Energy Audit Methodology of Sponge Iron Manufacturing Units Using DRI Process

Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kWth/kWe) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant. The main & only source of thermal energy is coal and the entire coal is fed to the rotary kiln. Therefore we find that “Kiln” is the “Black-Box” of this industry and the success of energy efficiency is hidden in the kiln process chemistry. This article tries to establish detailed energy audit methodology of sponge iron manufacturing process or kiln operation with a view to finding out major energy saving potential of the unit. In the research work we find that it is the incomplete reaction of coal that causes the major energy inefficiency in the process. Substantial amount of un-reacted carbon comes out with the char (by-product) which has virtually zero commercial value. The article also puts a question mark on the justification of using high-grade imported coal in such energy inefficient industries.

ISO 50001: Are the Auditors Equipped Enough?

This paper tries to address the issue of expertise and awareness level of ISO-50001 [1] certification auditors in judging the efficacy of existing energy management (EnMS) and suggest the methodology to ensure continual improvement in EnMS. This article also tells about the need of thorough understanding of legal & other mandatory requirements which need to be addressed properly before framing the energy policy and setting up objectives & targets for the organization. Particularly SMEs, while implementing any standard or adopting any new system, largely depend on the consultant/ system auditor because of their limited knowledge and resources. In such cases the auditors need to play a larger role by making appropriate ENCON recommendations and guide them how to achieve the compliance. Further in India, most of the companies have got poor metering system. Even crucial energy data like flow rate of LPG, natural gas, FO, steam etc are quoted from judgment or past experience. Meters are not there to measure motor power, liquid temp or gas prss. In such cases auditors need to guide the clients how to establish the energy monitoring & targeting system and how to establish proper M&V (Measurement & Verification) protocol. In nut shell the ISO-50001 auditor needs to play the role of a friend, philosopher & guide to ensure that at the end of the day his client has complied with all the energy regulations and at the same time achieved some significant reduction in energy consumption.

HVAC vs Geothermal Heat Pump—Myth &Truth

In India energy auditors in some cases have recommended ground water based heat pump in place of common HVAC system to achieve better efficiency. However the users were made to understand that heat pumps are not suitable for Indian climatic condition and it produces no better result than the conventional system. This article tries to find answer to this debate thru an impartial analysis with the available data. First the concept is tested thermodynamically to compare the derived COPs and next from the experimental data on specific energy consumption.