# ORNL/TM-2010/146



# RESULTS FROM THE U.S. DOE

2008 SAVE ENERGY NOW ASSESSMENT INITIATIVE:

DOE’s Partnership with U.S. Industry to Reduce

Energy Consumption, Energy Costs,

and Carbon Dioxide Emissions

DETAILED ASSESSMENT OPPORTUNITY DATA REPORT

July 2010

Prepared by

Anthony Wright, Michaela Martin, and Sachin Nimbalkar

Oak Ridge National Laboratory

James Quinn, Sandy Glatt, and Bill Orthwein

DOE Industrial Technologies Program

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# ORNL/TM-2010/146

Energy and Transportation Science Division

RESULTS FROM THE U.S. DOE

2008 SAVE ENERGY NOW ASSESSMENT INITIATIVE:

DOE’s Partnership with U.S. Industry to Reduce

Energy Consumption, Energy Costs,

and Carbon Dioxide Emissions

DETAILED ASSESSMENT OPPORTUNITY

DATA REPORT

Prepared by

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, Tennessee 37831-6283

Managed by

UT-BATTELLE, LLC

For the

U.S. DEPARTMENT OF ENERGY

Under contract DE-AC05-00OR22725

3

# RESULTS FROM THE U.S. DOE

2008 SAVE ENERGY NOW ASSESSMENT INITIATIVE:

DOE’s Partnership with U.S. Industry to Reduce

Energy Consumption, Energy Costs,

and Carbon Dioxide Emissions

DETAILED ASSESSMENT OPPORTUNITY DATA REPORT



# 1. INTRODUCTION

In October 2005, U.S. Department of Energy Secretary Bodman launched his Easy Ways to Save

Energy campaign with a promise to provide energy assessments to 200 of the largest U.S.

manufacturing plants. DOE’s Industrial Technologies Program (ITP) responded to the Secretary’s

campaign with its Save Energy Now initiative, featuring a new and highly cost-effective form of

energy savings assessment.

The approach for these assessments drew heavily on the existing resources of ITP’s technology

delivery component. Over the years, ITP Technology Delivery has worked with industry partners to

assemble a suite of respected software tools, prov en assessment protocols, training curricula, certified

energy experts, and strong partnerships for deployment.

The Save Energy Now assessments conducted in calendar year 2006 focused on natural gas savings

and targeted many of the nation’s largest manufacturi ng plants – those that consume at least 1 TBtu of

energy annually. The 2006 Save Energy Now assessments focused primarily on assessments of steam

and process heating systems, which account for an estimated 74% of all natural gas use by U.S.

manufacturing plants.

Because of the success of the Save Energy Now assessments conducted in 2006 and 2007, the

program was expanded and enhanced in two major ways in 2008: 1) a new goal was set to perform at

least 260 assessments; and 2) the assessment focus was expanded to include pumping, compressed

air, and fan systems in addition to steam and pro cess heating. DOE ITP has also developed software

tools to assess energy efficiency improvement opportunities in pumping, compressed air, and fan

systems.

The Save Energy Now assessments integrate a strong training component designed to teach industrial

plant personnel how to use DOE’s opportunity assessme nt software tools. This approach has the

advantages of promoting strong buy-in of plant personnel for the assessment and its outcomes and

preparing them better to independently repli cate the assessment process at the company’s other

facilities.

Another important element of the Save Energy Now assessment process is the follow-up process used

to identify how many of the recommended savi ngs opportunities from individual assessments have

been implemented in the industrial plants. Plant personnel involved with the Save Energy Now

assessments are contacted 6 months, 12 months, and 24 months after the assessments are completed

to determine implementation results.

A total of 260 Save Energy Now assessments were successfully completed in calendar year 2008.

This means that a total of 718 assessments were comp leted in 2006, 2007, and 2008. As of July 2009,

we have received a total of 239 summary reports from the ESAs that were conducted in year 2008.

Hence, at the time that this report was prepared , 680 final assessment reports were completed (200

from year 2006, 241 from year 2007, and 239 from year 2008). The total identified potential cost

savings from these 680 assessments is $1.1 billion per year, including natural gas savings of about 98

1

# TBtu per year. These results, if fully implemented, could reduce CO 2 

# emissions by about 8.9 million

metric tons annually.

When this report was prepared, data on implemen tation of recommended energy and cost savings

measures from 488 Save Energy Now assessments were available. For these 488 plants, measures

saving a total of $147 million per year have been implemented, measures that will save $169 million

per year are in the process of being implemented, and plants are planning implementation of measures

that will save another $239 million per year. The implemented recommendations are already

achieving total CO 2 

# reductions of about 1.8 million metric tons per year.

This report provides detailed information on key results for all of the 2008 assessments of steam,

process heating, pumping, compressed air, and fan systems. This report discusses the opportunities in

the top 10 categories, and identified savings a nd payback summary for different system type

assessments. A separate report (Wright et al. 2010) provides a summary of the key results of the Save

Energy Now assessments completed in 2008, the 6-month, 12-month, and 24-month implementation

results obtained to date, an evaluation of th ese implementation results, and key accomplishments,

findings, and lessons learned from the Save Energy Now assessments completed to date.

Two prior reports (Wright et al. 2007 and Wright et al. 2009) detail the results from the 2006 and

2007 assessments and discuss the major components of the assessment process and improvements in

the process made in 2007.



# 2. OVERVIEW OF THE 2008 SAVE ENERGY NOW ASSESSMENT PROCESS

2.1 A Unique Approach

The Save Energy Now in-plant energy efficiency assessments use a unique approach. Energy audits or

assessments are typically done by energy experts who go into a plant, identify potential savings

opportunities, and write reports that are left with plant personnel after the assessments are completed.

Save Energy Now assessments, in contrast, have a training element. These assessments focus on

hands-on demonstrations to industrial plant pe rsonnel specifically on how to use the DOE steam,

process heating, pumping, compressed air, and fan software tools. Assessments are done in no more

than three days, so, by necessity, they are very focused assessments. When making contact with a

plant, the Energy Expert identifies a Plant Lead who has to agree to stay with the Energy Expert

during the entire three-day assessment. The Energy Expert, Plant Lead, and ot her plant personnel who

participate in the assessment identify some “target” opportunities to investigate using the DOE

software. The target opportunities chosen are often those with the potential to achieve significant

plant energy and cost savings. The Energy Expert and plant personnel identif y any data requirements

for assessing the target opportunity, obtain or measur e data as necessary, and enter that data in the

DOE software to quantify a specific energy savings opportunity. Often no more than three or four

target opportunities are investigated during an assessment.

On the last day of the assessment, a required Clo seout Meeting is held to review and discuss the

opportunities identified in the assessment. Plant ma nagement personnel are invited to attend and

participate. Prior to the Closeout Meeting, th e Energy Expert and the Plant Lead agree on the

opportunities that will be highlighted at the meeti ng and documented in the final assessment report.

Only the opportunities approved by the Plant Lead are presented or discussed at the Closeout

Meeting.

The positive effect of using this approach for c onducting assessments is that: 1) plant personnel get

hands-on experience in effectively using the DOE software tools and the opportunity to see the value

2

# of applying these tools to their operations; 2) plant personnel are willing to buy-in to the opportunities

identified and evaluated during the assessment, wh ich increases the likelihood that the identified

opportunities will implemented ; and 3) opportunities are investigated that often can result in

significant energy and cost savings for the plant.

A full discussion of the Save Energy Now assessment process is provided in the 2006 Save Energy

Now Assessment Summary Report (Wright et al. 2007).



# 2.2 DOE ITP Decision Software Tools Used in 2008 Save Energy Now Assessments

The ITP program developed a suite of software-based decision tools to help industrial plant personnel

identify energy efficiency improvements for pl ant process and utility systems. These tools use

analytical models to evaluate process heating, steam, pumping, compressed air, fan, motor, and other

plant utility systems. There is also a Quick Plant Energy Profiler, or “Quick PEP,” online software

tool that helps industrial plant personnel to quickly understand how energy is used at the plant and

how they might save energy and reduce costs.

All of the software tools focus on energy efficiency “opportunity” assessments — quantifying the

potential savings from specific improvements. For example, there are often potential savings from

increasing condensate return in steam systems or reducing excess oxygen to furnaces for process

heating.

DOE ITP has partnered with key trade associations and focused technical groups to develop the

software tools. For example, DOE worked with th e Hydraulics Institute to develop the pump tool,

with the International Heating Equipment Associa tion to develop the process heating tool, with the

Compressed Air Challenge to develop the AirMaster + tool, and with the Air Movement and Controls

Association to develop the fan tool.

The DOE steam, process heating, pumping, compressed air, and fan system software tools, described

below, were used for the2008 assessments.

More details about all of the DOE ITP decision so ftware tools can be found at the following Web

link: http://www1.eere.energy.gov/industr y/bestpractices/software.html

.

2.2.1 Steam System Scoping Tool (SSST), Steam System Assessment Tool (SSAT) and 3E-Plus

Three tools address steam systems. SSST is a pre-screening tool that allows plant personnel to

develop a greater awareness of steam system im provement opportunities in their facilities. An SSST

analysis was performed for each steam assessment. SSAT estimates the impacts of key improvements

for models of representative steam systems. SSAT generates results detailing the energy, cost, and

emissions savings that could be achieved by up to 18 different improvements. 3E-Plus calculates the

most economical thickness of industrial insulation for operating conditions specified by the user.

2.2.2 Process Heating Assessment and Survey Tool (PHAST) and Process Heating Scorecard

PHAST is a tool for surveying process heating equipm ent that uses fuel, electricity, or steam (though

modeling for only the direct-fuel-fired systems is presently developed) and identifying the most

energy-intensive equipment. PHAST performs energy (heat) balances on furnaces to identify ways to

improve efficiency. PHAST has several calculators that compare the performance of individual pieces

of equipment under various opera ting conditions. The Process Heating Scorecard is a pre-screening

tool.

3

# 2.2.3 Pump System Assessment Tool (PSAT)

PSAT uses data that are typically available or easily obtained in the field (e.g., pump head, flow rate,

and motor power) to estimate potential energy and do llar savings in industrial pump systems. PSAT

assesses current pump system operating efficiency by comparing field measurements of the power

delivered to the motor with the fluid work (flow a nd head) required by the application. It estimates a

system’s achievable efficiency based on pump efficiencies and performance characteristics of pumps

and motors. PSAT also provides a pre-screening filte r to identify areas that are likely to offer the

greatest savings.

2.2.4 AirMaster+ Compressed Ai r System Performance Software

AirMaster+ provides a systematic approach for asse ssing the supply-side pe rformance of compressed

air systems. Using plant-specific data, the software effectively evaluates supply-side operational costs

for various equipment configurations and system profiles. It provides useful estimates of the potential

savings to be gained from selected energy effici ency measures and calculates the associated simple

payback periods for implementing these measures.

2.2.5 Fan System Assessment Tool (FSAT)

FSAT helps users quantify energy consumption and energy savings opportunities in industrial fan

systems. With FSAT, users can calculate the amount of energy used by a fan system, determine

system efficiency, and quantify the savings potential of an upgraded fan system. FSAT estimates the

work done by the fan system and compares that to th e estimated energy input to the system. The tool

also provides a pre-screening filter to identify fa n systems that are likely to offer optimization

opportunities.



# 3. DETAILED ASSESSMENT OPPO RTUNITY RESULTS FOR THE 2008 SAVE

ENERGY NOW ASSESSMENTS

In 2008, 239 Save Energy Now assessments (assessments with summary reports submitted) were

performed in large U.S. industrial plants. A total of 74 steam assessments, 51 process heating

assessments, 60 compressed air assessments, 29 pumping assessments, 17 fan assessments, and 8

multi-system paper assessments were completed.

At the time this report was prepared, assessment re ports for 134 of the plants visited in 2008 were

available. The data from completed 2008 assessment reports is for 41 steam assessments, 34 process

heating assessments, 37 compressed air assessments, 13 pumping assessments, and 9 fan system

assessments.

Figure 1 is a color-coded U.S. map that illustra tes how many of the 2006, 2007 and 2008 assessments

have been performed in each state. The map s hows that there are 24 states where at least 10 Save

Energy Now assessments were completed. More than 20 assessments have been conducted in the

states of Texas, Wisconsin, Michigan, Illinois, Indiana, Ohio, Pennsylvania, Tennessee, Louisiana,

Alabama and Georgia, respectively.

Table 2 provides a summary of how many of each type of Save Energy Now assessments were

conducted in each state. The states with the largest number of assessments of one or two type include

Texas (28 steam assessments and 23 process heating assessments), Wisconsin (32 steam

assessments), and Michigan (17 compressed air assessments and 17 steam assessments). Many of

these states rank high in terms of industrial energy consumption.

4

# Table 3 and Figure 2 show the industrial sectors in which the Save Ener gy Now assessments were

performed. Of the 680 assessments that were finalized in 2006 through 2008, 582 were performed in

chemical manufacturing, paper manufacturing, food, primary metals, transportation equipment, nonmetallic mineral, petroleum and coal, and plastic and rubber product plants. The industries in which

the most assessments were performed were:

● 73 steam and 26 process heating assessments in chemical manufacturing plants,

● 59 steam assessments in pa per manufacturing plants,

● 59 steam assessments in food processing plants,

● 55 process heating assessments in primary metals plants,

● 28 compressed air and 24 steam assessments in transportation equipment plants, and

● 35 process heating assessments in non- metallic mineral product plants.

Figures 3 and 4 provide a broad comparison of r esults of the 2006 through 2008 assessments. The

potential $284 million of annual energy cost savings and 43.3 TBtu of annual source-energy savings

identified and recommended in the 2008 assessments were substantial. In general, however, the

recommended cost and energy savings from th e 2008 assessments were less than from the 2006

assessments. The total recommended cost savi ngs from the 239 assessments from 2008 were about

55% of those from the 200 assessments from 2006; recommended source-energy savings from the

2008 assessments were about 75% of those from the 2006 assessments.

A major difference between the 2006, 2007, and 2008 assessments was the addition of pumping,

compressed air, and fan assessments in 2007 and 2008. The potential annual cost savings identified

by the 2008 assessments of 106 pumping, compressed ai r, and fan systems (where there is available

data), is about $48.5 million (see Figure 3), much less than $195.4 million potential annual cost

savings identified by 125 steam and process hea ting assessments from 2008. Much of the difference

between 2006 and 2007-2008 assessment results is at tributable to the greater identified savings

opportunities in steam and process heating assessment s than in pumping, compressed air, and fan

system assessments.

In performing the Save Energy Now assessments, the Energy Experts u sed standard — or “pick-list”

— wordings whenever possible to classify the identified opportunities. This was done so that the

savings opportunity data could be analyzed using these pick-list categories. Tables 4 through 8

present the opportunity pick-list categories for steam, process heating, pumping, compressed air, and

fan system assessments.

Tables 9 through 13 present detailed inform ation on potential cost, energy, and CO 2 

# emissions

reductions for all available 2006 through 2008 assessment results. Figur es 5 through 10 illustrate the

potential cost savings that could result from the “Top 10” energy savings opportunities — ranked by

total recommended cost savings — for steam, proce ss heating, pumping, compressed air, fan, and

multi-system paper plant assessments. For each of the assessment areas, the Top 10 opportunities

capture the majority of the energy cost savings identified from assessme nts completed in 2006

through 2008 (Table 1):

Table 1. Identified energy cost savings captured by Top 10 opportunities

System type assessed Annual potential savings

captured in Top 10 Percentage of total savings for

system type

Steam $514 84%

Process heating $222 70%

Pumping $16.2 99%

Compressed air $18 93%

Fan $40.7 100%

Multi-system paper $40 100%



# 5

# 6 The Energy Experts estimated high and low va lues of the capital costs for implementing each

identified savings opportunity and used the hi gher values to estimate payback periods. Savings

payback period (in years) is defined as (cost to implement opportunity)/ (yearly savings for the

opportunity). Most industrial plants will not consid er implementing savings opportunities that have

payback periods longer than two years.

Estimated payback results for the 2006 through 2008 Save Energy Now assessments are summarized

in Table 14 and Figures 11 and 12. Some of the key results shown in the table and figures are

summarized below:

● A total of 3,823 energy saving opportuniti es were identified for the 680 assessments, an

average of 5.6 opportunities per assessment.

● When all results are averaged, almost 70% of all identified opportunities have estimated

paybacks of 2 years or less.

● The estimated paybacks of about 70% of th e identified steam, process heating, and

compressed air opportunities had estimated paybacks of 2 years or less.

● The data for pumping and fan assessments is sli ghtly different — about 40% to 50% of the

identified opportunities had estimated paybacks of 2 years or less.

The available data can be analyzed to determine average percentages of plant energy cost and sourceenergy use represented by each pick-list category. Tables 15 through 19 present this data. Figures 13

through 18 show the “Top 10” identified opportun ities for each assessment area, based on estimated

average plant source-energy savings. The following are the key results presented in these tables and

figures. It should be noted that this data is b ased on plant source-energy use, which in many cases is

largely for fired systems at these large plants.

● The data for steam and process heating assessm ents show that many of the identified

opportunities could save more than 1.5% of plant source-energy use.

● A number of the compressed air and fan opportunities could also save 1% or more of plant

source-energy use.

● Potential source-energy-use savings for individual opportunities identified in pump system

assessments are somewhat lower than for the other systems. Savings opportunities, however,

are still substantial, in the range of 0.2% of plant source-energy use.



# 4. REFERENCES

Wright, Anthony, Michaela Martin, Sachin Nimbalkar, James Quinn, Sandy Glatt, and Bill Orthwein,

2010. Results from the U.S. DOE 2008 Save Energy Now Assessment Initiative: Summary and

Lessons Learned. Oak Ridge National Laboratory, ORNL/TM-2010/145.

Wright, Anthony, Michaela Martin, Sachin Nimbalkar, James Quinn, Sandy Glatt, and Bill Orthwein,

2009. Results from the U.S. DOE 2007 Save Energy Now Assessment Initiative: Summary and

Lessons Learned. Oak Ridge National Laboratory, ORNL/TM-2009/075.

Wright, Anthony, Michaela Martin, Bob Gemmer, Paul Scheihing, and James Quinn, 2007. Results

from the U.S. DOE 2006 Save Energy Now Assessment Initiative. Oak Ridge National Laboratory,

ORNL/TM-2007/138.>2520-2515-2010-155-102-51-2Figure 1. More than 25Save EnergyNowassessments were completed in Texas, Wisconsin,Michigan, Indiana, Illinois, Tennessee,Ohio,Pennsylvaniaand Georgia, respectively, in2006, 2007and 2008. (Based on718 completed assessments (200 assessments in year2006, 258in year 2007and 260 in year 2008).Asof July 1,2009, summary reports areavailable for 680assessments.7

# Figure 2. Of the 680 Save Energy Now assessments completed in 2006, 2007, and 2008, 535 were

completed in the chemical, paper, food, primar y metals, transportation equipment, and nonmetallic mineral industries. 0 20 40 60 80 100 120 325 CHEMICAL MANUFACTURING 322 PAPER MANUFACTURING 311 FOOD 331 PRIMARY METALS 336 TRANSPORTATION EQUIPMENT 327 NON-METALLIC MINERAL PR ODUCTS

324 PETROLEUM AND COAL PRODUCTS 326 PLASTICS AND RUBBER PRODUCTS 332 FABRICATED METAL PRODUCTS 212 MINING 334 COMPUTER AND ELECTRONIC PRODUCTS 333 MACHINERY MANUFACTURING 321 WOOD PRODUCTS 339 MISCELLANEOUS MANUFACTURING 314 TEXTILE PRODUCT MILLS 323 PRINTING AND RELATED SUPPORT ACTIVITIES OTHER 313 TEXTILE MILLS 335 ELECTRICAL EQUIPMENT, APPLIANCES,

...

312 BEVERAGE AND TOBACCO PRODUCTS 315 APPAREL MANUFACTURING

337 FURNITURE AND RELATED 541 PROFESSIONAL, SCIENTIFIC & TECH. SERVICES



# NUMBER OF ASSESSMENTS YEAR 2006 - 2008 (680 SENA's) 

# INDUSTRY TYPE ( NAIC )



# 89$368$110$133$151$107$62$13$28$10$10$6$10$0$50$100$150$200$250$300$350$400200620072008YEARSteamProcess HeatingFansCompressed AirPumps(86)(114)(56)(89)(46)(15) (35)(51)(74)(60)(17)(29)(No. of SENAscompleted withsummary reports)RECOMMENDED ENERGY COST SAVINGS (Million $/Year)Figure 3. The total recommended energy cost savings from 241Save Energy Nowassessments (SENAs) completed in 2007 was $244 million peryear, and $284 million per year for the 239 assessments completedin 2008. These are about 47% and 55% of the recommended costsavingsfrom the 2006 assessments.10Figure 4. The total recommended source-energy savings from the 241Save Energy Nowassessments (SENAs) completed in 2007 was 36 TBtuper year, and from the 239 assessments completed in 2008 was 43.3 TBtu per year. These are about 60% and 75% of the recommendedsourceenergy savings from the 2006 assessments respectively.361622211582512120510152025303540200620072008YEARSteamProcess HeatingFansCompressed AirPumps(86)(114)(56)(89)(46)(15)(35)(51)(74)(60)(17)(29)(No. of SENAs completedwith summary reports)RECOMMENDED SOURCE ENERGY SAVINGS (TBtu/Year)

# TOP “10” STEAM OP PORTUNITIES

$0 $50 $100 $150 1.1 - Reduce Steam Demand by Changing the Process Steam

Requirements 1.2 - Use an Alternate Fuel 1.3 - Change Boiler Efficiency 1.7 - Add or Modify Operation of Backpressure Steam Turbine

1.8 - Add or Modify Operation of Condensing Steam Turbine 1.11 - Change Condensate Recovery Rates 1.14 - Implement Steam Trap Maintenance Program 1.16 - Improve Insulation 1.10 - Modify Feedwater Heat Recovery Exchanger using

Boiler Blowdown

1.4 - Change Boiler Blowdown Rate



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)



# Figure 5. Opportunities in the top 10 steam categories for the 2006, 2007, and 2008 Save Energy

Now assessments could result in plant energy savings of $514 million per year.



# 11

# TOP “10” PROCESS HEAT ING OPPORTUNITIES

$0 $10 $20 $30 $40 $50 3.1 - Use of flue or Exhaust gas heat for combustion air

preheating 1.1 - Reduce oxygen content of flue (exhaust) gases 3.4 - Heat recovery from hot products or other heat sources

3.3 - Heat cascading - use of flue or Exhaust gas heat from

higher temp. process 1.5 - Use of oxygen for combustion 1.3 - Use of proper heating methods - replace inefficient and

uneconomical methods 4.1 - Proper insulation and maintenance of furnace structure

or parts 3.2 - Load or charge preheating using heat from flue gas

3.5 - Use of waste heat for water or air cooling, steam

generation or absorption cooling 5.1 - Furnace scheduling, loading, shut down - avoiding

delays



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)

Figure 6. Opportunities in the top 10 process heating categories for the 2006, 2007, and 2008 Save

Energy Now assessments could result in plant energy savings of $222 million per year.



# 12

# TOP “10” PUMP OP PORTUNITIES

$0.0 $1.0 $2.0 $3.0 $4.0 $5.0 1.2 - Excessive valve friction loss all of the time 1.9 - Other 1.7 - Less than optimal equipment for the application 1.1 - Excessive valve friction loss part of the time 1.5 - More flow than required to meet system requirements 1.3 - Excessive recirculation 1.8 - Degraded equipment performance 1.12 - Change time of use 1.10 - Excessive friction loss due to system design

1.11 - System specs exceed system requirements



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)



# Figure 7. Opportunities in the top 10 pumping categories for the 2007 and 2008 Save Energy Now

assessments could result in plant ener gy savings of $16.2 million per year.



# 13

# TOP “10” COMPRESSED AIR OPPORTUNITIES

$0.0 $2.0 $4.0 $6.0 1.2 - Improve End Use Efficiency 1.1 - Reduce Air Leaks 1.6 - Multiple Compressor Control (install / improve) 1.3 - Reduce System Air Pressure 4.1 - Other 3.8 - Open Blowing 1.4 - Improve Trim Compressor Part Load Efficiency 1.7 - Reduce Run Time 3.12 - Sparging 1.5 - Adjust Cascading Set Points



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)



# Figure 8. Opportunities identified in the top 10 compressed air categories for the 2007 and 2008

Save Energy Now assessments could result in $18 million per year of plant energy savings.



# 14

# TOP “10” FAN OPPORTUNITIES

$0.0 $5.0 $10.0 $15.0 $20.0 1.14 - Other 1.16 - Recover heat from stack 1.1 - Use Variable Speed Drive 1.7 - Install new appropriately sized fan 1.13 - Shut off unneeded fans 1.6 - Install new appropriately sized impeller 1.15 - Recover heat from exhaust air 1.2 - Change belt drive ratio 1.11 - Improve arrangement of air intake 1.9 - Rearrange ductwork at fan inlet or discharge



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)



# Figure 9. Opportunities identified in the top 10 fan categories for the 2007 and 2008 Save Energy

Now assessments could result in $41 million per year of plant energy savings.



# 15

# 16 

# TOP “10” MULTI-SYSTEM PA PAR OPPORT UNITIES

$0 $5 $10 $15 $20 1.1 - Change operating parameters 1.5 - Recover heat 1.12 - Develop a water system balance 1.2 - Improve paper machine performance 1.7 - Inspect/test papermaking equipment 1.6 - Repair papermaking equipment 1.8 - Install more energy-efficient equipment 1.9 - Install more energy-efficient paper machine clothing



# TOTAL ENERGY COST SAVINGS IDENTIFIED (Million $/Year)

Figure 10. Opportunities identified in the top 10 multi-system paper categories for the 2007 and

2008 Save Energy Now assessments could result in $40 million per year of plant energy savings.PROCESS HEATING ASSESSMENTS1%10%21%33%35%ALL SYSTEM TYPES1%38%32%10%19%0 - 9 months9 months - 2 years2 - 4 years4+ yearsspinoffSTEAM ASSESSMENTS1%9%39%32%19%Figure 11. About 70% of all opportunities identified in 2006, 2007, and 2008Save Energy Nowassessments have estimated paybacks ofless than 2 years.17PUMP ASSESSMENTS4%23%30%25%18%COMPRESSED AIR ASSESSMENTS1%46%34%10%9%FAN ASSESSMENTS0%26%31%24%19%ALL SYSTEM TYPES1%38%32%10%19%0 - 9 months9 months - 2 years2 - 4 years4+ yearsspinoffFigure 12. About 80% of the opportunities identified in compressedair assessments have estimated paybacks of less than 2 years. About40 to 50% of the opportunities identified in the pumping andfan assessments have estimated paybacks of less than 2 years.18

# TOP “10” STEAM OP PORTUNITIES

0.0 2.0 4.0 6.0 8.0 1.2 - Use an Alternate Fuel 2.2 - Clean heat transfer surfaces - radiant tubes, heat

exchangers 1.1 - Reduce Steam Demand by Changing the Process Steam

Requirements 1.8 - Add or Modify Operation of Condensing Steam Turbine 1.20 - Multiple Boiler Optimization 1.18 - Feedwater Heat Recovery - General 1.19 - Deaerator Heat Recovery - General 1.7 - Add or Modify Operation of Backpressure Steam Turbine 1.3 - Change Boiler Efficiency 1.14 - Implement Steam Trap Maintenance Program



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%)

Figure 13. Each of the individual identified steam oppo rtunities in eight categories, if implemented, could

typically save industrial plants at leas t 1% of their total source-energy use.



# 19

# TOP “10” PROCESS HEAT ING OPPORTUNITIES

0.0 2.0 4.0 6.0 1.4 - Use of alternate fuel or energy source 3.5 - Use of waste heat for water or air cooling, steam

generation or absorption cooling 1.3 - Use of proper heating methods - replace inefficient

methods with efficient system 3.4 - Heat recovery from hot products or other heat sources 1.5 - Use of oxygen for combustion 3.1 - Use of flue or Exhaust gas heat for combustion air

preheating 5.3 - Control (reduce) make up air for ovens to meet the

process safety requirements 5.1 - Furnace scheduling, loading, shut down - avoiding delays,

waits, cooling between operations etc. 2.1 - Improving heat transfer in a furnace-oven 3.3 - Heat cascading - use of flue or Exhaust gas heat from

higher temp. process



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%)

Figure 14. Many of the individual identified process he ating opportunities, if implemented, could typically

save industrial plants at least 2% of their total source-energy use.



# 20

# TOP “10” COMPRESSED AIR OPPORTUNITIES

0.0 0.5 1.0 1.5 2.0 3.1 - Aspirating 1.4 - Improve Trim Compressor Part Load Efficiency 3.3 - Cabinet Cooling 3.4 - Condensate Drain 3.8 - Open Blowing 1.6 - Multiple Compressor Control (install / improve) 1.1 - Reduce Air Leaks 1.7 - Reduce Run Time 4.1 - Other 1.5 - Adjust Cascading Set Points



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%)

Figure 15. Each of the individual identified compressed air opportunities in six categories, if implemented,

could typically save industrial plants at le ast 0.6% of their total source-energy use.



# 21

# TOP “10” PUMP OP PORTUNITIES

0.0 0.2 0.4 0.6 1.9 - Other 1.10 - Excessive friction loss due to system design 1.1 - Excessive valve friction loss part of the time 1.3 - Excessive recirculation 1.2 - Excessive valve friction loss all of the time 1.11 - System specs exceed system requirements 1.8 - Degraded equipment performance 1.7 - Less than optimal equipment for the application 1.5 - More flow than required to meet system

requirements 1.4 - Unneeded flow path



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%)

Figure 16. Each of the individual identified pumping o pportunities in six categories, if implemented, could

typically save industrial plants at least 0.2% of their total source-energy use.



# 22

# TOP “10” FAN OPPORTUNITIES

0.0 1.0 2.0 3.0 1.15 - Recover heat from exhaust air 1.16 - Recover heat from stack

1.13 - Shut off unneeded fans 1.14 - Other 1.7 - Install new appropriately sized fan 1.6 - Install new appropriately sized impeller 1.2 - Change belt drive ratio 1.10 - Use factory designed inlet box 1.1 - Use Variable Speed Drive 1.11 - Improve arrangement of air intake



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%) 4.0

Figure 17. Each of the individual identified fan oppo rtunities in six categories, if implemented, could

typically save industrial plants at least 0.5% of their total source-energy use.



# 23

# 24 

# TOP “10” MULTI-SYSTEM PAPER OPPORTUNITIES

0.0 1.0 2.0 3.0 4.0 1.12 - Develop a water system balanc e 1.5 - Recover heat 1.6 - Repair papermaking equipmen t 1.1 - Change operating parameters 1.7 - Inspect/test papermaking equipmen t 1.8 - Install more energy-efficient equipment 1.9 - Install more energy-efficient paper machine

clothing 1.2 - Improve paper machine performanc e



# AVERAGE PERCENT SOURCE ENERGY SAVINGS (%)

Figure 18. Each of the individual identified multi- system paper opportunities in six categories, if

implemented, could typically save industrial plants at least 0.3% of their total source-energy use.

# Table 2. Total number of 2006, 2007, a nd 2008 assessments conducted per state

State Compressed

Air Fans Process

Heating Pumps Steam Multi-System

Paper Grand Total

TX 6 3 23 9 28 69

WI 3 4 8 11 32 2 60

MI 17 1 6 4 17 45

GA 6 2 11 1 12 1 33

IN 10 1 11 1 10 33

TN 6 1 12 4 7 1 31

OH 8 1 12 4 5 30

PA 2 1 14 4 7 28

IL 5 2 5 3 12 27

AL 2 1 7 2 9 1 22

LA 4 16 1 21

MN 2 4 7 1 7 21

CA 3 1 5 2 8 19

KY 6 1 7 4 18

NY 1 5 2 8 16

AR 1 3 1 8 13

VA 1 2 3 1 5 12

MO 2 2 1 7 12

MA 2 5 4 11

OR 1 4 6 11

OK 3 3 1 4 11

MS 1 4 2 4 11

WA 1 3 1 5 10

NJ 1 3 6 10

NC 1 3 1 2 1 8

WV 1 4 3 8

UT 1 4 1 2 8

SC 3 2 2 1 8

ME 1 6 1 8

KS 2 2 1 3 8

IA 2 4 1 7

AZ 3 1 1 2 7

FL 1 2 3 6

CT 2 1 3 6

ID 1 4 5

NE 2 2 4

DE 1 3 4

PR 1 1 1 1 4

WY 2 1 3

MD 3 3

RI 2 2

CO 1 1 2

NV 1 1 2

ND 1 1

SD 1 1

NM 1 1



# Grand

Total 106 32 193 64 277 8 680



# 25Table 3. Number ofSave Energy Nowassessments completed in20 major U.S. industry sectors in 2006, 2007, and 2008Industry SectorCompressedAirFansProcessHeatingPumpsSteamMulti-SystemGrandTotal325 CHEMICAL MANUFACTURING8226773116322 PAPER MANUFACTURING451015597100311 FOOD1611355994331 PRIMARY METALS855511887336 TRANSPORTATION EQUIPMENT2821062470327 NON-METALLIC MINERAL PRODUCTS17735968324 PETROLEUM AND COAL PRODUCTS31011327326 PLASTICS AND RUBBER PRODUCTS7211020332 FABRICATED METAL PRODUCTS11112419212 MINING1352213334 COMPUTER AND ELECTRONIC PRODUCTS2221411333 MACHINERY MANUFACTURING214310321 WOOD PRODUCTS11417339 MISCELLANEOUS MANUFACTURING21137314 TEXTILE PRODUCT MILLS66323 PRINTING AND RELATED SUPPORT ACTIVITIES4116OTHER111216313 TEXTILE MILLS1124335 ELECTRICAL EQUIPMENT, APPLIANCES,COMPONENTS1214312 BEVERAGE AND TOBACCO PRODUCTS112315 APPAREL MANUFACTURING11337 FURNITURE AND RELATED11541 PROFESSIONAL, SCIENTIFIC & TECHNICALSERVICES11Grand Total1063219364277868026Table 4. The steam system “pick-list” recommendation classifications that streamline assessment and data analysisSteam assessment "pick-list" savings projectsDescription1.1 - Reduce steam demand by changing the processsteam requirementsEliminating or optimizing the operation of steam-using process equipment reduces required steamgeneration rates which in turn reduces boiler fuel (and energy) consumption rates.1.2 - Use an alternate fuelWhen switching from a fuel with a lower theoretical combustion efficiency (e.g. natural gas) to a fuelwith a higher efficiency (e.g. fuel oil with a lower hydrogen content), a lower boiler fuel (and energy)consumption rate results. Switching to a less costly fuel (on an energy basis) will reduce operatingcosts.1.3 - Change boiler efficiencyEnergy is saved if boiler efficiency is improved since boiler losses are reduced, and less fuel(andenergy) is needed to achieve a desired steam production rate.1.4 - Change boiler blowdown rateBoiler blowdown constitutesa pressurized, hot water loss from a boiler (energy loss). Actions (e.g.improved boiler water treatment) which allow a reduction in this loss improve boiler efficiency.1.5 - Install blowdown flash to low pressure steamBlowdown water (superheated liquid) flashes to steam when pressure is lowered in the exit stream.Flash steam directed to a low pressure header reduces needed boiler steam generation rate. This inturn reduces boiler fuel (and energy) use rate.1.6 - Change steam generation conditionsFor boilers producing superheated steam, reducing output temperature (e.g. by removing asuperheater) will reduce boiler fuel (and energy) use.For boilers producing saturated steam, improvingsteam quality (decreasing wetness) improves downstream process1.7 - Add or modify operation of backpressure steamturbineIf a backpressure turbine is taken out-of-service,steam usage, boiler load and fuel (and energy)consumption rate are reduced. If a new backpressure turbine is added to reduce steam flow throughpressure reducing valves, steam flows through pressure reducing valves will be reduced but totalsteam usage will increase. This action will reduce totalenergy costs if the electricity savings (related tothe turbine drive) are greater than theincreased boiler fuel consumption rate.1.8 - Add or modify operation of condensing steam turbine(high pressure to condensing)If the isentropic efficiency of a utilized condensing turbine is improved (e.g. by rebuilding), a lowersteam flow is required to drive the turbine load. Thisin turn reduces boiler load and fuel (and energy)consumption rates. If a condensing turbine is taken out-of-service, steam usage is reduced, boiler loaddecreases and boiler fuel (and energy) consumption is lowered.1.9 - Modify feedwater heat recovery exchanger usingcondensate tank ventThe main condensate receiver is typically vented to atmosphere when flash steam forms at thereduced receiver pressure. Flash steam passed through a heat exchanger can be used for boilerfeedwater heating. The addition of hotter water tothe feedwater system reduces boiler fuel (andenergy) consumption rate.1.10 - Modify feedwater heat recovery exchanger usingboiler blowdownWhen superheated blowdown water undergoes a pressure reduction after leaving the boiler, somewater flashes to steam and a hot water fraction remains. This hot water may be passed through a heatexchanger to heat feedwater or process fluids thereby reducing steam use for heating.27Table 4 (continued)Steam assessment "pick-list" savings projectsDescription1.11 - Change condensate recovery ratesIf the amount of formedcondensate returned to the boiler is increased, hotter water isfed back into theboiler feedwater system, lowering feedwater heating requirements and feedwater chemical treatmentneeds.1.12 - Modify the medium pressure condensate flashsystemWhen the pressure of condensate formed in a high-pressure system is reduced, flash steam forms.When this steam is supplied to the medium-pressure steam header, an amount of boiler-producedsteam is displaced and boiler load and fuel (and energy) consumption rates are reduced.1.13 - Modify low pressure condensate flashsystemWhen the pressure of condensate formed at a given pressure is reduced flashsteam forms. When thissteam is supplied to the low-pressure steam header, an amount of boiler-produced steam is displacedand boiler load and fuel (and energy) consumption rates are reduced.1.14 - Implement steam trap maintenance programAn improved steam trap maintenance program results in a reduced number of traps failed in theleaking steam mode. If trap steam leaks are reduced,less steam energy is lost in the condensatesystem and boiler load and fuel (and energy) consumption rates are reduced.1.15 - Implement steam leak maintenance programAn improved steam leak maintenance program reduces the number of steam leaks (lost energy). Lesssteam must be generated in the boiler to satisfy process loads and boiler fuel (and energy)consumption rates are reduced.1.16 - Improve insulationImproving insulation quality (e.g. replacing ineffective wet insulation orincreasing insulation thickness)and insulating uninsulated components will reduce energy loss from hot steam components.1.17 – OtherMiscellaneous projects may minimize or eliminate the need for boiler-generated steam. These projectssave energy by reducing the use of process energyor by improving the efficiency of converting fuelenergy to process heating (e.g. steam) energy.1.18 - Feedwater heat recovery - generalAvailable process waste heat other than condensate tankvent energy or liquid blowdownheat can beused in a heat exchanger to heat boiler feedwater. Hotter water fed back into the boiler feedwatersystem lowers feedwater heating requirements.1.19 - Deaerator heat recovery - generalBoiler water deaeratorsare often vented to atmosphere. The installation of a heat exchanger canrecover heat for feedwater or process heating. This heating reduces needed boiler output.1.20 - Multiple boiler optimizationOptimization of overall steam generation efficiency in multi-boiler systems requires selection ofindividual boiler loads to maximize their efficiencies and minimize total boiler fuel use while meetingtotal steam production requirements.1.21 - Reduce or recover vented steamSteam is vented from steam headers when steam supplied by backpressure turbines exceedsdownstream process needs. Steam is also vented from some plant processes (e.g. furnace decoking).If steam venting is reduced or vented steam is recovered (for process heating) boiler steam load andfuel (and energy) consumption rates are reduced.28Table 5. The process heating system “pick-list” recommendation classifications that streamlineassessments and data analysisProcess Heating assessment "pick-list" savingsprojectsDescription1.1 - Reduce oxygen content of flue (exhaust) gasesReduced oxygen reflects a reduction in excess air entering the heating equipment. This raises theavailable heat, and consequently, the efficiency. Excess air can be lowered by adjusting burner air-fuelratios, closing off air leaks into the equipment or maintaining a slightly positive chamber pressure toexclude outside air.1.2 - Eliminate excess unburned hydrocarbons (CO, H2,CH4, soot in the exhaust gases)Unburned hydrocarbons represent unburned or partially-burned fuel. They can be lowered byimproving the thoroughness of air-fuel mixing in burners or avoiding operating burners fuel-rich or withinsufficient excess air.1.3 - Use of proper heating methods - replace inefficientand uneconomical methods with economical/efficientsystemSome heating equipment is either obsolete or poorlymatched to the needs ofthe process. Replace itwith modern equipment which takes the unique needs of the process into account.1.4 - Use of alternate fuel or energy sourceIn certain situations, fuels like by-product gases may be available at lower costthan the primary fuel.Waste energy from other nearby operations mightbe able to be used in the process underconsideration.1.5 - Use of oxygen for combustionUsing oxygen to enrich or replace combustion air lowers the weight flow of nitrogen in theexhaustgases, increasing available heat and efficiency. Flame temperatures will also increase, and this mayenhance radiation heat transferto the furnace and its load.1.6 - Use of process or exhaust air for combustionIf this aircontains sufficient oxygen (usually 18% or more) and is at elevated temperature, it can beused as a combustion air source. Its heat content will raise the available heat of the combustionprocess.1.7 - Use of outdoor air for combustion or make-up airIn aclosed building with space heating in use, drawing combustion airfrom inside and then exhaustingit through the stack wastes the energy that aircontains. Heated replacement air will be needed.Drawing combustion air from outdoors bypasses thebuilding heating system, reducing the burden on it.2.1 – Improving heat transfer in a furnace-ovenThe work load must be exposed as effectively as possible to the source of radiant or convective heat.This will entail steps like changing loading patterns, increasing burner or hot air nozzle velocities orrelocating heat sources so they "see" more of the furnace load.2.2 - Clean heat transfer surfaces - radiant tubes, heatexchangers, heater tubes, electrical heating elementsBuildups of scale, soot and dirt reduce the thermal conductivity of tubes, heating elements and heatexchangers. Heat turned back by these deposits short-circuits out the exhaust, increasing losses,slowing the process and lowering efficiency.29Table 5 (continued)Process Heating assessment "pick-list" savingsprojectsDescription3.1 - Use of flue or Exhaust gas heat for combustion airpreheatingThis is one of the most effective ways to recyclewaste heat. Incoming ambient combustion air is routedthrough a heat exchanger and preheated withenergy extracted from the outgoing exhaust gases.Every unit of energy transferred to the air isone less that must be provided by burning fuel.3.2 - Load or charge preheating using heat from flue orexhaust gas or other source of waste heatInstead of exhausting flue gases from the process athigh temperatures, they are passed over incomingcold charge materials. This raises the load partway to its processing temperature and lowers theamount of energy need to support the process.3.3 - Heat cascading - use of flue or exhaust gas heatfrom higher temp. process to supply heat to lowertemperature processesWaste gases from one process can be usedto heat a lower temperature process.3.4 - Heat recovery from hot products or other heatsources (i.e. from walls) from a furnace - ovenProducts are often removed from ovens or furnacesat elevated temperatures and allowed to cool inthe open air. Cooling them with forced air in an enclosure will heat the air, which might be useful forheating another process.3.5 - Use of waste heat for water or air cooling, steamgeneration or absorption coolingHeated exhaust gases can be routed through wasteheat boilers, hot water generators or absorptionchillers to perform a variety of heating or cooling roles.4.1 - Proper insulation and maintenance of furnacestructure or partsMaintain furnace and oven insulation to avoid localized losses through the walls, roof and floor.Consider increasing the thickness or efficiency of the existing insulation to further lower wall losses.4.2 - Reduce-eliminate internal coolingSome furnaces contain components protected from overheating with cooling water and air.Make sureexcessive amounts of cooling media aren't used.4.3 - Reduce-eliminate openings and air leakage in thefurnaceOpenings allow radiant energy to escape and ambientair to leak in. As much as possible, seal thoseopenings and leaks. As an added measure, maintain thefurnace or oven at a slightly positive internalpressure to prevent in-leakage.5.1 - Furnace scheduling, loading, shut down - avoidingdelays, waits, coolingbetween operations etc.Heating equipment efficiency is highest at 100%of design capacity. Underloaded or overloadedequipment will consume more energy per unit of production.5.2 – Reducing weight of fixtures, trays,baskets etc.If fixtures, baskets and conveyors leave the heating process at higher temperatures than they entered,they contribute to wastedheat. Lowering their mass causes a corresponding decrease in the amount ofenergy they extract from the process.5.3 - Control (reduce) make up air for ovens to meet theprocess safety requirementsOvens handling flammable solvents or vapors must have sufficient fresh air ventilation to dilute thosecombustible materials well below their lower flammable limit. Any ventilation in excess of the saferequired amount wastes energy.5.4 - Eliminate use of continuous flame curtains, pilotswhere possibleFlame curtains and door pilots insure burnoff offlammable prepared atmospheres escaping aroundfurnace doors and out vents. If the process atmosphere has been changed to a non-flammable mixture,these ignition sources are no longer necessary.30Table 6. The pump system “pick-list” recommendation classifications that streamline assessments and data analysisPump assessment "pick-list" savings projectsDescription1.1 – Excessive valve friction loss part of the timeThrottled valve losses incurred periodically when system flow requirement has to bereduced.1.10 - Excessive friction loss due to system designCan be causedby unnecessary flow paths, excessive numbers of fittings, poor suctiongeometry, etc.1.11 - System specs exceed system requirementsOften the result of excessive conservatism during the design phase of a projector achange in process conditions/system function after the original design wasimplemented.1.12 - Change time of useSystems that are not required to operate continuously may be operated during a timeof day when the cost of electricity is lower.1.2 – Excessive valve friction loss all ofthe timeOften occurs when system capacity exceeds the current operating requirementor anundersized motor has been used.1.3 – Excessive recirculationUse of recirculation as amethod of flow control rather than turning off pumps orthrottling flow.1.4 – Unneeded flow pathFlow supplied to non-operating equipment to avoid changing valve alignment.1.5 - More flow than required to meet system requirementsSystem oversized, eitherby having a pump that is too large or operating multipleparallel pumps necessarily. Usually used with multiple parallel pumps. Use 1.11 foroversized pump.1.6 - Suction-related problemsInadequate suction head, poor suction geometry, or obstructions.1.7 - Less than optimal equipment for the applicationInstalled pump is the wrong sizeor type for current operating requirements.1.8 – Degraded equipment performanceEquipment wear/degradation (impeller damage,erosion, corrosion, wear rings, etc.)that prevents operation at design conditions.31Table 7. The compressed air system “pick-list” recommendation classifications thatstreamline assessments and data analysisCompressed Air assessment "pick-list"savings projectsDescription1.1 - Reduce air leaksEliminate compressed air waste to leakage.1.10 - Improve compressor intake conditionConditions that increase air density at the compressor intake will increase the delivered airflow and improve specificpower (kw / 100 scfm). This measure includes reducing pressure loss at the compressor intake and providing lower.1.11 - Heat recoveryAs much as 85% of the input energy to anair compressor is rejected as heat that can potentially be recovered andused to offset another energy use. To the extent that the alternate energy use is reduced, a system energy reductionis possible.1.2 - Improve end use efficiencyThe measure can cover a widerange of end use improvements thatreduce or eliminate the use ofcompressed air.See also items 3.1 through 3.9 which further classify the type of end use that is being improved.1.3 - Reduce system air pressureReducing system air pressureprovides two potential benefits. The energy of positive displacement compressors isreduced at lower working pressure. Also at reduced pressure unregulated air demands and leaks consume lesscompressed air. See also items 2.2, 2.3 and 2.4 for individual pressure reduction of supply or demand side pressure.1.4 - Improve trim compressor part loadefficiencyVarious compressor capacity control methods provide different power reduction characteristics at reduced capacity.Changing the control method of a single trim compressor can improve generation efficiency reducing specific power(kw / 100 scfm).1.5 - Adjust cascading set pointsAdjusting cascade set pointcan improve system efficiency by eliminating the part load operation of multiplecompressors.1.6 - Multiple compressor control (install /improve)Multiple compressor control can improve system efficiency by eliminating part load operation of multiplecompressors. The more sophisticated controls can alsorespond to changes in system air demand selecting theoptimum mix of various size compressors and compressorcontrol types to improve overall generation efficiency.1.7 - Reduce run timeReduce run time can result from system changes reducing air demand to a point that a compressor can simply beshut off during certain periods of time.1.8 - Add primary receiver volumePrimary storage installed for the purpose of reducing load / unload cycle rate of lubricant injected rotary screwcompressors. Longer unload time can reduce energy use by reducing part load power consumption.1.9 - Optimize air treatmentOptimizing air treatment can reduceenergy use by two means. First by reducing irrecoverable pressure drop throughtreatment equipment, system pressure might be reduced withthe associated energy savings. Second, if the air ispresently being treated to a greater level of contaminate removal than necessary, reducing the amount of airtreatment can reduce system energy use.For example changing from regenerative style to refrigerated style airdryers.2.1 - Stabilize control pressure signalControl pressure variations caused by system dynamics are corrected to provide a stablecontrol signal improvingcompressor efficiency.2.2 - Reduce supply side pressureReducing supply side operating pressure and the resulting lower compressor discharge pressurewill decreasepower consumption of positive displacement compressors.2.3 - Install flow pressure controlInstall a flow / pressure control to optimize compressed air storage and / or eliminate artificial demand. Bymaintaining a recoverable pressure differential storage of compressed air energy can be optimized. To the extentthat artificial demand is reduced, or stored energy preventsthe start-up of an air compressor in response to peak airdemand, system energy reduction is possible.2.4 - Reduce demand side pressureReducing demand side pressure to eliminate artificial demand. All unregulated air demand andleakage consumesless compressed air at reduced demand side operating pressure.32Table 7 (continued)Compressed Air assessment "pick-list"savings projectsDescription2.5 - Install primary storage for peak airdemandPrimary Storage to address peak air demand or permissive start-up event loads. Peak air demand may cause an aircompressor to operate, where-as application of storage may allow the compressor to be shutdown.2.6 - Install secondary storageApplication of Secondary Storage may allow savings through reduced system pressure, improved compressorcontrol, or other energy reduction measures madepossible through the used of Secondary Storage.2.7 - Reduce distribution piping pressuregradientExcessive piping resistance in distribution piping can leadto irrecoverable pressure loss, or excessive pressuredecay during peak airflow events. Eliminating piping pressure gradient can allow reduced system pressure withassociated energy savings.2.8 - Reduce component pressure dropPressure loss through a discrete component or group of components i.e. "filter pressure drop", "pressure dropthrough treatment", etc.2.9 - Resolve high pressure demandPerceived high pressure demands are modified or corrected to operate at normal working pressure. Valid highpressure demands are served by other means. The resultant system pressure reduction can save energy.3.1 – AspiratingUsing compressed air to introduce the flow ofanother gas (such as flue gas).As an alternative the application of afan or blower can provide a net energy reduction.3.10 – PaddingUsing compressed air to transport liquids and light solids. By pumping or using a low pressure blower as the energysource, a net energy reduction is possible.3.11 - Personal coolingComfort cooling with air, replacing compressed air use with a fan or air conditioner can be a net energy reduction.3.12 – SpargingAerating, agitation, oxygenating, or percolatingliquid with compressed air. Alternatives include pumping, mechanicalagitation, or a low pressure blower as the energy source. Alternatives can provide a net energy reduction.3.13 - Vacuum generationUsing air with venturi effect to create vacuum can be replaced by an electrically driven vacuum pump with net energyreduction.3.2 – AtomizingDelivering a liquid as an aerosol using compressed air may alternatively be accomplished with high pressure liquidpump and suitable spray nozzle. Alternatives can provide net energy reduction.3.3 - Cabinet coolingCooling of electrical panels with open tubesthat expand compressed air to create a cooling affect can alternativelybe accomplished with ventilation fans, heat tubes, or small mechanical refrigeration units.3.4 - Condensate drainOpen blowing drain, failed automatic drain, solenoid timer drain will waste compressed air. Appropriatemaintenanceactions and / or replacement with zero airloss style condensate drains can reduce waste.3.5 - Dense phase transportCompressed air is used to transport solids in a batch format. Alternatives such as mechanical conveyors or othermaterial handling methods can reduce energy use.3.6 - Diaphragm pumpsDiaphragm pumps are commonly found installed without regulators and speed control valves. By properly controllingthe pump air demand can be reduced. Alternatives may also include electrically driven pumps which provide.3.7 - Dilute phase transportDilute phase transporting solids suchas powdery material in a diluted format using compressed air. Alternativesmight include mechanical conveyors, or lower the use oflower pressure blowers or fans as the energy source.3.8 - Open blowingCompressed air blowing for cooling, drying, clean-up, etc. Alternatively a low pressure blower, vacuum, or somethinga simple a using a broom to sweep the floorcan result in a net energy reduction.3.9 - Open hand held blow guns or lancesAny unregulated hand held blowing is a variation of blowing described in item 3.8 withthe same alternatives andenergy reduction.4.1 – Other3334Table 8. The fan system “pick-list” recommendation classifications that streamline assessments and data analysisFan assessment "pick-list" savingsprojectsDescription1.1 - Use variable speed driveFans normally are driven by constant-speed motors. When the process load varies, the electronicVariable Speeddrive varies the speed of the motor to change the capacityof the fan in order to match the load. Also known asadjustable speed, variable frequency, or adjustable frequency drives.1.10 - Use factory designed inlet boxIf a 90 degree turn at thefan inlet is unavoidable, then a factory-designed inlet box isthe best way to minimizethose losses.1.11 - Improve arrangement of air intakeSharp-edged intakes can have significantly higher losses than flared or bell-mouth entrances.1.12 - Replace motorNewer motors are usually more efficient than the older motors found in some plants.1.13 - Shut off unneeded fansIf more fans are operatingthan the process needs, some fans can be shut off1.14 – OtherSometimes it is possible to do other things to improve the fans than the items on this list1.15 – Recover heat from exhaust airIf fan is handling hot exhaustair, it may be possible to recover heat (or cooling) from the air stream1.16 – Recover heat from stackIf the fan ishandling hot boiler exhaust gasses it may be possible to recover some of the heat1.17 - Reconfigure pollution controlequipmentSometimes older pollution control equipment my have a veryhigh pressure drop or may be configured inefficientlyby today’s best practices1.2 - Change belt drive ratioWhen fans that are oversized are belt-driven, the fan capacity can bede-rated to match the process needs bychanging the pulley ratio to slow the fan down.1.3 - De-tip fan bladesWhen fans that are oversized are direct-driven,the fan capacity can be de-rated to match the process needs bycarefully taking a little bit off the end of each blade on the impeller wheel.1.4 - Convert to belt driveWhen fans that are oversized are direct-driven, sometimes they can be converted to a belt drive inorder de-ratethe capacity to match process needs.1.5 - Use high-efficiency belt driveOlderstyle V-Belts can be upgraded to newer, more efficient belts made with modern materials and designs1.6 - Install new appropriately sized impellerSometimes the impeller can be changed out to a moreefficient configuration, ora different type in order toimprove performance1.7 - Install new appropriately sized fanIf the fan is the wrong type, performing poorly, or is too big or too small, then sometimes a new fan is the bestoption.1.8 - Replace outlet damper with variableinlet vanesOutlet Dampers are the least efficient means of controlling the fans. Variable inlet vanes usually have lowerlosses, although they too should be applied very carefully, and should not be used less than 70% open.1.9 - Rearrange ductwork at fan inlet ordischargePoor ductwork arrangements such as abrupt turns or abruptchanges in size immediatelyat the inlet or the outletof the fan can adversely performance.Table 9. Potential cost savings, energy savings, and reduction in CO2emissions from identified steamopportunities in pick-list categoriesYear 2006 - 08 Steam Savings Opportunity RecommendationsCost savings($/year)Source energysavings(MMBtu/year)Natural gassavings(MMBtu/year)CO2savings(metric tonsCO2/year)No. of timesthe opportunityapplied1.1 - Reduce Steam Demand by Changing the Process SteamRequirements$136,369,00023,393,00012,191,0001,718,0002531.2 - Use an Alternate Fuel$122,198,0005,908,00023,105,000937,000421.3 - Change Boiler Efficiency$69,516,0009,655,0006,513,000642,0003351.7 - Add or Modify Operation of Backpressure Steam Turbine$55,550,0007,793,000-1,155,000331,0001051.17 - Other and 6.2 - Other - Misc.$51,260,0005,975,0001,005,000299,0001591.8 - Add or Modify Operation of Condensing Steam Turbine$32,350,0003,149,0005,691,000270,000271.11 - Change Condensate Recovery Rates$32,185,0003,568,0002,725,000220,0001231.14 - Implement Steam Trap Maintenance Program$24,066,0003,232,0002,768,000215,0001331.16 - Improve Insulation$18,560,0002,456,0001,805,000158,0001971.10 - Modify Feedwater Heat Recovery Exchanger using BoilerBlowdown$11,884,0001,693,0001,452,00097,0001011.4 - Change Boiler Blowdown Rate$11,245,0001,263,0001,032,00073,000871.21 - Reduce or Recover Vented Steam$9,132,0001,338,000858,00084,000641.20 - Multiple Boiler Optimization$8,209,000199,000614,00081,000191.18 - Feedwater Heat Recovery - General$8,051,0001,191,0001,145,00064,000271.15 - Implement Steam Leak Maintenance Program$7,871,0001,580,000755,00059,0001001.13 - Modify Low Pressure Condensate Flash System$3,986,000532,000550,00027,000221.12 - Modify the Medium Pressure Condensate Flash System$2,002,000225,000225,00012,00081.5 - Install Blowdown Flash to Low Pressure Steam$1,913,000415,000245,00027,000251.6 - Change Steam Generation Conditions$1,419,000260,00024,00018,000191.19 - Deaerator Heat Recovery - General$1,021,000138,00090,0008,00061.9 - Modify Feedwater Heat Recovery Exchanger usingCondensate Tank Vent$684,00077,00082,0004,000103.1 - Use of flue or Exhaust gas heat for combustion airpreheating$302,00038,00027,0002,00022.2 - Clean heat transfer surfaces - radiant tubes, heatexchangers, heater tubes, electrical heating elements$233,00032,00032,0002,00013.5 - Use of waste heat for water or air cooling, steam generation$230,00024,00024,0001,00021.1 - Reduce oxygen content of flue (exhaust) gases$202,00028,00028,0001,00025.1 - Furnace scheduling, loading,shut down - avoiding delays,waits, cooling between operations etc.$74,0000001Grand Total$610,511,00074,163,00061,831,0005,349,000187035Table 10. Potential cost savings, energy savings, and reduction in CO2emissions fromidentified process heatingopportunities in pick-list categoriesYear 2006 - 08 Process Heating Savings OpportunityRecommendationsCost savings($/year)Source energysavings(MMBtu/year)Natural gassavings(MMBtu/year)CO2savings(metric tonsCO2/year)No. of timesthe opportunityapplied3.1 - Use of flue or Exhaust gas heat for combustionair preheating$44,808,0005,871,0005,495,000320,000996.2 - Other - Misc.$36,426,0004,428,0003,677,000244,000841.1 - Reduce oxygen content of flue (exhaust)gases$28,963,0004,114,0003,092,000246,0001643.4 - Heat recovery from hot products or otherheat sources$24,382,0003,633,0001,869,000207,000423.3 - Heat cascading - use of flue orExhaust gas heat from highertemp. process to supply heat to lower temperature processes$23,214,0003,223,0001,843,000164,000561.5 - Use of oxygen for combustion$21,315,0003,153,0002,588,000190,000351.3 - Use of proper heating methods - replace inefficient anduneconomical methods with economical/efficient system$19,821,0002,352,0002,163,000130,000464.1 - Proper insulation and maintenance of furnace structure/parts$18,677,0002,778,0002,039,000164,0001063.2 - Load or charge preheating usingheat from flue or exhaust gas$15,874,0001,966,0001,876,000106,000633.5 - Use of waste heat for water or air cooling,steam generation$12,658,0002,075,000531,000119,000205.1 - Furnace scheduling, loading, shut down - avoiding delays$12,330,0001,331,0001,298,00071,000364.3 - Reduce-eliminate openings and air leakage inthe furnace$11,040,0001,463,0001,298,00083,000671.6 - Use of process or exhaust air for combustion$8,104,000845,000845,00045,000166.1 - Other - Measures not directly related toprocess heating$7,814,000966,000-268,50058,000331.4 - Use of alternate fuel or energy source$7,438,0002,457,0001,038,000198,000114.2 - Reduce-eliminate internal cooling$6,671,000592,000536,00029,000101.2 - Eliminate excess unburned hydrocarbons (CO, H2, CH4, sootin the exhaust gases)$6,593,000831,000831,00044,000112.1 - Improving heat transfer in a furnace-oven$5,428,000713,000380,00040,000155.3 - Control (reduce) make up air for ovens to meet the processsafety requirements$2,705,000303,000318,00016,000142.2 - Clean heat transfer surfaces- radiant tubes, heat exchangers,heater tubes, electrical heating elements$2,224,000288,000209,00011,00091.16 - Improve Insulation$1,920,000237,000223,00012,00071.7 - Use of outdoor air for combustion ormake-up air$544,00054,00054,0003,00045.4 - Eliminate use of continuous flame curtains, pilots$181,00025,00025,0001,00031.3 - Change Boiler Efficiency$176,00018,00018,0001,00081.1 - Reduce Steam Demand by Changing the Process SteamRequirements$81,0008,0008,000035.2 - Reducing weight of fixtures, trays, baskets etc.$72,0007,0007,000031.20 - Multiple Boiler Optimization$12,0002,0002,00001Grand Total$319,469,00043,733,00031,994,0002,502,00096736Table 11. Potential cost savings, energy savings, and reduction in CO2emissions fromidentified pumpingopportunities in pick-list categoriesYear 2007 - 08 Pump Savings OpportunityRecommendationsCost savings($/year)Source energysavings(MMBtu/year)Electricitysavings(MWh/year)CO2savings(metric tonsCO2/year)No. of times theopportunityapplied1.2 - Excessive valve friction loss all ofthe time$4,481,000938,00027500055,000711.9 - Other$4,127,000761,00022300044,000361.7 - Less than optimal equipment for the application$2,359,000426,00012500025,000531.1 - Excessive valve friction loss part ofthe time$1,697,000304,0008900018,000251.5 - More flow than required to meet systemrequirements$1,298,000224,0006600013,000301.3 - Excessive recirculation$1,016,000175,0005100010,000221.8 - Degraded equipment performance$448,00068,000200004,000121.12 - Change time of use$334,00046,000130003,00061.10 - Excessive friction loss due to system design$206,00034,000100002,00031.11 - System specs exceed system requirements$200,00030,00090002,00031.4 - Unneeded flow path$178,00027,00080002,00081.6 - Suction-related problems$15,0002,0001000011.1 - Use Variable Speed Drive$10,0002,000100002Grand Total$16,368,0003,038,000890,000177,0002723738Table 12. Potential cost savings, energy savings, and reduction in CO2emissions fromidentified compressed airopportunities in pick-list categoriesYear 2007 - 08 Compressed Air Savings OpportunityRecommendationsCost savings($/year)Source energysavings(MMBtu/year)Electricitysavings(MMBtu/year)CO2savings(metric tonsCO2/year)Number of timesthe opportunityapplied1.2 - Improve End Use Efficiency$4,469,000551,000161,00032,0001001.1 - Reduce Air Leaks$3,763,000714,000209,00042,000921.6 - Multiple Compressor Control (install/ improve)$2,997,000546,000160,00032,000591.3 - Reduce System Air Pressure$1,656,000294,00086,00017,000624.1 - Other$1,582,000287,00084,00017,000343.8 - Open Blowing$1,355,000233,00068,00014,000231.4 - Improve Trim Compressor Part LoadEfficiency$806,000146,00043,0009,000201.7 - Reduce Run Time$730,000140,00041,0008,000243.12 - Sparging$359,0009,0003,0001,00031.5 - Adjust Cascading Set Points$319,00044,00013,0003,000103.1 - Aspirating$194,00035,00010,0002,00011.9 - Optimize Air Treatment$189,00023,0007,0001,00023.6 - Diaphragm Pumps$164,00031,0009,0002,00082.2 - Reduce Supply Side Pressure$154,00031,0009,0002,00091.11 - Heat Recovery$143,00026,0008,0001,00031.10 - Improve Compressor Intake Condition$122,00026,0008,0002,00092.4 - Reduce Demand Side Pressure$78,00019,0006,0001,00032.3 - Install Flow Pressure Control$68,00013,0004,00080043.5 - Dense Phase Transport$62,00012,0004,00070013.4 - Condensate Drain$57,0007,0002,00050043.3 - Cabinet Cooling$37,0007,0002,00050031.8 - Add Primary Receiver Volume$33,0006,0002,00040052.7 - Reduce Distribution Piping Pressure Gradient$18,0004,0001,00025022.8 - Reduce Component PressureDrop$10,0002,0001,00012022.6 - Install Secondary Storage$9,0002,0001,00012012.5 - Install Primary Storage for Peak Air Demand$9,0001,000010013.13 - Vacuum Generation$7,0001,000010013.7 - Dilute Phase Transport$4,00080005013.9 - Open hand held blow guns or lances$3,0003000201Grand Total$19,398,0003,213,000942,000188,000488Table 13. Potential cost savings, energy savings, and reduction in CO2emissions fromidentified fanopportunities in pick-list categoriesYear 2007 - 08 Fan Savings OpportunityRecommendationsCost savings($/year)Source energysavings(MMBtu/year)Natural gassavings(MMBtu/year)CO2savings(metric tonsCO2/year)Number of timesthe opportunityapplied1.14 - Other$18,034,0003,044,000892,00081,000231.16 - Recover heat from stack$8,000,0001,320,000387,00077,00011.1 - Use Variable Speed Drive$5,176,000925,000271,00054,000651.7 - Install new appropriately sizedfan$4,172,000670,000196,00039,000321.13 - Shut off unneeded fans$2,124,000326,00096,00018,000131.6 - Install new appropriately sized impeller$1,811,000379,000111,00022,000141.15 - Recover heat from exhaustair$931,000151,00044,0009,00011.2 - Change belt drive ratio$271,00050,00015,0003,000171.11 - Improve arrangement of air intake$121,00017,0005,0001,00041.9 - Rearrange ductwork at fan inlet ordischarge$91,00010,0003,00060011.10 - Use factory designed inlet box$40,0006,0002,00040011.3 - De-tip fan blades$21,0004,0001,00025021.4 - Convert to belt drive$15,0002,0001,0001501Grand Total$40,805,0006,903,0002,023,000306,00017539Table 14. Estimated payback periods for energy savings opportunities identified in the 2006, 2007, and 2008Save Energy NowassessmentsPayback categoryNumber of identifiedopportunitiesPotential cost savings($/year)Potential total source energy savings(MMBtu/year)Potential total CO2emissionreduction (metric tons/year)Payback data summary for all assessment completed in 2006 - 080 - 9 months1456$363,595,00055,394,0003,365,0009 months - 2 years1211$340,858,00040,071,0002,325,0002 - 4 years720$221,865,00024,301,0001,929,0004+ years395$87,231,00013,569,0001,061,000spinoff41$31,467,0003,000,000160,000Totals3,823$1,045,015,000136,335,0008,839,000Payback data summary for steam assessment completed in 2006 - 080 - 9 months736$207,885,00033,510,0002,063,0009 months - 2 years596$195,153,00020,276,0001,212,0002 - 4 years345$143,433,00012,016,0001,320,0004+ years166$50,569,0007,434,000706,000spinoff15$12,318,000907,00048,000Totals1,858$609,359,00074,143,0005,348,000Payback data summary for process heating assessment completed in 2006 - 080 - 9 months336$100,949,00013,823,000826,0009 months - 2 years316$123,631,00016,400,000916,0002 - 4 years202$57,666,0008,265,000468,0004+ years92$19,443,0003,205,000184,000spinoff10$17,380,0002,035,000108,000Totals956$319,069,00043,728,0002,502,000Payback data summary for fan assessment completed in 2007 - 080 - 9 months33$2,794,000441,00025,0009 months - 2 years42$9,132,0001,219,00068,0002 - 4 years55$15,059,0002,930,00078,0004+ years45$13,820,0002,313,000135,000spinoff0$000Totals175$40,805,0006,903,000306,00040Payback categoryNumber of identifiedopportunitiesPotential cost savings($/year)Potential total source energy savings(MMBtu/year)Potential total CO2emissionreduction (metric tons/year)Payback data summary for compressed air assessment completed in 2007 - 080 - 9 months224$8,573,0001,524,00089,0009 months - 2 years166$6,604,0001,150,00067,0002 - 4 years48$1,837,000370,00022,0004+ years44$810,000149,0009,000spinoff6$1,573,00020,0001,000Totals488$19,398,0003,213,000188,000Payback data summary for pump assessment completed in 2007 - 080 - 9 months62$4,340,000901,00053,0009 months - 2 years83$5,398,000911,00053,0002 - 4 years69$3,845,000718,00042,0004+ years48$2,589,000469,00027,000spinoff10$196,00038,0002,000Totals272$16,368,0003,038,000177,00041Table 15. Steam assessments — potential percentage savings in plant energy costs and source-energy usefrom all identified opportunities, by pick-list categoryPick-list category of identified savings opportunitiesFrequencyAverage energy costsavings (%)Average source-energy savings (%)1.2 - Use an Alternate Fuel4215.2*6.52.2 - Clean heat transfer surfaces - radiant tubes, heat exchangers12.62.51.1 - Reduce Steam Demand by Changing theProcess Steam Requirements2532.82.11.8 - Add or Modify Operation of Condensing Steam Turbine272.91.41.20 - Multiple Boiler Optimization192.21.21.18 - Feedwater Heat Recovery - General271.51.11.19 - Deaerator Heat Recovery - General61.00.91.7 - Add or Modify Operation of Backpressure Steam Turbine1052.20.91.3 - Change Boiler Efficiency3351.30.91.14 - Implement Steam Trap Maintenance Program1330.80.61.1 - Reduce oxygen content offlue (exhaust) gases20.80.81.21 - Reduce or Recover Vented Steam641.00.71.12 - Modify the Medium PressureCondensate Flash System81.30.71.13 - Modify Low Pressure Condensate Flash System221.00.71.11 - Change Condensate Recovery Rates1230.90.61.14 - Implement Steam Trap Maintenance Program1330.80.61.9 - Modify Feedwater Heat Recovery Exchanger using Condensate Tank Vent100.60.53.5 - Use of waste heat for water or air cooling,steam generation or absorption cooling20.70.51.6 - Change Steam Generation Conditions190.50.41.16 - Improve Insulation1970.60.41.10 - Modify Feedwater Heat Recovery Exchanger using Boiler Blowdown1010.50.41.5 - Install Blowdown Flash to Low Pressure Steam250.50.33.1 - Use of flue or Exhaust gas heat for combustion air preheating20.40.31.15 - Implement Steam Leak Maintenance Program1000.40.31.4 - Change Boiler Blowdown Rate870.40.26.2 - Other - Misc.10.20.15.1 - Furnace scheduling, loading, shut down - avoiding delays, waits, cooling between operations10.40.0* Includes energy savings from switching to an opportunity fuel.42Table 16. Process heating assessments — potential percentagesavings in plant energy costs and source-energy usefrom all identified opportunities, by pick-list categoryPick-list category of identified savings opportunitiesFrequencyAverage energycost savings (%)Average source-energysavings (%)1.4 - Use of alternate fuel orenergy source116.6*5.63.5 - Use of waste heat for water or air cooling,steam generation or absorption cooling206.04.91.3 - Use of proper heating methods - replace inefficient methods with efficient system463.73.33.4 - Heat recovery from hot productsor other heat sources423.42.91.5 - Use of oxygen for combustion353.32.73.1 - Use of flue or Exhaust gas heat forcombustion air preheating992.52.45.3 - Control (reduce) make up air for ovens to meet the process safety requirements142.72.35.1 - Furnace scheduling, loading, shut down- avoiding delays, waits, etc.363.12.32.1 - Improving heat transfer ina furnace-oven152.12.33.3 - Heat cascading - use of flue or Exhaust gasheat from higher temp. process562.52.23.2 - Load or charge preheating using heat from flue or exhaust gas or other source of waste heat631.71.41.1 - Reduce oxygen content of flue (exhaust) gases1641.31.24.3 - Reduce-eliminate openings and air leakage in the furnace671.41.16.1 - Other - Measures not directly related to process heating331.81.14.1 - Proper insulation and maintenance offurnace structure or parts1061.21.02.2 - Clean heat transfer surfaces - radiant tubes, heat exchangers, heater tubes90.80.91.16 - Improve Insulation70.70.94.2 - Reduce-eliminate internal cooling101.50.81.7 - Use of outdoor air for combustion or make-up air40.90.81.6 - Use of process or exhaust air for combustion161.10.71.3 - Change Boiler Efficiency80.80.71.1 - Reduce Steam Demand by Changing the Process Steam Requirements30.80.61.2 - Eliminate excess unburned hydrocarbons (CO,H2, CH4, soot in the exhaust gases)110.70.55.4 - Eliminate use of continuous flame curtains, pilots where possible30.30.35.2 - Reducing weight of fixtures, trays, baskets etc.30.20.21.20 - Multiple Boiler Optimization10.010.016.2 - Other - Misc.843.12.9* Includes energy savings from switching to an opportunity fuel.43Table 17. Compressed air assessments — potential percentagesavings in plant energy costs and source-energy usefrom all identified opportunities, by pick-list categoryPick-list category of identified savings opportunitiesFrequencyAverage energy costsavings (%)Average source-energysavings (%)3.1 - Aspirating11.31.41.4 - Improve Trim Compressor Part Load Efficiency201.01.03.3 - Cabinet Cooling30.60.73.4 - Condensate Drain40.70.73.8 - Open Blowing230.50.61.6 - Multiple Compressor Control (install / improve)590.50.61.1 - Reduce Air Leaks920.50.51.7 - Reduce Run Time240.50.54.1 - Other340.50.51.5 - Adjust Cascading Set Points100.40.41.11 - Heat Recovery30.30.33.5 - Dense Phase Transport10.60.33.6 - Diaphragm Pumps80.30.31.2 - Improve End Use Efficiency1000.50.31.9 - Optimize Air Treatment20.60.32.6 - Install Secondary Storage10.30.31.3 - Reduce System Air Pressure620.30.32.8 - Reduce Component Pressure Drop20.20.22.4 - Reduce Demand Side Pressure30.30.23.12 - Sparging30.40.22.7 - Reduce Distribution PipingPressure Gradient20.20.22.3 - Install Flow Pressure Control40.20.21.10 - Improve Compressor Intake Condition90.10.11.8 - Add Primary Receiver Volume50.20.12.2 - Reduce Supply Side Pressure90.20.12.5 - Install Primary Storage for Peak Air Demand10.10.13.13 - Vacuum Generation10.050.083.7 - Dilute Phase Transport10.040.023.9 - Open hand held blow guns or lances10.020.0144Table 18. Pumping assessments — potential percentage savings in plant energy costs and source-energy usefrom all identified opportunities, by pick-list categoryPick-list category of identified savings opportunitiesFrequencyAverage energy costsavings (%)Average source-energysavings (%)1.9 - Other360.40.41.10 - Excessive friction loss due to system design30.30.41.1 - Excessive valve friction loss part of the time250.40.31.3 - Excessive recirculation220.30.21.2 - Excessive valve friction loss all of the time710.30.21.11 - System specs exceed system requirements30.20.21.8 - Degraded equipment performance120.20.21.7 - Less than optimal equipmentfor the application530.20.21.5 - More flow than required to meet system requirements300.20.21.4 - Unneeded flow path80.10.11.12 - Change time of use60.20.11.1 - Use Variable Speed Drive20.10.11.6 - Suction-related problems10.030.044546Table 19. Fan assessments — potential percentage savings in plant energy costs and source-energy usefrom all identified opportunities, by pick-list categoryPick-list category of identified savings opportunitiesFrequencyAverage energy costsavings (%)Average source-energysavings (%)1.15 - Recover heat from exhaust air15.53.01.16 - Recover heat from stack12.22.51.13 - Shut off unneeded fans131.11.51.14 - Other232.41.11.7 - Install new appropriately sized fan320.70.71.6 - Install new appropriately sized impeller140.50.41.2 - Change belt drive ratio170.30.31.10 - Use factory designed inlet box10.30.21.1 - Use Variable Speed Drive650.20.21.11 - Improve arrangement of air intake40.10.11.9 - Rearrange ductwork at faninlet or discharge10.70.11.4 - Convert to belt drive10.10.11.3 - De-tip fan blades20.10.1