 "Recover heat to regain profitability")
According to some experts, processing industries utilise 50% more energy than required, thus escalating the cost of manufacturing manifold. Situation can be worst in developing countries, where manufacturers are still using old technologies and machineries in their production facilities. “If they were to switch to the best available technology, power consumption would drop by roughly 1200 GW. This is approximately three times the entire global nuclear power production,” claimed Jan Hedemann, Managing Director, Alfa Laval India Limited.
The Indian chemical industry, one of the major consumers of energy, finds itself in a double whammy. While fuel prices are rising, there is increased pressure to curtail greenhouse gases. Hence, improving production with optimum usage of energy is the only way out.
Pushan Sharma, Manager- Marketing and Business Development, Godrej Process Equipment, Godrej & Boyce Manufacturing, said, “Energy efficiency is very critical for customers in the chemical industry. Customers want to utilise every Joule of energy being produced or dissipated in various processes. As a result they are very conscious while selecting the process for their projects. This leads to advanced processes which require critical equipment in order to meet the energy efficiency needs.”
Energy saved is money earned
No wonder customers from chemical industry are demanding energy-efficient equipment from the suppliers. V Gokul Das, Managing Director, HRS Process Systems Ltd, said, “Energy efficient processing has always been the key for profitability running of chemical processing industry, since energy is one of the primary cost of operations. Customers are looking at ‘energy-efficient, cost-effective’ solutions these days.”
ALSO READ: Efficient cooling system improves productivity in plastic moulding
Agreed Hedemann, “Absolutely, energy means a lot to business and ever rising energy prices and environmental legislations are putting huge pressure on process industries around the world. To meet the obligations towards environment, most of the time means finding new ways to enhance production, while ensuring reduction in energy consumption. Companies are finding an unexpected answer to this dilemma, their waste heat – ie, don’t waste your waste, recover to profit by it.”
Investing in equipment for waste heat recovery and reuse has proven very profitable. Experts believe that the upside is often substantial and payback times are often shorter than a year. “An added bonus is reduction of CO2 emissions and climate impact, as a result,” opined Hedemann.
Waste heat recovery system
The key components in a waste heat recovery system are heat exchangers. Hedemann said, “These devices enable energy transfer from one stream (fluid or gas) to another. An industrial plant uses energy in numerous ways in its processes. With the help of heat exchangers the heat being used can be recovered and put to use again, either in the same process or in other parts of the plant.”
ALSO READ: Selecting right heat exchangers, the first step to energy efficiency
There are several different heat exchanger designs available in the market. Experts say that conventional shell-and-tube heat exchangers may suffer from very low efficiency, on the other hand plate type heat exchangers may offer better heat transfer efficiency. Hence, companies need to select a right type of heat exchanger to make a huge difference to the amount of heat that can be recovered, and the return on investment.
In transition
Traditionally, shell and tube type of exchangers were used in chemical process industry however now plate type compact heat exchangers provide optimum solution in terms of higher thermal efficiencies, compact size, low operational & maintenance cost and extended life of equipment.
Hedemann said, “Further continued growth is anticipated in this sector, based on improving life styles, urbanisation and increasing population, which should continue to put a backward thrust for this industrial growth.”
Make the right choice
Using right kind of equipment depends on multiple factors such as size, type, environment, etc of the manufacturing unit. Gokul Das said, “Selecting right equipment is the key to enhance productivity of the plant and improving the bottom line. Selecting right equipment ensures better quality product with optimum resource utilisation, as the equipment is energy efficient and low on maintenance.”
ALSO READ: Process equipment makers ready to ride investment cycle boom
According to G R Singh, Director - BD & Sales, Oil & Gas, Linde Engineering India Pvt Ltd, though energy efficiently is one of the key factors for selecting process equipment, other equally important factors are quality, delivery schedule and reliability as well as total live cycle cost. “It is observed that the performance track record of the offered equipment as well as the after sales services, by the suppliers, play a key role in the selection process,” he added.
The Indian chemical industry, one of the major consumers of energy, finds itself in a double whammy. While fuel prices are rising, there is increased pressure to curtail greenhouse gases. Hence, improving production with optimum usage of energy is the only way out.
Pushan Sharma, Manager- Marketing and Business Development, Godrej Process Equipment, Godrej & Boyce Manufacturing, said, “Energy efficiency is very critical for customers in the chemical industry. Customers want to utilise every Joule of energy being produced or dissipated in various processes. As a result they are very conscious while selecting the process for their projects. This leads to advanced processes which require critical equipment in order to meet the energy efficiency needs.”
Energy saved is money earned
No wonder customers from chemical industry are demanding energy-efficient equipment from the suppliers. V Gokul Das, Managing Director, HRS Process Systems Ltd, said, “Energy efficient processing has always been the key for profitability running of chemical processing industry, since energy is one of the primary cost of operations. Customers are looking at ‘energy-efficient, cost-effective’ solutions these days.”
ALSO READ: Efficient cooling system improves productivity in plastic moulding
Agreed Hedemann, “Absolutely, energy means a lot to business and ever rising energy prices and environmental legislations are putting huge pressure on process industries around the world. To meet the obligations towards environment, most of the time means finding new ways to enhance production, while ensuring reduction in energy consumption. Companies are finding an unexpected answer to this dilemma, their waste heat – ie, don’t waste your waste, recover to profit by it.”
Investing in equipment for waste heat recovery and reuse has proven very profitable. Experts believe that the upside is often substantial and payback times are often shorter than a year. “An added bonus is reduction of CO2 emissions and climate impact, as a result,” opined Hedemann.
Waste heat recovery system
Alfa Laval India's Jan Hedemann
The key components in a waste heat recovery system are heat exchangers. Hedemann said, “These devices enable energy transfer from one stream (fluid or gas) to another. An industrial plant uses energy in numerous ways in its processes. With the help of heat exchangers the heat being used can be recovered and put to use again, either in the same process or in other parts of the plant.”
ALSO READ: Selecting right heat exchangers, the first step to energy efficiency
There are several different heat exchanger designs available in the market. Experts say that conventional shell-and-tube heat exchangers may suffer from very low efficiency, on the other hand plate type heat exchangers may offer better heat transfer efficiency. Hence, companies need to select a right type of heat exchanger to make a huge difference to the amount of heat that can be recovered, and the return on investment.
In transition
HRS Process Systems' V Gokul Das
Traditionally, shell and tube type of exchangers were used in chemical process industry however now plate type compact heat exchangers provide optimum solution in terms of higher thermal efficiencies, compact size, low operational & maintenance cost and extended life of equipment.
Hedemann said, “Further continued growth is anticipated in this sector, based on improving life styles, urbanisation and increasing population, which should continue to put a backward thrust for this industrial growth.”
Make the right choice
Using right kind of equipment depends on multiple factors such as size, type, environment, etc of the manufacturing unit. Gokul Das said, “Selecting right equipment is the key to enhance productivity of the plant and improving the bottom line. Selecting right equipment ensures better quality product with optimum resource utilisation, as the equipment is energy efficient and low on maintenance.”
ALSO READ: Process equipment makers ready to ride investment cycle boom
According to G R Singh, Director - BD & Sales, Oil & Gas, Linde Engineering India Pvt Ltd, though energy efficiently is one of the key factors for selecting process equipment, other equally important factors are quality, delivery schedule and reliability as well as total live cycle cost. “It is observed that the performance track record of the offered equipment as well as the after sales services, by the suppliers, play a key role in the selection process,” he added.