Energy-Efficient Industrial Systems: Evaluation and Implementation / Edition 1

by Lal Jayamaha

Overview

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Proven Solutions for Maximizing Energy Efficiency in Today’s Industrial Systems

This practical guide features ten self-contained chapters that thoroughly analyze each component in large-scale industrial facilities and lay out best practices for reducing energy consumption and optimizing performance. Designed to help minimize costs and comply with environmental regulations, Energy-Efficient Industrial Systems: Evaluation and Implementation clearly explains the elements of successful energy management programs and offers ready-to-implement strategies and techniques. Real-world case studies throughout illustrate successful projects that have achieved significant energy conservation results.

Energy-Efficient Industrial Systems: Evaluation and Implementation covers:

· Energy Management

· Motors and Drives

· Pumping Systems

Product Details

ISBN-13:	9781259589782
Publisher:	McGraw Hill LLC
Publication date:	04/22/2016
Pages:	288
Product dimensions:	7.20(w) x 9.40(h) x 0.80(d)

About the Author

Lal Jayamaha has more than 25 years of industrial and academic experience in energy efficiency and is the Founder and CEO of LJ Energy Pte, Ltd. He holds a BSc from the University of London and a PhD in Mechanical Engineering from the National University of Singapore. Dr. Jayamaha has published numerous papers and has spoken at energy efficiency seminars.

Table of Contents

Preface xv

Abbreviations and Acronyms xvii

1 Energy Management 1

1.1 Introduction 1

1.2 Main Drivers for Energy Management 2

1.3 Typical Energy Management Program 3

1.4 Energy Policy 5

1.5 Energy Management Team 6

1.6 Energy Manager 8

1.7 Energy Usage and Baseline Data 8

1.8 Energy Accounting Centers and EnPIs 10

1.9 Targets and Action Plans 13

1.10 Energy Audits 14

1.10.1 Level 1 Audit 14

1.10.2 Level 2 Audit 14

1.10.3 Level 3 Audit 17

1.11 Training 18

1.12 Awareness 19

1.13 Documentation 20

1.14 Internal Audit 20

1.15 Management Review 20

2 Motors and Drives 21

2.1 Introduction to Motors 21

2.1.1 AC Induction Motors 21

2.1.2 DC Motors 23

2.1.3 Permanent-Magnet Motors 26

2.1.4 Synchronous Motors 27

2.2 Speed of Motors 28

2.3 Slip in Motors 28

2.4 Motor Efficiency 29

2.5 Losses in Motors 29

2.6 High-Efficiency Motors 31

2.7 Impact of Motor Loading on Efficiency 32

2.8 Estimating Motor Loading 33

2.8.1 Input Method 34

2.8.2 Slip Method 34

2.9 Economics of Energy Efficient Motors 35

2.10 Input Power Supply to Motors 38

2.10.1 Input Power 39

2.10.2 Supply Voltage 40

2.10.3 Power Factor 41

2.11 Maintenance of Motors 44

2.11.1 Lubrication 44

2.11.2 Cleaning 45

2.11.3 Motor Temperature 45

2.11.4 Voltage Testing 45

2.11.5 Insulation Testing 45

2.11.6 Vibration 45

2.11.7 Alignment 46

2.12 Motor Drives 46

2.12.1 Couplings 47

2.12.2 Belt Drives 48

2.12.3 Gear Drives 49

2.13 Variable-Frequency Drives 50

2.13.1 Introduction 50

2.13.2 Components of a VFD 51

2.13.3 Features of VFDs 53

2.13.4 Selection and Installation 55

3 Pumping Systems 57

3.1 Types of Pumps 57

3.2 System and Pump Curves 57

3.3 Pump Power 60

3.4 Affinity Laws 61

3.5 Pressure Losses in Pipes and Fittings 62

3.6 Parallel and Series Pumping 66

3.7 Pump Sizing 67

3.8 Constant-Flow versus Variable-Flow Systems 69

3.9 Effect of Pump Speed and Size on Efficiency 70

3.10 Avoiding Use of Bypass Systems 72

3.11 Use of Small Pumps to Augment Larger Pumps 73

3.12 Designing to Minimize Pressure Losses 73

3.13 Pump Efficiency 74

3.14 Overall Efficiency 76

3.14.1 Constant-Speed Pumps 76

3.14.2 Variable-Speed Pumps 78

4 Fan Systems 81

4.1 Types of Fans 81

4.2 Fan and System Characteristics 81

4.3 Fan Selection 83

4.4 Theoretical Fan Power Consumption 84

4.5 Affinity Laws 85

4.6 System Losses 86

4.7 Fan Discharge and Inlet System Effects 88

4.8 Filter Losses 90

4.8.1 Face Velocity 93

4.9 Coil Losses 93

4.9.1 Clean Coils 93

4.9.2 Face Velocity 93

4.10 Fan Efficiency 94

4.11 Right Sizing of Fans 96

4.12 Modulating Airflow Rate 97

5 Boilers and Steam Systems 99

5.1 Introduction 99

5.2 Fundamentals of Steam 99

5.2.1 Dryness Fraction of Steam 100

5.2.2 Sensible Heat of Water 101

5.2.3 Latent Heat of Water 101

5.2.4 Total Enthalpy of Steam 101

5.2.5 Steam Tables 101

5.3 Boilers 102

5.4 Boiler Efficiency 104

5.4.1 Combustion Efficiency 105

5.4.2 Thermal Efficiency 105

5.4.3 Overall Efficiency 105

5.5 Energy-Saving Measures for Boiler Systems 107

5.5.1 Improving Combustion Efficiency 107

5.5.2 Steam Pressure 108

5.5.3 Optimizing Operation of Auxiliary Equipment 108

5.5.4 Standby Losses 111

5.5.5 Minimizing Conduction and Radiation Losses 111

5.5.6 Heat Recovery from Flue Gas 112

5.5.7 Flash Steam Recovery 113

5.5.8 Automatic Blowdown Control 114

5.5.9 Heat Recovery from Blowdown 116

5.5.10 Condensate Recovery 117

5.5.11 Steam Traps 118

5.5.12 Steam Leaks 120

5.5.13 Feedwater Tank 121

5.5.14 Fouling and Scaling in Boilers 121

6 Process Cooling Systems 123

6.1 Introduction 123

6.2 Once-Through Systems 123

6.3 Cooling Tower Systems 124

6.3.1 Energy-Saving Measures for Cooling Tower Systems 125

6.4 Low-Temperature Cooling Systems 133

6.4.1 Energy-Saving Measures for Low-Temperature Cooling Systems 135

6.5 Refrigeration Systems 145

6.5.1 Energy-Saving Measures for Refrigeration Systems 147

7 Compressed Air Systems 157

7.1 Introduction 157

7.2 Typical System Components 157

7.3 Free Air Delivery 157

7.4 Standard Conditions 159

7.5 Utilization Factor 160

7.6 Types of Compressors 161

7.6.1 Reciprocating Compressors 162

7.6.2 Scroll Compressors 162

7.6.3 Screw Compressors 163

7.6.4 Sliding-Vane Compressors 163

7.6.5 Centrifugal Compressors 164

7.6.6 Axial-Flow Compressors 165

7.7 Basic Theory of Compression 165

7.8 Specific Power 168

7.9 Efficiency 170

7.10 Multistage and Intercooling 170

7.11 Heat Recovery 172

7.12 Dryers 173

7.12.1 Refrigerant Dryers 174

7.12.2 Desiccant Dryers 174

7.13 Receiver Tanks 177

7.14 System Pressure and Losses 178

7.15 Compressed Air Leaks 179

7.16 Using Blowers for Tank Agitation 180

7.17 Intake Temperature 181

7.18 Controls 181

7.18.1 On/Off Control 182

7.18.2 Load/Unload Control 182

7.18.3 Inlet Modulation 182

7.18.4 VFD Control 182

8 Heat Recovery Systems 187

8.1 Introduction 187

8.2 Modes of Heat Transfer 187

8.2.1 Conduction 187

8.2.2 Convection 189

8.2.3 Radiation 190

8.2.4 Heat Transfer through Composite Materials 190

8.2.5 Radial Heat Transfer 191

8.3 Heat Exchangers 192

8.3.1 Parallel-Flow Heat Exchangers 193

8.3.2 Counterflow Heat Exchangers 193

8.3.3 Cross-Flow Heat Exchangers 194

8.4 Performance of Heat Exchangers 194

8.5 Shell and Tube Heat Exchangers 200

8.6 Plate-Type Heat Exchangers 204

8.7 Rotary Heat Exchangers 204

8.8 Fouling in Heat Exchangers 206

8.9 Overall Heat Transfer Coefficient Values 207

9 Combined Heat and Power Systems 209

9.1 Introduction 209

9.2 Internal Combustion Engine 209

9.3 Gas Turbine 211

9.4 Steam Turbine 217

9.5 Combined Cycle 222

9.6 Need for CHP Systems 224

9.7 Types of Cogeneration Systems 224

9.7.1 Gas Turbine Topping 224

9.7.2 Microturbine 225

9.7.3 Steam Turbine Topping 226

9.7.4 Engine Topping Cycle 228

9.7.5 Combined Cycle Topping 230

9.7.6 Steam Turbine Bottoming Cycle 232

9.8 Applications and Considerations 232

9.8.1 Potential Applications 232

9.8.2 Factors Influencing Choice of System 233

9.8.3 System Design Strategies 236

9.9 Tri-Generation Systems 237

10 Financial Analysis 241

10.1 Introduction 241

10.2 Simple Payback Period 241

10.3 Return on Investment 242

10.4 Cash Flow Analysis 243

10.5 Time Value of Money 244

10.6 Net Present Value 244

10.7 Discounting Rate 247

10.8 Discounted Payback Period 248

10.9 Internal Rate of Return 249

10.10 Sensitivity Analysis 251

10.10.1 Case A-5% Reduction in Annual Net Cash Flows 251

10.10.2 Case B-20% Increase in Capital Cost 252

10.10.3 Case C-Reduction in Equipment Service Life by 1 Year 252

10.10.4 Case D-Combination of 5% Reduction in Annual Net Cash Flows and 10% Increase in Capital Cost 252

10.11 Life Cycle Cost 252

Bibliography 257

Index 259