Energy Analysis of a Powder Plant: A study at Sandvik in Coventry
Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
The purpose of this thesis is to perform an energy analysis. From that energy analysis areas where improvements can be made are selected. In these improvement areas measures are suggested to reduce energy inefficiencies. Where it is appropriate, replacement equipment are looked at and there are suggestions on which equipment is the most suitable substitute. Some of the new equipment has a calculated payback time and a life cycle cost analysis. In some areas environmental impacts are estimated and a carbon footprint calculated.
The energy analysis is carried out at the factory of an industrial company. The thesis describes what you need to consider before starting an energy analysis and what is a good way to present the data the analysis yields. Information and data comes from actual readings on site, calculations and estimates, interviews with engineers and other personnel as well as manuals and data sheets collected from archives and the internet. The site is visited once every fortnight for collection of data and to do interviews with the staff. To facilitate calculating the heat demand of the powder factory, the software called Energycalc is used but for most other calculations Excel is sufficient. The thesis furthermore describes how to find and evaluate measures that reduces the number of energy inefficient components. It also discusses barriers to why companies do not implement the suggested measures. The suggested measures with a payback time of less than three years are seen as successful. Special attention is given to replacing the chillers. The chillers are old, outdated and running on the soon to be banned R22. They have to be replaced and it is one of Sandvik’s top priorities.
Results from the energy analysis show that the steam boiler is the biggest energy consumer but the chillers are the most costly energy consumer. The steam boiler runs on gas and the chillers run on electricity. Since natural gas is a fifth of the electricity price the chillers are more costly to run. The cooling of the mill and the heat losses in the dryer is where most energy disappears. The basement compressors are too big and spend most of the energy idling and leaking. The building has an over dimensioned extraction fan system and poor insulation. The steam boilers are old, over-dimensioned and inefficient. The chillers are inefficient and a lot could be saved in repair and maintenance costs if they were replaced. By adding a free cooler the energy consumption could also be reduced and the carbon footprint lowered.
This thesis will contribute to a better environment due to reduced carbon dioxide emissions. It will help reduce the amount of energy used per product thus decreasing cost per product and therefore increasing profit. It will also increase awareness of how much energy and money that can be saved by looking over old systems and constantly looking for ways to reduce the amount of energy used. It will increase consciousness of both managers and employees about how and where they use energy. It will make a difference.
Place, publisher, year, edition, pages
2012. , 158 p.
Energy analysis, Sandvik Hard Materials, Powder production, Chillers, Air and
Economics and Business
IdentifiersURN: urn:nbn:se:kth:diva-143911OAI: oai:DiVA.org:kth-143911DiVA: diva2:709601