ANSWER TUTORTAL 1 IWEEK 1-2]

PLANT ENERqY EFFICIENCY BNL 40303

f . i) Kinetic Energl" - The energy of an object or system arising out of its motion vibration,
forr,r,ard motion and turning are referred as kinetic energy. Kinetic energy is directl-v
proportional to the mass of an object. When tw"o object which differ in their masses tw'ice
and move at the same speed, then the object with twice the mass will have twice kinetic
energy.

ii) Potential Energy - Energy that possessed by an object due to its position above the
ground and is c,onsidered as energy waiting to be released. It is the energy associated to
the gravitational force near the surface of the Earth.

iii) Thermal nr Heat Energy - The kinetic energy due to the motion or vibration of
molecules in a substance results in thermal energy or heat energy. As the atoms/molecules
in a substance move faster, the object become hotter and heat flows in or out of the
system. In heat energy transfer, heat flows from hot bodies to cold ones which increase
the kinetic energy of the particles of colder pafi and thus elevate their temperature.

iv) Mechanical Energy - It is the sum of its kinetic and potential energy which keeps
an1, object in motion. Wheels. pulleys and inclined planes are the basic elements in
mechanical energ.v.

2" Work Done: Force x I)istance moved in the direction of force

Distance I ravel along the Ramp :2.5 tsin 34o = 4.47 m

Component of weight along Ramp : 450 sin 34o : 251.64 N

lhis component of the weight, along the frictional fbrce opposes the motion. But since
the box moves at a steady speed, the resultant force on the box is zero (there is no
acceleration). This means that the person is providing a force equal to the sum of these 2
lorces.

Force provided by the person : 257.64N + 180 N : 431 .64 N

Work Done: 431.64 N x 4.47 m: 1929.43 J

3. Vy'lpurr.rg.r: F' d' cos (0 degree)

Vy'1pu,,.ns.,: (56.9 kg x 9.8mis)'7.8 m:4349.44 J

W27prrr.,,s., : 4349.44 J x2l passenger : tr 1, 7434.88 J

 Polver : Work / Time
Power :11,7434.88J/60s
Por,ver : 1957.248 W

4. Biomass Energy - Any plant matter used directly as fuel or converted into other fbrms
befbre combustion such as r,vood waste, animal materials and u.astes, and crop waste are
considered as solid biomass. Biogas and liquid biomass derived principally from the
anaerobic f'ermentation of biomass and solid wastes which can be combusted to produce
heat and electrical power. Ethanol is the main form of liquid biomass produced from
plants, which includes firewood from trees.

Solar Energy - Solar thermal power exploits solar radiation for hot w-ater production and
electricity generation by flat plate collectors or solar thermal-electric plants. Solar power
from photovoltaics involves the conversion of solar energy to electricity in photovoltaic
cells. Passive solar energy fbr the direct heating, cooling and lighting of dr,r'ellings is not
included in this category.

Geothermal Energy - It is available as heat emitted from earth's c:rust, usually in the
fonn of hot w.ater or steam u,hich can be exploited for electricity generation using dry
steam or high enthalpy brine after flashing, or directly as heat for district heating and
agriculture.
 ANSWER TUTORIAL 2 [WEEK 2]

PLANT ENERGY EFFICIENCY BNL 40303

1. Natural Gas

Sometimes natural gas is confused with gasoline, the fuel in cars. They are not the
same. Gasoline is a mixture of liquids, and natural gas is mainly methane and is piped
into homes and office buildings where it is used as energy source for heating, cooking
q.ashir-rg, and dlying. It is ralv material to make other chemicals, and is the cleanest
bumming fossil fuel. This means it contribr-rtes little environmental pollutants r'vhen
burnmed.

Petroleum or Oil

This is the black, thick liquid pumped from below the earth's surface wherever you
see an oil rig. To make it useful, it is refined. Refining sepalates the gasoline portion
r.vhich is used in transportation. Products from the remaining porlions include
synthetic rubber, detergents. ferlilizers, textiles, paints, and pharmaceuticals.

Coal

Coal is the most abunclant fossil fuel. It is not a u'idely used energy source due to the
cost of mining and its impurities. u'hich cause pollution (acid rain). There are two
\\.a\ s to r.pine coal; underground mining and strip mining. Disadvantage to these
methods is the environmental change caused in the process. New ways of using coal
are being explored, such as liquefaction, in which a product similar to oil is produced.

Wind

The unequal heating of the earth's surface by the sun produces wind energy, u'hich
can be convefted into mechanical and electrical energy. For a long time, the energy of
r.vind has been to drive pumps. Today windmills can be connected to electric
generators to turn the wind's motion energy into electrical energy, and wind over B
miles per hour can be used to generate electricity .It is a renewable, but unpredictable,
energy sollrce.

Z, The heart of the electric power plant is the boiler. In the boiler a fuel is bumed and the
heat from the hot combustion products is transferred to the water that flows through
the tnbes surrounding the combustion chamber. The water boils and is convefied to
steam. The steam reaches a high temperature and a high pressure, of the order of 1000
oF and 1000 pounds per square inch (roughly sixty times greater than atmospheric
pressure); it contains a lot of thermal energy. This steam is directed to the turbine,
rvhich consists of a bladed wheel set on a shaft. The impulse of the high-velocity
steam causes the rotation of the blades of the turbine, which in turn causes the rotation
of the shaft. In this process, the steam becomes 'exhausted'; it loses its energy, and its
 temperature decreases" It is transfonned back to water in the condenser and
recirculated into the boiler to repeat the cycle. The rotation of the shaft of the turbine
r,r,ithin a magnetic field of the electric generator produces electricity, according to the
principles of electromagnetic induction" We need not elaborate this statement fuilher;
cor-rsider the generator to be a black box that convefts mechanical energy to
electricitl'. The elaborate water cooling system is a necessary component of the power
plant. In f-act, when a cooling tower is used for this purpose, it is the most prominent
par-t of the plant. The entropy decreases within the pow.er plant. So it must increase in
the surroundings; the surroundings in this case are the river and the atmosphere,
u'hose temperature increases. It is the temperature decrease between the steam in the
boiler and the water in the condenser that provides the energy for the conversion of
ireat to rvork in the turbine. To understand how this happens, the following analogy is
helpful even though it is not totally valid. Water wheel converts the potential energy
of the falling water into the mechanical (or kinetic) energy of the wheel shaft. Only a
limited conr.ersion of potential energy to kinetic energy occurs before the water hits
the rvheel. It takes advantage of the conversion of rnost of the water's potential energy
to kinetic energy.

Water at high level falls to a lor.ver level and loses some of its potential energy. which
is converted to kinetic energy, In other words, the "driving force" for the conversion
of potential energy to kinetic energy is the difference in height of the two water
reservoirs. \\rater at high temperature (for example, steam) 'falls' to a lower
tenlperature level (fbr example, liquid water) and loses some of its thermal energy,
u'hich is convefied to mechanical energy" Therefore, the driving force for the
conversion of heat to u'ork is the temperature difference betlveen the two thermal
reservoirs. The larger this driving force, the greater the conversion of potential energy
to kinetic energy, and of heat to u,ork.

J. The temperatures, convefted into kelvins, are the following: 70 "F : 294 K; 40 oF :
277 K;15 oF : 263 K. Since the heat pump is r.rsed as a heater, r'u'e have the follor.ling
expression for the maximum COP:

TH TH
-Vianri: COP,,,", - TH_TL
Buffalo : COP,ro*
TH_TL
294 K 294 K
t/.3 = 9.5
294 K- 277 K - 294 K- 263 K

2473 K-293 K 293 K

4. E
Ll'n3\ : 1-;;^;: 0.88 (88%)
2473 K 2473 K
xThis values is much higher than that of a typical engine (25%).
 973 K-373 I{ 373 K
E
Lrrr:r\ : l-::0.62(62%)
g73 t{ g73 K

*This is, as expected. larger than the typical efficiency of abost 45oh.

6.

1 Ep,,,.,pr,mt: [E5011.J [Et,,.uin.] fEgeneratorJ

: (0.88) (0.40) (0.98):0.35 (35%)

Note that the eftlciency of the system is lower than any one of the efficiencies of the
individual components of the system. In the case of this electric power plant, only
35o/o of the chemical energy input is convefied to electricity. The rest is lost to the
environment, mostly as heat.

The function of a gas furnace is to converl the chemical energy of the gas into heat
(Thermal energy):

Useful energy output: fEnergy input] [Efficiency]

: [1000 BTU (clremical e1e1g\ ,,t

t1B-TU (thermatenergv)
BTU (chemtcal energyl

:750 BTU (thermal energy)

 ANSWER TUTORIAL 3 [WEEK 3]

PLANT ENPRGY EFFICIENCY BNL 40303

1. It is critical for the enelgy management coordinator and the steering committee to
have their fingers on the "pulse of energy consumption" in the plant. This
is best
The objective
achieved through an etTective ancl efficient system of energy reporling'
of an energy reporting s) stem is to measure energy consumption and compare
it either
to company goals oI some standard of energy consumption. Ideally, this should be
plants only meter
clone for each operation or production cost centre in the plant' Many
energy consumption at one place, r,vhere there are various sources that enters
the

plant. Systern that shoulcl be metered includes steam, compressed air, chilied and hot
rvater. As a1.va,vs. the reporting scheme needs to be reviewed periodically to ensure
that only necessary material is being generated'

)
Financial Energy
General Accounting Effective metering, development repofis,
calculation of energy efficiency indices.
Cost accouuting Calculation of energy flows and
efficiency of utilization for various costs
centres; requires substantial qe19!4g:-
Standard cost accounting historical Effective cost centre metering of energy
standards and comparisou to historical dala;
complete ',vith variance reports and
calculation of reasons for variation'
Standard cost accounting engineered Er.rgy consumPtion are determined
standards through accurate engineering q944!--

J.

42.5 total amps x 277 volts : 11,,773 r'vatts : 11 .77 kW

11 .77 kW x l5o/o x 70 hrs/week x 48 weeks per year

: 29, 660 kWh / year

1 1.77 kW x250/ox 120 hrs/r,veek x 50 weehs per year : 17,655 kWly'year

Total : 129, 660 + 17, 65 5l : 17 , 31 5 kWUyear

3. Safe Relief Valve
The safety valve is the most important safbty device in a boiler or domestic hot-
water system. It is designed to relieve internal pressure if a range of failures occur
within the system. Each boiler requires some sort of pressure-relieving device.
They are referred to as a safety, relief or safety relief valve. While these names
are often thought of as interchangeable, there are subtle differences between
them. According to the National Board of Boiler and Pressure Vessel lnspectors,
the safety relief valve is a device that will automatically relief pressure and is
actuated by pressure upstream of the valve. This type of valve will fully open at a
set pressure and remain fully open until the boiler pressure reaches a pre-set
pressure.

Blow Down Valve

To avoid boiler problems, water must be periodically discharged or "blown
do\.1'n" from the boiler to control the concentrations of suspended and total
dissolved solids in the boiler. Surface water blowdown is often done continuously
to reduce the level of dissolved solids, and bottom blowdown is performed
periodically to remove sludge from the bottom of the boiler.

In order to prevent the uncontrolled flashing of steam in the boiler room, the
blor,vdou'n r\.ater should be discharged into a vessel in which the flashing can
occur in a controlled manner. The vessel should be vented to a safe location.
Environmental regulations limit the temperature at which hot rvater can be
discharged to a sewer system. Hot water can lead to degradation in the sewer
lines and it can promote excessive growth of bacteria. These regulations require
that additional steps be taken to reduce the temperature of the blowdown water
from the boiling point to 140o F or less.

Pressure Gauges
The function of the pressure gauge is to measure the pressure exerted inside the
vessel. 1'he pressure gauge is connected with the boiler's steam space through a
U-tube siphon, The tJ-shaped pipe contains water, which fills the Bourdon tube.
The pressure of the steam acting through the water on the inside of the tube tries
to make the tube circular. One end is fixed, the free end moves. Because of pinion
& gear arrangement, the slight movement of the Bourdon tube is magnified
considerahly and the point gives a maximum deflection, which can be read on the
scale.

4. AFUE is the ratio of annual heat output of the fuinace or boiler compared to the
total annual fossil fuel energy consumed by a furnace or boiler. An AFUE of 90o/o
means that 90o/o of the energy in the fuel becomes heat for the home and the other
1070 escapes up the chimney and elsewhere.
 AF I.lE doesn't include the heat losses of the duct system or piping, which can be

as much as 35oh of the energy for output of the furnace when ducts are located in
the attic, garage, or other partially conditioned or unconditioned space' High-
efficiency oil furnaces tend to have sealed combustion systems of the condensing
variety. It works by using a plastic tube that carries combustion air to the
chamber. A secondary exhaust process, known as the condensing cycle, cools any
gases. As a result, no chimney is necessary. A high-performance system typically
operates at 96 perce nt (%) AFUE while the old furnace can operate at only 75 to
80 percent AFUE.

\=
 -t

ANSWER TUTORIAL 4 [WEEK 4l

PLANT ENERGY EFFICIENCY BNL 40303

1. tr nternet-only

Intemet-onl), tarills t.vpicaliy oller the cheapest gas and electricity prices,

lntclestingly, the.v arc olicn oniy available if yon choose thcm via r.vebsite(s), but
oiien thcy rvill be available over the plione b1' calling the suppliers dilectly.

'l'he n-rain point is that

loLr manage y'ouf ilccount yor"rrself; e.g. receiving bil1s in an

electronic lbrnt via email as opposed to papcr bills but the cost savitrgs are passed o11

to -vou via the i'cclucecl energy prices.

lirr viro n m ental/(J rccn Ttrifl s

Grccn taritls lct .voLr clo sornething positive fbr the cnvironmcnt. 'l'hey're nclw off'ered
tx'n-Lost suppliers and, regarclless of the greentaril'f .vou choose. you'11 be doing your'

bit tbr the c1inrate...

The ntain dii'leru'nce betneen the varioLrs green energy prices is clor,vn to what you are

actLrall1' getting in tenns of thc cncrg)' mix (i.e. holv your energy is geuerated and
u,hat the suppliel does rvith tlie money you spend r,vith them). Typically, hotvever,
thesr, lall inlo tu,o main categories:

Ilenerv able

This is rvhere tl-ie sr"r;rplier matches 1he anrount o1'energy that you buy lionr them rvith
an cclriivalcnt amount o1'cncrgy fiom renclvable lcsottrccs.

fireen energ\'

Nonnally, costs lnore to producc but. in most cases, il you have uot yct switched
supplier 1or; should still be able to reclLrce your energy prices lr,hilst helping suppoil
the envirounrent.
 2. Goals of EnereY Auc{it

a Clear'ly identify types and costs of energy use'

a Understaud hor,v energy is being used - and possibly rvasted
which ones
a Perlbrm an economic analysis on those alternatives and determine
are cost-effective for business or industry'
r in terms of:
Identify and analyse more cost-effective ways of using energy
/
i. implovedoperationaltechniques
ii. neiu equipment, new processes or new technology

Walk-'l'h ru linergY Audits

to identify-maintenance,
This audit consists of a rvalk-through inspection of a facility
areas which need fuither
op..uiionuf or deficient equipment issues and to also identify
evaluation.

Mini Audit
performing
This audit includes performing economic calculations and may include
and losses'
monitoringAneteringltesting to identify actual energy consumption

Mnxi Audit
the actual
This audit it-rcludes the perlormance of computer modelling to determine
vear round energ)' consumption'

5 cYcles 60 mtn 24lr x 30 da1'

3. Total crcles in a montn:ff * doy
";
750 Wx216000 c,vcles:162000000 W:162000 kWh

Or

25 seconds 24hr
Total hours t'un in a daY: -r-Td.aY
60 seconds
:10hr

Total hours in a month:10x30:300 hours in a month

 ANSWER TUTORIAL s [WEEK sl

PLANT ENERGY EFFICIENCY BNL 40303

1. Inspection of Boiler System Process - in a visual inspection of a boiler, look at

the gar.rges of the boiler. If the gauges do not $'ork, the boiler control system
might 1ot function correctly. If the boiler stack temperature exceeds the boiler
$,ater temperature by more than 1500F, the boiler is not operating as efficiently as
it shoulcl. Check the boiler exhaust gas. If it is black, too little outside air is being
used in combustion and if it clears, too much outside air is being used.

Load Management - Boilers differ in efficiencies and in a system with several

boilers: it makes sense to determine which boilers are the most efficient. The
allocation process can be done to the boilers either manually (turning boilers
dorvn off during the off-peak seasons or during the real tirne basis through the
computer control). A boiler operates inefficiently with low loads and it is usually
u,orlhrvhile to operate one boiler at g0o capacity rather than two boilers at 45o/o
capacity.

Components - Boiler efficiency also can be improved by replacing the burners

and other components r,r,ith more efficient models as they are developed. Reside
burners, other components that should be exarnined are those *'here the heat
balances indicate that rvaste heat may be successfully used. As
''rith other
products, efficiency claims for boilers and their components are often over-stated;
an).ne\\,product should be evaluated carefully before deciding to buy it.

Z. Radiative Loss:400 ft2 x (0.1714 x 10-8) x [(185"F + 460.)a - (85"F + 460)4 ]

: (6.ss6 x 10-7) x l(1.731") - (8.822'51

:58,193.73 Btu/h

Convective Loss:400 fr2 x (0.18) x l(185oF + 460) - (85"F + 460;1t+r:)

: (12) x (a6a.16)
:33,419.52 Btu/h

Total loss : (5 8, 193 .73 + 33, 419 .52) Btu/h

:91,613.25 Btu/h
 ANSWER TUTORTAL 6 [WEEK 6]

PI,ANT ENERGY EFF'ICIENCY BNL 40303

-\nsuer the objectives qlrestions below:

1. What t1,pe of steam that is generally used for power generation/application?

a) Wet steam r,vith very high pressure High pressure steam lvith super heat
c)
b) DLy saturated steam r,vith high pressured d) Dry saturated steam with low pressure

2. Determine the normal velocities that normally encountered in pipes for superheated
steam:

a) 20 - 25 m/s c) 50 - 70 m/s
b) 30 - 40 rn/s d) 15 - 20 rnis

3. The equipment usecl to remove dirt from steam lines before steam trap is:

a) Vent c) Strainer
b) Drain d) By pass line

-1. Water hatnurer is common in:

a) Water Pipes c) Steam Pipes lvith steam and condensate

b) N4ain Steam Lines n'ith good traps d) Condensate pipes

5. Mechanical steam traps works on the principle of:

a) Difference in thermodynamics properlies between steams and condensate

b) Dilf'erence in density befiveen steam and condensate
c) Difference in temperature betrveen steatn and condensate
d) None of above

6. Proper sizing o1'steam pipeline helps in minimising:

efliciency
a) Boiler c) Steam Requirement
b) Temperatule l)rop d) Pressure Drop

7. Which tl.pe of insulation is more economic or energ,v efficient for steam pipelines that
c arrying satr:ratecl steam?

a) Calcir-un Silicate c) Glass Wool

b) Ceramic Fibre d) Fibre Bricks

8. The velocitl. ol steam in steam pipe is directly proportional to:

a) Length of pipe c) Number of bends in pipe

b) Specific Volumc of Stearn d) None of above
Ansu-er the subjective cluestions belou':

1. Name the three t-vpes of classifications of steam traps and also give their principle of
operatior-r?

Types Working Principle Sub-group

Thermodynamic 'frap Difference in
thermodynamics between
steam and conclensate
Thermostatic Trap Diff-erence in temperature
betn'een steam and
condensate
N4eohanical Difference in density
betr,veen steam and
condensate
a Disc type
a Orifice type
a Bimetallic type
a Metal expansion type
Bucket Types:
i. Open bucket
ii. Inverted bucket
iii. Float type
iv. Float rvith lever
Free float

) As a plant engineers. please slate the important gr-ridelines to undergo proper dralnage
and layout of steam lines:

. The steam mains shoLrid be run with a falling slope of not less than 125mm for
every 30 meters length in the direction of the steam flow.
. Drain points should be pror..ided at intervals of 30 - 45 meters along the main.
. Drain points should also be provided at low points in the mains and where the
stealrl main rises. Ideal locations are the bottom of expansion joints and befbre
reduction and stop valves.
. The branch lines fi'om the mains should always be comected at the top. Otherlvise
the branch line itself rvill act as a drain for the condensate.
. To enslre dry steam in the process equipment and in branch lines, steam
separators can be ir-rstalled as required.

3. Assume that the heat in the exhaust steam to be 1100 Btu; the temperature /p : 100'C,
/r : 80
uC. oC.
and t2: 90 Calcr-rlate the amount of cooling water required to condense
1 lb of steanl. (Page 5 19)

H-(to-32)
Given: a- tz- tt
a: 1100 Btu (100"C - 32)
(90 - 80) "c
o: i 03.2 lb (the amount of u.ater to condense 1 lb of steam)
7

A steam generator drltm of 4ft diameter is made up of l-inch plate and the tensile
strength of the steel is 55,000 psi r,i,hile tlie eft-rciency of the joint is 85%. What is the
estirnated design pressure of the drum? Assume that the satety factor is 6. Page 1,16

Given;
P : internal design pressrire of drum (psi)
TSxtxE TS : ultimate strength of plate (psi)
n
RxFS t : plate thickness (in)
R : radius of drum
E : efficiency ofjoint
FS : Safety factor
P : (55,000 psi) x 1 in x 0.85 psi
2x6

P: 46,750
12

P : 3895.833 psi
 ANSWER TUTORIAL 7 [WEEK 7]

PLANT ENERGY EFFICIENCY BNL 40303

1. N{echanical Draft Cooling Torvers

N4echanical-draft cooling tor,ver use either single or multiple fans to provide a knorvn
l.olume of air through the cooling tower. Therefore, their thermal performance is
generally more stable and is affected by ferver air variables than natural draft cooling
to\\'ers. Nlechanical dlaft cooling to\,ver trre either forced draft or induced dratl. Fol
the forced draf1, tl'Le lan is located in the ambient air stream entedng the cooling
tower, and the air is blorvn through the unit. The induced draft fan is located at the
erit of the airflou, and drau,s air thlough the tower. Large cooling tor,ver usually
plovided with conclete basins. These basins should be water-light and deep enough to
store an adequate amormt of rvater.

Nntural-Draft Ilyperbolic Cooling Torvers

The nattirzil draft hypelbolic utilizes air flow that is produced by densit5z dift-erential
that exists betu,een heated air inside the cooling tow,er, which is less dense and the
reliitir.'ely cool ambient air outside the tou.er which is denser. This density differential
is such that no fans are required because natural draft results. These type of cooling
tou'er tc'nd 1o be quite 1arge, since thy often handle large quantities of cooling $rater.
up to 900, 000 gpm. Because of the relatively small temperatul'e and densitl
clillerences o1 the inside ancl orLtside air, the cooling water is generally tall. The shape
of the touier shell is hvperbolic shape. This shape has a iittle effect on the natural draft
capabilities, but it ofl.ers superior strength and resists

2. J'here is several design consideration that should be incorporated into a cooling tower
design, u,hether it is a rnechaniclrl or natural draft torver.

t. Tov,erFill or Packing
Cooling tower fill is one of the most irnportant components of the cooling
tou.er. Its purrpose is to increase the contact area betr,veen the air and water, as
well as the rvater residence time. Fill is classified as film type or splash type.
. F-ihn t"v-pe 1i11

This design allorvs a thin lr'ater layer to be dilected along a plate or'
sheet, and air is fbrced past the r,vater. Several plates are placed
together at fixed angles in order to maximize the air-water contact area.
. Splash t1'pe 1i11

By inducing a splashing action, the air-water contact area and the water
residence time are increased. In these units, water enters the tower and
lalls on the splash bars, nhich divide the large nater clroplets into
smaller ones ancl thus increase the surface area.
7

Fire Protecliort
There is the potential lbr fire on cooling to\,vers, especially when wood or
other combr.rstible materials are used. Wood towers are susceptible to fire after
they have been out of operation for period of time which would allow them to
dry. In older to provide protection, design incorporating rvood has fire-
protcctiorr as part of their design. In fact, during plant's construction, fire
protection system tnust be operational to protect against the possibilit-v of fire
as a result of lvelding operation and others. With the used of non-combustible
material such as PVC and concrete. approval of design without of fire-
protection systern has been granted.

J. Wet bulb tcmperature is an important 1'actor in performance of evaporative u,ateL

cooling equipment. It is a controlling f-actor fi'om the aspect of minimum colcl u,ateL
temperature to r,vhich u,'atel can be cooled by the evaporative method. The wet br-rlb
temperatLtre of the air entering the cooling w'ater determines operating temperature
levels tluoughout the plant, process or system.

lnitial selection of towers rv.r.t design r,vet bulb temperature rnust be rnade on the
barsis of conditions existing at the Iou,er side. The temperature selected is general11
close to tile average ruaxiruum vr,et bulb fbr the sLrmmer months.

4,

rtt;,i h"ihti:t ft,t r,ir irl ;,i; . = rj;..

ltlirr: t,.1-.,^.
-,.-"-. r- lJ,,filel:
ll,itiliif. I+f ft1.)i1r, ; ?11, = lll,1w. ? ?lt ,

r1lils]" l''rtl:.lce: *,,.ii,. + ri;,1t, = lii-.li. - ri ir

',,':t1. tr:=11t.1: r.'='rft-i] ;l:=dS.-l i._Ii;tiui ll:=1tlllJt: !i,l..'ur,t

tlr,lf,. j -l i-],:il. i-rii,a-{,,-I r=lii,If,""1i-Jt)+ir.ii., ]-lijr,-rli_{tr:-rr:;)c"tI_---:i

rir"r1 r-rr.;:-,-';'jji llri0;-10N {.1 tiiir=;ir l1 t.J0r-i-rtl:;l l-,0til=1100-iir"rll.0i{-0.01rjt+-. 13rr

fu:;ll'. -':r.;I, ;,- =-S i:: i

The cooling torver \\'as asslul]ed adiabatic in the energy balance abo,n,e, as
usual, i.e. there is no heat dissipation fbr that system. But the intention here is
to er''aluate the energy that would had to be extracted from the incoming w,ater-
to cool it down to the exit temperature, that is

y,tl -- ,.., .. t r-f

t,,1,1,, \ ,,- T. i :].!) \l\\-
Water Evapot'ation Loss (m3/hour) : 0.00085 x 1.8 x water circulation rate (m3/hour)
x Temperature DitTerence (AT)

(1 gprn: 0.003785 m3/rnin)

(1 m3/hour: 1000 lit/hor-rr)

Water Circulation Rate (30 gpm) : (30) x (0.003785) x (60 m3/hour)

Water Circulation Rate (30 gpm):6.813 m3/hour

Water Evapolation Loss lntr/houl1 : 0.00085 x 1 .8 x 6.813 m3/hour x (zl"C)

Water Evaporation Loss (m3/hotrr) : O.O4l m3/hour
 ANSWER TUTORTAL 8 [WEEK 8l

PLANT ENERGY EFFICIENCY BNL 40303

1. Hydraulic furbincs

The prodLrction of electrical energy b1' h-vdroelectric systems is dependent upon the
operation of the hydlaiilic turbines. Hydraulic turbines convert the energy produced
b1' the lblce of mor,ir.rg u,ater into mechanical energy. This type of turbine is
connected to the shalt of a generator at a hydroelectric plant. Since AC generators at
po\\ier plants must rotate at a constant speed, the h1'draulic turbine nrust turn a fixed
rlte of speed. The etficienc,v of hydraulic turbines is much greater (85%) than the
most of rotating machines. The type of hydraulic turbines used rvith a hydroelectric
power system determines whether the generators have irorizontal or vefiical shafts.
The electrical polver is produced by a thlee phase AC generator connected directly to
the shatj of hl,draulic turbine. The1, may be put into operation that is faster than
steam-driver po\\'er systems. it is also possible tbr the h1'clratrlic generators systeni to
be operated as three phase s1'nchronous motors dLrring lorv clemands periods. The
nlotor can rotate hydraulic turbine r,vhich is then capable of pumping water.

Purnped-Storage I[1'droelectric S1'stems

Ser eral megarvatts of electlical porver are procluced in the Unitecl States by pumpecl-
storage hy'droelectric systems. This type of s,,-stetn opet'ates by pumping watel' to a
higher elevation trnd storing it in a reservoir until it is released to drop to a lorver
elevation to dlive the hyclrar-rlic tr-rrbines of a hydroelectric power-generating plant.
The variable natrue of the electrical load demand makes pumped-storage s,vstems
desirable systems to operate. During loiv-loads periods, the hydraulic turbines may be
used as pumps to pump r,r,ater to a storage reservoir of a higher eievation, frotn a
\vatet' soLrce of- a lou'el elevation. The ii-atr--r in uppel t'eset'voir can be stored tbr a
long period of time. if necessarl,. When the electricai load demand on the power
sl,stem increases, the rvater in the upper resen oir can be allowed to florv through the
h,v-drar.rlic turbines, u4iich u,il1 then rotate the three phase generators in the power
plant. fhus, electricai powel can be generated w-ithout any appreciable consumption
o1 tr,re1. The pump-turbine and motor generator units are constructed so that they will
operate in tvr,o wllys: (1) as a pnmp ancl urotor, and (2) as a turbine ancl generattlr" It-L
both cases, the trvo rnachines are connected b,v a cofirmon shaft and operate together.
FIon.el,er. tlLe multiple uses of these machines, although economically very attractive.
Iimit the amount of time that a pr.rmped-storage system can generate electrical porver.
The tittr-rre of puurped storage s,vstems depends primarily on economic factors. lf fuel
and capital construction costs continue to rise, pumped storage systems nright be
cler elope cl.
 Energl'-ellicient rlotors last longer, ancl rna1, reqr:ire less maintenaltce. At lovver'
temperatures. bearing grease lasts longer: required time betrveen re-greasing
iucreases. Lorver tetnperatules translate to long lasting insulation. Generally. motot'
lilc'doubles 1br each lOoC reciuction in operating temperature. Speed control is crucial
it-t sot-ne applications. In polyphaser induction motors, slip is a measure of motor
u'inding losscs. The lolr,er the slip thLrs produced higher efficiency. Less slippage in
energ)' efficient motors reslrlts in speeds about 1% faster than in standard
countetparts. Starting torque 1'or efficient rnotors may be lolvel tlian for stanclard
motors. Facilitl' mauagers should be caretirl u,hen applying efficient motors to high
torclue applications.

\\ orliing Principlc
Constlr-rction ol a single -pl-iase induction motor is similar to that of a three-phase
induction lxoto1' except that lhe slator is pror ided a single- phase ivinding. 'fltus.
"vith
it has a stator with slots. and squirrel cage rotor with a small air-gap in betr,veen.
When it is connectecl to single- phase ac supply, alternating current floll's in its stator
u,inding ancl the polaritl,' of stator poles would alternately be N and S. The field so
procluced u'ill be pulsating i.e. polarities n'ill be alternating with the flux rising and
lalling in strength. The current indr:ced in the rotor w'ill tend to turn it in both
clirections alternatell, and thus the rotor rvill be at standstiil dtre to inertia. If rotor is
given a pLtsh b1,' irand or br. another means in any direction, it will rotate in the sarne
clilection dcveloping operating torque. Thus a single-phase indr,rction is not self-
stalting and requires special starling means.

Applications
Due to their relatir.,el), simple constn-tction. availabilit"v in variety of ciesigns, and
characteristics and prouloted by economics as well as meeting the special
recluireueuts. single-phzrse induction motors are rvidel.v used. particr-rlarly where
h'actional horse po\ver range is less than 2 H.P. For example motors in 1/8 to 3/4 H.P.
ranges are used in fatrs, lefi'igerators. u,'ashing machines, blor,vers, centrifugal pulnps,
1/30 to 1/20 I{.P. ra11ge, are used in toys, hair dryers, vending machines, etc.

J.

ii.
Average Load
Loacl F'actor - Average Load
Peak Load Capacitl' Factor:
Capacity

112 MW
220 MW
166 MW
295 MW
Capacity Factor:0.615
: 0.7 45
4.

vo:N, : Ps -l- losses

I,
VS NS
:, 15,000w+(200w+350w)
240 v :- 1000 Pp: 15.550 rvatts
120 v NS

N, : 500 tr,rrns

111. Io:vt
Is vp
Io _ 2400v
BOA 600V
Ip : 3,200 A

5.

Fluoresccnt LamP
'l'he neu, lorv energy and therefore highly cost effective compact fluorescent lamp is a recent
adclition to moclern lighting technologl, and is an attractive alternative to incandescent 1al.t-rps.

De'elopment of very,. stabie fluorescent powders thiLt can handle strong r-rltra violet radiation
has made it possible to reduce the internal diarneter of tubular fluorescent lamps as
much as
10,rrr-i. These srnall bore tubes lbrm the basis for various type of compact fluorescent. The
coilpact fluorescent lanp basically is a lorv wattage, lou'-pressure gas discharge lamp.
Because of the small diameter of the lamp tr-rbe and couseqnent high w'all loading, the
surlace

te*iterlture of this lamp is higher than that of a conventional f-lttorescet-it lamp. l-his resr-rlts in
i,crease in the vaporrr pressLu'e inside the tube and consequently lor,ver light otltput at nornlal
.r-rbient telrperatur-e uithin the luminaire. To counteract this either amalgam techniclue or
principle of cool spot is emplo1,ed. These measLlres reduce the vapour presslre and maintain
the light outprtt.
 Energl'S:rvings
It is seLf-cvidelt that price of srich a con-rplicated compact lluorescent lamp exceeds the
price sf a simple incandescent lamp many times. Flolvever', by virtue of much lower
energ), consllmption of these larnps the higher initial cost is more than paid back. The
energ-y cost comparison betrveen incandescent and compact fluorescent lamp is shown in
'Iab1e
Enclgl' Cost Comparisou.

Lamp Wrttage, W Ef1icac1,, LN{/W Average Life Energy saving, %

(I{rs)
Incandescent 6o 72 1000

Courpacrt 9 67 7500 Bo
Fluoresceut

6.

I:125unitsx3atnperes
: 314 alnperes

11. P:VxIXplr
: 120 x 375 x 0.75
:33, 750 r.vatts (33.75 kW)
 ANSWER TUTORTAL 9 [WEEK 9l

PLANT trNERGY EFFICIENCY BNL 40303

Objective Ansrlers:

I . T'he basic function o1'air dr,ver in a compressor is:

a" Reduce the tempelature of the airbefbre it enters the next state to increase efficiency
b. 'I'o remove rem:rining traces of moisture :rfter after-cooler
c. Storage and smoothening pr-rlsating air outlrtit
c1. Prevent dust fi'orn entering conlpressor

2. Fot' everr' 4oC laise in air inlet tenperature of an air compressor, the porver consumption lviil
increases by:

a. 4o/u c.l"h
b.7% d.10%

-1. l'he ratio of isothermal poner to actual rneasnred input por.ver of a compressor is knorvn
Irs:

a. Volumetric Efficiencr' c. Barornetric Efficiencv

b. lsothermal Ifficienct' d. Pou,er Isotliermal Efficiencv

'+. Identif,r.the correct staternent fbr air compressors.

0
a. For ever), .l C rise in thc inlet air temperature, the decrease in energl' consumption
is b1'1%

b. For ever,v 5.50C drop in the inlet air tenrperatnre, the increase in energy consumption
is h1 20,.

c. 'fhe energy consumption remains same irrespective of inlet air temperature.

cl. For every ,loC lise in the inter air temperature, the inclease in energy consurnption is
b-v 1%

5. From the point of iolver specific energy consumption, which of the follorving compressors
are suitable fol part load operation?

a" Centlilirgal cor"npressor c. Single stage screlv cor-npressor

b. 'llw'o stage reciprocating compressors d. Trvo stage scleu, compressor
 6. \'rrhich of the lbllolr-ing pararmeters are not requirecl for er,aluating volumetric efficiency of the

cornpressor ?

a. C,vlinder Bore Diarneter c. FAD

b. Strohe Length d. Pou,er

7. Which of the follor,r,ing statement is "TRUE" lbr the centrifugal compressors?

-lhe
:r. contprcssor should be operated at shr_rt off pressure
b. The con.Ipressor should not be operated with inlet-guide vane control

c. 'l'he compl'essor should not bc operated close to the surge point

d. The compressor should not be operated at 1u11 load

8. The compressor capacitl' of a reciprocating compressor is directly proportional to

a. Pressure c. Speed

b. Volurne d. Torqr-re

9. T'he volumetric elficieucy of tlie compressor with the increase in altitude

o f p1ace.

a. lncrease c. Decrease
b. Does not change d. None

10. TLre acceptnble pressr-rre drop at tl-ie larthest point in mains header of an indr.rstrial
compressed air netrvork is:

a. 0.2 bar c. 0.5 bar

b. 0.3 bar d. 1.0 bar

 Give nrajor clussificatiorts o/'contltressors and the basic principte of its r.vorking.

The najor classifications of compressors are positive displacement and dynamic type.
Positir.e displacentent can be firrtlier clividecl in to (a) Reciprocating (b) Rotary. Dvnamic
colltll1'essol's divicled into I{adia1 and Axial. In case of positive displacernent comprcssors

itrcrease the pressure of airlgas by reducing the volune. Dynamic colxpressors increase
the air or gas velocity, rvhich is then converted to increase the pressure.

) Ilotar'1 colllpressors hal'e rotors in place of pistons and give a continuous, pulsation lree
discharge. They operate at high speed and generally provide higher throughput than
reciplocatins compressors. They ale directly coupled to the prirne tnover and lecluire
lou'et' starting torque as colnpared to reciprocating machines. Also they require smaller
fburtdations" vibrate less, and have a lower number of parts r.vhich are subject to *.ear.

The tnain pur'llose of ti receir,er is to act as a pr-rlsation damper. al1olr,ing intermittent l-iigh
cleurattds for compressed air to be rnet florn a small compressor set, resnlting in lesser
energ)' consumption,

3. \Ier'1' olien iu au industry. difl'erent t1pes, capacities and malies ol c,ompressors are
couuectecl to a conxnon distribr"rtion netrvork. In such situations, proper selection of a

right coubination of compressors and optimal moduiation of different compressors can

conserve energ.Y.

Whele more than one compressor f-eeds a common header, cotnpressors have to be
operated in sttch a way that the cost of- cornpressed air generation is minimal.

. 11'all compressors are similar, the pressure setting can be adjusted such that onlt'

one colxpressor handles the load valiation, rvhereas the others operate more or
less at lull load.

If- cotnplessors al'e of clillerent sizes" the pressure srvitch should be set slrch Lhat
only the smallest compressor is allowed to modulate (vary in florv rate).
If difl-erent types of compressols are operatecl together, unload power
consltmptiolls are significant. The compressor with lowest no load power must
be modulated.
 hr getrerai. the courpt'essor r.vith lorver part Ioad power ccxtsumption shorLld be

nroclnlated.

Compressors can be gracled according to their specific energy consumption, at

clitlirent plessures and energy efficient ones must be rnade to meet most of the
den-rand.

System leakage
3
in 'm /min' : (Q*T / T + 9

\!'hele Q : Actual fi'ee air being supplied during trial in *'/-in

f Load tinre irr rrriurrtes
t: Unload time in minutes
:200x10/(10+20)
:67 m imin

(t =-,;.i#i
-!-',-t" l: i'273+r,\
1., ',:

1i - 1,-,It015 + t) t)5) , ,' l7j+ ll I

101(i jU 'lii+-tli
0.83 7 m3lmtn
 ANSWER TUTORIAL 10 [WEEK 10]

PLANT ENBRGY EF'FICIENCY BNL 40303

1. In the open systetn, the ref igerant air comes in direct contact r,vith the products
in the cold cl.ramber. The operation in the open system is not only at
atmospheric pressule. due to rvhich, the size of the unit incleases forproducing
the same refi'igerating effect as produced by the closed system. Open cycle
system. is that the moislure is regularly carried awa1,' b1' the air circulated
throurgh the cooled space. ln the closed or dense system, the refrigerant is
contained n'ithin the system lvithout coming in direct contact with the products
in the cold charnber. Closed s)'stem is r.rsed for absorbing heat from the other
t-Ir"rid ancl this coolec'l air is circulated into the space to be cooled.

Advantages of Closed System Disadvantases of Onen Svstem

1 . The size of air reli'igerator is
small to produce a specific
retligerating eflect.
2. Air does not mir u,ith moister
presenl in the procltLct space. No
chocking of valves"
3. Dense air could be used to
produce more refi'i gerati n s etl'ect.
1. The size is large to produce the
same refi igerating effect.
2. Chocliing of vaives dr"re to moister
mix up rvith air.
3. Dense air could not be used.

) Tr : -ti'c - 213 - 160 I(

Tz : 32oC + 273:305 K

a. C.O.P of leI'rigeration maohine

T1 260
(c.o.P)r{ 5.78
Tz-Tt 305-260

b. C.O.P of heat pump

T2 305
((-.O.t'})rr : :6.78
Tz-Tt 30 5 -260
-
c. C.O.P of heat pulrip
Tz-Tr 305-260
(('.O.l'] )rr : : u. t+7
T2 305
-
 fHeat extracted frorr [Heat extracted fi'om fHeat extracted from
+
ivater at 20.5"C to vrater at 0"C to ice at water at 0"C tcr ice rLt
rvater ()oC] 0"cl -3"C1

N : ntco,,,,(Tz - Tr) + (m x L) * mcpice (Tz - Tr)

:450 x 4.19 (20.5 -0) r (450 x 340) +450 x2 l0-(-3)l

- 1, 93. 692.83 kJ/lir

3. I'he lolv pressure refrigerant vapour coming out of the evaporator flows into
the comllressor. The compressor is driven by a prime mover. In the
compressor" the relrigerant vapour is compressed isentropic alll'. The hlgh
plessLrre refrigerant vapour ilorn the colnpl'essor is then passed through the
condenser" Vapour refrigerant condenses into high pressllre liquid refi'igerant.
l'he cooling medium in the condenser are air or lr,ater. The cooling medium
absorbs heat frorn the refigerant equivalent to its heat and the refrigerant
changes its state fiom vapor-rr to liquid. The high pressure liquid refrigerant
thc.n enters the expansion valve. Due to expansion the high pressure iicluid
rcti'igcrant lums into lorv pressure 1ou' tempererture liquicl. The lou,' pressllre
liqLrid retrigerant then flou's thlough evaporator where it absorbs heat lrom the
retri_qerated space. This heat equivalent to its latent heat of vaporisation
evaporates and changes its state from liqr-rid to vapour. The low pressure
\iapour reh'igelant is sucked by the compressor which is once again
cor-npressed and cycle is repeated.

f'he vaponr absorption s1'stem uses heat energy. instead of mechanical energy
as in r,apour compression s1,stem. In this syslern, the compressor is replaced by
an absorber" a pllmp, a generator and a pressure reducing 'u'alve. These
cor-nponents in r.apour absorption system perform the same function as that of
a compressor in l'apotu'compression system.

Vapour Compression System VaDour Absorption System

'I'he syster-n of the same capaoity has it is quiet and is subjected to little
more \\iear, tear aud uoise dlte to wear.
rloving part of the compressor.
This sy,stem is r-rsed rvhere high grade This system can also be used
at
rrechanical energy is available. rerxote place as it can work even u'ith
a sirnple kerosene oil lamp
This sl,stern has a poor perfbnnance at This s-vstem is not aft-ected b1," load
partial loacls. variations
There are lrr()re chances of leakage of There is no compressor or any
refligerant 1l'onr the system. reciprocating component to cause
leakage.
 t

'.1. The slngle-cfI-ect evaporation desalination system has very limited industrial
applications. The s.v-stem is used in marine vessels. This is because the system
has a thermal perlbrmance ratio less than one, i.e.; the amount of w'ater

prodr:cecl is less than the amount of heating steam used to operate the system.

Hoi.vever, understanding of this process is essential since it constitutes many of

the elements fbrmir-rg other single-effect vapollr compression systems as well
as the multiple effect evaporation processes. This r,vould facilitate
understanding of these systems. which are more complex.

A cascade leli'igeration system operates u,ith a lower evaporating temperature,

smaller complession ratio and higher compl'essor volumetlic efticiency when

comparecl r,r'ith a single-stage one. In a cascade system, the lor.ver cycle may
use a high-pressr-rre lefi'igerant providing refrigeration at a low temperature
u,ith nroderate evalrorating pressures, u,hile the higher c1,cle mav use a lorv-
pressure refrigerant rejecting heat at a high condensing temperature withor-rt
ertremely high condensing pressures. Horvever, due to the fact that a cascade
s)rstem requires at least 2 refrigeration cycles, it is more expensive to build and

more complicated than a single-stage system. Moreover, the overlap of the

condensing temperature of the lor,ver c1,cle and the evaporating ternperature of'
the liigher cycle, u,hich is caused by the heat transfer betlveeu the 2 cycles,
reduces the efticiency of a cascade system. An alternative to a cascade

refi'igeration systern is a compound refrigeration system, which uses 2 or more

compressors connected in series in the same refrigeration cycle. A variation of
compouncl lefiigeration systenrs, named as 2-stage refiigelation system rvitl-r
intercooler, utilises intercooling betr,veen the compression stages in order to
recluce the compression por,ver.

5. '1'r :'l'+ : -10"C + 273: 263 K Sn: 1 .2037

T: : T-. : 30"C + 273: 303 K hn : 135.37 kJ/kg

x:: 0.95 Sn :0.5443 kJlkg.K

h1., : h11 - 313.08 kJ 'kg St:5.4710 kJ/kg.K

hrg:: 1145.80 kJ/hg
,i ffi
w

t'

r ,i t.rlr .. I i...i.1,_lr
't

rl ' a ....r.t :
j"
 ANSWER TUTORIAL 11 [WEEK 11]

PLANT ENERGY EFFICIENCY BNL 40303

1. Stearn'furbincs
Steam tLu'bine systcms consist of a boiler and turbine. The boiler cau be fired b1' a
variet), of tirels such as oi1, natural gas. coal and r,r,ood. In many installations.
inclustrial b1,-products or mLrnicipal rvastes are used s fuel. Stearn turbines
cogeneration plants produce high pressure steam that is expanded through a turbine to
prodr,rce ntechanical energy lvhicir. in turn, drives a device such as electric generator.

Combustion Gas Turbines

Corlibustion gas turbine sr.,sterns are made up of one or more gas turbiues and a r.r'aste
heat recoverl, unit. These systerns are fuelled by natural gas or petroleutl prodr"rcts.
The ploducls of combustion drive a tr-rrbine r,vhich generates mechanical energy. The
nrechanical enelg,v can be used directly or converted to electricity rvith a generiitor.
Thc' hot erhaust gases ol the gas turbine can be Lrsed clirectly' in plocess heeting
applications, or thev can be r,rsed inclirectly', rvith a heat exchanger, to produce process
steanl or hot ri iiter.

A r-ariation on the cortrbr:stion gas turbine systern is one that uses high-pressure steam
to tlrive a steam tr,rrbine in conjunction r,vith the cogeneration p1'ocess. This is referred
lo as a corlbined c1'cle.

Internal Combustion
Illterni1l combustion engine systems rrtilize orle or more reciprocating engines together'
with a u'aste heat lecovery clevice" These ale fuelled b1' the natural gas or distillate
oils. Electric porver is produced by a generator which is driven by an engine shall.
T'hertnal euerg)r engine exhaust gases can be used lbr process heating or to generate
lou' plessure stcam. \\/as1e hcat is recoverecl li'om the eugine oil cooiitrg jacket iu tlte
folm cil'hot ll'ater.

Cogeneration p1an1s that use the internal combustion engine generate the greatest
amounts of electt'icit1' fbr the arnount of heat produced. Of the three t1,pes of prirne
ntovers" ho\r,e\rer. the fuel utilization efficiency is the lou,est, and the maximum steam
pressLrre that can be prodLtced is limited.

2. L-ar aitable : E.1sg11ign1 X 1(g

E : cogenelation s1'stem electrical rated capacity

1(. : cogeneration constant
lt'a'ailalrle : 20 MW x 1.212 25.4 N4\\'x 1000 KW/N{W x 3-113RttL
: 25.1 MW o1'trsetul ireat 01 lhWh x Therm i 100. 000 Btu
farailirbrc : 866.9 therms/hour
 Bottoming Cycles
In a botton,ing cycle system. themral energ\l is produced directli, from the combustion
of tirel. T'his euersl' nsua11y takes the lbmr of steam that supplies process heating
loacls. Waste heat frorl the process is recovered and Llse as an energy source to
produce electric or mechanical poll'er'. Bottoming cycle cogeneration systems are
t.uost comnronl,v found in the industrial plants that have equipment with high
temperature heat requirements such as steel reheat frlrnaces, clay and glass kilns and
allul ir-ii Lun lemelt fuurac es.

1'opping C1'cle
T'opping cycle cogeneration systems reverse the order of bottoming-cycle systems.
The electricity or mechanical porver is prodLrced first, and then heat is recovered to
meet the thermal loads of the facility. Topping cycle's sl,stems are generally found in
facilities r,l.hicir clo not have extremely high process temperatlire requirer-rients.
Topping cvcles cot-rsists tu,o sti'urcliird thermodynamics cycles w'hich arc Brytot't Cltclt
and lhnkirtc Cltgls. Bryton Cycle is the basic thermod5,namic cvcie for simple gas
tLrrbine po\\'er plant. The Rankir-re Cycle is the basic cycle fbr a vapour-liquid sysrem
tlpical ol steam power plants.

"1. applications o1'waste heat are as fbllows:

Sor-r-rc
o N'lediLur to higit tetnpereLture exhaust gases can be trsecl to preheat the,
combr-rstion for:
i. Boilels using preireaters
ii. Furnaces using lecr:perators
iii. Ovens using recr-rperators
ir,. Gas ttrrbines using regenerators
. Lou'1o tneclilu-t-t temperature exhaust gases can be usecl to preheat boiler leeci
water ol boiler tnakeup rvater using econorrizels, u,hich are simpiy gas-to-
iiquid rvater heating devices.
. Exhltust gases and cooling water fi'om condensers can be used to preheat
liquid ancl solid leedstocks in industrial processes. Finned tubes and tube-in-
shell heat exchangers are usecl.
o ExhrLttst gases can be used to generale steam in waste heat boilers to procluce
electrical power, urechauical porver, process steam, and ury combination of
abor e.
o Waste heat rna,v be transfered to liquid or gaseous process rinits directll'
through pipes and ducts or indirectly thror"rgh a secondary flLrid such as steam
or oil.

5. q: mcp
Af : 10, 000 x (190 -701 : 1.2 x 106 Btilhr
Savings : 7.2x 106 x 4000 x 6 I 106/ 0.8 : RM 36, 000
 J'he usual arangemelrt fbr tlLe finned-tr-rbe exchanger positioned in a duct and
details
6.
is
of a t1'pical flnnecl-ttrbe constrr.rction is shorvn in Figr-rre 1. This type of applications
11-Iore commonlr-knor.vn as economizer. The tttbes are ollen
connected all in series but
pressure drop'
can aLso be rrranged i1 series-parallel bundles to control the liquid side

The trir sicle plessr.u'e clrop is controlled by the spacing of the ttlbes and the number
o1'

rorvs oltr-rbcs nithin the iluct. Finned tube heat exchangers are available pre-packaged

in nodnlar sizes or can be made up to custom specifications very rapidly t}om

srandards components. Temperature control of the heated liquid is usually plovided
llou' rate of hot gases over the heat
b1, a bl,pass cluct arrarlgernent rvhich l'aries the

exchanger. N{aterials fbr the tubes ancl the t-rns can be selected to r'vithstand corrosive'
liquids or cotrosive exhaust gases.

ait:; ?l'i A',n' :l

:i i:,iai-.rra ii:i
t.,t ,, I 1:.1:, I t :; i l- l*

7. Q : V, AC,/h x 0.020'1'- Btttili3

uF
x LT'x t
I oF
r 20oF x 4 hor-trs
C): 8000 ft:r x 1.7 AC/hx 0.020 Btu/11r

t) - 8000 x 1.7 x 0'020" x 2:l

?: li0.56o Btu's