Natural Gas Savings in Industry

Transcription

1 Natural Gas Savings in Industry Why should I conserve when natural gas is cheap? Jerry Zolkowski, PE CEM Mitch Peret, EMIT 1

2 Key Takeaways The Industrial Energy Management Program Ovens, Heat Treat, Dryers Steam Systems Space Heating, Ventilation, Water Heating Insulation Conclusion 2

3 Industrial Energy Management (IEM) Energy Forums Quarterly meetings on an energy topic or at a plant site Energy Management Training Learn the elements of managing energy Coupled with a written site review to identify prospective savings opportunities (Level 1 audit) 3

4 Program Details The Industrial Energy Management Program or (IEM) A commitment to the ENERGY STAR Challenge for Industry or ISO 50001, IEM supports an Energy Management System Implementation Metric Development and Tracking Level 2 Energy Audit or Energy Kaizen (process audit) 4

5 Ovens, Heat Treat, and Dryers Tune burners to get correct fuel/air ratio Preheat combustion air with exhaust heat Control exhaust rate Excess flow is very common Base on pollutant load, moisture load, or combustion air 5

6 Additional Energy Management Exhaust rate control implementation Set the fan speed to the maximum required flow o Fixed speed Variable Frequency Drive (VFD) or drive ratio Vary the speed based on production rate, humidity, pressure differential, or firing rate o Variable input VFD A VFD exhaust fan can also be controlled by the Programmable Logic Controller (PLC) which may be tracking throughput or firing rate o During startup purge, the fan can run at full speed 6

7 Steam Systems - Operations Tune-ups to get correct fuel/air ratio Condensate recovery Steam trap inspection and repair Water treatment Improving Steam System Performance: A Sourcebook for Industry 2 nd Ed. Published by the Department of Energy, Energy Efficiency and Renewable Energy. DOE does not copyright their publications. 7

8 Steam Systems - Upgrades Blowdown minimization and heat recovery Economizers Linkageless controls Improving Steam System Performance: A Sourcebook for Industry 2 nd Ed. Published by the Department of Energy, Energy Efficiency and Renewable Energy. DOE does not copyright their publications. 8

9 Space Heating Radiant heaters Direct fire make-up air units High efficiency furnaces or boilers 9

10 Ventilation Minimize Exhausts Reduce exhaust rates from dust collectors, dryers and wall fans where safe to do so Methods VFD fan On/off or speed tied to process Reverse exhausts seasonally for hot spaces Route exhausts inside if clean enough, or add filtration if needed 10

11 Water Heating High efficiency water heaters Supplement with waste heat recovery Waste water, boiler blowdown, hot exhausts 11

12 Insulation Prioritize hottest to coolest Furnaces, steam lines, dryers, condensate, domestic hot water, building envelope Safety and energy 3E+ from NAIMA can be a useful tool 12

13 Conclusion Consumers Energy offers incentives to conserve natural gas and support for implementing Industrial Energy Management Systems Proper system maintenance and operation helps optimize fuel use Identify and evaluate upgrades to new and existing systems 13

14 Thank You! Jerry Zolkowski, PE CEM (517) Ext Mitch Peret, EMIT (517) Ext consumersenergy.com/mybusiness Phone: