Transformation of human life from past to present has shown a major shift from basic living needs to having best in the society. In recent years, high rising needs has worsen energy & environment issues to alarming level. Irreversible threatening visible effects are the major concern of worry for the global population. 

            Despite entry of various innovative energy saving products, energy scenario is worsening. Simple reason, energy usage for comfort are touching high while many are still deprived of energy to meet their basic needs. Looking present trends, energy inefficient manufacturing sectors will become extinct soon. 

            Nature has provided enough energy resources and keeps on replenishing exhausted fuel stocks at her own pace. Energy consumption rate faster than its natural generation is creating imbalance in energy demand & supply cycle. Microscopic viewing of process plant ensures finer control of energy wastage. 

         Scarcity of energy resources and environment related hazards are already visible. Whether they are natural or man-made, this controversy will always exist. Rising energy price, leading to major politico-economic crisis across the globe, can’t be simply ignored. Process industries, being one of the major energy consumers, are worst affected due to continuous rise of energy price. 

            Each one of us is dependent over the energy and may contribute for energy conservation by: 

Finding alternative energy sources Developing processes/equipment for effective utilization of available energy Decreasing usage of energy consuming units  

           Looking the necessity, 10 simple points are presented here to enhance the participation of large number of people for energy conservation drive. On similar lines, various workshops can be conducted to motivate more people towards energy conservation. 

1.) Sense Energy Wastage 

Though energy is required for the process transformation, unnecessary wastage of energy should not be acceptable. Thus, it is important to sense energy wastage in every process step. Realization of energy wastage is the starting step towards the energy conservation. Following are the typical examples in relation to sense energy wastage in every process operation:

Heat losses from stripped off insulation from hot pipes/equipment Excess cooling water circulation in the system Air leakage from the ducts Distillation column operating at high reflux

 

 2.) Stop Energy Appliance when not in use

 Realization of energy wastage followed by proper timely actions will definitely contribute for saving energy. Stop energy consuming appliances when they are not in use. For example, ensure stoppage of:

Pump motor after complete material transfer Utility circulation pump after process completion Conveyors when material transfer finishes Exhaust fans after gas removal from work place

 

3.) Search Energy Efficient Solutions

 Stop action will ensure today’s energy saving but search of new energy efficient solutions is desired for continuing energy conservation in future too. Following are some of the identified areas for innovating energy efficient solutions:

Energy efficient electric drives Up-gradation of low quality heat for reutilization Modified distillation column internals Reduced downtime for maintenance

 

4.) Select Energy Saving Devices

 This is the decisive stage when two or more alternatives need to be compared w.r.t. energy consumption and the energy efficient one need to be selected. Following are the typical industrial examples where choice needs to be made one over other:

Low pressure drop units over high pressure drop High pipeline size over small pipeline size Complicated pipe routing over simplified routing Heat recovery system over heat wastage

 

5.) Shift Towards Available Energy Sources

 Re-look the process plant for available waste energy or doing minor shift in working style or process streams reduces down energy requirement. For example,

Preheating stream using waste heat instead of use of fresh heat Utilizing available liquid head instead of using pump for liquid transfer Shift to natural drafts instead of electric exhaust fans Use of non-conventional energy sources instead of conventional

 

 6.) Service Energy Consuming Units

 Effectiveness of some of the energy consuming units used in the process plant reduces after some period of operation. Thus, they require servicing to regain their efficiency. Following examples depict the need of servicing:

Cleaning heat exchanger surface for high heat transfer Oiling rotary units for reduced friction Replacing damaged column packing for higher efficiency Cleaning filter media for reducing pressure drop

 

 7.) Scrapping Energy Inefficient Units

 Beyond a certain stage, servicing alone may not regain energy efficiency of the operating unit. Thus old units need to be scrapped and replaced by the new ones. Sometimes new innovative, energy efficient units may also replace older energy inefficient units. Following are the industrial examples:

Blocked, damaged heat exchanger Damaged distillation column packing Inefficient electric motors Old damaged insulation over pipelines/equipment

 

 8.) Schedule More Activities at a time

 Advanced planning helps in energy saving exercise. Thus, planning is required for carrying out more activities with the same energy consumption. For example;

Carrying out all maintenance activities in single plant shut down Plant modifications at the time of preventive maintenance Redesign operational cycle of batch operation to reduce idle time Hot stream directly for next processing step instead of sending for storage

 

9.) Sacrifice Comforts & Status

 Essential transformations can’t be avoided in the process plants, but energy conservation requires some level of compromise in our comforts. Thus attitudinal changes are desired. For example:

Don’t wait for others to stop idle running machinery Don’t switch on lights, fans until essentially required Don’t overlook energy saving suggestions Do provide additional time for energy conservation

 

 10.) Spread Energy Conservation Message

 Spreading the energy conservation learning to various levels of people becomes essential today. Following need to be considered:

Practice first then preach Awareness of environmental threats related to energy Share energy experiences at every levels Arrange energy conservation workshops


By: pankkaj khandelwal