# Presentation: 579160

## International Industrial Assessment Center

**I****nternational ****I****ndustrial ****A****ssessment ****C****enter**
**Industrial Energy Usage and Conservation Potential**
**January 16, 2003**

***Why Focus on Industry?***

- Energy Consumption by Sector

## U.S. Industrial Energy Consumption 

- Source: U.S. Department of Energy, Energy Information Administration

- Total consumption = 16.5 Quadrillion Btu

## U.S. Commercial Building Energy Consumption

- Source: U.S. Department of Energy, Energy Information Administration

- Total consumption = 5.3 Quadrillion Btu

***U.S. Commercial Building Energy Consumption***

## U.S. Household Energy Consumption

- Source: U.S. Department of Energy, Energy Information Administration

- Total consumption = 10.3 Quadrillion Btu

***U.S. Household ******Energy Consumption***

## U.S. Industrial Energy Consumption

- Total consumption = 16.5 Quadrillion Btu

- Source: U.S. Department of Energy, Energy Information Administration

- Source: DOE presentation, March 1999:
- Introduction to Motor Systems Management

***Industrial Electricity Use***

**Notes:**
Motors  represent the largest single use of electricity in most plants. Annual costs for operating motor systems can be substantial, so proper management of motor systems can result in significant cost savings.

## 	Source: United States Industrial Electric Motor Systems Market Opportunities Assessment, Office of Industrial Technologies, Office of Energy Efficiency and Renewable Energy, US DOE, December 1998,  Table 1-16, page 43

- 	Source: _United States Industrial Electric Motor Systems Market Opportunities Assessment_, Office of Industrial Technologies, Office of Energy Efficiency and Renewable Energy, US DOE, December 1998,  Table 1-16, page 43

***Industrial Motor Energy Use***

**Notes:**
Understanding how motors are used in industry is important for understanding where the largest potential savings reside. 

## Energy Consuming Systems and Common ECOs

## Combustion
Steam
Electricity/Fuel supply and demand reduction
Compressed air
Process equipment
Lighting
HVAC
Fuel switching

- Steam
- Electricity/Fuel supply and demand reduction
- Compressed air
- Process equipment
- Lighting
- HVAC
- Fuel switching

***Common Energy Conservation Categories***

## Motor Systems

- Source: _Energy-Efficient Motor Systems: A Handbook on Technology, Programs, and Policy Opportunities_, 1991, American Council for and Energy-Efficient Economy.

***Motor Systems***

**Notes:**
mo-tor (mo'ter) n. A device that converts electrical energy into mechanical energy, especially an arrangement of coils and magnets that convert electrical current into rotating mechanical power. 
The torque applied to the shaft is created by the interactions of two magnetic fields, one produced by the fixed part of the motor (stator) and the other by the rotating part of the motor (rotor).

Most of the energy put into a motor as electricity comes out as shaft power. Only a small fraction, as little as 5% in a large motor, is "consumed" by inefficiencies in the motor and comes out as heat. 

## Motor Recommendations

- 1. Replace motors with energy-efficient motors

- 2.  Install variable speed drive control

- 4.  Optimize motor size with load

**NEW HI-EFF MOTOR**

**MOTOR**
**REWIND**

***Motor Recommendations***

## Energy Efficient (E2) Motors

**NEW HIGH**
**EFFIENCY MOTOR**

**MOTOR**
**REWIND**

***Energy Efficient (E2) Motors***

## E2 Motors Background

-  Increase in efficiency of 1-10%
-  Larger motors yield smaller efficiency increases
-  Motormaster Program available at
- www.oit.doe.gov/bestpractices/software_databases/software.shtml

***E2 Motors Background***

**Notes:**
The reduction in losses are mainly from frictional and I2R losses; EEMs therefore run cooler; A downsized ventilation which decreases “windage” and a lower operating temperature help contribute to the longer life of most EEMs.

Motormaster program provides efficiency and cost premium information to help in making informed decisions about replacing motors.

## Adjustable Speed Drive (ASD)

***Adjustable Speed Drive (ASD)***

## ASD Background

- 	to process requirements.
- Potential Benefits Include:
- Improved product quality
- Improved process throughput
- Improved process control
- Energy savings
- 			power speed3
- Most effective for applications with varying loads.
- Common Applications: Fans,blowers, and pumps.

***ASD Background***

## Energy Efficient (E2) Belts

***Energy Efficient (E2) Belts***

## E2 Belts Background

- Efficiency of 90-96%
- Losses from flexing and slippage
- Cogged V-Belts
- 1-3% more efficient
- Lower flexing losses
- Synchronous Belts
- Efficiency of 98-99%
- No slippage
- Most expensive
- Not suitable for all applications

***E2 Belts Background***

**Notes:**
Flexing losses are caused by bending and unbending of the belt material when the belt enters and leaves the pulley.
As the belt wears it becomes more vulnerable to slip.
Cogged V-belts can be easily retrofitted on the same pulleys when V-belts wear out.  These become less efficient as load increases because the tendency to experience slip is greater.

Synchronous belts are noisier.

## Optimize Motor Size

***Optimize Motor Size***

## Motor Size Background

- Motor efficiency and PF drops sharply after about 40%
- At low loads larger motors still maintain better  and PF
- Focus on oversized motors with high operating hours
- Know the typical and maximum load characteristics

***Motor Size Background***

## Steam Boiler System

***Steam Boiler System***

## Optimal percentages of O2, CO2, and excess air in exhaust gases are 2.2%, 10.5%, and 10% for natural gas
Excess air burns more fuel than necessary
Measure excess air content with combustion analyzer

- Excess air burns more fuel than necessary
- Measure excess air content with combustion analyzer

***Air/Fuel Background***

## Reduces heat losses and associated energy costs 
Contributes to worker safety
3E Plus Insulation NAIMA Computer Program available at http://www.naima.org/ 

- Contributes to worker safety
- 3E Plus Insulation NAIMA Computer Program available at http://www.naima.org/

***Insulate Pipes Background***

## Reduces energy usage for heating of make-up water 
Contributes to worker safety  
Minimizes production requirements from boiler
Commonly found areas with leaks:
steam traps
faulty couplings and valves
cracks in steam lines

- Contributes to worker safety
- Minimizes production requirements from boiler
- Commonly found areas with leaks:
- steam traps
- faulty couplings and valves
- cracks in steam lines

***Steam Leaks Background***

## Releases steam prior to condensation
Wasted steam 
Increased boiler use  
Major warning sign is presence of steam downstream from trap 

- Wasted steam
- Increased boiler use
- Major warning sign is presence of steam downstream from trap

***Faulty Trap Background***

## Unused energy lost to surroundings
Warmer combustion air leads to increased combustion efficiency
Boiler efficiency increase of 1% for each 40F increase in combustion air temperature

- Warmer combustion air leads to increased combustion efficiency
- Boiler efficiency increase of 1% for each 40F increase in combustion air temperature

***Waste Heat Background***

## Compressed Air System Layout

***Compressed Air System Layout***

## Reduce Air Leaks

***Reduce Air Leaks***

## Air Leaks Background

-  Amount of lost air depends on:
-  line pressure
-  air temperature at leak
-  air temperature at compressor inlet
-  area of the leak
-  Percentage lost to leakage should be less than 10%
- in a well-maintained system

***Air Leaks Background***

## Outside Air To Intake

***Outside Air To Intake***

**Notes:**
Direct Drive Rotary Screw Compressor

## Outside Air Background

- Use cooler outside air as the supply
- Outside air is cooler and denser than indoor air
- Less work is required
- Energy requirements can be reduced

***Outside Air Background***

## Reduce Air Pressure

***Reduce Air Pressure***

## Air Pressure Background

- Demand and energy savings can be realized
- Pressure control setting can easily be lowered
- Plant personnel should lower in 5 psig increments

***Air Pressure Background***

## Recover Waste Heat

***Recover Waste Heat***

## Waste Heat Background

- Heat recovery unit recovers 50-90% of thermal energy
- Typical uses for recovered heat include:
- supplemental space heating
- industrial process heating
- water heating
- makeup air heating
- boiler makeup water preheating

***Waste Heat Background***

## Lighting Systems

## High Efficiency Lighting

***High Efficiency Lighting***

## Watt reducing recommendations include:
Fluorescent T-8s with electronic ballasts replacing fluorescent T-12s and magnetic ballasts.
Lower wattage lamps where the reduction in light levels are acceptable.
Metal halides replacing fluorescents in high bay ceilings.
Metal halides and high pressure sodium lamps replacing mercury vapor lamps.

- Fluorescent T-8s with electronic ballasts replacing fluorescent T-12s and magnetic ballasts.
- Lower wattage lamps where the reduction in light levels are acceptable.
- Metal halides replacing fluorescents in high bay ceilings.
- Metal halides and high pressure sodium lamps replacing mercury vapor lamps.

***E2 Lighting Background***

**Notes:**
Electronic ballasts save energy because they operate at a significantly higher frequency.  Magnetic ballasts uses only 60 Hz current, while electronic ballasts take the same 60 Hz current and converts it to 25,000 to 40,000 Hz.  This higher frequency helps to avoid flicker because the phosphor ions do not reach a relaxed state and therefore continuously emits light.

## Delamping

***Delamping***

## Determine overlit areas by measuring the amount of illumination in footcandles (lumens/ft2) or lux (lumens/m2).  Compare to IES standards.
Remove ballasts as well as lamps to achieve energy savings.
Consider the use of SORs to achieve energy savings.

- Remove ballasts as well as lamps to achieve energy savings.
- Consider the use of SORs to achieve energy savings.

***Delamping Background***

## Reduction of Lighting Hours

**ON**

**OFF**

***Reduction of Lighting Hours***

## Skylights reduce the number of lamps needed 
Photocells are light sensitive switches that can turn lights on when natural light is not sufficient
Occupancy sensors enable lights to be on only during occupied times
Passive Infrared – detect heat (directional)
Ultrasonic – use sound waves (non-directional)
Dual Technology

- Photocells are light sensitive switches that can turn lights on when natural light is not sufficient
- Occupancy sensors enable lights to be on only during occupied times
- Passive Infrared – detect heat (directional)
- Ultrasonic – use sound waves (non-directional)
- Dual Technology

***Reduce Lighting Hours Background***

**Notes:**
Skylights
Installation or cleaning existing skylights can reduce the amount of hours lights are on.  Also depending on the operating hours of the plant and the illuminance required lights can be removed.

Photocells
They can be designed to fail on to help with security.  Also can be used indoors in conjunction with dimmable ballasts to maintain a certain illuminance in an area.

Occupancy sensors
These can be wired to specific lamps or group of lamps to create a lighting zone.  Therefore, only the area occupied will be on.

## Decrease water consumption
Modify painting/coating process
Sell recyclable and reusable waste
Modify handling procedures
Recycle and reuse water
Dewater sludge before disposal
Repair equipment leaks

- Modify painting/coating process
- Sell recyclable and reusable waste
- Modify handling procedures
- Recycle and reuse water
- Dewater sludge before disposal
- Repair equipment leaks

***Common Waste Minimization Opportunities***

## Reduce defects
Automate process
Change operating procedure
Rearrange equipment layout
Repair or replace equipment
Improve employee training

- Automate process
- Change operating procedure
- Rearrange equipment layout
- Repair or replace equipment
- Improve employee training

***Common Productivity Improvements***

## Best Practices—DOE initiative to help plants improve their efficiency
http://www.oit.doe.gov/bestpractices/
Offers software tools, technical publications, case studies, newsletters, and training materials
Clean Power Resources
http://www.eren.doe.gov/power/info_res.html
Offers information, case studies and resource data about clean energy

- http://www.oit.doe.gov/bestpractices/
- Offers software tools, technical publications, case studies, newsletters, and training materials
- Clean Power Resources
- http://www.eren.doe.gov/power/info_res.html
- Offers information, case studies and resource data about clean energy

***DOE Programs***

## Motormaster
Software program that analyzes motor and motor system efficiency
http://mm3.energy.wsu.edu/mmplus/
Pumping System Assessment Tool
Tool to help industrial users assess the efficiency of pumping system operations
http://public.ornl.gov/psat/

- Software program that analyzes motor and motor system efficiency
- http://mm3.energy.wsu.edu/mmplus/
- Pumping System Assessment Tool
- Tool to help industrial users assess the efficiency of pumping system operations
- http://public.ornl.gov/psat/

***DOE Tools***

## Steam System Scoping Tool
Profiles and evaluates steam system operations
http://www.oit.doe.gov/bestpractices/software_databases/software.shtml
ASD Master
Software program to assist with the analysis, application, and specification of Adjustable Speed Drives
http://www.epri-peac.com/asdmaster/

- Profiles and evaluates steam system operations
- http://www.oit.doe.gov/bestpractices/software_databases/software.shtml
- ASD Master
- Software program to assist with the analysis, application, and specification of Adjustable Speed Drives
- http://www.epri-peac.com/asdmaster/

***DOE Tools***

## NAIMA 3E Plus Insulation Selector
Helps determine whether boiler systems can be optimized through insulation of boiler steam lines     
http://www.oit.doe.gov/bestpractices/software_databases/software.shtml

- Helps determine whether boiler systems can be optimized through insulation of boiler steam lines
- http://www.oit.doe.gov/bestpractices/software_databases/software.shtml

***DOE Tools***

## Combined Heat and Power Screening Tool
    http://www.eren.doe.gov/der/chp/st_development.html
Tellus Institute E2/Finance Total Cost
Analysis
http://www.tellus.org/risk/software/e2freq.html

-     http://www.eren.doe.gov/der/chp/st_development.html
- Tellus Institute E2/Finance Total Cost
- Analysis
- http://www.tellus.org/risk/software/e2freq.html

***DOE Software***

## DOE Homepage
	http://www.energy.gov
DOE Energy Efficiency and Renewable Energy Network (EREN)
	http://www.eren.doe.gov/
DOE Office of Industrial Technologies
	http://www.oit.doe.gov/

- 	http://www.energy.gov
- DOE Energy Efficiency and Renewable Energy Network (EREN)
- 	http://www.eren.doe.gov/
- DOE Office of Industrial Technologies
- 	http://www.oit.doe.gov/

***DOE Websites***

## DOE Office of Power Technologies
	http://www.eren.doe.gov/power/
DOE Federal Energy Management Program (FEMP)
	http://www.eren.doe.gov/femp/
Energy Information Administration
	http://www.eia.doe.gov

- 	http://www.eren.doe.gov/power/
- DOE Federal Energy Management Program (FEMP)
- 	http://www.eren.doe.gov/femp/
- Energy Information Administration
- 	http://www.eia.doe.gov

***DOE Websites***