Energy Management and Efficiency for the Process Industries.
- 1st ed.
- 1 online resource (399 pages)
Energy Management and Efficiency for the Process Industries -- Contents -- Foreword by The Honorable Charles D. McConnell -- Preface -- Acknowledgments -- Contributors -- Units of Measure -- Section 1: Energy Management Programs -- Chapter 1: Energy Management in Practice -- Assessing the Value of an Energy Management Program -- Launching the Program -- Energy Resources: Roles and Responsibilities -- Energy Manager and Energy Staff -- Site Energy Leads -- Operations Management -- Maintenance -- Process Control -- Components and Systems -- Data Collection and Analysis -- Ground Rules: Basis and Calculation Methods -- Measurement -- Accounting -- Benchmarking -- Goal Setting -- Identification of Opportunities -- Site Energy Reviews -- Energy Tools Overview -- Good Engineering Practices -- Energy Optimization -- Implementation of Opportunities -- Operating Changes -- Maintenance Programs -- Capital -- Reporting and Recognizing Achievements -- Re-evaluation and Renewal -- Onward and Upward! -- Reference -- Chapter 2: The Dow Chemical Company: Energy Management Case Study -- The Dow Chemical Company: Overview -- Energy Efficiency Strategy Overview -- Energy Efficiency and Dow'S Climate Strategy -- Internal Operations -- How the Eeandc Program Operates -- Data Collection and Reporting: the Global Asset Utilization Reporting System -- How Dow Achieves Energy Savings -- Finding the Funding for Energy Projects -- Pursuing Operational Improvements Versus Capital Investments -- Supply Chain -- Products and Services -- Conclusions -- Reference -- Chapter 3: Eastman Chemical'S Energy Management Program: When Good Is Not Enough -- Introduction -- Executive-Level Support -- Funding -- Data-Based Decisions -- Additional Linkage -- Strategy and Principles -- Well Defined, Auditable Measure with Meaningful Goals -- Use of External Resources -- Employee Awareness. Energy Initiatives -- Energy Projects -- Links With Other Initiatives -- Consistency -- Growth -- Results -- Conclusions -- Acknowledgments -- References -- Chapter 4: General Mills' Energy Management Success Story -- Overview -- Background -- Common Challenges With Energy Management Programs -- People -- Process -- Technology -- Future Challenges -- Summary -- Chapter 5: Energy Benchmarking -- What Is Benchmarking? -- Confidentiality -- Data Sensitivity -- Why Benchmark? -- Use of Energy Benchmarking to Drive the Improvement Plan -- Possible Benchmarking Methodologies -- Energy Survey -- Best Practice Reports -- Comparable Technology -- Establishing the Perimeter -- Local Factors -- Validation and Verification of Input Data -- Reporting of Results -- Energy-Intensive Industry Benchmarking Experience -- Metals -- Petroleum Refining -- Petrochemicals and Plastics -- Industrial Chemicals and Fertilizer -- Cement, Glass, and Pulp and Paper -- Food Products -- Future Developments -- Chapter 6: Energy Management Standards -- Introduction -- Iso Management System Basics -- Iso 50001 -- Significant Energy Use -- Energy Baseline -- Energy Performance Indicators -- Other Related ISO Energy Standards -- U.S. Context -- SEP Results to Date -- Workforce Qualifications -- International Context -- Government Efforts to Promote Energy Management -- International Collaboration to Increase Worldwide Implementation -- Workforce Qualifications -- Conclusions -- Acknowledgments -- References -- Chapter 7: Protecting the Environment and Influencing Energy Performance Within Process Industries -- Introduction to Energy Star -- Not Just Products -- A Strategy for Improving Energy Efficiency in the Process Industrial and Commercial Sectors -- Improving Performance and Changing Behavior. Unique Resources for Process Industries, Including Petroleum Refining and Petrochemical Sectors -- Networking: Another Form of Benchmarking -- Conclusion -- References -- Section 2: Energy Management Technologies -- Chapter 8. The Technologies of Industrial Energy Efficiency -- Departmental Classification -- Operational Improvements -- Effective Maintenance -- Engineered Improvements -- New Technologies -- Time Frame Classification -- Short-Term Stage: ``Quick Hit´´ Activities -- Medium-Term Stage: Core Program Components and Projects -- Long-Term Stage: Sustainment -- Equipment, Utility Systems, and Process Classification -- Section Overview -- Reference -- Equipment -- Chapter 9. Energy Efficiency in Furnaces and Boilers -- Introduction -- Drivers for Energy Reduction -- Thermal Efficiency -- Stack Loss: Stack Temperature -- Other Components of Thermal Efficiency -- Insulation and Sealing -- Furnace Capacity -- Radiant Coil Design -- Burners -- Uniform Flow to Radiant Coil -- Convection Section -- Blowdown Losses -- Heat Integration -- Quench Exchangers -- Induced Draft Fan and Stack -- Instrumentation and Control Philosophy -- Excess Oxygen Control in Boilers -- Maintenance of Furnace Components for Peak Efficiency -- Refractory Maintenance for Furnaces and Boilers -- Operating Above Design Firing Rates -- Burner Maintenance -- Tramp Air Infiltration -- Quench Exchanger Cleaning -- Convection Cleaning -- Furnace Instrumentation Maintenance -- Energy Management Strategy -- References -- Chapter 10: Enhanced Heat Transfer and Energy Efficiency -- Surface Treatment and Modification -- Single-Phase Surface Enhancements -- Boiling Surface Enhancements. -- Condensing Surface Enhancements. -- Extended Surfaces -- Inserts -- Applications in New Plant Design and Revamps -- Closing Thoughts -- References -- Chapter 11: Heat Exchanger Cleaning Methods. Hydroblasting -- Chemical Cleaning -- Comparing the Options -- Chapter 12: Monitoring of Heat Exchanger Fouling and Cleaning Analysis -- Fouling Monitoring in Complex Systems -- Elements of a State-Of-The-Art Fouling Monitoring Program -- Technical Considerations -- Instrumentation and Data Access -- Data Quality and Data Reconciliation -- Network Thermodynamic Performance Analysis -- Exchanger Thermal Performance Prediction: Single-Phase Systems -- Exchanger Thermal Performance Prediction: Two-Phase Systems -- Integrated Exchanger Network Analysis -- Cleaning Cycle Economic Analysis -- Cleaning Cycle Optimization -- Heat Exchanger Cleaning Cost Benefits Other Than Energy Savings -- Reporting Considerations -- Organizational Considerations -- The Future of Fouling Monitoring -- Closing Thoughts -- Acknowledgment -- References -- Chapter 13: Successful Implementation of a Sustainable Steam Trap Management Program -- What Are Steam Traps? -- Why Are Trap Management Programs Difficult to Implement? -- Motivations -- Getting Widespread Involvement -- Planning and Preparation -- Trap Selection and Installation -- Diagnosis Accuracy -- Survey Scope -- Onsite Data Collection -- Special Requirements for Testing Steam Traps -- Trap Replacement Philosophy -- Program Implementation -- Testing -- Maintenance Response -- Oversight -- Sustaining and Improving the Program -- Final Thoughts -- References -- Chapter 14: Managing Steam Leaks -- Case Study -- Estimating Steam Leaks -- Causes of Steam Leaks -- Managing Steam Leaks -- Closing Thoughts -- Acknowledgments -- References -- Chapter 15: Rotating Equipment: Centrifugal Pumps and Fans -- Introduction -- Centrifugal Pump Capacity Control Systems -- Centrifugal Pump Recirculation Flows -- Centrifugal Pump Recirculation Flows: Example System -- Centrifugal Pumps with Throttling Valve Control. Centrifugal Pumping System Analysis -- Centrifugal Pumps with Throttling Valve Control: Example System -- Energy Losses in Throttling Valves -- Pumping System Considerations -- Centrifugal Pumps Operating in Parallel -- Centrifugal Pumps Operating in Parallel: Example Systems -- Centrifugal Fans -- Comparison of VFD Speed Control to Inlet Guide Vane Control: Fan Example -- Process Compressor and Turbine Efficiency Improvements -- Closing Thoughts -- Appendix 15A: Centrifugal Compressor Surge Considerations -- Compressor Surge -- Surge Control in Process Compressors -- Centrifugal Air Compressor Control Implications -- Appendix 15B: Efficiency of Electric Motors -- References -- Chapter 16: Industrial Insulation -- Introduction -- Common Industrial Insulation Types and Applications -- Mineral Wool -- Perlite -- Calcium Silicate -- Cellular Glass -- Aerogel -- Economic Justification for Insulation Projects -- Rules of Thumb -- Cold Service Insulation -- Rotating Equipment Insulation -- Flange Insulation -- Maintenance and Renewal -- Final Thoughts -- References -- Utility Systems -- Chapter 17: Heat, Power, and the Price of Steam -- Thermodynamics Recap -- Steam System Types -- Price Equivalent Efficiency -- Simple Marginal Steam Pricing -- Enhanced Marginal Steam Pricing and Efficiency Improvements -- References -- Chapter 18: Balancing Steam Headers and Managing Steam/Power System Operations -- Steam Balances -- Steam Venting -- Steam Letdown Versus Steam Turbines -- Deaerator Steam -- Computing and Optimizing Steam Balances -- Building the Model -- Outputs from the Model -- Some Modeling Systems -- Modeling and Optimization -- References -- Chapter 19: Real-Time Optimization of Steam and Power Systems -- Historical Context and Background for Real-Time Energy Optimization Technology Development -- Key Elements of Real-Time Energy Optimization Systems. Steam and Power System Equipment Optimization.
9781119033394
Industries -- Energy conservation. Industries -- Power supply.