Annum, Rs.:1.5 9Lacs Simple payback6.0Year

S1el
VFD FOR CLARIFIED BRINE PUMP
INSTALLED VFD FOR CLRIFIED BRINE PUMP Total investment, Rs.:1. 15Lacs Energy saving/Annum, Rs. :1.36Lacs Simple payback0.8 Year

S1el
COOLING TOWER FAN
REPLACED CONVENTIONAL COOLING TOWER FAN WITH AERODYNAMIC DESIGN FRP FAN Total investment, Rs.:0.20L acs Energy saving/Annum, Rs.:0.4 0Lacs Simple payback-0.5 Year

REPLACED OVERSIZE PUMP WITH S1el CORRECT SIZE

REPLACED OVER DESIGN PUMP WITH CORRECT SIZE ENERGY EFFICIENT PUMP(MAKE:MATHER AND PLATT) Total investment, Rs.:0.46L acs Energy savings, Rs.:15Lacs Simple payback

S1el
CELL REFURBISHMENT
UNDER TAKEN MAJOR CELL REFURBISHMENT FOR IMPROVING CELL HOUSE EFFICIENCY Total investment, Rs.:832La cs Energy savings, Rs.:331Lacs Simple payback2.5years

S1el
CAPACITOR BANK
INSTALLED ADDITIONAL CAPACITOR BANK FOR POWER FACTOR IMPROVEMENT FROM 0.980 TO .997. SAVING:20 LACS/ANNUM INVESTMENT:24 LACS SIMPLE PAYBACK:1.2

S1el

1.00 1.00 1.00 1.00 1.00 1.00

September-08 August-08 July-08 June-08 May-08 April-08

0.99

March-08
0.98

Monthly Power Factor(PSEB)

February-08 January-08 December-07 November-07

POWER FACTOR

1.0

1.0

1.0

0.99 0.99

October-07 September-07 August-07

1.00

0.99

July-07 May-07

1.00

0.99

April-07 March-07
0.99 0.99 0.99

1.00

February-07 January-07 December-06

1.01

1.00

0.99

0.98

0.97

0.96

0.95

S1el
POWER EFFICIENCY
POWER EFFICIENCY
2700

KWH/MT OF CAUSTIC

2650 2600 2550 2500 2450 2400 2350 2300

2567 2440 2407

Yr-2004

YEAR

Yr-2005

Yr-2006

S1el
SAVINGS
SAVING IN LACS(ANNUAL) 500

RS LACS

400 300 200 100 0 Yr-2004 42

361

95

Yr-2005 YEAR

Yr-2006

OTHER INITIATIVE: CONSERVATION OF WATER

3-R CONCEPT(REDUCE,REUSE AND RECYCLE) RAIN WATER HARVESTING PROJECT TO TAKE CARE OF FALLING WATER TABLE.

S1el

Certifications

S1el

ISO 9001:2000 certification from DNV for manufacture and supply of SBP. ISO14001:2004 certification from DNV for the Environment Management System of the whole unit ISI certification for grade-1 and grade-2 SBP

Achievements

S1el

Punjab Safety Awards for the year 1999, 2000 and 2002. National Safety Award in 2004 for the year 2003 for outstanding performance in the field of health and safety in chemical and chemical products category by the Ministry of labour and employment, Government of India. Environment Excellence Award from PPCB for the year 2005 for consistence in outstanding performance in the field of Pollution Control. National Energy Conservation Awards-2006 in Chlor-alkali sector by The Ministry of Power, Government of India.

S1el
ENERGY CONSERVATION AWARD

S1el
NATIONAL ENERGY AWARD

S1el

hssandhu@sielchemical.com H.S.SANDHU

Slel