CASESTUDYonEnergySavingsinPaintingfacility

ProjectTitle:EnergyauditofPaintingfacility Background: M/sEnergeticConsultingPvt.Ltd.(ECPL)carriedoutenergyauditataClientfacility.The focusofstudywastoidentifyandevaluateenergyconservationopportunitiesintheplant. Description: Planthaspaintsection,pretreatment section,machineshop,adminbuilding,utilitieslikeHWG,oven whereelectricityisused. Paintsectionincludespaintbooth,paintkitchen,puttyarea,paintbakingoven. The electrical utilities included in paint section are blowers for oven, paint shop exhaust and supplyblower,sludgepitpumps,circulationblowers,coolzonesupplyandexhaustblowers,and also1no.ofcompressorofcapacity500CFMrunsinthissection. Pretreatment section has blowers for degreasing, derusting and passivation tank blower and blowersforWDO. Hotwatergeneratorhasfeedwaterpump,FDfanwhichconsumesenergy. Otherareaincludesmachineshop,overheadconveyorandadministrationofficeload.

Thermalenergyisusedinpretreatmentsectionandpaintshopsection. Pretreatmentsectionhaspretreatmenttankswherewaterisheatedandmaintainedat55C 60CandWaterdryingovenalsorequiresthermalenergywheretemperaturerequiredis110C. Paint section requires thermal energy in paint baking oven where temperature maintained is around130C.

PR ES EN T E NER G Y SCE NAR IO :

Energy ElectricalEnergy,KWh/annum ThermalEnergy(PNG)m3/Annum:

Consumptionperannum 28,67,800 2,50,000

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 gpiechartssh howtheelect tricaldistribu ution(left)andaveragefue elconsumption(right)in plant: Following

EnergySa avingMeasur res:

E NC O N W I T H O UT IN V E S TM T MEN T:

1. Im mprovementincombustion nefficiencyo ofthePaintB BakingOven: Pre esently,thec combustione efficiencyis8 85.70%with% 2as6%.T %CO Thiscouldbe eimprovedto o10% CO2 by tuning the oven fo better com O or mbustion efficiency. By th 3518 m3/Annum fue was his, el est timatedtobe esaved.
E NC O N WITH ME IU M I NV ESTM EN T ED V T:

1. Byi installingMeshforScrubb bingeffect: Thevelocityof airmaintaine edinmanualpaintingzon neis0.5m/se ecforeffectiv vesettlingof paint s w g ter provided to e ensure the p proper and fresh air supply. Below the moving skid, a wat duct is p ttlingofloss paint.Presen ntly,therear re4sludgep pitpumpsinst talledsoast tosupplywat terto set the Manual pai e inting zone, a auto painting and touch u section of paint booth shop. Out o this g up f h of oneiskeptasa astandbypump.Threepu umpsarerun nninginapre esentconditio onsoastos supply ewatertoth heManualpaintingzone,a autopainting gandtouchu upsectionof paintbooth shop. the He erethepumpsarethrottle edtomeetthe elevelofwat terinthepain ntshop. Ma anualpaintzonehavinga acrosssectio onalareaof6 6*4.52m2wit thavelocity maintaineda at0.5 3 m/ /sec.Thevolumetricflowrate=6*4.52 2*0.5=13.56 /sec. 6m

P r ep a r ed by : E nerg etic Co ns u d g ulting Pvt. L Ltd. T ha n ne

PresentAirscrubbingsysteminmanualPaintingZone Waterducthavingacrosssectionalarea=0.150*6m=0.9m2. Velocityofwaterflowingoverthisduct=13.56/0.9=15m/sec. ProposedSystem: By opening the valves of throttled pumps, the head required shall reduce which will increase the flow.AlsothewaterbeneaththebottomoftheskidinManualpainting,autopaintingandtouchup zone would be provided with mesh type screen which will help as a plate to contact the air with water.Thiswillreducethewaterconsumptioninthiszoneasaresulttwopumpscanbeeliminated.

Proposed Meshatwaterduct
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 Meshplatecrosssectionalarea=0.200*6m=1.2m2. Plateareawithmesh=2400*3.14*10^4=0.75m2. Velocityofwaterflowingoverthisduct=13.56/0.75=18m/sec. 2. LightingVoltageTimeController: It was recommended to install lighting voltage time controller of 4 kVA for metal halide lamps. Since Metal halide lamps required high voltage initially to light it will not be connected voltage controller.After5minutesofswitchingonvoltagecontrollerwillbeinlinewiththelamp. 3. FanTimeController: It was observed that at some of the places which are not occupied for longer time, man cooler fanswereONevenaftertheareaisvacantwhichleadstounnecessaryuseofenergy. By installing timer based control, once the fan is ON after some interval it will be OFF automaticallyandifitisrequiredforlongerperiodthenitcanbeswitchedONagain.Thiswould helpinsavingextrahoursofworkingoffans.
E NCO N WI TH MAJ OR IN VE STM EN T:

1. Arrestingcompressedairleakagesanddedicatedcompressors: Itwasfoundthatbyarrestingpresentleakagesfrom21%to15%,4.51kWhcanbesavedperhour. Forpaintmixing,compressorrunsonpartloadduetowhich5kWharewasted.Thiscouldbesaved byinstallingdedicatedcompressorsforboththesectionsinpaintareaandresultin400kWhper daysaving. 2. Modificationinpaintboothsection: PresentSystem: Theproductsformedaftertheweldingandassemblingarepassedthroughdifferentzonesofpaint shop.Theproductsarefirstsenttoairblowzonefordustremoval,thentoatackoragzonewhere theproductsarecleanedwiththecloth.Afterthistheproductsaresenttomanualpainting,auto paintingforpainting,thentoatouchupboothforrepaintingtheareawhichisleftunpaintedinthe manualandautopaintingzone.Theproductsthenmovetoaflashoffzonewherethevaporization ofsolventtakesplace,leavingthepainttosettleeffectivelyonthesurfaceofproduct.Theproduct then moves to the oven where its temperature is maintained at 90110 C for drying of paint to formastrongpaintfilmonitssurface.Theproductisfurthercooledatambienttemperatureand sent to inspection zone. The rejected products from inspection zone are passed through putty sectionandresenttothepaintshopforthefinalfinishing.

Pr ep ar ed by : E nerg etic Co nsulting Pvt . Ltd. T ha ne

 Presently the supply blower passes the air at required velocity to air blow, tackorag, manual & autopainting,paintkitchen,inspection&puttyapplicationzoneandthesameisbeenexhausted fromthemanual,autopaintandtouchupboothbytheexhaustblowerplacedbeneaththewater duct.Exhaustblowerductisprovidedbeneaththewaterductlineforthecontactofairandwater. Presently supply blower and exhaust blower consumes around 134 kW and 152 kW power respectively.

Presentsystem Presenttheoreticalairrequirementindifferentsections Area(m2) Airblowzone Tackragzone Manualpainting Autopainting Touchupzone Solventwipe Inspectionarea Puttyarea1 Puttyarea2 Paintkitchen
Pr ep ar ed by : E nerg etic Co nsulting Pvt . Ltd. T ha ne

Velocity Q (m/sec) (m3/hr) 0.25 0.35 0.5 0.35 0.5 0.35 0.25 0.25 0.25 0.25 24408 34171 48816 82152 40355 45208 24300 48600 48600 39600

Blower Identification Supplyblower1 Supplyblower2 Total

TheoreticalFlow (m3/hr) 238147 198062 436210

ActualFlow (m3/hr) 228501 255218 483719

Total 436210

 ProposedSystem: Intheproposedsystem,recirculationblowerwouldbeinstalledtocirculatetheairinaclosedloop by eliminating the use of supply and exhaust blower. Recirculation blower will be continuously circulatingtheairinthepaintshopwithapurgeprovisionatthetopforairpurging.Alsothesmall blower would be placed in the zone requiring fresh air supply. This would reduce the power consumption of existing two nos. of supply blower and help in reducing power by 46 kW.

Summaryofsavings: Section Scheme Electrical Energysaving kWh/Annum 13545 118800 138982 48870 320197 FuelSaving m3/Annum 3518 3518 Energy SavingLac Rs./Year 0.88 7.75 9.03 0.98 3.18 21.83 Investment (Approx.), LacRs. 12 10 22.00 SimplePay Back, Months 19 13 12.1

Arrestingleakages Compressor Dedicatedcompressor forPaintmixing Blowersin Paint RecirculationBlowers section PaintBakingOven Paint Tuning Section Pumps Total

Overall savings can be summarized as Rs. 21.83 lacs per annum which results in payback within 14 months.
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