Combustion, Cooling & Energy Conservation Workshop

Combustion, Cooling & Energy Conservation

Workshop

Combustion, Cooling & Energy Conservation

Workshop

Combustion, Cooling & Energy Conservation Workshop


Purpose

Help you• Save money• Reduce energy use • Reduce pollutant emissions

From your combustion, heating, and cooling operations



Governor Patrick Plans Conservation to Meet Rising Energy Needs

Aim is to avoid building new power plants

Make the State a Showcase for Energy Conservation



Program• 8:15 am Opening Session• 10:00 am -Coffee Break • 10:30 am Breakout Sessions• 11:30 am -Lunch• 1:00 pm Breakout Sessions• 2:00 pm -Break• 2:15 pm Panel – Energy Analysis• 3:30 pm Closing Remarks• 3:35 pm Tours



EPA’s Commitment to Energy Conservation & Municipal Energy

Challenge

Susan Studlien, Director

Office of Environmental Stewardship

EPA Region 1



State Energy Policy Changes to Encourage Energy Conservation &

Combined Heat & Power

David Cash

Assistant Secretary for Policy

Massachusetts Executive Office of Energy & Environmental Affairs



The Strategic Energy Management Process

Roy Crystal

Environmental Scientist

Assistance & Pollution Prevention Office

EPA Region 1

The Strategic Energy Management Aproach:How to

Reduce Energy Use, Cost, and Air Pollution

Roy CrystalU.S. EPA – Region 1

Combustion WorkshopCambridge, MA

June 27, 2007

Why Energy Performance?

– Energy use is the number one source of air pollution in NE and the nation

– When we use less energy, we reduce pollution that causes:

• Global warming

• Acid rain

• Smog and soot

• Mercury and Air Toxics

– Saves money

– Reduces business and financial risks

– Reduces strain on energy supplies: electricity blackouts/brownouts, natural gas shortages/costs

Strategic Energy Management Produces Superior Results

1. Reduce Demand – Energy Efficiency– Management, Operations, and Maintenance– Upgrade Technology

2. Clean Up Supply – On-Site and Purchased Energy– Efficient and properly sized boilers and chillers– Purchase Green Power– Combined Heat and Power (CHP)– On-Site Renewable Energy

3. Properly maintain your existing equipment (boilers and chillers)– Annual tuneup of boilers – required by NOx RACT in Massachusetts and other New

England states– Periodic maintenance according to a planned schedule; “continuous commissioning”

Reducing demand first is critical, because it makes supply side investments: Smaller, less expensive, more efficient, and cheaper to operate.

STEP 1:

Reduce Demand through Energy Efficiency

Based on successful practices of ENERGY STAR partners, EPA has identified the key components for a successful energy management program

Components of a Successful Energy Management Program

400% variation in energy use intensity of buildings

(Source: Commercial Buildings Energy Consumption Survey)

Variation that is not explained

by age, technology, hours, size, climate

EPA has extensively studied the status quo in building energy performance

Technology alone does not guarantee performance - management is critical

Weak Correlation: Code vs. Simulated EUI

y = 0.0021x

R2 = 0.1321

-20.0%

-10.0%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

0 20 40 60 80 100 120

Energy Star Score (based on National Average Occupancy)

% E

lect

rici

ty S

avi

ng

s re

lati

ve t

o c

od

e

Source: NBI, California Board for Energy Efficiency, EPA

California Office Buildings Buildings 20% better than code can have an energy performance score ranging from 1-100.

Not sending rightmarket signal.

• You can’t manage what you don’t measure!

• Until recently, a standardized, comparable metric of whole building energy performance did not exist.

• EPA’s Energy Performance Rating System developed to meet this need.

Do You Know How Your Facilities Perform?

Fuel Efficiency Rating: MPG

Is 10 MPG high or low for an automobile?

EPA Energy Performance Rating

Is 65.7 kBtu/sf/yr high or low for a building?

Performance Rating Systems

Common knowledge.

Even many building experts

don’t know.

Building Energy UseHighest Lowest

Nu

mb

er

of B

uild

ings

1001 25 50 75Benchmark Score

The rating system overlays a 1 to 100 scale over national census data, which gives

relative meaning to energy use

National Energy Performance Rating

How Does the Rating System Work?

Actual Energy Consumption Data (EIA Commercial Building Energy Consumption Survey [CBECS])

Easy-to-use web-based, simple data requirements

Easy-to-understand 1-100 performance score – “whole building mpg rating” – compared to peers in national building stock

Normalizes for Building Variables: weather, size, occupancy, hours, computers, other features

Use it to: Benchmark, Compare, Inform, Track and Measure, and Reward Success

Eligible Building Types

Hotels

Schools

Office Buildings Courthouse

Hospitals

Medical Offices

DormitoriesGrocery Stores

Warehouses

Time

Tune up LightingLoad

Reductions

Fan and Motor

Systems

PlantUpgrades

Focus on Sizing, Operations and Control

RO

I

Planning Improvements:The Five-Stage Approach

STEP 2:

Clean Up Supply through:Proper sizing

Combined Heat and Power

On and Off Site Renewable Energy

• 60% of building fan systems oversized on average 60%

(Source: EPA fan study)

• Chillers oversized by 50-200%

(Source: Lawrence Berkeley National Laboratory)

• Improper installation and poor maintenance

• Oversized equipment performs worse than its rated efficiency

Oversized Equipment is a Major Source of Inefficiency

Proper Sizing is Key When Replacing or Upgrading Equipment

• Assess energy use and reduce it– Everyone can improve energy efficiency

• Smaller units costs less• Properly sized equipment operates more

efficiently• Explore configurations that maximize

efficiency– E.g - Smaller units operated in series

Combined Heat and Power

• CHP – or cogeneration – is the generation of heat and

power from the same fuel source.

– Electricity primarily used on-site, but may be

sold back to grid. Grid can serve as back-up or

swing provider.

– Thermal energy used for heating/cooling or

process applications.

– CHP can work with numerous technologies

and fuels.

Advantages of CHP

CHP is more efficient than separate generation of electricity and heat:

• Higher efficiency translates to lower operating cost, but requires capital investment.

• On-site electric generation reduces grid congestion and avoids distribution costs.

• Higher efficiency reduces air emissions.

• Increased reliability and power quality.

Hospital of Saint Raphael, New Haven, CT

• Facility expanding; installed new residual

fuel oil-fired boiler in New Haven, CT EJ area – neighbors had health concerns

• City asked for EPA assistance to reduce air emissions from combustion sources

Compliance Assistance to Hospital of Saint Raphael

• EPA provided information on cogeneration options & potential energy, air pollution & cost savings, Energy Star benchmarking software

• Facilitated onsite engineering and contracting assessment of cogeneration options by contractors funded by EPA (Combined Heat and Power Applications Center - cogeneration experts from Eastern Ct. State University, UMass-Amherst, Pace University)

• Facility committed to construct 1.8 megawatt natural-gas fired cogeneration system – displaces purchased electric power and steam produced by onsite boiler; air emission reductions

On-Site Renewable Energy

• Broader application and lower cost than you may expect– State incentives available– Even small installation can have a big impact on

costs and risks

• Technologies– Wind– Solar– Ground Source Heating and Cooling– Dependent on site conditions and other factors

Opacity Problems & Particulate Emissions - Mystic Station, Everett, MA

Importance of Annual Boiler Tuneups & Improved Maintenance

• Annual boiler tuneups a NOx RACT requirement in Massachusetts and other New England States – ensures compliance (EPA inspections of facilities in New England with combustion sources planned in coming year)

• Higher efficiency will save fuel and money for you• Reduced emissions of greenhouse gases (CO, CO2),

NOx, SOx, air toxics (benzene)• Help meet any commitments for reducing greenhouse

gases

How do I pay for it?

• A variety of incentive programs exist in Massachusetts and other New England states:

– Energy efficiency - Utility programs– Free or reduced cost energy audits through utilities, universities, DOE, EPA

(CHP Partnership)– Forward capacity market – ISO New England– Renewable energy – Renewable Energy Trust, Massachusetts Technology

Collaborative– New incentives likely – RGGI, state legislation

• Energy efficiency cuts energy bills by 10-30+% • Federal and state tax credits• Sale of Renewable Energy Certificates (RECs)• Energy efficiency and clean and renewable energy can

dramatically reduce financial risks for businesses and institutions• Efficiency and supply upgrades increase asset value

Companies and Institutions can also earn Valuable Recognition

• EPA Voluntary Programs– ENERGY STAR Label;

Partner of the Year– Green Power Partnership– CHP Partnership

• State and Regional Awards/Recognition– Environmental Merit Awards

It’s not only about saving money!

Energy Efficiency and Clean Energy Reduce Costs, Risks, and Emissions

• Start with energy efficiency - assess and improve energy performance to reduce loads

• Right size central equipment - boilers, chillers, turbines, etc.

• Use appropriate clean and renewable technologies for on-site power generation: combined heat and power, solar, wind, etc.

• Take advantage of state and federal resources Funding, incentives, technical assistance, information, and recognition opportunities.

Contact Us

U.S. EPA – Region 1

Roy Crystal

Assistance & Pollution Prevention Unit

[email protected], 617-918-1745

Shubhada Kambli

Energy Team

[email protected], 617-918-1584

1-888-STAR-YES

www.energystar.gov

mailto:[email protected]





Tools and Resources Available from EPA’s Combined Heat & Power Partnership

Felicia A. Ruiz

Program Manager

Combined Heat and Power Partnership Energy Supply & Industry Branch

Office of Air & Radiation

U.S. EPA Headquarters

Supporting the Development of Combined Heat and Power Projects

Felicia A. RuizProgram ManagerCombustion, Cooling, & Energy Conservation WorkshopBoston, MassachusettsJune 27, 2007

EPA and Clean EnergyEPA and Clean Energy

• Clean energy offers a cost-effective way to meet growing demand for electricity and natural gas while reducing emissions of air pollutants and greenhouse gases, lowering consumers energy bills, and improving the reliability and security of our energy system.

• EPA’s Clean Energy Programs work with state policy makers, electric and gas utilities, energy customers, and other key stakeholders to deliver important environmental and economic benefits.

EPA’s Voluntary Clean Energy ProgramsEPA’s Voluntary Clean Energy Programs

The Benefits of CHP The Benefits of CHP

– Environmental - Well sited and sized systems reduce CO2, SO2 and NOx

– Technical - Fully commercialized technologies in proven applications nationwide

– Economic – High efficiency and power reliability benefits translate into compelling energy savings and avoided catastrophic losses

– Reliability – Decrease impact of outages and improve power quality for sensitive equipment

• The EPA CHP Partnership is a voluntary program that seeks to reduce the environmental impact of power generation by fostering the use of highly-efficient CHP

• Through 2006, the CHPP has helped Partners put into operation more than 250 CHP projects representing over 3,500 MW of capacity, resulting in the cumulative emission reductions of over 10 million tons CO2

• Work with multiple CHP applications and with multiplefuel types

EPA Combined Heat and Power PartnershipEPA Combined Heat and Power Partnership

Project ResourcesProject Resources

• Procurement Guides

• CHP Emissions Calculator

• Funding & Incentives Database

• Analyses of CHP potential in strategic markets - ethanol, hotels/casinos, wastewater treatment, and data centers

Technical Assistance for Candidate SitesTechnical Assistance for Candidate Sites

• Spark spread analyses, Level 1 feasibility studies, third-party review of feasibility/design studies

• Incentive/Policy Analysis

• Quantifying Environmental Benefits

• Technology/Vendor Lists

Public Recognition Public Recognition

• Profile on the Partnership Web site with information about each Partner.

• Annual Greenhouse Gas Reduction Report – Shows carbon reductions associated with Partner's

projects, as well as equivalent benefits in terms of acres of trees planted and car emissions prevented.

• ENERGY STAR CHP Awards– Performance- based award with review 1 year

operating data. – CHP must beat new gas combined cycle and 80%

efficient boiler by at least 5%.

For More Information or to Join CHPPFor More Information or to Join CHPP

Felicia A. RuizCombined Heat and Power PartnershipU.S. Environmental Protection Agency

[email protected].: (202) 343-9129 fax: (202) 343-2208

www.epa.gov/chp



Assessing & Improving Efficiency of Steam Systems

William Orthwein

Project Manager

U.S. Department of Energy

National Energy Technology Laboratory

Industrial Technologies Program Energy savings Environmental quality

Yield improvement/ Resource conservation

Economic viability

Energy security

Targeting the largest opportunity to save energyin the United States

Industry35%

Transportation28%

Commercial17%Residential

20%

2001 Energy Use

Delivering Technology Solutions

Energy Savings Assessments• Will have conducted 450 assessments of large facilities focusing on steam, process heating, compressed air,

pump, and fan systems by the end of 2007. • Assessments done by teams composed of DOE Qualified Energy Experts and plant personnel• Plant personnel and affiliates will be trained on DOE efficient tools• Energy Savings Assessment Report identifies potential energy and cost savings and possible next steps

Note: Does not include off-site losses

U.S. Manufacturing Energy Use by Type

of System (%)

Process Heating

38%

Steam 35%

Other4%Electrochemical - 2%

ProcessCooling

1%

Motor Systems

12%

Facilities 8%

Replicating Assessment Savings

Tools Available on Our Web Site

• Motor Master + Assists in energy-efficient motor selection and management. (International)

• Pumping System AssessmentTool Assesses the efficiency of pumping system operations.

• Fan System Assessment Toolquantifies potential benefits of a more optimally configured fan system

• Air Master+ Provides comprehensive information on assessing compressed air systems.

• ASDMaster Determines economic feasibility of an ASD application.

Tools Available on Our Web Site

• Steam System Scoping Tool Profiles and grades large steam system operations/management.

• Steam System Assessment Tool Assesses potential benefits of specific steam-system improvements.

• 3EPlus Insulation Assessment Tool Calculates most economical thickness of insulation for a variety of operating conditions.

• Process Heating Assessment and Survey Tool Assesses energy use in furnaces/ performance improvements

• NOx and Energy Assessment Tool (NxEAT) analyzes NOx emissions and energy efficiency improvements

• Plant Energy Profiler profiles plant energy supply along consumption streams and identifies energy savings opportunitie

New Steam Tool Now Available:Steam System Assessment Tool

(SSAT)• PURPOSE:

– Demonstrate magnitude – energy, cost, emission savings – of key steam system improvement opportunities

• AUDIENCE:– Engineers involved with operation and/or

improvement of steam systems

Industry Uses LOTS Of Steam!!% Total Energy To Produce Steam

45%

84%

50%

30%

23%

5%

2%

1%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

Weighted Average

Forest Products

Chemicals

Petroleum Refining

Steel

Glass

Metal Casting

Aluminum

You Can Use SSAT To Evaluate These KeySteam Improvement Initiatives

• Real Cost Of Steam• Steam Quality• Boiler Efficiency• Alternative Fuels• Cogeneration

Opportunities• Steam Turbines vs PRVs• Boiler Blowdown

• Condensate Recovery• Steam Trap Operating

Efficiency• Heat Recovery• Vent Steam• Steam Leaks• Insulation Efficiency• Emissions Calculations

Key SSAT Features• Choice of 1, 2, or 3

Header Pressure Models

• Schematics of Model Steam systems

• Estimates of Site Environmental Emissions

• Major Equipment Simulated:

– Boiler

– Back pressure turbines

– Condensing turbine

– Deaerator

– Steam traps, leaks, insulation losses

– Letdowns

– Flash vessels

– Feedwater preheat exchangers

Six SSAT Worksheets• Input

• Model

• Projects Input

• Projects Model

• Results

• User Calculations

Problem:

12% or 180 of the plants 1,500steam traps were failing andwasting steam.

Rohm and Haas, Kentucky

Benefits:

• $500,000 saved annually• Carbon emissions reduced by 2,000 tons/yr.• Payback averages 22 days/steam trap replaced

Solution:Replaced all failed steam traps and instituted regular inspection and maintenance program.

One Example: ROHM AND HAAS

3E-PlusMain Menu

3E-Plus Cost of Energy

Input Screen

3E-Plus Cost of Energy

Output Screen

One Example: GEORGIA PACIFICPlywood Plant in Madison, Georgia

• Goal: Reduce dependence on purchased fuel

• Determined optimal insulation thickness (NAIMA’s 3E Plus)

• Insulated several steam lines leading to plywood dryers and installed new traps

GEORGIA PACIFIC (cont.) Results:

15% increase in operating temperature More consistent process line temperature Faster, more efficient plywood production Cut steam usage by approximately 6,000

lbs./hour Eliminated the use of purchased fuel Reduced CO2 emissions by 6% Achieved a 6-month payback on

investment!

Training Opportunities for Software Tools

• Awareness Workshops (usually 1-2 hours)

• Webcasts (1 to 2 hours)

• End user training (1 to 2 days)

• Qualified specialist training (2 to 3 days)

- Potential resource forplant personnel

See www.eere.energy.gov/industry for details



Breakout Sessions

Session 1A - RDR 1-3 (upstairs)

Assessing Industrial Energy Conservation Options

Session 1B – Auditorium

Assessing Institutional, Commercial, and Municipal Energy Conservation Options

Documents

Combustion, Cooling & Energy Conservation Workshop