IN D USTR IAL EN ER G Y EN GINEERIN G Industria l Energy Engineeri ng IN D USTR IAL EN ER G Y EN GINEER ING C4S March 27, 2008
Jan 05, 2016
INDUSTRIAL
ENERGY ENGINEERING
Industrial Energy
EngineeringINDUSTRIAL
ENERGY ENGINEERING
C4SMarch 27, 2008
INDUSTRIAL
ENERGY ENGINEERING
Motivation
$
INDUSTRIAL
ENERGY ENGINEERING
U.S. Natural Gas Wellhead Price
0
2
4
6
8
10
12Ja
n-7
6
Ja
n-7
9
Ja
n-8
2
Ja
n-8
5
Ja
n-8
8
Ja
n-9
1
Ja
n-9
4
Ja
n-9
7
Ja
n-0
0
Ja
n-0
3
Ja
n-0
6
Do
lla
rs p
er
tho
us
an
d c
ub
ic f
ee
t
1976 Price$ 1.57 in 2007 dollars
Current Price
$ 6.46/mcf June 2007
Wellhead Price, Real Dollars
Source: EIA
INDUSTRIAL
ENERGY ENGINEERING
Cost per KWH
0.0400
0.0410
0.0420
0.0430
0.0440
0.0450
0.0460
0.0470
0.0480
0.0490
0.0500
0.0510
0.0520
0.0530
0.0540
0.0550
JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND
$ p
er K
WH
1998 20001999 2004200320022001 2005
Electricity Price
Existing Manufacturing Processes were
designed using this price
$ .045/kwh
Ohio AEP Price to Plant, Actual Rates $0.061/kwh2007
INDUSTRIAL
ENERGY ENGINEERING
40
21
18
812
0%
20%
40%
60%
80%
100%
1
Profit
SG&A
Direct Labor
Energy
Raw Material ($)
Components of Revenue
Components of Product Sale Price
INDUSTRIAL
ENERGY ENGINEERING
Energy Operating Costs
Monthly Service on Capital Expenditure
A BC
20081998
1988
Cost Minimization and Energy Impacts
INDUSTRIAL
ENERGY ENGINEERING
Energy Engineering Services
1. Energy Assessment2. Targeted Evaluation3. Energy Program Audit 4. Greenhouse Gas
Scorecard
INDUSTRIAL
ENERGY ENGINEERING
INDUSTRIAL
ENERGY ENGINEERING
Target Stack Temperature
0
200
400
600
800
1000
1200
1400
1 2 3 4 5 6 7 8 9 10Price Natural Gas ($/mcf)
Sta
ck T
em
pera
ture
(F
)
1968
1990
2007
Economical heat recovery temperature = 400 oF
INDUSTRIAL
ENERGY ENGINEERING
Rolling Annual Cost for Natural Gas
$0
$50,000
$100,000
$150,000
$200,000
$250,000
$300,000
$350,000
$400,000
$450,000
Jan-
06
Mar
-06
May
-06
Jul-0
6
Sep-0
6
Nov-0
6
Jan-
07
Mar
-07
May
-07
Jul-0
7
Sep-0
7
Nov-0
7
$/Y
ear
$100,000 Cost Increase
Overall Plant Natural Gas Consumption
0
5,000
10,000
15,000
20,000
25,000
30,000
Average mcf
Month
Co
nsu
mp
tio
n (
MC
F/m
o)
Stage I: Utility Bill Analysis
INDUSTRIAL
ENERGY ENGINEERING
Paint MCF DW MCF Resin MCF
J 9,608 848 12,740F 11,766 1,105 15,071M 8,834 773 13,202A 6,325 413 12,231M 3,533 240 10,311J 2,167 71 9,799J 1,054 3 7,213A 1,218 3 8,608S 1,262 3 8,309O 2,817 80 9,445N 5,729 404 11,836D 7,668 637 12,819
annual avg 61,981 4580 131,584
Paint Consumption
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
J F M A M J J A S O N D
MC
F/m
on
th
Resin Plant Consumption
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
J F M A M J J A S O N D
MC
F/m
on
th
DW Warehouse Consumption
0
200
400
600
800
1000
1200
J F M A M J J A S O N D
MC
F/m
on
th
Stage II: Production Operation Comparison
Energy Intensity = E /$ revenue
INDUSTRIAL
ENERGY ENGINEERING
Quantification of Top Users
Tunnel Kiln
Bickley RH
Bickley Bell
Drying Rooms
260 feet
70
fe
et
Ipsen RH
60
fe
et
Boiler 46%
21%
3%
21%
Ipsen or Bickley
Room Heaters9% winter
Major Users of Natural Gas
Tunnel Kiln
Bickley Bell Kiln
Ipsen RH Kiln
Bickley RH Kiln (not operating)
Boiler
Fired Room Heaters
Spray Dryer
INDUSTRIAL
ENERGY ENGINEERING
Operating
HP Name plate
Voltage (three phase) Efficiency
Power Factor
Full Load Amps
Percent Loaded when
operatingOperating
AmpsOperating Kilowatts
Time Operating
(%)
Time Operating
(Hours/ month) KWH/month
BR2MCC (SWG-050003: CKT-050003)HEX-423 Fulton Control Panel 452-MCCBR2 480 85% 70% 0 80% 0 0 100% 730 0HEX-046000 Fulton Oil Heater 452-MCCBR2 40 480 85% 68% 62 80% 50 28 100% 730 20502PMP-475 WFE Marley Cooling Water Pump Mid452-MCCBR2 40 480 85% 70% 60 55% 33 19 100% 730 14095PMP-474 WFE Marley Cooling Water Pump North452-MCCBR2 40 480 85% 70% 60 60% 36 21 100% 730 15376PMP-473 WFE Marley Cooling Water Pump South452-MCCBR2 25 480 85% 70% 38 80% 30 18 0% 0 0HEX-421 Marley Cooling Tower Fan 452-MCCBR2 40 480 85% 70% 60 20% 12 7 100% 730 5125 BR2MCC 55099Building 402 (SWG-050073:CKT-050004)FAN- BAC Cooling Tower Fan 40 480 85% 70% 60 13% 8 5 90% 657 2998PMP-424 BAC Cooling Tower Pump 40 480 85% 70% 60 60% 36 21 100% 730 15376PMP-447 BAC Cooling Tower Pump 40 480 85% 70% 60 60% 36 21 0% 0 0
Building 402 18375OFFICE
HVAC Supply 25 480 85% 70% 38 80% 30 18 100% 730 12814Recirculation HVAC 25 480 85% 70% 38 80% 30 18 100% 730 12814Chillers 192 480 85% 70% 290 80% 232 135 25% 182.5 24648Other and Small 30 480 85% 70% 45 80% 36 21 100% 730 15376
Office 65652Electrical Room #2
PMP-214 Cooling Tower Recirc Pump 208-MCC1 40 240 85% 70% 121 80% 97 28 100% 730 20502FAN-207 Cooling Tower Blower 208-MCC1 15 240 85% 70% 45 80% 36 11 100% 730 7688PMP-201 Silverson Pump 208-MCC1 25 240 85% 70% 75 80% 60 18 0% 0 0PMP-023022 Wastewater Transfer Pump 208-MCC1 15 240 85% 70% 45 80% 36 11 10% 73 769FAN-207201 Blower Vacuum Spent 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-202213 Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-203255 Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-101138 Filter Press Feed Pump west 208-MCC2 15 240 85% 70% 45 80% 36 11 10% 73 769PMP-101434 Filter Press Feed Pump east 208-MCC2 15 240 85% 70% 45 80% 36 11 10% 73 769PMP-233242 S.R.S. Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 20% 146 1538PMP-233243 S.R.S. Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 20% 146 1538PMP-259 Coolant Recirc Pump 208-MCC2 10 240 85% 70% 30 80% 24 7 80% 584 4100FAN-020100 SRO Vent Fan 208-MCC3 10 240 85% 70% 30 80% 24 7 100% 730 5125Misc Small 208 Misc Small and other 208 100 240 85% 70% 302 80% 242 70 80% 584 41004
Electrical Room #2 93027Electrical Room #4PMP-040220 R2 Vacuum Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040420 R4/R5 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041021 R10 Vacuum Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040720 R7 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041120 R11 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-040320 R3 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-040120 R1 Vacuum Pump 448-MCC1 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041001 R10 Agitator 448-MCC1 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041622 R10 Booster Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-041601 R16 Agitator 448-MCC1 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041620 R16 Vacuum Pump 448-MCC1 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-471 Transfer Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041621 Recirc Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040820 R8 Vacuum Pump 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-048022 R8 Vacuum Booster Pump 448-MCC2 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-045020 Incrosoft Loading Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041326 WFE Hot Oil Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-132 Fatty Alcohol Unload Pump 448-MCC2 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041325 WFE Vacuum Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075AGT-041401 R14 Agitator 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041420 R14 Vacuum Pump 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100AGT-103 Agitator Tank 112 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-149 Pastillation Bag Blower 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-127 South Pastillation Chiller Feed 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075CLR-105 South Pastillation Chiller 448-MCC3 75 480 85% 70% 113 80% 91 53 40% 292 15376AGT-104 Agitator Tank 113 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075AGT-419 R15 Agitator 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-041520 R15 Vacuum Pump 448-MCC3 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041522 R15 Vacuum Booster 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-147 Pastillation #2 Bag Blower 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-468 Transfer Pump Newark Tanks 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050AGT-426 Pastillation Flaker Storage Tank 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075
Stage III: Individual Process Listing and Analysis
•What are the top 100 Electrical Users? Quantify
•What are the top 20 Natural Gas Users? Quantify
INDUSTRIAL
ENERGY ENGINEERING
Stage IV: Alignment of Energy Use And Production
INDUSTRIAL
ENERGY ENGINEERING
Energy Alignment
1.1 MMBTU/hr$96,000/yr
Nitrogen Carrier Gas and VOC700 scfm5% O294% N2
1.1 MM BTU/hr1000 oF
Quench Air, Secondary800 scfm
600 oF
Combustion Air300 scfm
Heated Combustion Air
1800 scfm0.9 MMBTU/hr @600 F
Heat Lost 0.2 MM BTU/hr
INDUSTRIAL
ENERGY ENGINEERING
Energy Engineering Analysis
Input Natural Gas 4,000,000 BTU/hr for two rooms
Stack Losses 2,20,000 BTU/hr
Recirculation System and other Losses 475,000 BTU/hr
Transferred to Drying Rooms 975,000 BTU/hr
As Found Conditions BTU/hr Percent
Energy Input (natural gas) 4,000,000 100
Stack Losses 2,200,000 55%Boiler Shell Losses 350,000 9%Steam Piping Losses 475,000 12%Energy Delivered to Drying Room 975,000 24%Room Wall Losses 120,000 3%Infiltration Losses 180,000 5%Energy Transferred to Trays 500,000 13%Energy Transferred to Product 175,000 4%
Indirect Heating System Analysis
Steam
INDUSTRIAL
ENERGY ENGINEERING
Energy Recovery
Soaking Pits and
Reheat Furnace Steel
Natural Gas
Combustion Air
Preheat
Air
Steel at Rolling Temp
Hot Stack Gas
Recuperator
Waste Heat Boiler
Cool Stack Gas
Steam Water
Natural Gas
INDUSTRIAL
ENERGY ENGINEERING
Cost Effectiveness Ranking
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
$0 $20,000 $40,000 $60,000 $80,000 $100,000
Implementation Costs
Na
tura
l G
as
Sa
ve
d (
mc
f/y
r)Drying Room New Heating System
$17.5/mcf
$12.5/mcf
$ 8/mcf$ 6/mcf
ProductionPrioritization
$10/mcf
Boiler Replacement
Bickley Bell Kiln Retrofit
Not Cost Effective
Drying Room Cycling
Cost Effective
Action Plan for Energy Reduction