Page 188 - CW E-Magazine (30-4-2024)

Special Report Special Report

cities and villages. It will be worthwhile steam vent rate can be reduced maintain- quick corrective actions for signifi cant are observed. It is worthwhile to consider  New installations use electronic of electric/steam heaters for energy

to consider mounting solar panel on ing Dissolved Oxygen (DO) level. energy conservation. provision of Differential Pressure (DP) chokes. But old installations, still conservation.
public poles and connect 20-30 poles to meter across selected fi lter and clean have conventional electromagnetic
electricity grid through inverter for use EMS -65: Air leakage into furnace EMS -70: Cooling water exchangers periodically to save energy and improve ballast. Replace them by electronic EMS 81: Hydrocarbon loss manage-
of solar electricity. chamber is one of the major reasons for get fouled over time, irrespective of its reliability. chokes. ment in integrated and complex plants of
poor effi ciency. Operation of furnace treatment. Due to inbuilt dirt, margin  Use slim LED lights and replace old refi neries and petrochemicals is impor-
EMS-61: For an electric power sys- chamber at slightly positive pressure to available in downstream equipment as EMS-75: In many complex and com- 40-W standard fl uorescent tubes. tant. To reduce loss of hydrocarbon
tem, a load of induction motors with a reduce air leakage is one of the options. well as operation at low capacity, such mercial establishments, lighting load is  Use timer controls, photo-sensors or molecule, it is essential to know the areas

low power factor draws more current Regular inspection and repair of gaskets fouling is not affecting process and nor- very high. In such cases, auto-start and occupancy detectors for lighting and quantity of loss; fi nd, measure and
than a load with a high power factor for of peep door and manholes is good mally overlooked. Periodic review and stop of lighting load, based on timer or circuit control. manage. Following areas can be consi-
the same amount of useful power trans- practice to minimise air leakage. cleaning of an exchanger is an effective photo sensors in open space and motion  Use task-based lighting for focused dered to arrest loss of material:

ferred. The higher current increases the strategy for energy conservation and sensors in closed space, can save signifi - lux, instead of one or multiple light  Loss to fl are header;

energy lost in the distribution system, and EMS-66: Steam PRDS are designed reliability improvement. cant energy. in room.  Emission from storage tanks;
require larger wires and other equipment. for very high fl ow, but after optimisa-  Use lighting voltage transformer for  Drainage to process sewers;

Because of the costs of larger equipment tion of energy users normally fl ow is EMS-71: Provision of Variable Feed EMS-76: Task lighting is the concept industries and commercial building  Routine and non-routine purge;

and wasted energy, electrical utilities will minimised for energy conservation. At Drives (VFDs) or change of blade angle to providing adequate light where lighting circuit.  Passing of PSVs, CVs and manual
usually charge a higher cost to industrial lower fl ow, control of pressure and de- of fans for minimum required duty required, instead of illumination of whole  Segregate lighting circuits for easy valves;

or commercial customers where there is superheating is not effective. Many times reduces energy consumption. However, offi ce room or conference room. It is switch on and off, based on require-  Start-up and shut-down losses;
a low power factor. It is good practice to BFW passes lead to two-phase fl ow for multiple fans, turning off some fans energy-effi cient to provide task lighting as ment.  Sampling losses;
improve power factor by capacitor bank downstream. In such cases, it is worth- to meet minimum required load can be and where required based on illumination  Street lights are a signifi cant load.  Fugitive emission from seals, fl anges,

or integrating synchronous motor load to while to design PRDS with two control one of the easiest feasible options. survey. Replace them by LED lights. glands, etc.;
electrical network. valves, one for fi ne (small) fl ow and  Use of electronic chokes for high  Leakage due to holes, cracks, etc.;

other for coarse (large) fl ow. EMS-72: In any chemical complex, EMS-77: Many workshops and pressure sodium vapour (HPSV),  Ship and receipt loss;

EMS-62: At many locations in air and nitrogen compressors are closed large halls need large lighting high pressure mercury vapour  Tanker fi lling loss;

complex process, to improve reliability EMS-67: Boiler blowdowns are kept designed and operated at fi xed pressure. load to illuminate it even during day (HPMV) and halogen lamps.  Transportation loss;
of operations, liquid is pumped two fi xed by many operators to control Total These are high power consuming equip- time. Day lighting load can be reduced  Switch off lights when enough sun-  Losses due to poor measurement,

times using intermediate tank. Some Dissolved Solids (TDS), iron and silica. ment. By careful study of minimum signifi cantly by providing light pipes light is available. volume correction, as well as weight
examples are: pumping of hot and cold It can be optimised to reduce heat and pressure requirement, operating pres- and glass windows to use sun light for calculations;
water in chilling systems; pumping of chemical losses, taking advantage of sure of air and nitrogen compressors can energy saving. EMS 80: Energy conservation for  Coke on spent catalyst and carbon

liquid from refl ux drum to intermediate better quality of BFW. It will conserve be reduced for reducing loss in leakages mild heating. For heating of space deposits in process;
tank and then to fi nal tank; etc. Check both, energy and water. as well as reduce energy consumption of EMS-78: In large complex plants, or water, electric or steam heater is  Hydrogen leakage due to diffusion;

such cases. It is possible to avoid double compressors. only one pressure level of air and nitrogen normal practice. Here you need 1KW  Poor effi ciency of heaters, furnace &

pumping of liquid in many applications. EMS-68: Many furnaces require de- headers are provided. At many loca- power for 860 kcal/hr. Heat pump is boilers; and
coking to reduce tube metal temperature. EMS-73: Air compressors are pro- tions, low pressure air and nitrogen are a device, which can heat space with  Quality of crude feed, i.e. non-

EMS-63: Fans are used in many The frequency of de-coking requirement vided with intermediate and fi nal knock- required, which is let down from com- 3-5 coeffi cient of performance and can hydrocarbons in crude etc.
applications. Many fans are provided varies from few days to several months out drums to remove moisture. In order mon header. In such cases, providing provide refrigeration too in difference
with fan blade angle control system or based on feed composition and severity to reduce capex, the drain valves are two pressure levels of air and nitrogen space. Power requirements can be Professional chemical engineers can
possibility of adjusting blade angle to of operation. There are many possible fi xed drain with orifi ce or with air trap by design with intermediate withdrawal reduced to 20-34%. It is worthwhile to actively take up the ideas for sustainable
adjust load. Normally, blade angles are ways by which coke formation takes to pass water. Based on atmospheric or two different level compressors can consider usage of heat pump in place manufacturing.
not changed, even if plant load or fl ow place. Careful study and identifying root humidity, such moisture varies or due to be energy effi cient options.
requirement reduces. Signifi cant power cause, as well as hard and soft changes, malfunctioning trap passes, leading to ABOUT THE AUTHOR
savings are possible by regular blade can increase time between two decokes loss of pressurised air. It is worthwhile EMS-79: India has achieved Mr. Joy Shah is the Founder and Chief Consultant,
angle adjustment for required duty of fans. and save energy signifi cantly. to consider knockout drum with level major energy savings by replacing incan- Innov8 ProTech Solutions, The Sustainability and Man-
control valve to drain water. descent bulbs by CFLs. Following are agement Consultant. Formerly, he was Sr. Vice President
EMS-64: Deaerator is designed for EMS-69: Boiler and steam turbine some more initiatives which can further (Head - Technical) at Reliance Industries Ltd. He was
fi x vent rate with an orifi ce to remove effi ciency reduces over time and again EMS-74: Suction strainer of pump reduce lighting load: also a member of the IIChE Chemical Process Safety,
non-condensable. In some applications, regained after cleaning and periodic fouls, leading to high differential pres-  In workshops, sheds and house- Energy and Environment Committee from 2018 to 2022.
this vent with orifi ce plate does not have maintenance. Some manufacturers run sure. Sometimes it results in cavitation holds, use of natural day lighting For the last fi ve years, Mr. Shah has been consulting for
isolation valves. Combining chemical periodic boiler and turbine effi ciency of pumps and damage it. Similarly, saves energy. Transparent roofs, energy and water management, serving as an advisor for
and mechanical de-aeration can reduce maintenance programmes to identify discharge fi lters also gets fouled and is larger glass windows, and light sustainable manufacturing as well as process safety and risk management.
oxygen in Boiler Feed Water (BFW) and root cause of loss of effi ciency and take cleaned as and when process limitations pipes are some possibilities.

188 Chemical Weekly April 30, 2024 Chemical Weekly April 30, 2024 189

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