The document discusses replacing electrical heaters with a heat pump system for water heating applications in an automobile industry's crankcase process line. It aims to study the feasibility and design of a heat pump that can meet the hot water needs of the washing machines on the line while reducing energy consumption. The methodology involves measuring current energy usage, studying the washing machine components and heating loads, selecting a suitable refrigerant, and designing the major heat pump components like the compressor, condenser, and expansion valve based on the heating requirements. The objectives are to analyze energy savings potential and indoor environmental quality improvements from applying heat pump technology.

1. “ Energy Conservation by
Application of Heat Pump in
Process Line at Automobile
industry Ltd. ”
By
Mr. Shivraj N Nalawade
M . Tech- II (Energy Technology)
Under Guidance of
Prof. N. N. Shinde
Mr. S. A. Doshi

2. • Many industries use heating applications in their processes. These applications
could be by means of different energy inputs like electrical heating, thermal
heating, steam heating or few renewable heating. Out of these many
managements are unaware about significant energy source for their
applications. The heat energy gadgets adds heat in atmosphere
• Some organization are not much aware about energy efficient techniques
available in the market and this tends to high running and operating cost
resulting in losses.
• During the energy conservation studies at Process Industry is observed that the
highest consuming load centre is machining line. On HA crank case line
maximum energy consumption is because of electrical heaters which are used
for water heating purpose.
• The heat pumps are used now a days to recover heat and can be used as energy
gadgets as it helps maintains the cooling of working space. Comfort is very
important for increasing productivity.
• Hence the topic is selected as “Energy Conservation by Application of Heat
Pump in Crankcase Process Line at Automobile industry Ltd. ”
Relevance of the Project

3. Certificates

4. Heat pumps
 Heat pump technology
1. Air Source
2. Ground Source
3. Water Source
 Heat Pump cycle

5.  Components of Heat Pump
1. Compressor
2. Condenser
3. Expansion Valve
4. Evaporator
5. Refrigerant
 Heat Pump Benefits
1. Heat Pump used for Heating
2. Heat Pump used for Cooling i.e. Air Conditioning
3. Heat Pumps control the climate
4. Heat Pumps are convenient
5. Heat Pumps are safe
6. Heat Pumps are very energy efficient

6. • Applications of Heat Pump
i. Industrial washing machines
ii. Commercial building
iii. Restaurants
iv. Hotels
v. Health club
vi. Schools
vii. Hospitals
• IEQ (indoor environmental quality)
The quality of the air and environment inside industries that contribute to
a healthy and comfortable place to live and work. Indoor environmental
quality is affected by electrical equipment’s that release heat in to the
building. Heat pump is the major part when we consider IEQ for any
industry.

7.  Energy Conservation and Heat Pumps
Water Heater Type
Storage
Tank
Site-to-Source
Ratio
Energy
Factor
Source COP
Electric Resistance Tank 3.365 0.90 0.27
Heat Pump Tank 3.365 2.00 0.59
Fuel Oil Tank 1.158 0.59 0.51
Natural Gas Tank 1.092 0.59 0.54
Natural Gas Tank less 1.092 0.82 0.75
Condensing Natural Gas tank less 1.092 0.94 0.86
Propane Tank 1.151 0.59 0.51
(source: Energy Efficiency and Renewable Energy U.S. Department of Energy)

8. Problem Definition
 Industry case under consideration
1. In many developing countries HPWH system in widely used for water
heating application rather than that of conventional water heating
systems.
2. These applications could be by means of different energy inputs like
electrical heating, thermal heating, steam heating or few on renewable
heating.
3. In Automobile industrial sector for washing of various components
hot water is used in large amount. This requirement of hot water can
be generally fulfilled by electrical heaters. But, electrical heaters can
consumes lots of electrical energy in comparison with that of heat
pump.in developing country like India many industries are using
electrical heaters for hot water application.
4. Presently in industry, the water is heated by electrical energy
(electrical Heater). This electrical heater has consumed lot of
electrical power. Considering all condition, to study such
systems and check the feasibility for the alternate innovative
energy source for such applications.

9.  Overview of Existing System 1. Washing
chamber
2. Drum filter
3. Dirty tank
4. Transfer Pump
5. Compact band
filter
6. Clean tank
7. Spray pump

10.  Condition of Water Heating

11. Objectives
1. Study of final components of washing machine on crank
case machining line at automobile industry.
2. Feasibility of energy saving at component washing
machine and application of heat pump.
3. Designing of suitable heat pump considering requirement
of water heating for washing application.
4. Data collection and analysis of suitable heat pump with
respect to IEQ in the vicinity of final washing machine on
crank case line.
5. Conclusion and recommendations.

12. Literature Review
 This chapter covers about various literatures which contain lots of various
technologies for heat pump also it covers most important parameters like IEQ,
HPWH as well as various properties of various refrigerants.
 The various papers of national and international authors which are working
on this heat pump technology and also indoor environmental quality factor in
industry.
 While studding heat pump and refrigeration systems there are standards from
which the system is to be designed and these standards are ANSI/AHRI, some
ISO standards and also ASHRAE standards. After studying electrical hearers
and heat pump systems hardly any reference is found for study.
 Energy conservation is achieved by the heat pump. Many citation’s exists for
application of heat pump specifically in refrigeration system to recover the
waste energy in a closed loop.in this case the problem considered in chapter 2
is specifically phenomenon of replacing electrical energy by heat pump in
which the cooling load is created which can be used for cooling the air nearer
to level of the comfort which is new concept for help to maintain and IEQ in
the environment nearby. This project therefore is concentrated in designing
the heat pump for the crankcase process line at Kirloskar oil engine ltd. and to
find out energy conservation potential which will lead to reducing energy
consumption by improving system energy efficiency in general. This will
provide guidelines for the future work for maintain environment in the
industry.

13. Scope of the Project
1. Studied energy consumption pattern in different shops at
industry.
2. Prepare pie charts for energy balance.
3. From pie charts, machine shop is major consuming load center.
4. In depth, analyze machine shop consumption for different lines
and machine on the lines. It is observed that component washing
machine is highest energy consuming machine.
5. Studied the same for the feasibility alternative sources.

14. Methodology
1. Measuring energy consumption at various load centers.
2. Feasibility of energy saving at component washing machine
and application of heat pump.
3. Study of final components for wash on washing machine on
crank case machining line
4. Data Collection and analysis by Fluke analyzer (Heating
Load Measurements) on washing machine.
5. Study of vapor compression refrigerant system.
6. Designing of Suitable Heat Pump Considering Requirement
of Water Heating For Washing Application.

15. 1. Measuring energy consumption at various load centers.
 Variable Energy Consumption at industry (In Kwh)
Centre Unit 10-11 11-12 12-13 13-14
Machine Shop Mn Units 8.01 6.76 8.49 6.51
Medium
Engine
Mn Units 2.56 2.15 2.21 2.04
GENSET Mn Units 1.15 0.99 1.50 1.00
Small Engine Mn Units 1.60 1.38 1.18 1.63
Total Mn Units 13.32 11.28 13.38 11.18

16. 58%18%
9%
15%
Variable Energy Balance
Machine Shop
Medium Engine
GENSET
Small Engine

17. 2. Feasibility of energy saving at component washing
machine and application of heat pump.
3.74
1.76
1.64 1.62 1.57
1.45 1.4 1.31 1.27 1.19 1.19 1.15 1.15 1.14 1.1 1.07 0.99 0.98 0.92
0.91
0
20
40
60
80
100
120
0
0.5
1
1.5
2
2.5
3
3.5
4
%contribution
energyconsumption(kw)
machine name
parato chart per component energy consumption on ha crank case line

18. 3. Study of final components for wash on washing
machine on crank case machining line.
component
Weight(
kg)
Dimension(mm)
Compone
nts Per
Shift
Temperature(0C)
Mean
Temperature
Difference
Heat loss in
component(
kWh)
Height Width
Before
washing
(t1)
After
washing
(t2)
2 Cylinder
Head
64 335.8 587 63 26.3 36.4 10.1 0.09
3 Cylinder
Head
81 335.8 457 60 26 36.1 10.1 0.12
4 Cylinder
Head
98 335.8 309 58 25.5 35.4 10 0.15
Picture before Component Washing Picture after Component Washed

19.  List of measuring instruments
Fluke Power Analyzer Thermal Imager Mass Flow Meter
Actual measurement on
site

20.  Actual pictures of machine
Washing chamber Drum filter
Electrical Heater position Crank case Component

21.  Data Collection and analysis by analyzer (Heating Load
Measurements) on washing machine.
Measurement – Initial stage heating (From 27°C to 55°C)
Total Energy Consumption-46 kWh
Measurement – Shift 1
Time of Shift- 8 hrs. (Initially Power analyzer is set to 0 Reading)
Total Energy Consumption for shift 1-288.6 kWh
Measurement – Shift 2
Time of Shift- 8 hrs. (Initially Power analyzer is set to 0 Reading)
Total Energy Consumption for shift 2-293 kWh
Total Energy Consumption of Heaters in 1 Day=46+288.6+293=627.6kWh
Time(Hrs.) Consumption (kWh)
1 46
Time 1 hr. 2 hr. 3 hr. 4 hr. 5 hr. 6 hr. 7 hr. 8 hr.
Consumption(kWh) 36 38 37 37.5 35.3 34.5 36.3 34
Time 1 hr. 2 hr. 3 hr. 4 hr. 5 hr. 6 hr. 7 hr. 8 hr.
Consumption(kWh) 34.9 36.8 36.3 38 35.6 38 36.4 37

22. 0
5
10
15
20
25
30
35
40
45
50
0 2 4 6 8 10 12 14 16 18
Consumption(kWh)
Time(Hrs)
Energy Consumption of Electrical Heater

23. Proposed system
Block diagram of washing machine Block diagram of washing machine compatible
with heat pump

24. Heat capacity
Initial Condition
water flow = 1450 Litres
mh = 1450 kg
mh = 1450 kg/3600 = 0.402 kg/s
Cold fluid inlet Temperature = TCin = 270
C
Hot fluid inlet Temperature = TCot = 550
C
From steam tables,
Enthalpy of water at 270
C = hf27 = 118.8 kJ/kg
Enthalpy of water at 550
C = hf55 = 231.6 kJ/kg
∴ ∆h = hf55 −hf27
∴ ∆h = 112.8 kJ/kg
Hence, heat required to be added,
H = mh∆h
= 1450 × 112.8
= 163560 kJ
Time required to heat= 1Hr=3600 sec
Heat capacity of heater =
Heat added
time
=
90240
3600
= 45.33 kW
In Tons of refrigeration,
=
45.33
3.5167
= 12.88TR
Design of Heat Pump

25. Running condition
water flow = 210 Liters/min
mh = 210 kg/min
mh = 210 kg/60 = 3.5 kg/s
Inlet Temperature of water = TCin = 450
C
Outlet Temperature of water = TCot = 550C
From steam tables,
Enthalpy of water at 450C = hf27 = 217.29 kJ/kg
Enthalpy of water at 550
C = hf55 = 231.6 kJ/kg
∴ ∆h = hf55 −hf27
∴ ∆h = 12.95 kJ/kg
Hence, heat required,
H = mh∆h
= 3.5 × 12.95
= 45.33kW
In Tons of refrigeration,
=
45.33
3.5167
= 12.88TR
By considering both the above initial and running condition, capacity output of heat
pump required is about 45.33 kW or 12.88 TR. All the technical parameters are
designed on the basis of 45.33 kW output of Heat Pump.

26. Selection of Suitable refrigerant
Criteria Refrigerants
1= Poor 5= Excellent R-22 R-290 R-410A R-404A R-407c R-134a
Cooling capacity 3 2 5 3 2 1
Input power 3 4 1 2 3 5
Cooling COP 4 5 3 3 2 5
Refrigerant mass flow 4 1 5 5 3 2
Discharge temperature 3 5 3 5 3 5
Pressure ratio 5 5 5 5 1 2
Vol. ref. capacity. 4 3 5 4 3 1
ODP 1 5 5 5 5 5
GWP 2 5 2 1 2 3
Cost 3 5 1 2 1 2
Non-toxicity 5 5 5 5 5 5
Non-flammability 5 1 5 5 5 5
Compatibility 5 5 5 5 5 5
Total 47 51 50 50 40 46
As seen in above table the rating of R-134a having total of 46 which was middle among all
refrigerant used conventionally, selection of refrigerant as R-134a for project work.

27. PH Chart for R134a at 12.8°C Evaporating and 60°C Condensing
(source: PH chart is plotted using COOLPACK software)

28. 2. Heat pump operating temperature and pressure
Assuming ADP (Apparatus Dew Point Temperature) of cooling coil of evaporator = 40
C
Properties of R134a at 40
C
P = 3.3755 bars
Minimum of 50C temperature difference is necessary to heat the fluid, in order to
avoid the limitation of heat transfer by finite temperature difference
∴ Condensor temperature = 55 + 5 = 600C
for R134a
@600
C , P = 16.815 bar
Point Temperature(°C) Pressure(Bar) Enthalpy(Kj/Kg)
1 23.89 4.54 415.33
2 79.06 16.81 451.10
3 79.06 16.81 451.10
4 57.23 16.81 282.88
5 N/A 4.54 282.88
6 23.9 4.54 415.33
15 N/A 16.81 282.88

29. 3. Refrigerant mass flow rate
Now at 600
C, total heat content of refrigerant,
∆hr=enthalpy of gas @600C-enthalpy of liquid @600C
∴from properties of R134a
= 451.1 − 282.88 kJ/kg
∆hr = 165.22 kJ/kg
By 1st law of thermodynamics,
Heat added to cold water = heat rejected from condersor
∴ 45.33 = mr∆hr
∴ mr = 0.27 kg/sec
Final compressor specifications
Theoretical COP of the system 3.7
Actual COP of the system 3.6
Refrigerant mass flow rate 0.27 Kg/sec
Compressor work 9.65 kW
EPR 7.05
Isentropic efficiency of compressor 66%
4. Compressor Specifications

30. Condenser Design Using Trial And Error Method
Heat Flow diagram

31. Condenser Specifications
Condenser heat output 45.33 Kw
Tube ID 0.017 M
Tube OD 0.025 M
No. of tubes 44
No. of passes 2
No. of baffles 8
Baffle spacing 0.122 M
Tube length 1 M
Bundle diameter 0.23 M
Shell diameter 0.3 M
Tube side pressure drop 0.61 Bar
Shell side pressure drop 0.3 Bar

32. • Condenser Drawing

33. 6. Expansion valve selection
The most important technical parameter for selection of thermostatic expansion valve is
MOP (Maximum Operating Pressure)
Evaporator pressures are limited to a maximum value to protect compressor from
overload conditions. MOP selection should be within maximum allowed low pressure
rating of the compressor and should be at approximately 3 K above maximum
evaporating temperature.
MOP Upper limit of evaporating temperature
Bar °C R407C R22 R 410a R134a
6.9 17 14
6.9 15 12
3.8 14 10
12.1 16 14
Note-All pressures are gauge pressure

34. Expansion valve specifications
Condensing Pressure 16.8 Bar
Evaporating Pressure 12.8 Bar
Total Pressure Loss 1.5 Bar
Effective pressure difference across valve 10.77 Bar
Correction factor for pressure differential 0.78
Correction factor for evaporating temperature 1.35
Evaporator specifications
Heat absorbed in evaporator 35.76 Kw
Tube diameter 0.01 M
Fin pitch 0.034 M
Fin thickness 0.048 Cm
Air mass flow rate 7.31 kg/sec
No. of tubes 28
Fine width 0.043 M
 Evaporator design

35.  Final Temperature and pressure on heat pump cycle

36. Heat Pump Compatible With Tank

37. Heat Pump Drawing

38. Proposed System Replacements

39. Energy, Cost saving and Environmental
Analysis
 Energy saving potential
0
5
10
15
20
25
30
35
40
45
50
0 2 4 6 8 10 12 14 16
Consumption(kWh)
Time(Hrs.)
Comparision of Electric Heater and Heat Pump Energy
Consumption in 1 day
Electric Heater
Heat Pump

40. • Estimated Energy and Cost saving Analysis
•Estimated Energy consumption Calculation for Electrical Heaters and
Heat Pump
Total Energy Consumption of Heaters in 1 Day =627.6 kWh (Actual
Measurements)
Total Energy consumption by heat pump=12.54kw
Therefore, total energy consumption by heat pump in 1 day= 200.64kWh (for
16hrs. of operation)
Energy Savings /Day = Consumption of Heaters in 1 Day- consumption by
heat pump in 1 day
Energy Savings /Day =627.4-200.64=426.76 kWh/day
Energy saving per year= 426.76*300=1,28,028 kWh/Year

41. It means that heat pump can be save up to 61,680 units of electricity per year.
•Estimated Cost saving analysis
Base rate of electricity for 1 unit= 8 Rs.
Therefore,
Cost saving per day=8*426.76=3414.08 Rs.
Cost saving per Year=3414.08*300=10,24,224 Rs.
•Payback period Calculation
Market prize of heat pump from manufacturing company is nearly= Rs. 9,
50,000/- (With installation)
Therefore, Payback period of heat pump = 1 Year

42. Indoor Environmental Quality (IEQ)
improvement
There are 2 main contains in IEQ as per ASHRAE 2009 handbook are
as follows:
•Thermal Comfort Indoor Environmental Health
•Air Contaminants
For consideration of IEQ the below readings are taken on site.
Limits are taken as per factory act 1948.
Sr. no Parameters Values Limit as per factory act, 1948
1. Ambient temp 0C
Dry bulb 28 290C to 340C
Wet bulb 24 220C to 260C
2. Relative humidity% 64 ---
3. Noise level in dB(a) 87.9 90
4. Suspended particular matter, mg/m3 0.09 <=10
5. Oil mist mg/m3 0.019 <=5

43. • Estimated room dimensions for cooling

44. • This chapter includes energy saving potential of electrical
heater as well as Heat Pump.
• Which clearly shows energy saving potential of
• heat pump is very high.
• This also includes cost beneficial analysis and impact of
heat pump output on IEQ at working condition.
Summary

45. 1. On the existing system, study is done on electrical water heating system for
crankcase machine line which shows that it has an average electrical energy
consumption of 627.6 kWh,15,690 kWh and 1,88,280 kWh for daily, monthly
and yearly respectively.
2. The design data is created for the existing process layout.
3. A heat pump system has been designed and electrical consumption has been
worked out.
4. The theoretical analysis clearly indicates that the energy conservation has been
achieved 426.76 kWh, 10669kWh, 128028 kWh on daily, monthly and yearly
basis respectively.
5. This energy consumption is in accordance with the prevailing designed data
and the surrounding climatology for automobile industry.
6. The cost saving is achieved Rs 3,414.08 , Rs 85,382, Rs 10,24,224 on daily,
monthly and yearly basis respectively.
7. The actual amount of heat pump by market price is nearly Rs 9,50,000 and
savings achieved by theoretical calculations is Rs 10,24,224 yearly at base price
of electricity Rs 8 per unit. So the calculated payback period is nearly one year.
Conclusion

46. In view of conclusion heat pump is recommended for energy conservation for such
applications in industry. Its value addition like cooling the surrounding is also of prime
importance in the view of IEQ.
Due to limitations of cost of heat pump and time of period of completion,
prototype of heat pump development is remained
Future scope
• Development of heat pump model.
• Analysis of heat pump performance by various refrigerants.
• Testing results and analysis performance of heat pump with impact on IEQ

47. Recommendations
1. At the crank case line washing machine there are various
other options to replacer that electrical heaters with solar
water heater, heat pump, biogas and briquette fire
technology and also other renewable energy sources for
washing application.
2. After installing any other system for water heating do
regularly maintenance and check whether the system works
correctly and energy efficiently.
3. Use clean water for washing application and also regularly
add makeup water in tank.

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53. Paper Publications
 “ENERGY CONSERVATION ANALYSIS BY APPLICATION OF HEAT PUMP SYSTEM-
A CASE STUDY” paper is published in “INTERNATIONAL JOURNAL OF
ENGINEERING SCIENCES & RESEARCH TECHNOLOGY.(IJESRT)”
Shivraj Nalawade Thesis123_ENERGY CONSERVATION ANALYSIS BY
APPLICATION OF HEAT PUMP SYSTEM- A CASE STUDY.pdf
 “PERFORMANCE EVALUATION OF HEAT PUMP USING SIMULATION
TECHNIQUES FOR REPLACING ELECTRIC WATER HEATING SYSTEM TO
ACHIEVE ENERGY CONSERVATION AND IMPROVE IEQ IN AN PROCESS
INDUSTRY” paper is published in “INTERNATIONAL JOURNALOF CURRENT
RESEARCH”
Shivraj Nalawade ThesisPERFORMANCE EVALUATION OF HEAT PUMP USING
SIMULATION TECHNIQUES FOR.pdf

54. Thank You