Energy conservation and auditing of master industrial complex /

Abstract

The energy demand is increasing annually by 5% because of the increasing population and industrial expansion in Pakistan. The major source of electrical consumption by industry is 34% in Pakistan. Energy conservation and auditing techniques were applied to Master Industrial Complex, manufacturer of upvc, pprc, sanitary-ware products. Our Aim was to minimize the cost of energy, operational cost, reconstruction and demolishing cost by proper selection of space. The Master Industrial Complex was selected for the proposed solution of the equipment selection and energy efficient equipment. The efficiency of Injection Molding machines and some other machines were determined with the help of old and new machines. The production is maximized by proper selection of man, machine and material. The different techniques of audit have been conducted by using the walk through audit technique and detail audit technique for the analysis of machines. The financial report and data analysis report has been used for the Master Industrial Complex Project. Energy flow processes were studied in detail and improvements were suggested for overall energy efficiency gain of system without compromising on operating conditions. For this study walk through interviews, investigation of energy flows and physical inspection of equipment were carried out. The installed capacity of the Master Industrial Complex is 3008 KW. This study analyzes not only the selection for VFD drive systems for compressors, pumps and fans, but also analyzes the energy conservation opportunities for lighting, motors, peak load control. Energy action plan was implemented for PF control as well. This study suggests the replacement of CFL’s (Compact fluorescent light) with LED (Light emitting diode) lamps. It also analyzes the diesel and gas generator exhaust for the waste heat recovery boiler as case study. In this study we observe the impact of energy and cost savings by relocation of factory, also we study the risk assessment of the project. Recommendations are provided to the management of Master Industrial Complex about their energy consumption, which include redefinition of the energy load and installation of solar street lighting for energy conservation and annual energy saving. This study analyzes all types of energy consumption like electricity consumption and production rate per hour, and also analyzes the impact of VFD for the pumps and motors as it saves 30-50 % energy. The VFD were placed on the compressors, pumps and fans where motors have been used. The capacitor bank were used to maintain the PF and save penalty in utility bills.