Hello friends,

Energy saving in Boiler and steam system is also very important in Industry. I have collected various files PDF that contain the calculations, questions and answers etc. related to boiler and steam system.

You can download it here

http://www.fileserve.com/file/GdX6h9S

Vertical Shaft Brick Kiln (VSBK) - a most energy efficient technology for brick making

Continuous Vertical shaft Brick Kiln (VSBK), the brick kiln technology that are known as a most energy saving brick making technology in theworld. Original in China from 1970s, this technology was proved the ability ofreducing the specific energy consumption from almost 2MJ/kg brick in traditional vertical kiln to about 1 MJ/kg brick. However, the original VSBK can only produce low capacity of brick with quite high breakage. Brick quality is also not so good in surface and not suitable for the clay with high shrinkage. The operation of the kiln is also difficult that need a good training for the firing master. Since those reasons, GEF/SGP have been proposing a 2 phase project in Vietnam to introducing the VSBK (from 2001 - 2003) and to completing design and dissemination of VSBK (from 2005 - 2007). Until now, there are about 400 VSBKs working in Vietnam. After the project supported by GEF/SGP Việt Nam, the project PECSME (Promoting Energy Conservation in Small and Medium Enterprise) was also supported to develop the VSBK technology further with 3 demonstration project in Vietnam. The design of the VSBK is now modified with the following terms:

• Perfecting the combustion chamber design using the suitable standard insulation and refractory materials to reduce the wall thickness, increase the heat insulation of the walls, increase the service life of the kiln and product quality.

• Improving brick unloading system using hydraulic lifting and lowering device or screw with motor to reduce labor force and to solve the problems easily.

· Using temperature measuring equipment to measure and control the operation of the kiln to obtain operational stability and reduce breakage;

· Altering the design of the kiln by replacing load-bearing walls with a system of concrete frame and floor, enhancing the industrial shape and enabling convenient operation.

· Design a fuel inserting holes at the central part of the combustion chamber to simplify start firing process and give an ability to adjust combustion inside the kiln. Design a new flue gas withdrawing system that can protect the labors health that work at the top of the kiln. The new system reduce number of stacks from 1 combustion chamber with 2 stacks to 2 combustion chamber with 1 stack; optimize the holes and tunnels system to simplify the construction and improving the gas withdrawing efficiency.

· Introduce a suitable green brick producing system that suits the capacity and operation process of VSBK technology,

With those modification the VSBK in Vietnam now have following characteristics

· The design of combustion chamber now can produce 2000 solid brick/batch and 10000 solid brick/day. For the hollow brick, the capacity could be increase double.

· The specific Energy consumption is from 0.7 – 1 MJ/kg brick with the coal consumption of 40 – 50 g coal/kg brick with the heating value of coal is 5000 kcal/kg.

· The environment of the working labor in the top of the kiln is solved completely.

·

In order to disseminate VSBK technology, there are already the following tools:

- Guideline for design, construction and operation of VSBK.

- The video guide for design, construction and operation of VSBK.

In order to have more information, please send email to; quangcom@hotmail.com or nguyenserious@gmail.com

Motor Energy Saving Tips

Industrial fans, pumps and air compressors use more than 50% of the total motor related electricity used. According to the U.S. Department of Energy (DOE), industry could reduce energy used by motors by 11 to 18% if it implemented all existing cost-effective technologies and practices for improved efficiency.

Significant air emissions are released when electricity is produced. In Minnesota, one-fourth of the energy-related emissions of carbon dioxide, sulfur dioxide, lead and mercury are from generating electric power. Industry uses over 50% of this electricity. Reducing electricity use by motors will help improve Minnesota’s air quality.

As of October 1997, the Energy Policy Act (EPACT) requires all motors sold in the U.S. to meet efficiency standards. In 2001 a new class of premium efficiency motors was designated, setting efficiency standards for new motors beyond those of EPACT.

Although high efficiency motors have been available for years, they make up less than 10% of all industrial motors in current use.

If your motors are not part of this 10%, they could be using excess electricity—increasing your operating costs.

Motor Energy Costs
Use the following equations to calculate demand and energy costs. Together these equal your annual cost to operate motor driven equipment. Once you have calculated your annual cost, compare it to the annual cost to operate EPACT and premium efficiency motors.

To calculate the energy cost per year, multiply:

• motor’s horsepower (hp)
• conversion factor 0.746 kW/hp
• number of operating hours per year (hr/yr)
• cost per kilowatt-hour ($/kWh)
• load factor (LF) = average amps/full load lamps

Divide the product by the motor’s efficiency. Load factor is the fraction of the motor’s horsepower actually used to drive a load. One way to determine load factor is to measure the amperage (amp) draw of the motor under load then divide by the motor’s full load rating.

Energy cost per year =

(hp)(0.746 kW/hp)(hr/yr)($/kWh)(LF)

motor efficiency

To method estimate the demand cost per year for operating a motor depends on how power factor is taken into account. A power factor—ratio of true power used to the power drawn from the source—is found on a motor’s specification sheet where there is a demand charge in KW and separate power factor adjustments.

Multiply:

• motor’s horsepower (hp)
• conversion factor 0.746 kW/hp
• load factor (LF)
• cost per kilovolt amp per month ($/kVA/mo)
• 12 months per year (12 mo/yr)

Divide the product by:

• motor’s efficiency
• motor’s power factor

The cost per kVA is found on your electric bill.

Demand cost per year =

(hp)(0.746 kW/hp)(LF)($/kVA/mo)(12 mo/yr)

(motor efficiency)(power factor)

Example Calculations
For the example calculations that follow use these factors:

• Motors are five horsepower
• Motors run 4,000 hours per year
• Motors run at 0.75 load factor
• Energy cost is $0.05 per kWh
• Unit demand cost is $3.00 per kVA per month

	Standard	EPACT	Premium
Efficiency	83%	86%	88%
Power Factor	0.82	0.84	0.86

The following is an example of how to calculate the annual energy, demand and total cost of a standard efficiency motor.

Energy cost per year =

(5 hp)(0.746 kW/hp)(4,000 hr/yr)($0.05/kWh)(0.75)

0.83

= $674 per year

Demand cost per year =

(5 hp)(0.746 kW/hp)(0.75)($3.00/kVA/mo)(12 mo/yr)

(0.82)(0.83)

= $148 per year

The total annual cost to operate the motor is $795.

After 10 years the motor’s operating cost exceeds its purchase cost more than 20 times.

The table below summarizes the cost for each motor. Payback periods for EPACT and premium efficiency motors, compared to standard efficiency motors, are based on purchase price and energy savings.

	Standard	EPACT	Premium
Purchase price	$375	$445	$575
Energy cost (yr)	$674	$651	$636
Demand cost (yr)	$148	$140	$133
Operating cost (yr)	$822	$791	$769
Payback years	—	2.3	3.8

Motor Repair and Replacement Policy
Implement a motor replacement policy to replace older, rewound motors. This can benefit your operation in many ways, including:

• Increased efficiency, which lowers operating costs
• Reduced downtime, which lowers production costs
• Lower operating temperatures, which lowers maintenance costs

Policy Example
The following policy was developed by the Industrial Electrotechnology Laboratory. It covers open drip-proof (ODP) and totally-enclosed fan-cooled (TEFC) motor enclosures.

• When purchasing a new motor or piece of equipment, specify energy efficient motors.
• When an existing motor fails:
• If it is energy efficient, send it for repair. This applies to ODP and TEFC enclosures and one to 200 hp motors.
• If it is not energy efficient and is an ODP enclosure replace it with an energy efficient model. This applies to one to 200 hp motors.
• If it is not energy efficient and is a TEFC
  enclosure use the table below to select a
  breakpoint horsepower—a motor size that
  provides at least a two year payback—for the
  number of hours you operate motors.

Annual Operating Hours	Horsepower*
One shift (2,912 hr/yr)	25
Two shifts (5,824 hr/yr)	70
Three shifts (8,736 hr/yr)	130

• * For energy cost at $0.05 per kWh.
• When a motor is larger than the breakpoint horsepower send it for repair. When a motor is smaller than the breakpoint horsepower replace it with an energy efficient motor.
• When repairing a motor will cost more than 60 percent of the purchase cost of a new energy-efficient motor, buy the new motor.

Conservation Strategies
Energy efficient motors. When purchasing a motor choose the most energy efficient and affordable. Premium efficiency motors cost about 20% more, but will payback in under four years with one-shift operation and a cost of $0.05 per kWh. Payback will be shorter for a 24-hour, seven-day-per-week operation.

Oversized motors. Motors are oversized when they power end uses that require less horsepower than the motor is capable of producing. For example, when a 10hp motor is used for an application that calls for a five hp motor, the motor is 100% oversized, or operates at 50% full-load. At smaller load factors motor efficiency is lower, leading to increased operating costs. Select a lower power motor and operate it at a higher load factor to help justify the motor replacement. Motors operated at low load factors have lower power factors.

Motor replacement. Some motors may warrant replacement before they fail. Evaluate motors that are used for two or more shifts per day and are oversized.
Synchronous belts. Optimize transmission efficiency by using synchronous belts instead of v-belts. V-belts can slip and deteriorate efficiency at higher loads.

Variable speed drives. Consider using a variable speed drive motor system instead of traditional motors when loads vary significantly over the course of daily use.

Voltage. The voltage at the motor should be as close to the design limits, found on the nameplate, as possible. Changes of more than five% can lead to two to four% drops in efficiency and increase temperatures, which decrease the motor’s life. Voltage at the motor that is not within the design limits leads to a decrease in power factor. Low power factors may be penalized by your power company.

Lighting system, how to reduce energy consume

Lighting or illumination is the deliberate application of light to achieve some aesthetic or practical effect. Lighting includes use of both artificial light sources such as lamps and natural illumination of interiors from daylight. Daylighting (through windows, skylights, etc.) is often used as the main source of light during daytime in buildings given its low cost. Artificial lighting represents a major component of energy consumption, accounting for a significant part of all energy consumed worldwide. Artificial lighting is most commonly provided today by electric lights, butgas lighting, candles, or oil lamps were used in the past, and still are used in certain situations. Proper lighting can enhance task performance or aesthetics, while there can be energy wastage and adverse health effects of poorly designed lighting. Indoor lighting is a form of fixture or furnishing, and a key part of interior design. Lighting can also be an intrinsic component of landscaping.

Lighting fixtures come in a wide variety of styles for various functions. The most important functions are as a holder for the light source, to provide directed light and to avoid visual glare. Some are very plain and functional, while some are pieces of art in themselves. Nearly any material can be used, so long as it can tolerate the excess heat and is in keeping with safety codes.

An important property of light fixtures is the luminous efficacy or wall-plug efficiency, meaning the amount of usable light emanating from the fixture per used energy, usually measured in lumen per watt. A fixture using replaceable light sources can also have its efficiency quoted as the percentage of light passed from the "bulb" to the surroundings. The more transparent the lighting fixture is, the higher efficacy. Shadingthe light will normally decrease efficacy but increase the directionality and the visual comfort probability.

Here are some tips to reduce energy use for lighting

• Replacing all incandescent light globes withcompact fluorescent globes or light emitting diodes (about $100-300).
• Switch off lights when they are not needed ($0)
• Try to use as much as possible daylighting.
• Design a good lighting system with automatic control device.
• Using suitable lamp for a different purposes
• Sellecting a high quality lamp

How much can you save with energy efficient boilers ...

Boilers account for around 60% of all domestic CO2 emissions according to the Energy Saving Trust.

So it's no surprise that one of the most effective ways of reducing your energy bills is to replace an old or inefficient boiler, generally those over 15 years old. All modern boiler systems are designed to be energy efficient and need less fuel to run with the most efficient condensing boilers using 30-40% less.

Installing a new boiler is expensive but the savings you could make through lower heating bills can help you recover the cost within 3-5 years and the savings would continue long after. Even so, there may be grants available in your area to help you with the cost of purchase and installation. Contact your local Energy Saving Trust Advice Centre on 0800 512012 for more details.

How to buy a high efficiency condensing boiler?

You could first contact your local Energy Saving Trust Advice Centre for information on any grants that are available and a list of approved installers.

You should also check that the installer is an approved member of either CORGI for gas appliances, or OFTEC for oil fired appliances. For gas-fired boilers contact a local CORGI registered installer or for oil-fired boilers contact OFTEC.

When choosing a particular make and model, look out for the Energy Saving Recommended logo and bear in mind that boilers are rated according to how much of the fuel they consume is converted to heat, as a percentage. This rating is called SEDBUK or Seasonal Efficiency of Domestic Boilers in the UK. These ratings are from A to G with A-rated boilers being more than 90% efficient.

Energy saving tips

Household greenhouse gas emissions

With climate change now an acknowledged problem, many people are keen to know what they can do as individuals to reduce greenhouse gas emissions. There are several measures you can take to reduce your "carbon footprint" without compromising your lifestyle. You can reduce the energy used in your home (or office) and your carbon footprint and save money by these fairly easy actions:

• Replacing all incandescent light globes withcompact fluorescent globes or light emitting diodes (about $100-300).
• Switch off appliances when they are not in use, rather than leaving them on standby mode ($0).
• Switch off lights when they are not needed ($0)
• If you have a second fridge, turn it off when it is not needed. Don't just leave it running.
• Use a kettle on gas stove to heat hot water for beverages rather than an electric jug. If you do use an electric kettle, make sure to only fill it with as much as is needed, but that the heating elements are still covered with water.
• Set your thermostat to 18-20C in winter and 26C in summer.
• Seal draughts and gaps around external doors and windows, and make sure you close curtains after dark.
• Commute to and from your workplace by carpooling, using public transportation, cycling, or -- best of all -- telecommute from your home.

Some more costly actions are:

• Install a solar hot water heater (about $2000, rebates available). Hot water accounts for about 30% of domestic energy consumption, so this is one of the most effective ways to reduce household carbon emissions.
• Buy green power - this means a percentage of the electricity you consume is sourced from renewable energy. Make sure you check how green the power is as some retailers are better than others. Ask them what the percentage of their green power comes from clean energy sources. This will add about 10% to your electricity bill.
• Install a grid interactive solar array so you can generate your own electricity and feed clean power back into the grid ($5,000 to $20,000 depending on the number of panels, rebates available).

Energy Conservation, hot topic in the world

Energy conservation.

Energy conservation refers to efforts made to reduce energy consumption in order to preserve resources for the future and reduce environmental pollution. Energy conservation can be achieved through increased efficient energy use, in conjunction with decreased energy consumption and/or reduced consumption from conventional energy sources.

Energy conservation can result in increased financial capital, environmental quality, national security, personal security, and human comfort. Individuals and organizations that are direct consumers of energy choose to conserve energy to reduce energy costs and promote economic security. Industrial and commercial users can increase energy use efficiency to maximize profit.

Energy conservation policies

Electrical energy conservation is an important element of energy policy. Energy conservation reduces the energy consumption and energy demand per capita and thus offsets some of the growth in energy supply needed to keep up with population growth. This reduces the rise in energy costs, and can reduce the need for new power plants, and energy imports. The reduced energy demand can provide more flexibility in choosing the most preferred methods of energy production.




Climate change.

By reducing emissions, energy conservation is an important part of lessening climate change. Energy conservation facilitates the replacement of non-renewable resources with renewable energy. Energy conservation is often the most economical solution to energy shortages, and is a more environmentally being alternative to increased energy production.

Issues with energy conservation.

Advocates and critics of various forms and policies of energy conservation debate some issues, such as:

*Standard economic theory suggests that technological improvements increase energy efficiency, rather than reduce energy use. This is called the Jevons Paradox and it is said to occur in two ways. Firstly, increased energy efficiency makes the use of energy relatively cheaper, thus encouraging increased use. Secondly, increased energy efficiency leads to increased economic growth, which pulls up energy use in the whole economy. This does not imply that increased fuel efficiency is worthless, increased fuel efficiency ena bles greater production and a higher quality of life. However, in order to reduce energy consumption, efficiency gains must be paired with a government intervention that reduces demand (a green tax, cap and trade).

*Some retailers argue that bright lighting stimulates purchasing. However, health studies have demonstrated that headache, stress, blood pressure, fatigue and worker error all generally increase with the common over-illumination present in many workplace and retail settings ^[7][8]. It has been shown that natural daylighting increases productivity levels of workers, while reducing energy consumption.

*The use of telecommuting by major corporations is a significant opportunity to conserve energy, as many Americans now work in service jobs that enable them to work from home instead of commuting to work each day.

*Electric motors consume more than 60% of all el ectrical energy generated and are responsible for the loss of 10 to 20% of all electricity converted into mechanical energy.

*Consumers are often poorly informed of the savings of energy efficient products. The research one must put into conserving energy often is too time consuming and costly when there are cheaper products and technology available using today's fossil fuels.

*Technology needs to be able to change behaviour al patterns, it can do this by allowing energy users, business and residential, to see graphically the impact their energy use can have in their workplace or homes. Advance real-time energy metering is able to help "people" save energy by their actions. Rather than become wasteful automatic energy saving technologies, real-time energy monitors and meters such as the Energy Detective, Enigin Plc's Eniscope, Ecowizard, or solutions like EDSA'a Paladin Live are examples of such solutions.

CCAT energy conservation.

Currently, most of the energy we use comes from finite natural resources such as coal and natural gas, or from the destructive processes of nuclear fission and large dams. Environmental problems including air pollution, acid rain, and increased carbon dioxide emissions are upsetting natural ecosystems. Global warming, climate changes and respiratory illnesses are becoming more prevalent every day as a result of non-renewable energy consumption.

At CCAT, our goal is to conserve energy wherever possible and to utilize renewable energy sources. Among the variety of ways to conserve energy, CCAT has adequate wall and ceiling insulation, unplugs appliances and turns off lights when not in use, uses energy efficient appliances (laptop computer and Sunfrost refrigerator), uses an efficient wood-burning stove and an on-demand water heater, and has switched to compact fluorescent light bulbs that last up to fifteen years and use 1/4 the energy of a standard light bulb. We also use a cold cabinet for refrigeration part of the year, an insulated box that allows food to continue cooking without energy from the stove, a skylight and Solatube to bring in natural lighting, and thermal curtains that help to retain heat inside the house at night. As a result, CCAT uses only 17KWh per week, while the average US home uses 40 to 60 KWh.

Energy Concervation Tips

*Quick and Dirty Side-Pull Thermal Curtain Instructions PDF 611.7KB
*Thermal Curtains: Making Your Windows Warm PDF 140KB

Greener Gadgets: Power Hog and Energy Conservation

Here’s a cool entry to Greener Gadgets that aims to teach kids about energy consumption and conservation. The Power Hog is an a power consumption metering piggy bank. Simply plug your kids TV, or Xbox, computer… whatever power hungry thing they use into the Power Hog then plug the hog’s tail into the wall. Now when junior wants to start rockin’ out on Rock Band, he/she will have to put some of their money into the hog.

By associating a cost to their play time power consumption they’ll learn to be more conscious about the amount of energy they they consume. Assuming your kids aren’t rolling in the doe, it’ll also give them a little financial incentive to go play basketball rather than play NBA Live on the Xbox… Instead of playing Tony Hawk, they’ll go skating… and instead of playing Grand Theft Auto.

Mechanical Energy and Energy Conservation

Kinetic energy and potential energy are together referred to as mechanical energy. The total mechanical energy (U) of an object is then the sum of its kinetic and potential energies:

Now,

IN THE ABSENCE OF FRICTION

Mechanical energy is conserved

Ubefore = Uafter

This principle of conservation of mechanical energy can be a very powerful tool for solving physics problems. However, in the presence of friction some of the mechanical energy is lost:

IN THE PRESENCE OF FRICTION

Mechanical energy is not conserved

(The mechanical energy lost is equal to the work done against friction)

Thank You !