1. UC-Irvine Meeting 030205 1 Identifying Energy Saving Opportunities in Process Heating through Waste Heat Recovery and Power Generation Bryan Warren Southern California Gas Company Chris Cockrill Department of Energy EERE-ITP Arvind Thekdi E3M, Inc.

2. UC-Irvine Meeting 030205 2 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

3. UC-Irvine Meeting 030205 3 Energy Use Pattern for Major Industries

4. UC-Irvine Meeting 030205 4 What Is Process Heating ? Furnaces Ovens Heaters Kilns Dryers Supplying heat to materials using for further processing in manufacturing operations

5. UC-Irvine Meeting 030205 5 Energy distribution in a typical heating system Furnace Heat Input Heat in Flue Gases

6. UC-Irvine Meeting 030205 6 How much heat is wasted? 60% of the total heat input is wasted in flue gases at 2000 deg. F.

7. UC-Irvine Meeting 030205 7 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.

8. UC-Irvine Meeting 030205 8 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

9. UC-Irvine Meeting 030205 9 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

10. UC-Irvine Meeting 030205 10 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

11. UC-Irvine Meeting 030205 11 Process Heating Assessment and Survey Tool (PHAST)

12. UC-Irvine Meeting 030205 12 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 Process Heating Assessment and Survey Tool (PHAST)

13. UC-Irvine Meeting 030205 13 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). Process Heating Assessment and Survey Tool (PHAST)

14. UC-Irvine Meeting 030205 14 Major Sections of PHAST Introduction Plant Equipment Information Furnace Analysis – Heat Balance Reports Transfer (Import/Export) of Data Files

15. UC-Irvine Meeting 030205 15 Use Plant Information section of PHAST to enter and analyze the data for process heating equipment Process Heating Assessment and Survey Tool (PHAST)

16. UC-Irvine Meeting 030205 16 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 Process Heating Assessment and Survey Tool (PHAST)

17. UC-Irvine Meeting 030205 17 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 Process Heating Assessment and Survey Tool (PHAST)

18. UC-Irvine Meeting 030205 18 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 Process Heating Assessment and Survey Tool (PHAST)

19. UC-Irvine Meeting 030205 19 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

20. UC-Irvine Meeting 030205 20 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

21. UC-Irvine Meeting 030205 21 Energy Savers Tips for Industries Visit Our Web Sites: www.energysavers.gov/industry www.oit.doe.gov

22. UC-Irvine Meeting 030205 22 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 areawww.oit.doe Sign-up for the end user training at the end of this meeting

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