“ Energy Conservation by Application of Heat Pump in Process Line at Automobile

industry Ltd. ” By

Mr. Shivraj N Nalawade M . Tech- II (Energy Technology)

Under Guidance of

Prof. N. N. Shinde

Mr. S. A. Doshi

• Many industries use heating applications in their processes. These applications could be by means of different energy inputs like electrical heating, thermal heating, steam heating or few renewable heating. Out of these many managements are unaware about significant energy source for their applications. The heat energy gadgets adds heat in atmosphere

• Some organization are not much aware about energy efficient techniques available in the market and this tends to high running and operating cost resulting in losses.

• During the energy conservation studies at Process Industry is observed that the highest consuming load centre is machining line. On HA crank case line maximum energy consumption is because of electrical heaters which are used for water heating purpose.

• The heat pumps are used now a days to recover heat and can be used as energy gadgets as it helps maintains the cooling of working space. Comfort is very important for increasing productivity.

• Hence the topic is selected as “Energy Conservation by Application of Heat Pump in Crankcase Process Line at Automobile industry Ltd. ”

Relevance of the Project

Certificates

Heat pumps

Heat pump technology

1. Air Source

2. Ground Source

3. Water Source

Heat Pump cycle

Components of Heat Pump

1. Compressor

2. Condenser

3. Expansion Valve

4. Evaporator

5. Refrigerant

Heat Pump Benefits

1. Heat Pump used for Heating

2. Heat Pump used for Cooling i.e. Air Conditioning

3. Heat Pumps control the climate

4. Heat Pumps are convenient

5. Heat Pumps are safe

6. Heat Pumps are very energy efficient

• Applications of Heat Pump

i. Industrial washing machines ii. Commercial building iii. Restaurants iv. Hotels v. Health club vi. Schools vii. Hospitals

• IEQ (indoor environmental quality) The quality of the air and environment inside industries that contribute to a healthy and comfortable place to live and work. Indoor environmental quality is affected by electrical equipment’s that release heat in to the building. Heat pump is the major part when we consider IEQ for any industry.

Energy Conservation and Heat Pumps

Water Heater Type Storage

Tank

Site-to-Source

Ratio

Energy

Factor Source COP

Electric Resistance Tank 3.365 0.90 0.27

Heat Pump Tank 3.365 2.00 0.59

Fuel Oil Tank 1.158 0.59 0.51

Natural Gas Tank 1.092 0.59 0.54

Natural Gas Tank less 1.092 0.82 0.75

Condensing Natural Gas tank less 1.092 0.94 0.86

Propane Tank 1.151 0.59 0.51

(source: Energy Efficiency and Renewable Energy U.S. Department of Energy)

Problem Definition Industry case under consideration 1. In many developing countries HPWH system in widely used for water

heating application rather than that of conventional water heating systems.

2. These applications could be by means of different energy inputs like electrical heating, thermal heating, steam heating or few on renewable heating.

3. In Automobile industrial sector for washing of various components hot water is used in large amount. This requirement of hot water can be generally fulfilled by electrical heaters. But, electrical heaters can consumes lots of electrical energy in comparison with that of heat pump.in developing country like India many industries are using electrical heaters for hot water application.

4. Presently in industry, the water is heated by electrical energy (electrical Heater). This electrical heater has consumed lot of electrical power. Considering all condition, to study such systems and check the feasibility for the alternate innovative energy source for such applications.

Overview of Existing System

1. Washing chamber

2. Drum filter 3. Dirty tank 4. Transfer Pump 5. Compact band

filter 6. Clean tank 7. Spray pump

Condition of Water Heating

Objectives

1. Study of final components of washing machine on crank case machining line at automobile industry.

2. Feasibility of energy saving at component washing machine and application of heat pump.

3. Designing of suitable heat pump considering requirement of water heating for washing application.

4. Data collection and analysis of suitable heat pump with respect to IEQ in the vicinity of final washing machine on crank case line.

5. Conclusion and recommendations.

Literature Review This chapter covers about various literatures which contain lots of various

technologies for heat pump also it covers most important parameters like IEQ, HPWH as well as various properties of various refrigerants.

The various papers of national and international authors which are working on this heat pump technology and also indoor environmental quality factor in industry.

While studding heat pump and refrigeration systems there are standards from which the system is to be designed and these standards are ANSI/AHRI, some ISO standards and also ASHRAE standards. After studying electrical hearers and heat pump systems hardly any reference is found for study.

Energy conservation is achieved by the heat pump. Many citation’s exists for application of heat pump specifically in refrigeration system to recover the waste energy in a closed loop.in this case the problem considered in chapter 2 is specifically phenomenon of replacing electrical energy by heat pump in which the cooling load is created which can be used for cooling the air nearer to level of the comfort which is new concept for help to maintain and IEQ in the environment nearby. This project therefore is concentrated in designing the heat pump for the crankcase process line at Kirloskar oil engine ltd. and to find out energy conservation potential which will lead to reducing energy consumption by improving system energy efficiency in general. This will provide guidelines for the future work for maintain environment in the industry.

Scope of the Project 1. Studied energy consumption pattern in different shops at

industry.

2. Prepare pie charts for energy balance.

3. From pie charts, machine shop is major consuming load center.

4. In depth, analyze machine shop consumption for different lines and machine on the lines. It is observed that component washing machine is highest energy consuming machine.

5. Studied the same for the feasibility alternative sources.

Methodology 1. Measuring energy consumption at various load centers.

2. Feasibility of energy saving at component washing machine and application of heat pump.

3. Study of final components for wash on washing machine on crank case machining line

4. Data Collection and analysis by Fluke analyzer (Heating Load Measurements) on washing machine.

5. Study of vapor compression refrigerant system.

6. Designing of Suitable Heat Pump Considering Requirement of Water Heating For Washing Application.

1. Measuring energy consumption at various load centers.

Variable Energy Consumption at industry (In Kwh)

Centre Unit 10-11 11-12 12-13 13-14

Machine Shop Mn Units 8.01 6.76 8.49 6.51

Medium

Engine Mn Units 2.56 2.15 2.21 2.04

GENSET Mn Units 1.15 0.99 1.50 1.00

Small Engine Mn Units 1.60 1.38 1.18 1.63

Total Mn Units 13.32 11.28 13.38 11.18

58% 18%

9%

15%

Variable Energy Balance

Machine Shop

Medium Engine

GENSET

Small Engine

2. Feasibility of energy saving at component washing machine and application of heat pump.

3.74

1.76 1.64 1.62 1.57

1.45 1.4 1.31 1.27 1.19 1.19 1.15 1.15 1.14 1.1 1.07 0.99 0.98 0.92 0.91

0

20

40

60

80

100

120

0

0.5

1

1.5

2

2.5

3

3.5

4

% c

on

trib

uti

on

en

erg

y c

on

sum

pti

on

(kw

)

machine name

parato chart per component energy consumption on ha crank case line

3. Study of final components for wash on washing machine on crank case machining line.

component Weight(

kg)

Dimension(mm)

Compone

nts Per

Shift

Temperature(0C) Mean

Temperature

Difference

Heat loss in

component(

kWh) Height Width

Before

washing

(t1)

After

washing

(t2)

2 Cylinder

Head 64 335.8 587 63 26.3 36.4 10.1 0.09

3 Cylinder

Head 81 335.8 457 60 26 36.1 10.1 0.12

4 Cylinder

Head 98 335.8 309 58 25.5 35.4 10 0.15

Picture before Component Washing Picture after Component Washed

List of measuring instruments

Fluke Power Analyzer Thermal Imager Mass Flow Meter

Actual measurement on site

Actual pictures of machine

Washing chamber Drum filter

Electrical Heater position Crank case Component

Data Collection and analysis by analyzer (Heating Load Measurements) on washing machine.

Measurement – Initial stage heating (From 27°C to 55°C) Total Energy Consumption-46 kWh Measurement – Shift 1 Time of Shift- 8 hrs. (Initially Power analyzer is set to 0 Reading) Total Energy Consumption for shift 1-288.6 kWh Measurement – Shift 2 Time of Shift- 8 hrs. (Initially Power analyzer is set to 0 Reading) Total Energy Consumption for shift 2-293 kWh

Total Energy Consumption of Heaters in 1 Day=46+288.6+293=627.6kWh

Time(Hrs.) Consumption (kWh)

1 46

Time 1 hr. 2 hr. 3 hr. 4 hr. 5 hr. 6 hr. 7 hr. 8 hr.

Consumption(kWh) 36 38 37 37.5 35.3 34.5 36.3 34

Time 1 hr. 2 hr. 3 hr. 4 hr. 5 hr. 6 hr. 7 hr. 8 hr.

Consumption(kWh) 34.9 36.8 36.3 38 35.6 38 36.4 37

0

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25

30

35

40

45

50

0 2 4 6 8 10 12 14 16 18

Co

nsu

mp

tio

n (

kWh

)

Time(Hrs)

Energy Consumption of Electrical Heater

Proposed system

Block diagram of washing machine Block diagram of washing machine compatible with heat pump

Heat capacity Initial Condition

water flow = 1450 Litres mh = 1450 kg

mh = 1450 kg/3600 = 0.402 kg/s Cold fluid inlet Temperature = TCin = 270C

Hot fluid inlet Temperature = TCot = 550C From steam tables,

Enthalpy of water at 270C = hf27 = 118.8 kJ/kg

Enthalpy of water at 550C = hf55 = 231.6 kJ/kg

∴ ∆h = hf55 −hf27

∴ ∆h = 112.8 kJ/kg

Hence, heat required to be added,

H = mh∆h

= 1450 × 112.8 = 163560 kJ Time required to heat= 1Hr=3600 sec

Heat capacity of heater =Heat added

time=90240

3600= 45.33 kW

In Tons of refrigeration,

=45.33

3.5167= 12.88TR

Design of Heat Pump

Running condition water flow = 210 Liters/min

mh = 210 kg/min mh = 210 kg/60 = 3.5 kg/s

Inlet Temperature of water = TCin = 450C Outlet Temperature of water = TCot = 550C

From steam tables, Enthalpy of water at 450C = hf27 = 217.29 kJ/kg Enthalpy of water at 550C = hf55 = 231.6 kJ/kg

∴ ∆h = hf55 −hf27 ∴ ∆h = 12.95 kJ/kg

Hence, heat required, H = mh ∆h

= 3.5 × 12.95 = 45.33kW

In Tons of refrigeration,

=45.33

3.5167= 12.88TR

By considering both the above initial and running condition, capacity output of heat pump required is about 45.33 kW or 12.88 TR. All the technical parameters are designed on the basis of 45.33 kW output of Heat Pump.

Selection of Suitable refrigerant

Criteria Refrigerants

1= Poor 5= Excellent R-22 R-290 R-410A R-404A R-407c R-134a

Cooling capacity 3 2 5 3 2 1

Input power 3 4 1 2 3 5

Cooling COP 4 5 3 3 2 5

Refrigerant mass flow 4 1 5 5 3 2

Discharge temperature 3 5 3 5 3 5

Pressure ratio 5 5 5 5 1 2

Vol. ref. capacity. 4 3 5 4 3 1

ODP 1 5 5 5 5 5

GWP 2 5 2 1 2 3

Cost 3 5 1 2 1 2

Non-toxicity 5 5 5 5 5 5

Non-flammability 5 1 5 5 5 5

Compatibility 5 5 5 5 5 5

Total 47 51 50 50 40 46

As seen in above table the rating of R-134a having total of 46 which was middle among all refrigerant used conventionally, selection of refrigerant as R-134a for project work.

PH Chart for R134a at 12.8°C Evaporating and 60°C Condensing

(source: PH chart is plotted using COOLPACK software)

2. Heat pump operating temperature and pressure Assuming ADP (Apparatus Dew Point Temperature) of cooling coil of evaporator = 40C

Properties of R134a at 40C P = 3.3755 bars

Minimum of 50C temperature difference is necessary to heat the fluid, in order to avoid the limitation of heat transfer by finite temperature difference

∴ Condensor temperature = 55 + 5 = 600C for R134a

@600C , P = 16.815 bar

Point Temperature(°C) Pressure(Bar) Enthalpy(Kj/Kg)

1 23.89 4.54 415.33

2 79.06 16.81 451.10

3 79.06 16.81 451.10

4 57.23 16.81 282.88

5 N/A 4.54 282.88

6 23.9 4.54 415.33

15 N/A 16.81 282.88

3. Refrigerant mass flow rate Now at 600C, total heat content of refrigerant, ∆hr=enthalpy of gas @600C-enthalpy of liquid @600C ∴from properties of R134a

= 451.1 − 282.88 kJ/kg ∆hr = 165.22 kJ/kg

By 1st law of thermodynamics, Heat added to cold water = heat rejected from condersor

∴ 45.33 = mr ∆hr ∴ mr = 0.27 kg/sec

Final compressor specifications

Theoretical COP of the system 3.7

Actual COP of the system 3.6

Refrigerant mass flow rate 0.27 Kg/sec

Compressor work 9.65 kW

EPR 7.05

Isentropic efficiency of compressor 66%

4. Compressor Specifications

Condenser Design Using Trial And Error Method

Heat Flow diagram

Condenser Specifications

Condenser heat output 45.33 Kw

Tube ID 0.017 M

Tube OD 0.025 M

No. of tubes 44

No. of passes 2

No. of baffles 8

Baffle spacing 0.122 M

Tube length 1 M

Bundle diameter 0.23 M

Shell diameter 0.3 M

Tube side pressure drop 0.61 Bar

Shell side pressure drop 0.3 Bar

• Condenser Drawing

6. Expansion valve selection The most important technical parameter for selection of thermostatic expansion valve is MOP (Maximum Operating Pressure)

Evaporator pressures are limited to a maximum value to protect compressor from overload conditions. MOP selection should be within maximum allowed low pressure rating of the compressor and should be at approximately 3 K above maximum evaporating temperature.

MOP Upper limit of evaporating temperature

Bar °C R407C R22 R 410a R134a

6.9 17 14

6.9 15 12

3.8 14 10

12.1 16 14 Note-All pressures are gauge pressure

Expansion valve specifications Condensing Pressure 16.8 Bar

Evaporating Pressure 12.8 Bar

Total Pressure Loss 1.5 Bar

Effective pressure difference across valve 10.77 Bar

Correction factor for pressure differential 0.78

Correction factor for evaporating temperature

1.35

Evaporator specifications

Heat absorbed in evaporator 35.76 Kw

Tube diameter 0.01 M

Fin pitch 0.034 M

Fin thickness 0.048 Cm

Air mass flow rate 7.31 kg/sec

No. of tubes 28

Fine width 0.043 M

Evaporator design

Final Temperature and pressure on heat pump cycle

Heat Pump Compatible With Tank

Heat Pump Drawing

Proposed System Replacements

Energy, Cost saving and Environmental Analysis Energy saving potential

0

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Co

nsu

mp

tio

n(k

Wh

)

Time(Hrs.)

Comparision of Electric Heater and Heat Pump Energy Consumption in 1 day

Electric Heater

Heat Pump

• Estimated Energy and Cost saving Analysis

•Estimated Energy consumption Calculation for Electrical Heaters and Heat Pump Total Energy Consumption of Heaters in 1 Day =627.6 kWh (Actual Measurements) Total Energy consumption by heat pump=12.54kw Therefore, total energy consumption by heat pump in 1 day= 200.64kWh (for 16hrs. of operation) Energy Savings /Day = Consumption of Heaters in 1 Day- consumption by heat pump in 1 day Energy Savings /Day =627.4-200.64=426.76 kWh/day Energy saving per year= 426.76*300=1,28,028 kWh/Year

It means that heat pump can be save up to 61,680 units of electricity per year. •Estimated Cost saving analysis

Base rate of electricity for 1 unit= 8 Rs. Therefore, Cost saving per day=8*426.76=3414.08 Rs. Cost saving per Year=3414.08*300=10,24,224 Rs. •Payback period Calculation

Market prize of heat pump from manufacturing company is nearly= Rs. 9, 50,000/- (With installation)

Therefore, Payback period of heat pump = 1 Year

Indoor Environmental Quality (IEQ) improvement There are 2 main contains in IEQ as per ASHRAE 2009 handbook are as follows: •Thermal Comfort Indoor Environmental Health •Air Contaminants For consideration of IEQ the below readings are taken on site. Limits are taken as per factory act 1948.

Sr. no Parameters Values Limit as per factory act, 1948

1. Ambient temp 0C

Dry bulb 28 290C to 340C

Wet bulb 24 220C to 260C

2. Relative humidity% 64 ---

3. Noise level in dB(a) 87.9 90

4. Suspended particular matter, mg/m3 0.09 <=10

5. Oil mist mg/m3 0.019 <=5

• Estimated room dimensions for cooling

• This chapter includes energy saving potential of electrical heater as well as Heat Pump.

• Which clearly shows energy saving potential of • heat pump is very high.

• This also includes cost beneficial analysis and impact of

heat pump output on IEQ at working condition.

Summary

1. On the existing system, study is done on electrical water heating system for crankcase machine line which shows that it has an average electrical energy consumption of 627.6 kWh,15,690 kWh and 1,88,280 kWh for daily, monthly and yearly respectively.

2. The design data is created for the existing process layout. 3. A heat pump system has been designed and electrical consumption has been

worked out. 4. The theoretical analysis clearly indicates that the energy conservation has been

achieved 426.76 kWh, 10669kWh, 128028 kWh on daily, monthly and yearly basis respectively.

5. This energy consumption is in accordance with the prevailing designed data and the surrounding climatology for automobile industry.

6. The cost saving is achieved Rs 3,414.08 , Rs 85,382, Rs 10,24,224 on daily, monthly and yearly basis respectively.

7. The actual amount of heat pump by market price is nearly Rs 9,50,000 and savings achieved by theoretical calculations is Rs 10,24,224 yearly at base price of electricity Rs 8 per unit. So the calculated payback period is nearly one year.

Conclusion

In view of conclusion heat pump is recommended for energy conservation for such applications in industry. Its value addition like cooling the surrounding is also of prime importance in the view of IEQ.

Due to limitations of cost of heat pump and time of period of completion, prototype of heat pump development is remained

Future scope

• Development of heat pump model.

• Analysis of heat pump performance by various refrigerants.

• Testing results and analysis performance of heat pump with impact on IEQ

Recommendations

1. At the crank case line washing machine there are various other options to replacer that electrical heaters with solar water heater, heat pump, biogas and briquette fire technology and also other renewable energy sources for washing application.

2. After installing any other system for water heating do

regularly maintenance and check whether the system works correctly and energy efficiently.

3. Use clean water for washing application and also regularly

add makeup water in tank.

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Paper Publications

“ENERGY CONSERVATION ANALYSIS BY APPLICATION OF HEAT PUMP SYSTEM- A CASE STUDY” paper is published in “INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY.(IJESRT)”

Shivraj Nalawade Thesis\123_ENERGY CONSERVATION ANALYSIS BY

APPLICATION OF HEAT PUMP SYSTEM- A CASE STUDY.pdf “PERFORMANCE EVALUATION OF HEAT PUMP USING SIMULATION

TECHNIQUES FOR REPLACING ELECTRIC WATER HEATING SYSTEM TO ACHIEVE ENERGY CONSERVATION AND IMPROVE IEQ IN AN PROCESS INDUSTRY” paper is published in “INTERNATIONAL JOURNALOF CURRENT RESEARCH”

Shivraj Nalawade Thesis\PERFORMANCE EVALUATION OF HEAT PUMP USING

SIMULATION TECHNIQUES FOR.pdf

Thank You