UC-Irvine Meeting 030205 1 Identifying Energy Saving Opportunities in Process Heating through Waste Heat Recovery and Power Generation Bryan Warren Southern.

UC-Irvine Meeting 030205 1

Identifying Energy Saving

Opportunities in Process Heating

through Waste Heat Recovery and

Power Generation

Bryan WarrenSouthern California Gas Company

Chris CockrillDepartment of Energy EERE-ITP

Arvind ThekdiE3M, Inc.


Primary Energy Use in Industries

• Process/Assembly (P/A)

– Process heating

– Process Atmosphere - gases

– Machine drive (Pumps, Fans, Blowers, Compressors, Vacuum pumps, Other Electric Motor Driven Systems)

– Water and other utilities

• Building (HVAC, Lighting etc.)

• Boiler-Steam-Cogeneration


Energy Use Pattern for Major Industries


What Is Process Heating ?

• Furnaces• Ovens• Heaters• Kilns• Dryers

Supplying heat Supplying heat to materials using to materials using

for further processing in for further processing in manufacturing operationsmanufacturing operations


Energy distribution in a typical heating system

Furnace Heat Input

Heat inFlue Gases


How much heat is wasted?

60% of the total heat input is wasted in flue gases at

2000 deg. F.


Waste Heat from Process Heating Equipment

• Waste heat from furnaces, boilers, heaters etc. accounts for 25% to 60% of the total heat input.

• The waste heat is primarily in the form of combustion products or flue gases at varying temperature.

• The flue gas temperature depends on the process temperature and the equipment design.

• The flue gases may contain combustion products (CO2, H2O, N2 etc.) and, depending on the process operation, other contaminants such as SO2, particulates and corrosive gases

• For any one equipment the flue gas mass flow, temperature and composition may change during the operation.


Power generation using waste heat recovery

Considerations “Quality” of heat • Presence of contaminants (Corrosive gases, condensable,

particulates etc.)• Temperature and its variation• Mass flow variations (down-times, “start-up and shut-down time

etc.)• “Seasonality” of waste heat availability (i.e. food, forest products

industries)• Use of waste heat within the heating system or in process • Possibility of using heat within the integrated plant operations• Economics of power generation using waste heat (capital cost.

Operation and maintenance etc.)• Availability of reliable technology for low (<400 deg. F.)

temperature waste heat streams


Waste heat recovery methods used

• In-process (Most preferred)– Combustion air preheating– Charge heating– Water heating – Steam generation

• Within the system or plant (preferred)– Cascading of heat from higher to lower

temperature processes– Water or air heating for the plant– Steam generation– Absorption cooling

• Export (For very large installations)– Steam generation– Steam - Power generation


How to estimate waste heat availability?

Process Heating Assessment and Survey Tool (PHAST) can be used to

– Estimate total heat used by the process heating equipment used in a plant

– It can give values magnitude and temperature of waste heat gases from “quality” of The Department of Energy has developed a tool


Process Heating Assessment and Survey Tool (PHAST)


What is PHAST?

A tool that can be used to:

• Estimate annual energy use and energy cost for furnaces and boilers in a plant

• Perform detail heat balance and energy use analysis that identifies areas of energy use, efficiency and energy losses for a furnace

• Perform “what-if” analysis for possible energy reduction and efficiency improvements through changes in operation, maintenance and retrofits of components/systems

• Obtain information on energy saving methods and identify additional resources



• The Process Heating Assessment and Survey Tool (PHAST) was developed

by Oak Ridge National Laboratory in cooperation with the Industrial Heating

Equipment Association (IHEA).

• A subcommittee consisting of members from major industries (i.e.,

petroleum refining, chemical) and equipment suppliers acted as an advisor

during the tool’s development.

• Development efforts were supported by The Office of Industrial

Technologies Program (ITP) of the US Department of Energy (DOE).



Major Sections of PHAST

• Introduction

• Plant Equipment Information

• Furnace Analysis – Heat Balance

• Reports

• Transfer (Import/Export) of Data Files


Use “Plant Information”

section of PHAST to enter and

analyze the data for process

heating equipment

Process Heating Assessment and Survey Tool(PHAST)


The report shows:

• Estimated annual energy use

and estimate annual cost of

energy for heating equipment

(furnaces, ovens etc.)

• List of heating equipment and

% of total energy cost used

for each equipment in order

of annual cost of energy used



• Use survey forms to collect data

for each item listed in various

Tabs of the form

• Use instructions given for each

entry to collect the required

data

• Review values of energy use or

losses are for each major

category of energy use



The report shows

• Analysis of energy used in

various parts of a furnace

under a given operating

condition

• Comparison of energy use

for current operations and

with possible changes

(what-if analysis) in

operating conditions for the

furnace



•Enhanced heat transfer, •Temperature profile control•Optimal process atmosphere•Material handling/fixtures

•Air-fuel ratio control, •Use of O2 enrichment, •Air/Fuel preheating, •Turn down capability•Flame size, shape

•Optimum insulation•Radiation losses•Pressure control•Cracks, openings etc.•Cooling losses

PHAST – Resources and Guide for Energy Efficiency Improvement Opportunities


PHAST – Resources and Guide for Energy Efficiency Improvement Opportunities

•Air preheating•Load preheating•Steam generation•Cascading to lower temperature processes

•Draft – pressure control•Controlled “head” heating•Use of process models •Direct load temp. control

•Use of low-NOx burners•Flue gas CO control •Fugitive emission control


Energy Savers Tips for Industries

Visit Our Web Sites: www.energysavers.gov/industrywww.oit.doe.gov


Next steps

• Attend one-day end-user PHAST training to learn capabilities of PHAST and its use

• Attend qualified specialist training to become a qualified trainer to teach others how to use PHAST. This is a 2 to 2 ½ days course offered at selected locations throughout the country

• Refer to DOE-OIT web page (www.oit.doe) for schedule and location in your area

• Sign-up for the end user training at the end of this meeting




UC-Irvine Meeting 030205 1 Identifying Energy Saving Opportunities in Process Heating through Waste Heat Recovery and Power Generation Bryan Warren Southern.

Documents

ucirvine meeting

total heat input

flue gases slide

waste heat capital cost

process temperature

process operation

flue gas temperature

process possibility