11-13 August 2014

Energy conservation in foundry QUIZ

TERI

12th June 2014

11-13 August 2014

1. How do you calculate efficiency (direct / indirect method)

• Efficiency (%)=(Output×100) / Input

• Efficiency (%) = 100-Total losses in %

11-13 August 2014

2. Difference between contract demand and billing demand

• Sanctioned demand from electricity company

• Billed demand: Actual demand billed for the month

11-13 August 2014

3. Location of APFC

• Automatic Power Factor Controller

• Location at distribution panel

• Individual capacitor near load centre

11-13 August 2014

4. Estimation of TOE

• TOE: tonnes of oil equivalent

• Converting all source of energy to one common unit

– E.g. Coke in MT, Electricity in kWh, FO in Litre

11-13 August 2014

5. Scope of CLCSS

• Credit Link Capital Subsidy Scheme for Technology Up-gradation

• 15% upfront capital subsidy for Technology Up-gradation

• Maximum subsidy capped to 15 lakh

11-13 August 2014

6. Scope of TEQUP

• Feasibility study – 75% of the cost (cap to 75 thousand)

• DPR preparation (set of 3) - 75% of the cost (cap to 9

lakh @ 3/DPR)

• EE technology adoption support -25% of the capital

cost (cap to 10 lakh & 15% energy saving equipment -

ONLY FOR APPROVAL)

11-13 August 2014

7. Calculate SEC of Induction furnace Raw material charged 525 kg Liquid metal poured 501 kg

Electrical units consumed 313 kWh

• SEC = 313 kWh / 0.525 ton

= 596 kWh per ton

11-13 August 2014

8. Calculate coke to metal ratio of cupola

• Charging coke = in kg

• Booster coke = in kg

• Total coke = Charging + Booster in kg (A)

• Total charging metal in kg (B)

• Coke to Metal ratio = B / A (typically 1: 10)

11-13 August 2014

9. Parameter to be considered while obtaining quotation of pump

• Flow rate, lpm/lps/cu.m.hour

• Head, m

• Efficiency, %

• Power rating, kW/hp

11-13 August 2014

10. How to perform leakage loss in air compressor

• Ton = loading time

• Toff = unloading time

• When no usage of compressed air

• % Leakage = Ton / (Ton + Toff) * 100%

11-13 August 2014

11. Performance evaluation of air compressor

FAD=(P2-P1)×V / P1×t • FAD = actual pumping capacity of the compressor

(m3/minute),

• V = total volume (m3) = V´ + v,

• V´ = volume of the receiver (m3),

• v = volume of the pipe line connected from air compressor to air receiver (m3),

• P1 = atmospheric pressure (1.013 bar absolute),

• P2 = final pressure of the receiver (bar absolute),

• t=average time taken (minutes) (t1+t2+t3)/3

11-13 August 2014

12. Specific power consumption of air compressor

• FAD = in cfm or m3/hr

• Power consumed = kW

• SPC = kW/cfm (typical for SCREW AC 0.16 – 0.18)

11-13 August 2014

13. Optimum velocity in piping for a. Pumping system

b. compressed air system

• Pumping system = 1.8 – 2.0 m/s

• Compressed air system = 6 – 10 m/s

11-13 August 2014

14. Affinity law for pump and fans

• Q proportional N

• H proportional N2

• P proportional N3

11-13 August 2014

15. Specific Electricity Generation Ratio SEGR

• The quantity of electricity generated (kWh) per litre of fuel consumption (kWh / litre)

• SEGR to 3 – 4 kWh / litre

11-13 August 2014

END

THANK YOU