1 Training Session on Energy Equipment Industry Sectors Presentation to Energy Efficiency Guide for Industry in Asia Chapter 15 © UNEP GERIAP Industry

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Training Session on Energy Training Session on Energy EquipmentEquipment

Industry SectorsIndustry Sectors

Presentation to Presentation to

Energy Efficiency Guide for Industry in AsiaEnergy Efficiency Guide for Industry in Asia

Chapter 15Chapter 15

©© UNEP GERIAP UNEP GERIAP

Indust ry Sector s

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©© UNEP 2005 UNEP 2005

Training Agenda: Industry SectorsTraining Agenda: Industry Sectors

1) Iron & Steel• Sector description• Process flow• Energy conservation

2) Chemical• Sector description• Process flow• Energy conservation

Indust ry Sector s

3) Cement• Sector description• Process flow• Energy conservation

4) Pulp & Paper• Sector description• Process flow• Energy conservation

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Iron & Steel IndustryIron & Steel Industry

Two categories:

1. Primary steel production

• Manufactured right from the basic iron and steel ore to final product

2. Secondary steel production

• Conversion metal scrap, ignots and metal scraps manufactured through various routes

Sector Description

Indust ry Sector s

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Process Flow

Indust ry Sector s

Basic primary steel process• High grade iron ore is crushed for sizing and to produce both fine and lump ore

• Pelletizing is a process that mixes very fine ground particles of ore with limestone, dolomite etc

©© UNEP 2005 UNEP 2005

Figure: Primary steel making process Source: JFE

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Process Flow

Indust ry Sector s

Basic secondary steel process

• Raw material

• Melting

• Refining

• Casting

• Rolling

• Re-rolling

• Re-heating furnace

• Rolling mill

• Cooling

• Shearing

• Inspection dispatch

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Process Flow

Indust ry Sector s

Steel foundry• Can be classified into a) melting, b) moulding, c) fettling and d) heat treatment

Arc furnace• Melting of scrap by application of intense heat generated by the arc

Induction furnace• Transfers energy through a magnetic field and its

intensity decides the amount of absorbed energy

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Process Flow

Indust ry Sector s

Energy flows

• Rolling

• Thermal energy

• Electrical energy

• Steel foundry

• Arc melting

• Induction melting

Cutting

Reheating Furnace

Rolling

Cooling

Shearing

Electricity

Fuel

Electricity

Electricity

Electricity

Electricity

Finished Product

Raw material

Figure: Energy flow in rolling

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Process Flow

Indust ry Sector s

Material & energy balance

Figure: Energy balance in reheating furnace

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CP-EE measures:

Energy Conservation Opportunities

Indust ry Sector s

Figure: Reheating furnace

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Indust ry Sector s

CP-EE measures in reheating:

Improvement Area Energy-Saving Measure Energy Saving Potential

Efficient Combustion Maintain minimum required free oxygen in combustion products.

2% to 10%

Efficient Combustion (burners)

Eliminate formation of excessive amount of CO or unburned hydrocarbons. Also eliminate or minimize air leak-age.

2% to 10%

Flue Gas Heat Recovery Preheat and/or dry combustion air and the charge/load. After-burn the combustibles and cascade the exhaust gas heat.

5% to 25%

Heat Loss Reduction Use optimum insulation for equipment and maintain it regularly. Employ furnace pressure control.

1% to 5%

Table: CP-EE measures in reheating and heat treatment furnaces

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CP-EE measures in reheating:


Indust ry Sector s

Improvement Area Energy-Saving Measure Energy Saving Potential

Design of Furnaces and Heating

Select proper burner and furnacedesign to enhance heat transfer to the load.

5% to 10%

Furnace Operation Clean heat transfer surfaces frequently. 5% to 10%

Furnace andHeating System Heat Transfer

Replace indirect heat systems with direct heat systems where possible.

5% to 10%

Improved Scheduling and Load Management

Operate with full load; minimize idle time, shutdowns, and start-up cycles.

2% to 5%

Use of Process Simulation Use models to optimize temperature settings to avoid long "soak" times or overheating.

5% to 10%

Equipment Design Materials Use advanced and improved materials. 2% to 5%

Table: CP-EE measures in reheating and heat treatment furnaces

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CP-EE measures in arc furnace melting:• Scrap preparation• Scrap segregation• Use of oxygen lancing• Temperature control

CP-EE measures in induction melting:• Idling periods• Charge metals• Optimizing heel• Radiation losses


Indust ry Sector s

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Energy efficient technologies:

• Melting

• Ceramic recuperator

• Ceramic fiber

• Ceramic coatings

• Regenerator


Indust ry Sector s

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Indust ry Sector s


©© UNEP 2005 UNEP 2005Figure: Regenerative burner system operating principle

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Indust ry Sector s



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Chemical IndustryChemical Industry

• Production of graphite for brake linings and lubricants, chemical catalysts for plastics, elastomers and pharmaceuticals and more

• Most chemical applications require spray drying or milling why particle size is important

• Most milling processes comprise a grinder, a classifier, a cyclone and a blower

• The formed material size needs to be measured

Sector Description

Indust ry Sector s

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Process Flows

Indust ry Sector s

Fertilizer industry• 85% of the world’s ammonia production is used for making chemical fertilizer

• Fertilize production accounts for 2% of total global energy consumption

• Fertilize production accounts for 1% of global carbon dioxide emissions

• Ammonia manufacture is expensive and is about 70-80% of the production costs

• Natural gas is the most commonly used hydro-carbon feedstock for new fertilizer plants

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Process Flows

Indust ry Sector s

Primary reforming• The natural gas that leaves the desulphurization tank is mixed with process steam

• It is preheated in the primary reformer

Secondary reforming• Only 30-40% of the hydrocarbon feed is reformed in the primary reformer

• In a secondary, the temperature is increased to increase conversion

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Process Flows

Indust ry Sector s

Energy balance• Compared to natural gas, ammonia manufacturing with heavy oil is 30-40% more energy intensive and with coal route 80% more

• Steam reforming ammonia plants have surplus heat available for steam production and modern plants can be energy self sufficient

• The theoretical minimum energy consumption for ammonia manufacture through steam

reforming is ~21.6 GJ/t of ammonia (HHV)

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©© UNEP 2005 UNEP 2005


Process Flows

Indust ry Sector s

Material balance

Natural gas

Ammonia synthesis

Compression

Methanation

Carbon dioxide Removal

Shift conversion

Reformer (Secondary)

Reformer (Primary)

Sulphur Removal

NH3

Condensate CO2

Heat

Heat

ZnS

Power

Heat, Power

Air, Power

ZnS

H2O, Fuel

Power

Figure: Material balance for an ammonia plant

• Emissions from ammonia plants include SO2, NOx, CO, CO2, VOCs, particles, hydrogen sulfide, methane, hydrogen cyanide and ammonia

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©© UNEP 2005 UNEP 2005


Areas for CP-EE measures in ammonia plants:


Indust ry Sector s

• Shift conversion

• Carbon dioxide removal section

• Leakage of CO2 from compressors

• Flue gas from the furnace

• Cogeneration

• Primary reformer

• Excess air reforming

• Heat exchange auto terminal reforming

• Reformer catalyst

• Reformer tubes

• Furnace design

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©© UNEP 2005 UNEP 2005


Areas for CP-EE measures in ammonia plants:


Indust ry Sector s

• Ammonia converter

• Carbon dioxide removal section

• Leakage of CO2 from compressors

• Compressors

• Better purification techniques

• Pre-reformer

• Ammonia synthesis converter

• Absorption refrigeration system

• Cooling of synthesis gas

• Desulphurization

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Indust ry Sector s

Energy efficiency technologies:

• Gas heated reformers

• Selectoxo unit

• Lower syngas inert level

• Heat exchange auto terminal reforming

• Purge gas recovery unit

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Energy efficiency technologies:

• Pre-reformer

• Improved catalyst

• Carbon dioxide removal processes


Indust ry Sector s

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Indust ry Sector s



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Cement IndustryCement Industry

• Cement is produced by grinding, blending and burning limestone, sand, clay, bauxite or laterite

• These contain a suitable mixture of calcium oxides, silicon oxides, aluminum oxides and iron oxides

• Two types of CO2 emissions occur:1. From the energy consumption2. As a by product from the calcination process

• The global cement industry contributes to ~20% of all man made CO2 emissions

• The energy consumption in the cement industry is about 2% of the global primary energy consumption

Sector Description

Indust ry Sector s

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Process Flows

Indust ry Sector s

Production processes• Mining

- surface mining is more eco-friendly

• Crushing- size is reduced to 25 mm

• Raw material preparation- roller mills for grinding and separators or classifiers for separating ground particles

• Coal milling - provides dried pulverized coal to the kiln and precalciner

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Process Flows

Indust ry Sector s

Production processes• Pyro processing

- transform the raw material mix into gray clinkers in the form of spherically shaped nodules

• Pre heater and pre calciner- from the preheater/precalciner process 60 % of flue go to the raw mill and 40 % to the conditioning tower

• Clinker cooler- heat recovery from the hot clinker and temperature reduction of the clinker

• Finish milling- grinding of clinker to produce a fine grey powder

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Process FlowsIndust ry S

ector s

Limestone MiningLimestone MiningLimestone MiningLimestone Mining

CrushingCrushingCrushingCrushing

Raw MillingRaw MillingRaw MillingRaw Milling

Pyro ProcessingPyro ProcessingPyro ProcessingPyro Processing

Clinker CoolingClinker CoolingClinker CoolingClinker Cooling

Cement GrindingCement GrindingCement GrindingCement Grinding

Packing & DispatchPacking & DispatchPacking & DispatchPacking & Dispatch

Coal MillingCoal MillingCoal MillingCoal Milling

TransportTransportTransportTransport

Dieselfor loaders, dozersand compressors

Diesel for dumpers and trucks/ Electrical energy for ropeway

Electrical Energy for crushers

Electrical Energy forMill drive and fans

Heat Energy from kiln off gases

Heat Energy from fuel input

Electrical Energy for fans, drive and clinker breaker

Electrical Energy for Mill drive and fans

Bauxite, Ferrite

Gypsum

Pre calcinationPre calcinationPre calcinationPre calcinationHeat Energy from fuel input

Electrical Energy forKiln drive, fans and ESP

Electrical Energy for mill drive and fans

Heat Energy from fuel input/waste heat from clinker cooler

Energy flows

• Energy consumption nearly 40-40% of production costs

• Mill drives, fans and conveying systems are major energy consumers

Figure: Energy flows in a cement plant

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©© UNEP 2005 UNEP 2005


Process Flows

Indust ry Sector s

Electrical energy flows• Clinker burning: ~30%

• Finish grinding: ~30%

• Raw mill circuit: ~24%

Thermal energy flows• 50% of the energy costs

• The kiln and precalciner are major users

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©© UNEP 2005 UNEP 2005


Process Flows

Indust ry Sector s

Material & energy balance• Important for optimized operation of the cement kiln, diagnosing operational problems, increasing production and improving energy consumption

• In a cement plant processes involve gas, liquid and solid flows with heat and mass transfer, the combustion of fuel, reactions of clinker compounds and any undesired chemical reactions

• Parameters to consider include velocity, static pressure, dust concentration, surface temperature and power

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©© UNEP 2005 UNEP 2005


Energy Efficiency Opportunities

Indust ry Sector s

CO2 reductions involves a two pronged strategy:

1. Improving energy efficiency

2. Promoting blended cements that can decrease the clinker percentage in the cement

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

Raw material process Clinker burning process Finish process

First step

1) Selection of raw material2) Management of fineness3) Management of optimum grinding media

1) Prevention of stoppages2) Selection of fuel3) Prevention of leak

1) Management of fineness2) Management of optimum grinding media

Second step

1) Use of industrial waste material2) Replacement of fan rotor3) Improvement of temperature and pressure control system4) Improvement of mixing & homogenizing system

1) Use of industrial waste material2) Recovery of preheater exhaust gas3) Recovery of cooler exhaust gas4) Replacement of cooler dust collector

1) Installation of closed circuit dynamic separator2) Installation of feed control system

Third step

1) From wet process to dry process2) From ball and tube mills to roller mill

1) From wet process to dry process2) Conversion of fuel3)From SP to NSP4)Use of industrial waste 5)From planetary and under coolers to grate cooler

Table: Classification of CP-EE measures in three steps

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Indust ry Sector s

CP-EE measures:

a) Raw meal mix design change

b) Elimination of run-on equipment

c) Finish Mill Optimization

d) Avoidance of air supply leakage

e) Installation of more efficient fan motors

f) Employees’ awareness

g) Power monitoring and targeting

h) Process Replacement Measures

10 -20 % electrical energy reductions have been achieved in a cement plant by:

©© UNEP 2005 UNEP 2005

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

CP-EE measures:

• Capacity utilization-Essential for energy efficiency-Brings down the fixed energy loss component-At least 90% required to achieve low specific energy

consumption

• Fine tuning equipment-Only requires marginal investment-Can yield 3-10% energy savings if efficiently performed

• Technology upgrades

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©© UNEP 2005 UNEP 2005



Indust ry Sector s


• Process control and management systems

• Raw meal homogenizing systems

• Conversion from wet to dry process

• Conversion from dry to multi stage pre-heater kiln

• Conversion from dry to pre-calciner kiln

• Conversion from cooler to grate cooler

• Optimization of heat recovery in clinker cooler

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©© UNEP 2005 UNEP 2005



Indust ry Sector s


• High efficiency motors and drives

• Adjustable speed drives

• Efficient grinding technologies

• High-efficiency classifiers

• Fluidized bed kiln

• Advance comminution technologies

• Mineral polymers

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Indust ry Sector s



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©© UNEP 2005 UNEP 2005

Pulp & Paper IndustryPulp & Paper Industry

Sector Description

Indust ry Sector s

• World production of paper and paperboard is about 323 million tons (year 2000)

• World pulp and paper devours over 4 billion trees annually

• The industry produces the net addition of 450 million tones of CO2 per year (IIIED)

• The fuels within the sector are coal, oil, gas and bio fuels

• There are significant opportunities for reduction of CO2 gas emissions

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©© UNEP 2005 UNEP 2005


Process Flows

Indust ry Sector s

Manufacturing process

• Wood preparation

• Pulping

• Washing

• Bleaching

• Stock preparation

• Paper making

• Chemical recovery

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Process Flows

©© UNEP 2005 UNEP 2005


Indust ry Sector s

BarkingBarking

ChippingChipping

Chemical PulpingChemical Pulping MechanicalMechanical PulpingPulping

Waste Paper Waste Paper PulpingPulping

KneadingKneadingBleach PlantBleach PlantBleach PlantBleach Plant

Liquor concentrationLiquor concentration

Energy RecoveryEnergy Recovery

RecausticizationRecausticization

RefinerRefiner

Bark ( fuel)

Electricity

Steam

Electricity

Trees Used Paper

Fuel

Electricity

Steam

Electricity

Steam

Electricity

Wood Preparation

Pulping

Bleaching

Chemical Recovery

Paper making

Steam

Electricity

Electricity

Figure: Process flow diagram of the pulp and paper industry

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Process Flows

Indust ry Sector s

Stock PreparationStock Preparation

FormingForming

PressingPressing

DryingDrying

Steam

Electricity

Electricity

Paper making

Steam

Electricity

Steam

Electricity

Paper

Figure: Process flow diagram of the pulp and paper industry

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Process Flows

Indust ry Sector s

Energy flows in the paper industry:

• Thermal energy-mainly consumed in the drier-some mills use steam for drying the after coating

• Electrical energy-used to power the rotor or impeller-also used as rotary power for the cylinder, transportation, motive power and lighting loads

• Water flow-water consumption is significant both in terms of

consumed quantities as well as environmental aspects

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Indust ry Sector s

Process FlowsProcess Flows

Vac

uu

m B

oxe

s

Pre

ss R

oll

I,

52.5

Kw

Pre

ss

Ro

ll I

, 52

.5 K

wI

Co

uch

Ro

ll,

96 K

w

Figure: Energy balance in a paper machine

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

CP-EE measures:

• Raw material preparation-Enzyme-assisted barker-Chip conditioners-Improved screening process-Belt conveyers

• Mechanical pulping-Refiner improvements-Low consistency refining (LCR)-Heat recovery in thermo mechanical pulping

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Indust ry Sector s

CP-EE measures:

• Chemical pulping-Continuous digesters-Continuous digester modification-Batch digester modification

• Chemical recovery-Falling film black liquor evaporation

• Paper making-High consistency forming-Extended nip press (shoe press)

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

CP-EE measures:

• General measures-Optimization of regular equipment-Efficient motor systems

• Efficient steam production & distribution-Boiler maintenance-Improved process control-Flue gas heat recovery

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

EE technologies:

• Alcohol based solvent pumping

• Bio pulping

• Ozone bleaching

• Black liquor gasification

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©© UNEP 2005 UNEP 2005



Indust ry Sector s

EE-technologies:

• Impulse drying

• Infrared drying

• Press drying

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1 Training Session on Energy Equipment Industry Sectors Presentation to Energy Efficiency Guide for Industry in Asia Chapter 15 © UNEP GERIAP Industry