Hot Water Balance Requirement Balance

SN Particulars of Supply KLPD @ SN Particulars of Demand Qty of KLPD @

70⁰C M/C 70⁰C
1) CRP (Caustic Recovery 70 1) Shee Dyeing Machine 1 70
Plant) Condensate No. 1

2) CRP (Caustic Recovery 7 2) Shee Dyeing Machine 1 70

Plant) Caustic WHR No. 2
(Proposed. Currently not
installed.)
3) WHR from Centri- 360 3) Rope Dyeing Machine 1 70
compressor (4000 cfmX02
Nos) (Proposed. Currently
not installed.)
4) CBR (Continuous 1 65
Bleaching Range)
5) Mercer 1 1 60
6) Mercer 2 1 60
7) Other (Sizing 1 25
Receipee, Cleaning,
System Loss, Buffer)
Total 437 Total 420
Note :- The above balance indicates that if Waste heat recovery (WHR) as mentioned above can be done
for hot water generation i.e. for Centri-compressor & CRP caustic WHR, almost all hot water can be
consumed by the process.

EC by Pre-heating process water by CRP & Centri Compressor WHR

By providing centrifugal compressor (with Waste heat recovery unit) instead of screw compressor and
providing thermal insulated pipe line in CRP will result in hot water generation as mentioned above.
SN Description Unit Price Total Price
1 Centrifugal Air Compressor 4300 CFM - 2 124 248 Rs Lakhs
No.s
2 Heat Recovery Unit ( HRU)- 1 no. 47.33 47.33 Rs Lakhs
3 Suitable Soft Starter - 2 no.s 10.4 20.8 Rs Lakhs
4 20 M3 Air Receiver - 2 no.s 15.65 31.3 Rs Lakhs
5 Refrigirated Air Dryer -6000 CFM - 2 no.s 28 56 Rs Lakhs
6 Cooling tower - 300 TR 4 8
7 50 KL Storage tank & Pipe Line for Hot water 19.6 19.6 Rs Lakhs
utilisation - 1 set
Total 431.03

Out of this investment, except centrifugal air compressor (43000 cfm X02 Nos) all other investment will
be considered for Waste heat recovery section i.e. thermal energy saving. Thus for waste heat recovery
in compressor, 1.83 Crore INR will be required. Balance 2.48 Crore (Rounded 3.00 Crore will be
considered for electrical energy savings.)

For CRP section provision of thermal insulated pipe line & allied mountings for WHR as per feedback
received from plant, 19.6 Lacs INR will be required.
Thus total investment required for hot water generation will be Rs.2.03 Crore INR. Balance investment
will be considered in electrical saving due to centrifugal compressor instead of screw compressor.

T Title of Energy Saving Measure = Waste Heat Recovery from CRP

(Caustic Recovery Plant) caustic &
 Centrifugal compressor for Hot
water generation. Hot water to be
utilized for the process.
Description of Energy Saving Measure = Energy can be saved by generating hot
water from all available and waste heat
recovery from centrifugal compressor
for hot water generation. The hot water
can be used for the process as per
requirement mentioned in hot water
balance.
Type of Energy Conservation Proposal = Thermal
Energy / Fuel proposed be saved = Coal
Present System
Cold water used in the process and heated using steam. This results in steam consumption and
needs higher process time.
Proposed System
Both direct energy in the form of steam and indirectly electricity in terms of reduction in process
time can be achieved by providing hot water
Scenario
Before After
Cold water 420 Kl per day used in the process Pre-heated hot water at 70⁰c can be
used for the process requirements
Existing Consumption Particulars
Energy saving by preheating 420 KLPD water at = 16800000 kcal/day
70⁰c from 30⁰c
Combined boiler efficiency = 79 %
Expected Saving of Coal = 269 Kgs per Hour
No of Hours Operation per day = 24 Hrs/Day
No. of Working Days per Annum = 340 Days/Annum
Cost of Coal = 3.5 Rs./Kg
GCV of Coal = 3296 Kcal/Kg
Expected Saving Calculations
Total Expected Yearly Saving of Coal = 2195040 Kgs/Annum
Expected Saving in Rupees per Annum = 7682640 Rs.
Investment Needed for Retrofit/Modification = 20300000 Rs.
(Waste heat recovery system of two compressors
considered. Cost of centricompressor will be
considered in saving in compressed air for
replacing screw compressor. Also cost of waste
heat recovery of CRP caustic cosidered along
with central 500 KL thermal insulated hot water
tank)
Saving Summery & Cost Benefit Analysis
Total Expected Yearly Saving of Coal = 2195040 Kgs/Annum
Expected Saving in Kloe/Annum = 723.49 Kloe/Annum
Expected Saving in Rupees per Annum = 7682640 Rs./Annum
Investment Needed for Retrofit/Modification = 20300000 Rs.
Simple Payback Period = 2.64 Yrs.
= 32 Months
Additional Remark for this saving measure
Apart from direct coal saving, electricity due to increase in process time can be saved in process.

EC by Replacing Lower Efficiency Screw Compressor with Centrifugal Air Compressors

E Title of Energy Saving Measure
Description of Energy Saving
Measure
= Electrical energy saving by replacing
the screw compressor with lower
specific energy consumption
centrifugal air compressors
= The SEC of existing screw compressor is
0.19 kW per cfm. While the SEC
confirmed by OEM for centrifugal
compressor is 0.14 kW per cfm. Thus
0.05kW/cfm can be saved for 2 Nos X
 4300 cfm =8600 cfm compressed air
demand
Type of Energy Conservation Proposal = Electrical
Energy / Fuel proposed be saved = Electricity
Present System
The screw compressors are provided with 0.19 kW/cfm.
Proposed System
Proposed 02 Nos X4300 cfm =8600 cfm air compressor with 0.14 kw/cfm centrifugal
compressors
Scenario
Before After
8600 cfm air supply from higher SEC 8600 cfm air supply from lower SEC
screw compressor centrifugal compressor
Existing Consumption Particulars
Existing Electricity Consumption for = 1634 Kwh per Hour
8600 cfm @ 0.19 kw/cfm
Expected Saving Percentage = 26.32 %
Expected Saving of Electricity = 430 Kwh per Hour
No of Hours Operation per day = 24 Hrs/Day
No. of Working Days per Annum = 340 Days/Annum
Cost of Electricity = 5 Rs./Kwh
Expected Saving Calculations
Total Expected Yearly Saving of = 3508800 Kwh/Annum
Electricity
Expected Saving in Rupees per Annum = 17544000 Rs.
Investment Needed for = 30000000 Rs.
Retrofit/Modification (WHR equipment
cost considered in thermal energy
saving measure by WHR. For electrical
saving remaining investment of
Rs.3,00,00,000\- considered)
Saving Summery & Cost Benefit Analysis
Total Expected Yearly Saving of = 3508800 Kwh/Annum
Electricity
Expected Saving in Kloe/Annum = 301.76 Kloe/Annum
Expected Saving in Rupees per Annum = 17544000 Rs./Annum
Investment Needed for = 30000000 Rs.
Retrofit/Modification
Simple Payback Period = 1.71 Yrs.
= 21 Months
Additional Remark for this saving measure
Apart from energy saving, the maintenance cost of centrifugal compressor will be lower
than that of screw compressor.