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Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Copyright © 2013 North Carolina Advanced Energy Corporation. All rights reserved. No part of this presentation may be reproduced, distributed or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by use of any information storage and retrieval system, without the written consent of North Carolina Advanced Energy Corporation.
Energy Efficiency in Foundries and
Melting
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Introduction
Energy Efficiency in Foundries and Melting
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Introduction
Sustainable Energy Efficiency
Foundry Industry Data
Foundry Energy Consumption
Energy Prospecting
Teamwork
Case Studies
Wrap-Up
Topic Outline:
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sustainable Energy Efficiency
Sustainable: The capacity to support, maintain, or endure
Energy: The ability of one physical system to do work on another physical system causing a transformation
Efficiency: The ratio between a specific, useful output and the required energy input
Sustainable Energy Efficiency:
ENDURING TRANSFORMATION with an ever increasing OUTPUT per unit of INPUT
More TONS per BTU:
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sustainable Energy Efficiency
Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-140
1
2
3
4
5
6
7
Melt Energy Intensity
MONTH
BTU
x 1
06 p
er T
ON
of M
elt
A Good SUSTAINED Trend
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sustainable Energy Efficiency
Fuel Group Energy Source Pounds of CO2 Per Million BTU
Coal Bituminous and Anthracite Coal
Lignite Coal
205.3
215.07
Natural Gas Natural GasPropane
117.1139.2
Nuclear Nuclear 0.0
Renewable ( non-Biomass)
Solar (PV)Geothermal
HydroWind
0.016.60.00.0
Biomass Landfill gasSludge Waste
Wood waste solids
115.1199.5195.0
Note:1 Million BTU = 0.293 MWh1 MWh =3.412 Million BTU
Source: http://cta.ornl.gov/bedb/biopower/Carbon_Dioxide_Uncontrolled_Emission_Factors.pdf
CO2 Emissions by Electrical Power Generation Type
Depending on your utility
electrical generation mix,
you can determine your
electrical consumption
CO2 footprint.
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Foundry Industry Data
Ferrous Metal Foundry Info (NAICS Code 33151)
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Foundry Industry Data
Estimated Metal Casting Energy Use by Metal Type
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Foundry Industry Data
Estimated Metal Casting Energy Use by Energy Type
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Foundry Industry Data
Estimated Metal Casting Energy Use by Process Type
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Foundry Energy Consumption
Total Annual Primary Energy Usage in Industrial and Other Sectors in USA
A big slice of the pie!
Source: US Energy Information Administration (EIA), Annual Energy Outlook(AEO) Report, 2012; www.eia.gov/forecasts/aeo
~12%
The really BIG Picture…..
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Foundry Energy Consumption
Perspective…..
> 383 Trillion BTUs =
>Equivalent to the reactors on 1,439 James
Madison Class ballistic missile nuclear subs
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Foundry Energy Consumption
Total Gas Intensity (kBtu/sqft, annual basis): 1,183.64Average Gas Consumption per Establishment (kBtu): 206,894,400Average Enclosed Floorspace per Establishment (sqft): 174,795
Source: EIA energy intensity data from CBECS and MECS, EPRI, and other third party energy use datasets.
Natural Gas Energy Usage - Primary Metals
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Foundry Energy Consumption
Total Electric Intensity (kWh/sqft, annual basis): 262.73Average Electric Consumption per Establishment (kWh):
45,923,890Average Enclosed Floorspace per Establishment (sqft): 174,795
Source: EIA energy intensity data from CBECS and MECS, EPRI, and other third party energy use datasets.
Electrical Energy Usage - Primary Metals:
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Foundry Energy Consumption
Manufacturing Energy – FOUNDRIES (NAICS 3315)
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Foundry Energy Consumption
Energy Use per TON for Various Processes -STEEL
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Foundry Energy Consumption
Energy Use per POUND for Various Processes - ALUMINUM
Isothermal
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Energy Prospecting
Combing through the foundry, often through basements, side rooms, in utility buildings and in boiler rooms, often on hands and knees looking for signs of wasted BTU’s in the infrastructure. In the case of heat, all streams in a plant should be checked at the appropriate production points looking for an opportunity to improve energy efficiency in the transformation processes.
Prospecting for Energy Savings in the Foundry
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Energy Prospecting
PRODUCT: An article or substance that is
manufactured or refined for sale
PROCESS: A series of actions or steps taken to
achieve an end; procedures involving chemical or
mechanical steps to aid in the manufacture of an item or
items, usually carried out on a very large scale
TRANSFORMATION: A thorough or dramatic change
in form or appearance
ENDURING TRANSFORMATION with an ever increasing OUTPUT per unit of INPUT
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
For foundries, the transformation is focused on MELTING
>The energy intensity is focused on BTU per Ton
>60% to 80% of the energy is used for the melting & holding
>Other potential areas to look for energy savings: Demand Side Management Waste Heat Recovery Compressed Air Motors & Variable Frequency Drives Boilers / Furnaces / Combustion The Plant Team
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Demand Side Management
>Typical electrical invoices are composed of two major portions:
Energy charge for actual kilowatt-hours consumed during the billing period
Demand charge for the level of the single highest kilowatt demand power level for any given interval period over the entire billing cycle
>This demand charge is based on a peak power level. By establishing both procedural controls and possibly automated controls, there is an opportunity to reduce this peak demand and therefore reduce the demand portion of the electrical bill
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Demand Side Management
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Energy Prospecting
Waste Heat Recovery
>From Melting
>From Holding
>From Boilers
>From Combustion
>From Compression
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Energy Prospecting
Some Possible Uses for Waste Heat
>Building Heating
>Steam Production
>Preheating Combustion Air
>Preheating Feed Water for Boilers
>Absorption and Adsorption Chillers
>Heat Pumps
>Dehumidification of Cupola Blast Air
>Downstream Drying or Curing Processes
>On-Site Electrical Power Generation
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Energy Prospecting
Compressed Air
>Compressed air systems have an efficiency of around 15%
>A 150 hp air compressor, fully loaded for one year at $0.05 per kWhr will cost $50,000 per year for the electricity
>Typically there is an attitude in the plant that compressed air is free, which can lead to improper uses
>Compressed air systems always have leaks
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Energy Prospecting
Compressed Air
>Educate Employees on the real COST of compressed air
>Conduct Plant Surveys on END USES – Remove Improper Uses
>Develop and Maintain a strong LEAK Repair Program
>Right Size compressors and base load / trim with VFD’s
>Reduce Overall System Pressure to minimum possible
>Evaluate and Update systems controls
>Evaluate Alternatives: Motors, Blowers, Mechanical Actuators, etc.
>Evaluate Waste Heat Recovery
>Bag Houses – Evaluate the System
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Energy Prospecting
Motors and Variable Frequency Drives (VFD’s)
>Electric motors typically account for around 30% of all the electricity consumed in primary metals manufacturing plants
Air Compressors, Chillers & HVAC, Fans for Cupola Operations, Hydraulics, Material Handling, etc.
>Effectively managing the motor population in a manufacturing plant can typically save up to 8% in motor energy costs
>VFD’s on properly selected motors can result is dramatic savings
Horsepower is proportional to speed (rpm) CUBED▫ HP ~ rpm3
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Energy Prospecting
Motors and Variable Frequency Drives (VFD’s)
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Energy Prospecting
Motors and Variable Frequency Drives (VFD’s)
>On-site training on Motor Management Policy concepts for:
Maintenance Staff, Engineers, Purchasing, Operations
>Set up a system for collecting and processing motor nameplate data
>Establish motor repair or replace guidelines
>Motor and drive testing and evaluation
>Right size motors: Below 40% Load
Efficiency DROPS significantly
>Evaluate Use of Premium Efficient Motors
Use Life Cycle Costing
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Energy Prospecting
Boilers / Furnaces / Combustion
Balance Air and Fuel
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Energy Prospecting
Boilers / Furnaces / Combustion >Understand Losses
>Each 40⁰ F decrease in stack temperature results in a 1% increase in efficiency
>Preheat Combustion Air
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Energy Prospecting
Involve Everyone on the Plant Team in Energy Efficiency:
>Product Design
>Purchasing
>Finance
>Operators
>Maintenance
>Plant Engineering
>Energy Teams
>Utility Account Managers
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Energy Prospecting
Remember Renewable Energy Opportunities
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Energy Prospecting
Other Benefits of Energy Efficiency Improvements
> Increase plant productivity
> Improve product quality
> Improve worker comfort
> Increase available floor space
> Improve work flow
>Reduce emissions
> Improve safety
> Increase profits
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Teamwork
Foundries are very ENERGY INTENSE
>Your local utility or energy consultant can HELP
Assistance with Capital Projects▫ New Equipment Planning
▫ Capital Expansions
▫ Greenfield Projects
Infrastructure
Business Continuity
Incentive Programs
Other Energy Efficiency Programs
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Teamwork
Assistance with Capital Projects
>Consider Electrical Rate Structure Options
Best Rates Analysis
Demand Response Programs
Energy Efficiency Options>Economic Development Discounts for new load and job
creation expansions>Contact your local utility or account manager EARLY in
the planning process of your project
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Teamwork
Infrastructure
>Take delivery at the primary voltage
>The Utility can bid and turn key install:
Substations
Transformers
Switchgear
Main Feeder lines to Furnaces
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Teamwork
Business Continuity
>Backup Generation for:
Entire plant loads
Critical loads only
>The Utility can design, build and install:
On-Site Generation
Uninterruptible Power Supplies
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Teamwork
Incentive Programs
>Typical Areas for Standard Incentives
Lighting
Demand Side Management Controllers
Variable Speed Drives and Motors
Chillers and HVAC Units
>Custom Incentives
Plan Ahead. Approval is required BEFORE issue of the purchase order for equipment and energy savings typically need to be verified.
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Teamwork
Other Energy Efficiency Programs
> ISO 50001 – Energy Management System
>Department of Energy, Superior Energy Performance (DOE SEP)
>Government Incentives for Renewable Energy = DSIRE™
>Electrical Power Research Institute (EPRI)
>Environmental Protection Agency (EPA) Energy Star
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Teamwork
To Find the Best Available Energy Efficient Solution
Vendors
ConsultantsUtilities
Foundries working together with:
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Case Study - Teamwork
Working together for the Best Solution
>End User
>Equipment Vendor
>Utility
Planning Infrastructure Energy Efficient Equipment
Induction Melting
Total Turn Key Solution
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Case Study - Teamwork
Early in the Project
Bring in the UTILITY for project planning:
>New Melting Project
>Economic Development Review
>Utility Rate Options
>Utility Process Heating Expertise
>Electrical Infrastructure Planning and Proposal
>Turn Key Installation Solution
Site Selection: GREENWOOD, SC
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Ingersoll Rand Mocksville NC
Case Study - Teamwork
Electrical Infrastructure
>Delivery of Primary Voltage to site Using unique voltage gave us the opportunity to
provide custom transformation and high voltage lines directly to the furnaces – Duke Energy
> Installation of Substation, Switchgear, and Main Feeder Lines in a Turn Key Solution
>Crown Casting - A Satisfied Customer: Duke Energy was able to provide a total solution which
lead us to select this location for our new foundry – Crown Casting
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Ingersoll Rand Mocksville NC
Case Study - Teamwork
Equipment Vendor-Best TechnologyInduction Melting - Benefits> Reduced Emissions– Lower CO2 footprint
> Energy Efficiency – Overall 55-75% efficient
> Higher Yield – No oxidation losses
> Faster Start-Up – Full “Power ON” instantaneously
> Product Optimization – Precise temperature control and good stirring effect for homogeneous batches
> Flexibility and Automation – Cold Start, Alloy Changes, Automated Controls
> Space Saving – High melt rates per furnace footprint
> Improved Working Environment – Quieter, no combustion, reduced waste heat
ENDURING TRANSFORMATION with an ever increasing OUTPUT per unit of INPUT
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Case Study-Teamwork
Equipment Selection: The new equipment at the Crown Casting facility is a 4000 kW VIP Dual
Trak Induction Melting System , with two 5 MT coreless furnaces for IRON melting. When one furnace is melting, the other furnace is holding.
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Case Study-Demand Side Mgmt
“Powerit Solutions provided our business with a system that controls our electrical demand very well and they were able to meet our tight delivery requirements at a competitive cost.” Doug Smith, Project Engineer, Rochester Metal Products
Prior to implementing the system, Rochester Metals´ typical monthly peak demand was 21,000 kW. They tested the system for a month at 18,000 kW, and when they were able to maintain production, they adjusted the set point to 17,000 kW. Again, there was no production loss, so they readjusted the set point to 16,000 kW, which is where it remains today with no production loss.
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Case Study-Demand Side Mgmt
“We are very satisfied. Powerit Solutions' system has fulfilled all our expectations as well as the estimated savings.” Mark Regus, Plant Manager, Pacific Alloy
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Training Opportunity
1st Annual Electrotechnologies Seminar
Oct. 21-22, 2013, The Conrad Hotel, Indianapolis, IN
> There are two tracks: Track ONE: Electrotechnologies for Drying, Curing, and Finishing
Track TWO: Electrotechnologies for Processing Metals
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Wrap Up
Review Our Topics: Sustainable Energy Efficiency
Foundry Industry Data
Foundry Energy Consumption
ENDURING TRANSFORMATION with an ever increasing OUTPUT per
unit of INPUT
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Wrap Up
Review Our Topics (continued): Energy Prospecting – Plant Wide
Teamwork▫ To identify the most efficient melting technology
▫ To provide guidance on infrastructure
▫ To assist with financial analysis and capital requests
Case Studies
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Contributors
Michael P. LoobyDistrict Manager,
Southeast USA
Baskar Vairamohan, CEMSenior Project EngineerGeorge Bowyer
VP Operations
W. Roger Paules, Jr., PE, CEMProgram Manager | Energy
Utilization
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sources
INFORMATION SOURCES:> Advanced Energy:
www.advancedenergy.org
> Advanced Energy Motor Info:
www.advancedenergy.org/md/knowledge_library/resources/Horsepower%20Bulletin.pdf
> Advanced Manufacturing Office – Compressed Air Systems
www1.eere.energy.gov/manufacturing/tech_deployment/compressed_air.html
> Advanced Manufacturing Office – Energy Resource Center
www1.eere.energy.gov/manufacturing/tech_deployment/ecenter.html
> American Foundry Society
www.afsinc.org/
> Dibalog
www.dibalog.com/
> Duke Energy
www.duke-energy.com/company.asp
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sources
INFORMATION SOURCES (continued):> Duke Energy Smart $aver® Incentive Program
www.duke-energy.com/north-carolina-large-business/energy-efficiency/nclb-smart-saver-incentives.asp
> Energy Footprints by NAICS Codes
www1.eere.energy.gov/manufacturing/pdfs/mfg_footprint_2012.pdf
> Energy Star
www.energystar.gov/index.cfm?c=business.bus_index
> Electric Power Research Institute (EPRI)
www.epri.com/Pages/Default.aspx
▫ Melting Technologies for Aluminum and other Non-ferrous metals – EPRI Technical Commentary –Product Id:1001025, 2000
▫ Induction and Cupola Melting: A cost comparison model: CR-108697, CMP – Report No 89-4, 1989
▫ Efficient Electric Technologies for Industrial Heating, product Id – 1014000, 2007
▫ Good Practice Guide 50 – Efficient Melting in Coreless Induction Furnaces, 2000
▫ Ind Heat WS Code - Cost Comparison Worksheet for Induction Heating, Version 1.0, EPRI Product Id: 1001500, May 2001
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Sources
INFORMATION SOURCES (continued):> Industrial Heating Equipment Association (IHEA)
www.ihea.org
> Inductotherm
www.inductotherm.com/index.htm
> ISO 50001 – Energy Management System
www.eere.energy.gov/energymanagement
> Powerit Solutions
www.poweritsolutions.com/
> Superior Energy Performance Overview
www.superiorenergyperformance.net/
> Superior Energy Performance Demonstration
www.eere.energy.gov/industry/energymanagementdemonstrations/
> Theoretical/Best Practice Energy Use in Metalcasting Operations
J.F. Schifo, J.T. Radia, KERAMIDA Environmental, Inc., Indianapolis, IN, 2004
Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved.
Questions
ENDURING TRANSFORMATION with an ever increasing OUTPUT
per unit of INPUT
Michael Stowe(919) 857 – 9043 {desk}(919) 904 – 0279 {cell}
Energy Efficiency in Foundries and Melting