Abstract
Electric motors and boilers lead the industrial components which consume the largest portion of energy in an industry. This study explores the energy audit data of the condiment industry in India. The study mainly focuses on the estimation of the load factor, energy use, energy savings and annual bill savings with payback period of the electric motors of the plant. During the audit, it was found that there were several motors running under loaded conditions despite non-availability of variable speed drives installed in the plant. Therefore, variable speed drives are recommended to be installed to save energy by reducing the motors speed by up to 60%. According to the estimation, about 276 MWh, 551 MWh and 827 MWh electrical energy can be saved for 20%, 40% and 60% speed reduction of the motors using variable speed drives, respectively, where in most of the cases the payback period remains below 1 year. Furthermore, some suggestions are made to improve the poor power factor of running motors by using capacitor banks to save the reactive power. Besides, an estimation of energy saving is performed with a 2-ton capacity boiler. Since, there was no heat recovery system in the boiler; an air-preheater is suggested to be installed at the end of flue gas exhausting path of the boiler with the purpose of saving 68 tons of fuel per annum and having a payback period of 12 months. Moreover, a digital monitoring system, namely, “The Smart Joules” has been proposed to be installed in the plant aiming at saving about 3–5% of total energy per annum and having a payback period of 19 months. Finally, a summarization is made concluding in the fact that about 90 MWh energy and 95 tons of fuel can be saved (excluding motor energy savings) per annum by implementing proposed measures with a payback period of 15 months.
Highlights
The efficient use of energy with the current phenomenon of the limitations of its resources and the negative impact on environment is considered as one of the most burning issues of the current world [1]
In the case of panels, the motors used in the cooling water pump, cooling tower fan, workshop panel reading, roller A, roller B, boiler total panel, water pump and DM pump have lower power factors
The audit consists of the energy use and possible energy savings of various electric motors along with two boilers installed in the plant
Summary
The efficient use of energy with the current phenomenon of the limitations of its resources and the negative impact on environment is considered as one of the most burning issues of the current world [1]. Salam et al [46] focused on the energy consumption of building sectors of some South Asian countries, where they critically analyzed the main performance indicators over a period of about 50 years to intensify the existing policies, and summarized the impacts on socio-economic development of the countries Even though they discussed several renewable energy resources to support the energy demand in building sectors, the industrial energy consumption including policies is yet to be discussed. The study consisted of various national and international policies, standard tools and measures required for energy audit They showed that HVAC and lighting systems might have decreased a significant amount of energy consumption for both commercial and non-commercial sectors. Pandey and Prakash [48] conducted an energy audit in the pulp and paper industry in India They estimated the electrical and thermal energy consumption of various electric pumps, boilers and lighting systems along with the reduction of CO2 emissions, and figured out the corresponding energy saving opportunities with payback periods. This study is expected to act as a footprint for the researchers and the industrial personnel of developing countries towards achieving future economic and sustainable industrial sectors
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