Heating consists of the majority of the energy demand in Industries. Around 123 Gwh of energy is consumed every year. The workshop was conducted to give an understanding of the various ways to sustainably provide heat for processes.

2. Leader in Industry scale solar thermal plants with over 2 MW installation and industrial
heat pump with over 500 kW
Rooftop solar installation for 40-120o C industrial processes
Industry’s first 90/95 °C Heat pump
Replace fossil fuel and reduce carbon emission with clean green solar energy
Technical expertise for hybridization
Unique PPA model for solar industrial heating
Proud Pioneers
About Aspiration Energy

3. Solar Heating For Industries
Industrial Processes suitable for Solar
/ Heat pump
Drying Electroplating
Bleaching Cleaning
Cooking Pickling
Degreasing Steaming
Evaporating Phosphating
Preheating Washing

4. Solar
Power
Active
Solar PV
Solar
Thermal
Passive Heat Pump
Solar Power: Classification

5. Solar Heating For Industries
Active Solar
Solar Thermal System
Passive Solar
Heat Pump System

6. Ambient Heat
Primary power
(Electricity)
Heat Pump
USABLE
ENERGY
Renewable
Energy
Conventional
Energy
Heat Pump

7. AC vs Heat Pump

8. COP
WHAT IS MEANT BY EFFICIENCY?
Efficiency =
𝑶𝒖𝒕𝒑𝒖𝒕
𝑰𝒏𝒑𝒖𝒕

9. WHAT IS THE EFFICIENCY OF A
NORMAL INDUCTION MOTOR?
Example: For 7.5 kW
IE1 = 84 - 86%
IE2 = 87 - 88%
IE3 = 89 - 90%
COP

10. COP
WHAT IS THE EFFICIENCY OF FAN?
CENTRIFUGAL/AXIAL FAN = 60-70%

11. COP
WHAT IS THE EFFICIENCY OF BOILER?
Typical efficiency of boilers = 70-90%

12. 10 kW
Useful energy
(compressed air)
1 kW
Efficiency of Air Compressor = 10%
9 kW – as
waste heat
Efficiency of Air Compressor

13. COP
WHAT IS THE EFFICIENCY OF A CAR?
IF YOU FILL 10 LITRES OF FUEL IN A CAR, HOW MUCH
ENERGY IS USED TO MOVE IT ON THE
ROAD?
10 lts 1.5 lts
Fuel Efficiency = 15%

14. COP

15. 1 kW
900 W
90%
How Efficient Is Electric Heater ?

16. COP
DO YOU KNOW ANY MACHINE WHICH CAN
HAVE 100% EFFICIENCY ?
IS IT POSSIBLE?

17. COP
WHAT IS THE EFFICIENCY OF AN AIR CONDITIONER?
EG. 1.5 TR AC
Power consumption = 2 kW
1 Ton of Refrigeration= 3512 W
Energy output = 3512 X 1.5 TR
= 5268 W
= 5.268 kW
EFFICIENCY or COP = Output / Input
= 5.268/2 = 2.634
WHAT IT MEANS?
IF YOU GIVE 1 KW OF ENERGY IT WILL GENERATE 2.6 kW OF
ENERGY. HOW?

18. TYPES OF HEAT PUMP
BY SOURCE
AIR SOURCE HEAT PUMP
WATER SOURCE HEAT PUMP
BY TEMPERATURE
55/60 DEG C HEAT PUMP
75/80 DEG C HEAT PUMP
90/95 DEG C HEAT PUMP

19. Ambient Heat
Primary power
(Electricity)
Heat Pump
USABLE
ENERGY
Renewable
Energy
Conventional
Energy
Heat Pump

20. 1 kW1 - 2 kW 2- 3 kW+ =
Heatistakeninfromtheambient
The system pumps heat from a low
temperature reservoir to a high temperature
Heat Pump - Principle

21. COP
WHAT IS THE EFFICIENCY OF A HEAT PUMP?
300% TO 500% WITH COP OF 3 TO 4
WHAT IT MEANS?
IF YOU GIVE 1 KW OF ENERGY IT WILL GENERATE 3 kW TO 5
KW OF ENERGY.

22. Free Cooling
DO YOU NEED LIFE LONG FREE AC?
HEAT PUMP GIVES YOU FREE COLD WATER UPTO 7
DEG C WHILE SIMULTANEOUSLY PRODUCING HOT
WATER AROUND 55 DEG C
7 DEG C 55 DEG C

23. Water Source Heat Pump
Hot Water Tank
Air Conditioner
Water source heat pump
50℃
8℃
55℃
13℃

24. Air Source Heat Pump

25. Expansion Valve
Evaporator: Helps
transfer heat from
atmosphere to the
refrigerant
Condenser:
refrigerant loses the
heat to the water
Compressor:
compresses
refrigerant to high
temperature and
pressure
Heat Pump: Components

26. Industrial Application of Heat Pump

27. Steam @ 2000C
250C
250C Steam @ 2000C900C
Boiler Feed
Assisted Boiler Feed

28. Component Washing
Industrial Washing Machine Pre-treatment Plants

29. Dish Wash

30. Bathing & Hand Wash

31. Boiler Efficiency
&
Calorific Value

32. FUEL IN (100 Litres)
COLD WATER IN
STEAM / HOT
WATER OUT
(70%)
FLUE GAS OUT
+
OTHER LOSSES
(30%)
BOILER EFFICIENCY
BOILER EFFICIENCY = 70%
Boiler Efficiency

33. Through Fuel Consumption
Energy required = Fuel Consumption x Calorific Value x Boiler Efficiency
Energy
required for
Process
Fuel Consumption Boiler Efficiency
Fuel Calorific Value
= 20 x 9422 x 70%
= 1,31,908 kcal/hr
= 131908/860
Energy required = 154 kW
20 litres/hr
9422 kcal/l
70%

34. Calorific Values
Liquid Fuel
Fuel kJ/kg
kcal/kg
(0.239 x kJ/kg)
Specific Gravity kcal/litres
Diesel 44,800 10707.2 0.88 9422.3
SKO 46,200 11041.8 0.8 8833.4
FO 43,000 10277 0.92 9454.8
Gaseous Fuel
Fuel kJ/kg
kcal/kg
(0.239 x
kJ/kg)
Propane 50,350 12033.65
LPG 46,100 11017.9
Solid Fuel
Fuel kJ/kg
kcal/kg
(0.239 x
kJ/kg)
Coal 15,000 3585
Coke 28,000 6692

35. Fuel Calorific Value Litre/kg
Boiler
Efficiency
kW Litre/kg Fuel Price
Cost of Energy
Spent per kW (Rs)
kcal kW
Furnace oil 9454.84 11.00 per litre 60% 6.6 per litre 36 5.45
HSD 9422.3 11.00 per litre 60% 6.6 per litre 63 9.55
SKO 8833.3 10.30 per litre 60% 6.18 per litre 50 8.09
LPG 11017.9 13.00 per kg 60% 7.8 per kg 43 5.51
Propane 12033.7 14.00 per kg 60% 8.4 per kg 42 5.00
Coal/Coke 5250 6.00 per kg 60% 3.6 per kg 8 2.22
Briquette
(Sugarcane
husk)
3996 4.65 per kg 60% 2.79 per kg 4.5 1.61
Electricity 860 1 per unit 95% 0.95 per unit 8 8.42
Calorific Values

36. Boiler Efficiency
The maximum rated efficiency
of the boiler can be,
Liquid Fuel : 80 – 85%
Gaseous Fuel : 90 – 95%
Solid Fuel : 75 – 80%
Boiler Efficiency

37. Boiler Losses

38. Did you know….?
Volume of water for the production of normal food stuffs..
Food Stuff Quantity Water consumption
(liters)
Rice 1 kg 2,497
Chicken 1 kg 4,325
Mutton 1 kg 10,412
Beef 1 kg 15,415
Chocolates 1 kg 17,196
Pizza 1 unit 1,239
Apple 1 kg 822
Banana 1 kg 790

39. LOAD CALCULATIONS - BASICS

40. Load Calculation
CALCULATION TYPES:
Through litres per day of water
• Canteen & Boiler Feed water application
Through Fuel Consumption
• Process heating & washing machine applications

41. Through Litres per day of Water
Q = m x Cp x ΔT
Canteen & Boiler feed application
Q = Energy required (kW)
m = Mass flow of water in LPD
Cp = Specific heat of water (kcal/kg K)
ΔT = Temperature difference (deg C)
Example:
10000 LPD has to be raised
from ambient to 80 deg C
Q = 10000 x 1 x (80 – 30)
= 500000 kcal
= 500000/860
= 581 kWh per day

42. Through Litres per day of Water
LOAD ESTIMATION FOR HEAT PUMP SYSTEM
Effective working hours = 16 - 18 hours per Day
Heat Pump Capacity =
𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲
𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐇𝐨𝐮𝐫𝐬
= 581/16 = 36 kW

43. TYPE - 2 Thru Fuel Consumption
Amount of Fuel consumed by the Boiler?
Boiler Efficiency?
Example:
Average Fuel consumed by the boiler per hour = 10 Litres of Diesel
Calorific value of Diesel = 11 kW per litre
Total energy = 110 kWh of Energy
With Boiler efficiency of 70%,
the effective Output per hour = 110*0.7 = 77 kW

44. TYPE-2: THRU FUEL CONSUMPTION
FUEL IN (10 Litres) or 110 kWh
COLD WATER IN
HOT WATER
OUT (70%) or
77 kWh
FLUE GAS OUT (30%)
BOILER EFFICIENCY
BOILER EFFICIENCY = 70%

45. Solar Capacity
Actual Energy
required for
Process
Pipe Heat
Loss
Pipe Heat Loss will normally be 10% to 20%

46. Did you know….?
Carbon negative……….Has anyone heard?

47. Canteen Cooking / PLATE WASH /
HAND WASH / BOILER FEED

48. Heat Pump schematic

49. Features of Indirect Heating
Constant Hot water 24/7
Suitable for raw water application
Water transfer to secondary tank happens automatically
Microprocessor controlled
Less maintenance

50. Component Washing
Industrial Washing Machine Pre-treatment Plants

51. Indirect Heating – Immersed coil

52. Indirect Heating – 2 PHEs

53. HEAT PUMP INTEGRATION

54. Process heating application
Temperature required
Fuel Consumed
Hours of operation
Fuel used
Boiler Efficiency
Fuel Cost

55. Sample data
65 Deg C
Temperature
60 kg/shift of LPG
Fuel Consumed
70%
Boiler efficiency
8 hrs
Operation Hours
6, 8, 7.5, 9, 9, 8.5, 6, 6
Hourly Load
pattern/shift (kg/hr)
LPG
Fuel Used
Rs. 55/kg
Cost of Fuel

56. Load Estimation
Fuel Consumed per hour = 9 kg/hr (during peak load)
Calorific value of LPG = 12.8 kW/kg
Boiler Efficiency = 70%
Energy required for process = Fuel Consumption * Calorific value * Boiler efficiency
= 9 * 12.8 * 0.70 = 80.64 kW
Total Energy required for one hour = 80.64 kW

57. Did you know….?
How much energy from the
sun reaching earth is
equivalent to Annual human
usage…?

58. Sizing of Pipes

59. • Flow Rate
• Pressure drop
• Pressure Drop
∝ to Flow rate
• More the flow
rate, more the
pressure drop
and vice versa
Pipe Selection Criteria

60. Which size to be selected??

61. 0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
PressureDropinm(for100mtrofpipelinelength)
Flow Rate (LPH)
Pressure Loss in Pipe line for 100 mtr of Length - Pump Head
Calculation
1.5" Pipe Pressure Drop 2" Pressure Drop 2.5" Pressure Drop 3" Pressure Loss
Pressure Loss

62. 0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
PipeSize(Inches)
Flow Rate (LPH)
1.5 Inch Pipe
from 0 LPH to 3750 LPH
2 Inch Pipe
From 3750 LPH to 6250 LPH
2.5 Inch Pipe
From 6250 LPH to 8750 LPH
3 Inch Pipe
From 8750 LPH to 13750 LPH
3.5Inch Pipe
From 137500 LPH to 18300 LPH
4 Inch Pipe
From 18300 LPH to 23500 LPH
Pipe Sizing

63. Maintenance

64. Strainer Maintenance

65. Piping Maintenance

66. Tank maintenance

67. Did you know….?
How much CO2 is produced on burning a litre of diesel or
Petrol..?
1 litre of Diesel = 2.6 kg of CO2
1 litre of Petrol = 2.3 kg of CO2

68. Water Quality

69. Parameter Unit LPD Specifications Process Specifications
Colour Colourless Colourless
Odour Unobjectionable Unobjectionable
Turbidity NTU 5 5
pH 6.5 to 8.5 6.5 to 8.5
Total Dissolved Solids mg/L 300 50
Total Alkalinity mg/L 120 20
Total Hardness mg/L 180 30
Calcium mg/L 45 7.5
Magnesium mg/L 18 3
Chloride mg/L 150 25
Sulphate mg/L 120 20
Iron mg/L 0.018 0.003
Nitrate mg/L 27 4.5
Fluoride mg/L 0.6 1
Water quality

70. pH is a numeric scale used to specify the acidity or alkalinity
of an aqueous solution
Effects of pH
Acidity Alkalinity
Neutral
• pH below 6.5 causes erosion of material which results in leakage
• pH above 8.5 causes scale formation inside tube.

71. Case Study @ Brakes
India,Padi
Existing Process
Conventional Heat
Source
Electrical Heater
Application Component washing
Temperature Range 50-60 ⁰C
Electricity
Consumption
24 kWh per hour
After Heat Pump
Project size 28 kW
Present Consumption 12 kWh per hour
Units saved per year 86,400 kWh
Annual Carbon
Abatement
73, 440 kg

72. Case Study @ Lucas TVS
Project Size 160 kW
Conventional Heat Source SKO
Application Pre-Treatment
Temperature Range 70 - 90 ⁰C
ZERO Investment from Customer
Rs. 8
per
MCal
Present
Cost
Rs. 5.5
per
MCal
Offered
Cost
Unique
PPA
Model

73. Execution Credibility
Aspiration Energy provides comprehensive
EPC solutions for solar projects. We design,
integrate, install and commission with our in-
house design and development team.
From concept to commissioning to
operation and maintenance we take care of
complete lifespan of the plant. Over the
years, we have developed expertise in
engineering and technology.

74. Same
founders
• Rs. 300 Cr, 1500 people
• A Deloitte and Touche
Fast 500 Asia Company
Award winner for
consecutive 4 years
Profitable IT firm
• Fast Forward to
the Solar Future.
Vision
• 7 Years in Solar
• 3 Years in Industrial
Heating
• Pioneers of RESCO
model - Capex to Opex
in Solar Thermal
Our Experience
Promoter Background

75. 20+ years experienced entrepreneur
Co-founder, Aspire Systems
Chairman, Energy Committee, South Indian Chamber of
Commerce
Mechanical Engineer from Pondicherry University
MBA from Kellogg School of Management, Northwestern
University, USA
Certified PV Designer from Solar Energy International (SEI)
Bhoovarahan Thirumalai, Founder and CEO
Management

76. Satyanarayanan S, CTO
Faculty at IIT Madras, Co-ordinator of Industrial Assessment Centre
Formerly head of exploratory R&D at Forbes Marshall, US$250 company
in the domain of industrial process heating and control instrumentation
Research experience with General Electric – Global Research Centre in
the area of Aero Thermal and Mechanical Systems
PhD, Mechanical Engineering from Texas A&M University, College Station
Gowri Subramaniam, Director and Co Founder
20+ years experienced entrepreneur
Co-founder and CEO of Aspire Systems,
Mechanical Engineer from Pondicherry University
MS - Industrial Engineering from Texas A&M, USA
Management

77. Photo : Bhoovarahan Thirumalai, CEO and Manoharan Head Solar Thermal, receiving the award from The Honurable Union Minister
Shri Prakash Javedakar.
CLIMATE SOLVER AWARD: WWF

78. PARIVARTAN SUSTAINABILITY AWARD

79. Bhoovarahan Thirumalai of Aspiration Energy was awarded by MNRE for successful development of ESCO projects under UNDP/GEF Global
water heating market transformation and strengthening initiative India country program.
MNRE AWARD

80. TESTIMONIALS
The crowning glory of the UNDP
GSWH Program… an undisputed
example of a win-win situation for
client and the ESCO…marks the
beginning of a new chapter in
energy savings by industries through
the ESCO route.. would help the
industries in fulfilling their
renewable purchase obligation and
reduce the consumption of an
expensive fossil fuel. I expect all
forwarding looking companies would
embrace what Aspiration Energy has
demonstrated.
~Sandeep Tandon, UNDP

81. ASPIRATION ENERGY IN THE NEWS

82. Be the proud
pioneer and save
the future…
>> Fast Forward to the Solar Future!! >>
Contact us @
info@aspirationenergy.com/044-42185301