Industrial Energy Systems Handbook

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Half-Title
RIVER PUBLISHERS SERIES IN ENERGY ENGINEERING AND SYSTEMS
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Copyrights
Contents
List of Contributors
List of Figures
List of Tables
Chapter 1 Global Energy Situation on Climate Change
1.1 The Negative Impacts and Forecasts of Climate Change
1.1.1 Sea levels
1.1.2 Ocean currents
1.1.3 Coral reefs
1.1.4 Ocean acidity
1.1.5 Wildlife
1.1.6 Hurricanes
1.1.7 Floods
1.1.8 Fires
1.1.9 Forests
1.1.10 Droughts
1.1.11 Human health
1.1.12 Social cost
1.2 The Positive Global Trends to meet the Goals of the Paris Agreement
1.2.1 Coal
1.2.2 Wind
1.2.3 Solar
1.2.4 Employment
1.2.5 Industrial energy efficiency
1.3 International Protocols and Conventions
1.3.1 Paris agreement
1.3.2 Kyoto protocol
Chapter 2 Fundamental Principles of Energy
2.1 Forms of Energy
2.1.1 Definition of energy
2.1.2 Different forms of energy and energy flowimportant to energy audits
2.2 Definition of Energy Efficiency
2.3 Definition of Energy Density
2.4 Units of Energy
2.4.1 Calorie
2.4.2 Joule
2.4.3 Pascal
2.4.4 Ampere
2.4.5 Ampere-hour
2.4.6 Volt-Ampere
2.4.7 kiloVolt-Ampere reactive
2.4.8 Watt
2.4.9 Watt-hour
2.4.10 kiloWatt and gigaWatt
Chapter 3Energy Conversion and EfficiencyLouis Lagrange
3.1 Energy Conversion, Electricity and Energy Efficiency
3.1.1 Total energy, useful and not useful energy
3.2 The Four Thermodynamic Laws
3.2.1 Definition and interpretation of thermodynamic law nr 0
3.2.2 Definition and interpretation of thermodynamic law nr 1
3.2.3 Definition and interpretation of thermodynamic law nr 2
3.2.4 Definition and interpretation of thermodynamic law nr 3
3.3 Energy Performance Criteria
3.4 Calculation of Energy Efficiency Performance
3.4.1 High level benchmarking metrics
3.4.2 Energy use index
3.4.3 Energy cost index
3.4.4 Productivity metrics
3.4.5 Energy efficiency rating, seasonal and integrated
3.4.6 System performance metrics
3.4.7 Typical system performance indexes
3.5 Calculation of Point of Use (PoU) costs
3.5.1 Energy conservation and energy conversion (energy flow)
3.5.2 Heat flow and heat loss
3.5.3 Mass- and energy-balance
3.5.4 Energy demand
Chapter 4Fundamentals of Electrical EnergyLouis Lagrange
4.1 Electrical Power and Electrical Power Quality
4.2 Electrical Voltage
4.3 Electrical Current
4.4 Electrical Power
4.5 Demand
4.6 Types of Current Flow
4.7 Direct Current
4.8 Batteries
4.9 Alternating Current
4.10 The Different Types of Loads
4.10.1 Electrical circuitry
4.10.2 Resistive loads
4.10.3 Inductive loads
4.10.4 Capacitive loads
4.11 Electrical Power Factor
4.11.1 Lower utility fees
4.11.2 Power factor penalty is eliminated
4.11.3 Increase voltage levels in the electric system and distribution system
4.11.4 Power factor correction in linear loads
4.11.5 Power factor correction in non-linear loads
4.11.6 Passive power factor correction (PFC)
4.11.7 Active power factor correction
4.11.8 Dynamic power factor correction
4.12 Demand Management
4.13 Load Factor
4.14 Load Shifting
4.14.1 Demand response
4.14.2 Dynamic demand
4.15 Load Shedding
4.16 Total Harmonic Distortion (THD)
4.16.1 THD voltage
4.16.2 Harmonic voltage distortions
4.16.3 Harmonic current distortion
4.17 Problems with Harmonics
4.18 Measuring Electrical Energy Consumption
4.18.1 Calculating power, energy and power factor inalternating current circuits
4.18.2 Calculate power, voltage, current andpower factor in AC circuits
4.18.3 Voltage
4.18.4 Current
4.18.5 Power
4.19 Methods to Correct the Power Factor
4.20 Calculating Energy Efficiency forElectrical Equipment
4.21 Uninterruptible Power Supply
Chapter 5Fundamentals of Thermal EnergyAlbert Williams
5.1 Types of Thermal Energy: Sensible and Latent
5.2 Concept of Useful Thermal Energy
5.3 Temperature
5.4 Pressure
5.5 Phase Changes
5.5.1 Evaporation
5.5.2 Condensation
5.5.3 Steam
5.5.4 Moist air and humidity
5.6 Psychrometric Charts
5.6.1 Air temperature
5.6.2 Relative humidity
5.6.3 Mean radiant temperature
5.6.4 Air flow movement
5.6.5 Infiltration loads in buildings
5.7 Calculating Thermal Energy
5.7.1 Heat loss calculations
5.8 Energy Efficiency Measures in Thermal Processes
Chapter 6Energy Management Systems andIndustrial Energy AuditsAlbert Williams1 & Yolanda de Lange1
6.1 Energy Management Systems (EnMS)
6.1.1 Overview
6.1.2 Energy performance indicators
6.1.3 Calculation of energy efficiency performance
6.1.4 High level benchmarking metrics
6.2 Industrial Energy Audits
6.2.1 The types of energy audits
6.2.2 The energy audit process
Chapter 7Instrumentation and ControlAlbert Williams
7.1 The Need for Automated Control
7.2 Control Components
7.2.1 Switches
7.2.2 Sensors
7.2.3 Transducers
7.2.4 Controllers
7.2.5 Control loops
7.2.6 Control devices
7.3 Control Modes
7.3.1 On/Off control
7.3.2 Floating control
7.3.3 Proportional only control (P)
7.3.4 Proportional-plus-integral control (PI)
7.3.5 Proportional-integral-derivative control (PID)
7.4 Sensor Types
7.4.1 Thermostats
7.4.2 Electric meter
7.4.3 Smoke sensors/detectors
7.4.4 Light sensors
7.4.5 Occupancy sensors
7.4.6 Carbon dioxide sensors
7.4.7 Carbon monoxide sensors
7.5 The Principles of Efficiency with Control andControl Applications
7.5.1 Efficiency through control
7.5.2 Efficiency through control applications
Chapter 8Energy Investigation Support ToolsAlbert Williams
8.1 Measurement of Power
8.2 Measurement of Temperature
8.3 Measurement of Pressure
8.4 Measurement of Humidity
8.5 Measurement of Heat Capacity and Heat Storage
8.6 Combustion Measurement
8.7 Measurements of Air Velocity
8.8 Measurements of Flow
8.9 Measurements of Compressed Air Systems
8.9.1 Compressed air flow measurements
8.9.2 Leak detection in compressed air system
Chapter 9Fuels, Furnaces, and Fired EquipmentAlbert Williams
9.1 Fuel Fired Systems
9.2 Fuels
9.2.1 Properties of solid fuels
9.2.2 Properties of liquid fuels (Oil)
9.2.1 Properties of gaseous fuels
9.3 Combustion
9.3.1 Combustion of carbon
9.3.2 Combustion air requirement
9.4 Optimizing Combustion Conditions
9.5 Fuel Fired Equipment and Applications
9.5.1 Furnaces
9.5.2 Dryers
9.5.3 Kilns
9.6 Flue Gas and Other Losses in Process Furnaces, Dryers and Kilns
9.7 Burners
9.7.1 Liquid fuel combustion
9.7.2 Pressure jet burners
9.7.3 Rotary cup burners
9.7.4 Air blast burners
9.7.5 Common problems in burners
9.8 Thermal Efficiencies
9.9 Air Pollution Control - Process and Equipment
9.9.1 Greenhouse gas effect
9.9.2 Acid rain
9.9.3 Ground level ozone
9.9.4 Reduction of pollutant emissions fromcombustion process
9.9.5 Energy efficiency improvements
9.9.6 Refinement to the combustion process
9.9.7 Flue gas treatment
9.9.8 Fuel switching
9.10 Energy Efficiency Measures
9.10.1 Maintain proper burner adjustment
9.10.2 Check excess air and combustibles in the flue gas
9.10.3 Keep heat exchange surfaces clean
9.10.4 Replace/Repair missing and damaged insulation
9.10.5 Check furnace pressure regularly
9.10.6 Schedule production to operate furnaces at ornear maximum output
9.10.7 Replace damaged furnace doors or covers
9.10.8 Install adequate monitoring instrumentation
9.10.9 Recover heat from equipment cooling water
9.10.10 Install a heat exchanger in the flue gas outlet
Chapter 10Heat Exchange SystemsAlbert Williams
10.1 Concepts of Conduction, Convection and Radiation
10.1.1 Conduction
10.1.2 Convection
10.1.3 Thermal radiation
10.2 Specific Heat Capacity
10.3 Insulation
10.3.1 Heat loss through a wall
10.3.2 Heat loss from a pipe
10.3.3 Heat loss from an industrial freezer
10.3.4 Insulating materials
10.3.5 Protective coverings and finishes
10.3.6 Accessories
10.3.7 Insulation energy efficiency measures
10.3.8 Vapor loss from open processing tanks
10.4 Heat Recovery with Heat Exchangers
10.4.1 Shell and tube
10.4.3 Heat wheel
10.4.4 Heat pipes
10.4.5 Run around system
10.4.6 Plate or Baffle type heat exchanger
10.4.7 Heat pumps
10.4.8 Waste heat boilers
10.4.9 Recuperators
10.4.10 Heat recovery ventilation systems
10.4.11 Mechanical and natural ventilation
Chapter 11Steam SystemsAlbert Williams
11.1 Generation
11.1.1 Steam
11.1.2 Sensible heat and latent heat
11.1.3 Steam quality
11.1.4 Superheated steam
11.1.5 Example of the effects of increasing surface area
11.1.7 Combustion losses
11.1.8 Blowdown losses
11.1.9 Feedwater treatment
11.1.10 Condensate tanks
11.1.11 Flash tanks
11.1.12 Flash steam heat recovery
11.2 Distribution
11.2.1 Condensate return
11.2.2 Steam leaks
11.2.3 Insulation
11.2.4 Steam pressure
11.2.5 Steam pipes
11.2.6 Heat transfer from steam
11.2.7 Steam traps
11.2.8 Routine maintenance of traps
11.3 End-Use
11.4 Energy Efficiency Measures
11.4.1 Boiler house – Operation opportunities
11.4.2 Boiler house – Maintenance opportunities
11.4.3 Boiler house – Retrofit opportunities
11.4.4 Steam distribution system opportunities
11.4.5 End-use equipment opportunities
Chapter 12Motors and DrivesAlbert Williams1 & Eustace Njeru2
12.1 Electric Motor Types
12.1.1 Direct-Current motors (DC)
12.1.2 Synchronous motors
12.1.3 Induction motors
12.2 Motor Nameplate Data
12.2.1 kW or HP
12.2.2 Service factor
12.2.3 Efficiency
12.2.4 Amps
12.2.5 Volts
12.2.6 Slip
12.2.7 RPM motor speed
12.2.8 Motor pole
12.2.9 Hertz
12.2.10 Duty
12.2.11 Bearings
12.2.12 Temperature
12.3 Torque
12.4 Power
12.5 Motor Losses
12.5.1 Core loss
12.5.2 Stator and rotor resistance (I2R) Loss
12.5.3 Friction and windage loss
12.5.4 Stray load loss
12.6 Motor Efficiency
12.6.1 Energy efficient motors
12.7 Motor Loads
12.8 Motor Rewinding
12.9 Motor Protection
12.9.1 Overcurrent protection
12.9.2 Overload protection
12.9.3 Other protection
12.10 Electric Motor Standards Compared to Actual Measurement
12.11 Energy Efficiency Measures
12.11.1 Motor load scheduling
12.11.2 Motor drive maintenance and alignment
12.11.3 Motor power factor correction
12.11.4 Balance motor phase voltages
12.11.5 Energy efficient motors
12.11.6 Cost implications of motor replacement versus maintenance
Chapter 13Fan SystemsAlbert Williams
13.1 Fan Types
13.1.1 Centrifugal fans
13.1.2 Axial fans
13.2 Fan Performance
13.2.1 Airflow measurement
13.2.2 Pressure measurements
13.2.3 Fan power requirement
13.2.4 Fan performance curves
13.2.5 Density consideration
13.2.6 Fan laws
13.3 Flow Control
13.3.1 System effect factors
13.4 Energy Efficiency Opportunities
13.4.1 Maintenance opportunities
13.4.2 Low cost opportunities
13.4.3 Retrofit opportunities
Chapter 14Pump SystemsAlbert Williams
14.1 Pump Types
14.1.1 Centrifugal pumps
14.1.2 Positive Displacement Pumps
14.2 Pump System Fluid Relationships
14.2.1 Friction head
14.2.2 Velocity head
14.2.3 Static head
14.3 Pump Performance Characteristics
14.3.1 Pump and system performance curves
14.3.2 Pump power requirements
14.3.3 Multiple pump systems
14.3.4 Cavitation and NPSH
14.4 Pump Maintenance
14.4.1 Packing glands
14.4.2 Mechanical seals
14.5 Energy Efficiency Measures
14.5.1 Housekeeping - Maintenance
14.5.2 Retrofit opportunities
Chapter 15Compressed Air SystemsAlbert Williams
15.1 Supply Side
15.1.1 Specific power for various compressor types
15.1.2 Positive displacement compressors
15.1.3 Dynamic compressors
15.1.4 Compressor lubrication
15.1.5 Inlet air temperature
15.1.6 Inlet air pressure
15.1.7 Compressor control
15.1.8 Individual compressor control
15.1.9 Multiple compressor control
15.1.10 Sizing
15.1.11 Compressor scheduling
15.1.12 Heat recovery
15.1.13 Maintenance
15.1.14 Compressor package
15.1.15 Supply side energy efficiency measures
15.2 Distribution and Treatment
15.2.1 Distribution main
15.2.2 Condensate drain traps
15.2.3 Air quality
15.2.4 Condensate
15.2.5 Distribution piping
15.2.6 Desiccant dryers
15.2.7 Heat of compression dryers
15.2.8 Deliquescent (Absorption) dryers
15.2.9 Refrigeration dryers
15.2.10 Dryer installation
15.2.11 Dryer sizing
15.2.12 Filters
15.2.13 Storage
15.2.14 System isolation
15.2.15 Distribution and treatment energy efficiency measures
15.3 Demand Side
15.3.1 Leakages
15.3.2 Inappropriate use
15.3.3 System operating pressure
15.3.4 Artificial demand
15.3.5 Perceived high pressure demands
15.3.6 High volume intermittent demand events
15.3.7 Demand side energy efficiency measures
15.4 Compressed Air Systems Assessments
15.4.1 Leakage assessment
15.4.2 End users assessment
15.4.3 Distribution assessment
15.4.4 Air treatment assessment
15.4.5 Compressor room assessment
15.4.6 Demand profile
15.4.7 Pressure profile
Chapter 16Large Scale Cooling and Industrial Refrigeration SystemsAlbert Williams
16.1 Refrigerants
16.1.1 Desirable refrigerant characteristics
16.2 Vapor Compression Refrigeration Cycle
16.2.2 Practical considerations for vapor compression refrigeration systems
16.3 Absorption Cycle
16.4 Refrigeration System Components
16.4.1 Refrigerant compressors
16.4.2 Evaporators
16.4.3 Throttling devices
16.4.4 Condensers
16.4.5 Heat rejection equipment
16.5 Industrial Refrigeration Applications in Food Industry
16.5.1 Still air or blast freezing
16.5.2 Cryogenic freezing
16.5.3 Plate freezing
16.5.4 Scraped surface freezing
16.6 Energy Efficiency Ratios
16.7 Sensible and Latent Heat
16.7.1 Sensible heat
16.7.2 Latent heat
16.8 Energy Efficiency Measures for CR Systems
List of Abbreviations
Definitions
Resources
Index
About the Author
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