Program Name or Ancillary Texteere.energy.gov Process Heating Assessments Michael R. Muller USA Rutgers University, Center for Advanced Energy Systems U.S.- Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August, 2011

2 | Industrial Energy Efficiencyeere.energy.gov Introduction Elements of an ESA in Process Heating The PHAST Tool Case Study: Powder Processing Case Study: Cast Iron Pipes Outline

3 | Industrial Energy Efficiencyeere.energy.gov What Is Process Heating ? Furnaces Ovens Heaters Kilns Dryers Supplying heat to materials using for further processing in manufacturing operations

4 | Industrial Energy Efficiencyeere.energy.gov Importance of Process Heating Process Cooling 1% Process Heating 38% Steam 35% Other 4% Electro-chemical 2% Motor Systems 12% Facilities 8% Manufacturing Energy Use by Type of System (%)

5 | Industrial Energy Efficiencyeere.energy.gov Hot = Metal Melting –Blast furnaces: 900 °C to 1300 °C (1600 °F to 2300 °F) Process Heating Temperatures

6 | Industrial Energy Efficiencyeere.energy.gov Low Temperature Drying Processes: 70 °C (160 °F) Low Temperature Processes

7 | Industrial Energy Efficiencyeere.energy.gov Energy distribution in a typical heating system Furnace Heat Input Heat in Flue Gases

8 | Industrial Energy Efficiencyeere.energy.gov “Save Energy Now” Energy Assessments Assessments of targeted industrial systems by Qualified Specialist using the DOE software tools Energy Assessment Report identifies potential energy and cost savings Plants are selected by DOE based on several factors, including:  The plant’s energy consumption  The company’s intention to include other similar plants within their company 8

9 | Industrial Energy Efficiencyeere.energy.gov A Process Heating ESA Conduct Plant Visit Analyze and Report Results Gather Preliminary Data Follow-up Train Plant Staff Teams are DOE Energy Experts and plant personnel Teams focus only on process heating systems Plant personnel trained on DOE software tools

10 | Industrial Energy Efficiencyeere.energy.gov Energy Expert spends 3 days on site Day 1 Safety briefing, tour plant Overview of DOE PHAST Tool to plant personnel Agree on potential energy efficiency opportunities to investigate Initiate data collection for potential opportunities Day 2 Continue data collection Apply PHAST tool to quantify potential opportunities Plant lead and expert agree on opportunity results Day 3 Wrap up tool analyses Plant lead and expert ensure they agree on opportunity results Closeout meeting in p.m. to review results

11 | Industrial Energy Efficiencyeere.energy.gov 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). What is PHAST? Process Heating Assessment and Survey Tool (PHAST)

12 | Industrial Energy Efficiencyeere.energy.gov 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 What is PHAST? Process Heating Assessment and Survey Tool (PHAST)

13 | Industrial Energy Efficiencyeere.energy.gov Where: Delaware, USA What:Microcrystalline Cellulose How:Wood pulp is cooked with bleach, caustic soda and steam – then spray dried Case Study

14 | Industrial Energy Efficiencyeere.energy.gov Cellulose reacts with chemicals at 50°C for 2-3 hrs. –the reaction changes the physical form from fiber to powder Slurry is then pumped to a spray tower where it is dried by heated air –NOTE – the dryers evaporate water from the slurry, and therefore remove water at below boiling temperatures it was necessary to make adjustments to the PHAST inputs because water removed from process stream is required to be at 100 °C Resultant power retains water absorbency which is very useful Case Study

15 | Industrial Energy Efficiencyeere.energy.gov Two of three dryers had waste heat recovery using a glycol loop Third dryer had no space for air preheat –But, waste heat could be used to preheat other two dryers!! Plant had not included energy associated with evaporation in their analysis Waste Heat From Dryers

16 | Industrial Energy Efficiencyeere.energy.gov Data Logger Results The second plot shows the datalogger readings from another cooling loop which is not operating correctly. Apparently the setpoint on the air coolers is set too high or are offline and the process is running relatively uncontrolled. Cooling overnight in the second plot is about ½ the cooling of the other cooling loop although temperatures are higher. It is suspected that the heating systems on the units being served are not being setback after the day’s production run. In addition, the temperature difference between the two plots shows that there is significant play in how cool the cooling loop needs to be to achieve fast turn arounds. If 260 °F is cool enough than keeping the other loop at 180 °F is wasting energy. Temperature sensors on two cooling loops overnight shows correct behavior (upper) and total valve failure (lower) Multiple days were needed to be able to see this

17 | Industrial Energy Efficiencyeere.energy.gov Results For Powder Processing

18 | Industrial Energy Efficiencyeere.energy.gov Where: NJ, USA What:Cast Iron Pipe for Water Systems How:Cupula Furnace and Annealing Oven Case Study

19 | Industrial Energy Efficiencyeere.energy.gov Cast iron is made from pig iron in a tall furnace Liquid cast iron is spun into a pipe form Concrete is sprayed on the pipe and provides a coating Cold pipes are then painted Case Study

20 | Industrial Energy Efficiencyeere.energy.gov Major savings were identified by annealing pipes before they cooled down Plant felt mixing pipe sizes in the ovens let them be more fully utilized –But to do this there were long waiting times and pipes cooled to nearly room temperature Melt Room and Annealing Disconnect

21 | Industrial Energy Efficiencyeere.energy.gov Natural gas use was monitored closely for three days Comparing to bills showed large amount of natural gas use unaccounted for Cause is failure to setback ovens when not in use Ghost Use of Natural Gas

22 | Industrial Energy Efficiencyeere.energy.gov Results for Iron Pipe Foundry

23 | Industrial Energy Efficiencyeere.energy.gov Process heating assessments can find very large savings for plants Some important recommendations require the three days to be observable Using the PHAST tool can quantify savings –Works best on very hot processes Training plant people on gathering data and analyzing data can have lasting impacts Conclusions

24 | Industrial Energy Efficiencyeere.energy.gov Obrigado!! Perguntas???