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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.
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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
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Energy Use Pattern for Major Industries
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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
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Energy distribution in a typical heating system
Furnace Heat Input
Heat inFlue Gases
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How much heat is wasted?
60% of the total heat input is wasted in flue gases at
2000 deg. F.
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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.
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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
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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
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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
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Process Heating Assessment and Survey Tool (PHAST)
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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)
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• 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)
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Major Sections of PHAST
• Introduction
• Plant Equipment Information
• Furnace Analysis – Heat Balance
• Reports
• Transfer (Import/Export) of Data Files
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Use “Plant Information”
section of PHAST to enter and
analyze the data for process
heating equipment
Process Heating Assessment and Survey Tool(PHAST)
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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)
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• 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)
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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)
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•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
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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
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Energy Savers Tips for Industries
Visit Our Web Sites: www.energysavers.gov/industrywww.oit.doe.gov
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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
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