Industrial Energy Management VC

Energy Management
Opportunities
Reduce Energy Intensity and
Carbon Emissions by Changing the
Way You Use Energy
This document was specifically prepared to aid Tech Resources clients that wish to inform their customers about available
energy management solution options that these customers may wish to consider. Any other use of this material (in whole or in
part) is not allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.
2009 Tech Resources, Inc.
Energy Management
Mike Carter
Mark Farrell
Energy Management Benefits

Bottom line cost savings today!
Energy
Maintenance
Reduced noise levels

Better indoor air quality
Reduced air emissions
Energy Management Opportunities
Basics
Energy Management
Insulation
HVAC
Lighting
Heating Systems
Motors
Transformers
Compressed Air
Energy Efficiency Basics

Power versus Energy
Kilowatt (kW) is a measure of power, like the
speedometer of your car that records the
rate at which miles are traveled.
A bigger engine is required to travel at a faster rate.

Peak power demand is usually measured as an average
over a 15-minute period.
Spikes and surges from motor startup and other short-term
anomalies have little influence on peak demand.
Kilowatt-hour (kWh) is a measure of energy/load

consumptionsimilar to the odometer on your car
which measures miles traveled.
Energy Efficiency Basics

Power versus Energy (contd)
Energy Cost = Energy Consumption x Unit Cost =
kWh x $/kWh
A 113-Watt four-lamp light fixture costs about $66 annually

when operating 16 hr/day (113 W x 5,840 hr x $0.10/kWh
1,000 W/kW)
Motor power (kW) = Horsepower x 0.746/efficiency

A 10 HP motor = 10 HP x 0.746/0.90 = 8.3 kW
A 10 HP motor costs about $4,850 annually (8.3 kW x 5,840 hr
x $0.10/kWh) when operating 16 hr/day
Pay the price for improved energy efficiency!
The operating cost over the lifetime of a motor or light fixture

can far exceed the original purchase price.
Energy Basics
Load Factor
Ratio of average load over peak load
LF = kWAvg/kWP = kWh/hrs kWP
Assume 30-day billing
(30 x 24 hrs = 720 hrs)

10,000 kWh load
21 kW peak
LF = 10,000/720 21 kW
LF = 66%
Energy Basics
Peak Demand Curtailment
Separate loads into three categories:
Life, health, and safety-driven

Mission critical
Non-critical
Start by considering curtailment of non-critical loads
Non-safety lighting
HVAC
Consider installing sub-metering to identify high

intensity loads
Energy Basics
Power Factor
Real/active power (kW) does real work
Reactive power (kVAR) bound up in magnetic fields
Apparent power (kVA) must be supplied by utility to
accommodate reactive component
PF = kW/kVA
kVA2 = kW2 + kVAR2
(kVA) = (kW) + (kVAR)
= (75) + (75) = 11,250
Apparent Power = 11,250 = 106 kVA
Then: Power Factor = kW/kVA = 75/106 = 70.8%
Energy Basics
Power Factor
Add capacitance to correct power factor
Does not change demand (kW) or save much
energy (kWh)
10
Energy Basics
Carbon Footprint
Metric tons (2,205 lbs or 19,550 ft3) of CO2
Natural
Gas - 12 lbs CO2/ccf

Electricity - 0.95 lbs CO2/kWh
Carbon = CO2 3.67 (100 tons CO2 = 27 tons C)
Pine trees can absorb roughly 1 metric ton of carbon per
acre per year
Direct emissions from company-owned stacks

Indirect emissions from travel
11
Corporate Energy Management

Key Components of Energy Management
Commitment by upper level management
Clearly stated goals on energy efficiency, waste
reduction, and sustainability
Delegation of responsibility and accountability to the
appropriate personnel
Sustained tracking and assessment of energy use and
technology application
Continuous investigation of potential energy reduction
projects
12
Corporate Energy Management

Energy Information Systems
Measure and Evaluate
Knowledge is power
If you can't measure it, you can't manage it!"
Access to real-time energy consumption/demand and cost data

across multiple plants and facilities
Plan
Benchmark
Against yourself
Against similar facilities
Prioritize solutions
Implement
13
Insulation
Insulation has diminishing returns
R-value is resistance to heat flow (additive)
R-7 + R-21 = R-28 (4 times R-7, and 75% better than R-7)
R-7 + R-49 = R-56 (8 times R-7, but only 12% better than R-28!)
U-value is conductance of heat; inverse of R-value

U(R-7) = 1/7 = 0.143
U(R-56) = 1/56 = 0.018 (87% less than R-7)
U(R-21) = 1/21 = 0.048 U(R-28) = 1/28 = 0.036 (75% less than R-7)
Insulating Value
U-Value (Btu/ft.2 F hr)
0.300
R-3.5
0.250
0.200
R-7
0.150
0.100
R-14
R-28
0.050
R-56
0.000
0
10
15
20
25
30
R-Value
14
35
40
45
50
55
60
Insulation
Insulate steam pipes with at least " insulation
For a 350F process steam pipe, savings are $5,000 for 2"
dia. and $10,000 for 4" dia. pipe

Diminishing returns for insulation
thickness > "
Type
Fiberglass
2.2-3.1
Vermiculite/perlite
2.4-2.8
Polystyrene
4.0-5.0
Polyurethane
Polyisocyanurate
15
R-value per inch
6.0
6.0-7.1
HVAC
Implementation
Load (kWh)
Peak (kW)
Temperature Setback
Economizers
Heat/Energy Recovery Ventilators/Wheels
Chiller Water Temperature
New HVAC Equipment
Geothermal Heat Pump
Air Doors/Curtains
16
HVAC
Temperature Setback/Setforward
Save 3% per F per 24 hrs
72F 68F (4F) for 12 hrs
saves 6%
Economizers Bring in Cool Outside Air

Typical 2 to 5 year payback for economizers
Most appropriate for large systems
(>5 tons in West and >11 tons in Midwest)
Not very effective in high humidity climates
17
HVAC
Heat Recovery Ventilators
Can recover about 60% to 70% of heat in exiting air
A solution to ASHRAE 62 IAQ requirements
Photo source: George Retseck Illustrations
18
HVAC
Energy/Enthalpy/Desiccant Wheels
Can recover about 70% to 80% of the energy in the
exiting air and deliver that energy to the incoming air.
Desiccant wheels are most cost effective in climates with

extreme winters or summers, and where fuel costs are high.
In mild climates, the cost of the additional electricity

consumed by the system fans and drum motor may
exceed the energy savings from not having to condition
the supply air.
19
HVAC
Narrow Your Chiller Water Temperature Set Points
Typical conditions are chilled water temperature of 42F
and condensing water temperature of 80F to 85F.
2% savings per F that chilled water temperature is raised

5F to 10F increase is possible; more may cause damage and
reduce cooling capacity (ton rating)
Efficiency benefits from lowering condensing water

temperature are offset by increased fan and pump
operation, along with reduced cooling capacity.
Variable Frequency Drives (VFDs) and oversizing the cooling

tower can help
The larger the system, the greater the net energy savings
20
HVAC
Upgrade Older HVAC (10 to 15 years)
Chillers: 0.8 kW/ton 0.5 kW/ton (37% less!)
Unitary rooftop: 1.5 kW/ton 1.2 kW/ton (20% less!)
Geothermal or Water-Source Heat

Pump
Roughly 30% savings compared to
AC/Boiler or AC/Furnace
combination
Geothermal requires higher capital
investment and requires significant
amounts of real estate
New construction accommodates
verticals and pond loop
21
HVAC
Use Air Doors/Curtains
A door 14 feet wide and 11feet high, indoor
temperature of 70F, outdoor temperature of
20F, zero wind velocity, loses 600,000
Btu/h at a cost of roughly $7 per hour
Any wind at all triples the loss!

Air door recovers 75% of heat loss
1 to 2 year payback possible ($3,500 cap. + $100 op.)
Exhaust fans (negative pressure) and wind tunnel
effect are problems
22
Lighting
Implementation
Load
(kWh)
Peak
(kW)
Replace T12 with T8 or T5
Replace Metal Halide with T8 or T5HO
Replace Incandescent with CFL
23
Lighting
Replace existing T12 fluorescent lamps with T8 fluorescent lamps (up
to 30% savings).
Four-lamp T12 versus T8 Fixtures
Lamp Type
Fixture
Watts
Fixture
Lumens
LPW
F32T12
148
9,120
62
F32T8
113
10,600
94
No magnetic ballasts for new installations sold or manufactured after

March 2005.
More stringent magnetic ballast performance requirements after July

2009.
No magnetic ballasts manufactured for replacement after June 2010.

24
Lighting
Super T8 lamps, with high-efficiency ballasts, are high lumen (>3,000
versus 2,850 std.) and extended life (>24,000 versus 20,000 hrs std.)
products.
Only saves energy when combined with a lower ballast factor ballast.
Type
Initial
Lumens
Initial
Watts
Ballast
Factor
Fixture
Lumens
Fixture
Watts
T8
2,950
33
0.85
2,496
28
Super T8
3,200
34
0.78
2,496
26
Group relamping recommended at 60% to 80% of rated life.

Every 2 to 3 years for 20,000 hour fluorescents
Can be 30% to 40% cheaper to group relamp due to labor savings
25
Lighting
Metal Halide (MH) versus Fluorescent for Highbay
Probe start (PS) MH with low lumen maintenance (<65%) is best target for
replacement
The lumen maintenance of metal halides can decrease to 45% during its
lifetime, whereas fluorescents maintain 90% to 95% in optimal conditions.
Compare 320 W PS MH with 20,000 EOL lumens and six F32T8 with
18,000 EOL lumens at 220 system watts
Lumen output of fluorescents declines with heat/cold
Compact Fluorescent Lighting (CFL)

You get the same or more light output (lumens) with a
75% energy reduction and over six times the rated life!
Energy savings far outweigh difference in lamp price

Use reflector flood CFLs in recessed can lights
Issue of mercury content can be addressed
26
Heating Systems
Implementation
Load (Btu)
Load (kWh)
Peak (kW)
Waste Heat Absorption Chillers
Industrial Heat Pumps for Drying/Heating
Radio Frequency/Microwave Drying/Heating
Gas Burner Air:Fuel Ratio
Modern Gas Burners/Controls
Steam Traps
Stack Heat Recovery
Infrared Booster Heaters
Induction Process Heating
27
Heating Systems
Measuring Boiler Efficiency
Fuel-to-steam efficiency is the best efficiency metric
Boiler output (Btu)/boiler input (Btu)

Accounts for both combustion and thermal efficiency, radiation, and
convection losses
Efficiency mainly influenced by boiler design
Number of passes more important than add-on (turbulator)

Burner/boiler compatibility (accounts for geometry, heat transfer, and so on)
Burner controls (independent control of fuel and air is best)
Heating surface (square feet/boiler HP; 5 ft2/HP is desired)
Other factors
Flue gas temperature directly correlates with efficiency

Fuel hydrogen/carbon ratio (fuel oil > natural gas)
Excess air (10% to 12%)
Ambient temperature (every 40F ~ 1% efficiency change)
28
Heating Systems
Proper Boiler Air:Fuel Ratio
Combustion Efficiency of Natural Gas
Excess %
Temp. F (Flue-Comb.)
Air
Oxy
200F
600 F
9.5
2.0
85.4%
76.0%
28.1
4.0
84.7%
74.0%
81.6
6.0
82.8%
68.2%
Efficiency improvements
82.8% 85.4% = 2.6%
68.2% 76.0% = 7.8%
29
Heating Systems
Upgrade to Modern Burners
Motor-controlled flue gas recirculation dampers

Swirl vanes
Turbulence enhancement
Premixing chambers
Leak-tight modulating air dampers
Tangential diluent injection
Rotating concentric blade air registers
Fuel atomizers
Venturi tube air registers
Tapered burner tiles with baffles
30
Heating Systems
Use Electronic Burner Controls (typical savings)
Linkless burners have no backlash (1%)
Increased turndown (5%)
Burner on/off cycles and their associated cold air purges also
will be reduced
A second PID control (10%)
Some electronic fuel:air ratio controls have two internal

proportionalintegralderivative (PID) modulation circuits.
If a plant does not run continuously then this second PID
controls setpoint can be used to switch the boiler to a lower
steam pressure or hot water temperature during periods of
reduced activity.
Adaptive oxygen trim (2% to 3%)
Large boilers only (>$100,000 fuel per year)
31
Heating Systems
Use Electronic Burner Controls (contd)
Fan speed control
With mechanical cam control and with basic electronic fuel:air

ratio controls, processors sacrifice combustion efficiency at
low fire to achieve an improvement in burner turn-down.
By adding fan speed control, burner turn-down can be
increased without compromising efficiency, and additional fuel
savings can be achieved.
Boiler sequencing (lead/lag) control and

communication software
Boiler sequencing control enables the plant operator to achieve

better utilization and additional energy savings are possible.
32
Heating Systems
Fix Broken Steam Traps
One 1/8" diameter stuck-open steam trap
orifice on a large boiler can cost $1,000 (15
psig) to $5,000 (140 psig) per year in increased
natural gas consumption
1 lb/hr ~ 1,000 Btu/hr
There are Several Ways to Test Steam Traps

Plugged traps are cool while operating and leaking traps are
hot. Use a non-contact, infrared thermometer.
In acoustic testing, an inspector listens for the variances in the
acoustic patterns of working or failed traps.
The electronic procedure typically involves touching the trap
on the downstream side with the instruments contact probe
and adjusting the sensitivity to better hear the flow.
33
Heating Systems
Stack Heat Recovery
Each 40F reduction in stack
temperature results in a 1%
improvement in efficiency.
Preheating combustion air

A 200F air preheat saves 5%
Best applications >900F stack temperature
1,000F 800F results in 5% savings
Recuperators, regenerators, and heat exchangers

Infrared Booster Heaters
Reduces curing times of coatings by 25% to 40%
Best in conjunction with convection and for
thin simple shapes
34
Heating Systems
Absorption Chillers
Fueled by waste heat but high
capital costs
Best for high peak demand

charges, CFC or HCFC
environmental concerns, waste
heat temperature >270F and
>500 tons capacity
Yazaki Energy Systems (Plano, TX) and Thermax

(Piscataway, NJ) claim to have low temperature (185F
to 203F) absorption chillers (20 to 30 ton max
capacity)
35
Heating Systems
Industrial Heat Pumps

Process
Key Enabler
Applications
Separation
Reduced column pressure enables distillation

at low temperatures
Propane/propylene,
butane/butylenes
Concentration
Low (<50F) temperature lift results in gentle

evaporation cycle
Beer, sugar solutions, milk and

whey, juice, steep water, syrup
and radioactive waste.
Drying
Upper temperature limit; Slow dry time desired;

Continuous operation
Lumber and paper
Dehumidification
High temperature air used for drying; Slow dry

time desired
Brick, ceramics
Space Heating
Higher thermal efficiency than other furnaces
Shop, warehouse
36
Heating Systems
Radio Frequency/Microwave
Process
Key Enabler
Applications
Pre-drying
Selective heating (water only) to avoid product

damage; Speed
Fiberglass packaging and mats;

Dyed yarn spools; Ceramic
fiberboard, powder, and extrusions
Post-drying
(20%->8%)
Low final moisture content; Uniform (small

temperature gradient) heating; No surface
crust
Foods such as cookies, potato

chips, and pasta; Dry pet foods;
Polyurethane foam
Tempering
Volumetric heating; Speed
Frozen meats; Room temperature

bacon; Chocolate
Cooking
Reduce drip loss (water, fat, nutrients, and

flavor)
Sausage, bacon
Curing
Uniform heating; Precise temperature control;

Speed
Adhesives for wood and laminates
37
Heating Systems
Induction
Process
Key Enabler
Applications
Metallurgical processing
(Hardening, Tempering,
Annealing)
Selective heating; Speed;

In-line continuous process
Gear teeth; Cutting blades;

Pulleys; Axles; Camshafts;
Galvanized sheet
Preheating prior to deformation

(Forging; Swaging; Upsetting;
Bending; and Piercing)
Reduced scale formation;

Speed
Turbine engine blades; Billets; Mill

rolling of slabs and strips
Melting
Speed; Flexibility
Steel; Iron; Copper alloys;

Aluminum; Zinc
Brazing and Soldering
Localized heating; Precise

temperature control and
uniformity
Dissimilar materials; Carbide tips;

Turbine blades; Eyeglass frames
38
Motors and Transformers
Implementation
Load
(kWh)
Replace motors
Use variable speed drives
Right size the motor
Disconnect unused transformers
39
Peak
(kW)
Motors
Repair or Replace Motors
Replace motors <40 HP
Replace if cost of rewind >65% of new motor
Replace motors last rewound before 1980
Variable Speed Drives/Adjustable Speed Drives
Best for variable torque loads often found in variable flow
applications (pumps, fans, and blowers) and greater than

2,000 hours operation
Horsepower varies as the cube of speed/flow
Cut speed/flow by 50%, you cut energy consumption by
nearly 90%! (0.5 x 0.5 x 0.5 = 0.125)
Converts 60 Hz to 120 to 400 Hz in pulse width modulation
Pulse-width modulation most common

Current-source inverter used for 100+ HP motors
40
Motors
Right Size the Motor
Motor efficiency plummets at <40% rated load
Premium Efficiency Motors
Good motor efficiency varies
from about 85%
( 1 HP) to 95% (>75 HP)
NEMA Premium Efficiency
motors are 1% to 3% basis
points more efficient than
baseline (EPACT 1992)
41
Transformers
Transformer Losses
Remove power from unused transformers
No load losses (NL)
Caused by the magnetizing current

to energize the core
Do not vary according to the loading

on the transformer
<0.5% of rating (for example,

roughly 125 watts on a 50 kVA
transformer)
Full load losses (FL)
Heat losses, or IR losses, in the

winding materials
Roughly 5x NL losses (600 watts on a 50 kVA transformer)
High-Efficiency Transformer
Paying a little more upfront ($400 to $4,000) leads to long term

savings (>$20,000 for a 1500 kVA transformer)
42
Compressed Air
Implementation
Load
(kWh)
Only use when there is no other option
Fix leaks
Right size
Use variable speed compressor motor drives
Peak
(kW)
Implement heat recovery

Use two-stage, lubricated or centrifugal
43
Compressed Air
Compressed Air energy cost for 6,000 hrs

at $0.10/kWh = $125/CFM
At 4 CFM/HP, a 250 HP compressor costs about $125,000 annually
Only use compressed air when it is absolutely

necessary!
If possible, switch to motors, mechanical actuators, and other means

to accomplish the same function
Leaks often account for 20% to 30% of compressor

output
A 1/32" leak in a 90 psi compressed air system would cost
approximately $185 annually
44
Compressed Air
Compressors operate at highest efficiency at full load
or off
Optimum controls results in big savings
For example, at 50% full-load flow, kW input varies from 51% to 83%.
Percent kW Input at Operating Capacity
for Lubricant-Injected Rotary Screw
% FullLoad Flow
Load/No-load
(5 gal/cfm)
Modulation
Variable
Displace
Variable
Speed
90%
95%
97%
92%
91%
80%
92%
95%
83%
81%
70%
85%
90%
78%
71%
60%
78%
85%
68%
61%
50%
72%
83%
63%
51%
40%
63%
80%
60%
42%
Source: Improving Compressed Air System Performance: A Sourcebook for Industry, DOE
45
Compressed Air
Variable speed is best applied to compressors that
operate primarily as trim units, or as single units with
loads below 75% to 80% demand
Below 85% loading, variable displacement units
become less efficient than variable speed, and are
very poor at loads below 50%
Reducing system pressure by 10 psi saves 8% to 10%

Use " diameter hose for >3 HP tools or >50' lengths
46
Compressed Air
Heat Recovery
Air-cooled compressors offer recovery efficiencies of
80% to 90%
Ambient atmospheric air is heated by passing it across the

systems aftercooler and lubricant cooler.
As a rule, approximately 50,000 British thermal units per hour
(Btuh) of energy is available for each 100 cfm of capacity (at
full-load).
Air temperatures of 30F to 40F above the cooling air inlet
temperature can be obtained.
Space heating or water heating.
Water-cooled compressors offer recovery efficiencies

of 50% to 60% for space heating only.
Limited to 130F
47
Compressed Air
Reciprocating air cooled compressor has lowest first cost, but is
inefficient
Spend a little more for a two-stage unit and achieve better efficiency
Lubricated compressors are often more efficient than a similar nonlubricated unit, but they contribute oil content to the system and may
impact the compressor air quality
Air Compressor Efficiency Benchmarks
Reciprocal
Rotary Screw
Centrifugal
Air
cooled
Water
cooled
Water
cooled
Lubricated
Lubricated
Nonlube
Units
SingleStage
SingleStage
TwoStage
SingleStage
Two-Stage
TwoStage
BHP per 100

CFM
26-32
25
19-22
23-26
20-22
20-26
22-27
kW per 100
CFM
22-27
21
16-18
19-22
17-18
17-22
18-22
48
<250 HP
Questline
Go to www.questline.com
Provided by:
Tech Resources
2025 Riverside Drive
Columbus, OH 43221
800-824-0488
mcarter@questline.com
This document was specifically prepared to aid Tech Resources clients that wish to inform their customers about available
energy efficient options that these customers may wish to consider. Any other use of this material (in whole or in part) is not
allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.
49
Whats Next?
If you would like more information about the four strategies to increase cash flow,
contact your local Manufacturing Extension Partner.
Arizona Manufacturing Extension Partnership
California Manufacturing Technology Consulting
Maryland Technology Extension Service
Montana Manufacturing Extension Center
The Oklahoma Manufacturing Alliance
Rhode Island Manufacturing Extension Services
South Carolina Manufacturing Extension Partnership
Texas Manufacturing Assistance Center
University of Tennessee Center for Industrial Services
This document was specifically
prepared to aid Manufacturing
Extension Partnerships and their
customers. Any other use of this
material (in whole or in part) is not
allowed without the expressed written
consent of Tech Resources, Inc.,
2025 Riverside Drive, Columbus, OH
43221.
West Virginia Manufacturing Extension Partnership
50

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Energy Management

2009 Tech Resources, Inc.

2009 Tech Resources, Inc.

Energy Management Benefits

Reduced noise levels

2009 Tech Resources, Inc.

Energy Management Opportunities

2009 Tech Resources, Inc.

Energy Efficiency Basics

A bigger engine is required to travel at a faster rate.

Kilowatt-hour (kWh) is a measure of energy/load

2009 Tech Resources, Inc.

Energy Efficiency Basics

A 113-Watt four-lamp light fixture costs about $66 annually

Motor power (kW) = Horsepower x 0.746/efficiency

Pay the price for improved energy efficiency!

The operating cost over the lifetime of a motor or light fixture

2009 Tech Resources, Inc.

(30 x 24 hrs = 720 hrs)

2009 Tech Resources, Inc.

Life, health, and safety-driven

Start by considering curtailment of non-critical loads

Consider installing sub-metering to identify high

2009 Tech Resources, Inc.

2009 Tech Resources, Inc.

2009 Tech Resources, Inc.

Gas - 12 lbs CO2/ccf

Direct emissions from company-owned stacks

2009 Tech Resources, Inc.

Corporate Energy Management

2009 Tech Resources, Inc.

Corporate Energy Management

Access to real-time energy consumption/demand and cost data

2009 Tech Resources, Inc.

U-value is conductance of heat; inverse of R-value

2009 Tech Resources, Inc.

dia. and $10,000 for 4" dia. pipe

2009 Tech Resources, Inc.

R-value per inch

Heat/Energy Recovery Ventilators/Wheels

Chiller Water Temperature

New HVAC Equipment

Geothermal Heat Pump

2009 Tech Resources, Inc.

Economizers Bring in Cool Outside Air

2009 Tech Resources, Inc.

Photo source: George Retseck Illustrations

2009 Tech Resources, Inc.

Desiccant wheels are most cost effective in climates with

In mild climates, the cost of the additional electricity

2009 Tech Resources, Inc.

2% savings per F that chilled water temperature is raised

Efficiency benefits from lowering condensing water

Variable Frequency Drives (VFDs) and oversizing the cooling

2009 Tech Resources, Inc.

Geothermal or Water-Source Heat

2009 Tech Resources, Inc.

Any wind at all triples the loss!

2009 Tech Resources, Inc.

Replace T12 with T8 or T5

Replace Metal Halide with T8 or T5HO

Replace Incandescent with CFL

2009 Tech Resources, Inc.