copyright © 2013, north carolina advanced energy corporation. all rights reserved. copyright ©...

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


Introduction

Energy Efficiency in Foundries and Melting


Introduction

Sustainable Energy Efficiency

Foundry Industry Data

Foundry Energy Consumption

Energy Prospecting

Teamwork

Case Studies

Wrap-Up

Topic Outline:



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:



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



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.



Ferrous Metal Foundry Info (NAICS Code 33151)



Estimated Metal Casting Energy Use by Metal Type



Estimated Metal Casting Energy Use by Energy Type



Estimated Metal Casting Energy Use by Process Type



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…..

http://www.eia.gov/forecasts/aeo



Perspective…..

> 383 Trillion BTUs =

>Equivalent to the reactors on 1,439 James

Madison Class ballistic missile nuclear subs



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



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:



Manufacturing Energy – FOUNDRIES (NAICS 3315)



Energy Use per TON for Various Processes -STEEL



Energy Use per POUND for Various Processes - ALUMINUM

Isothermal


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


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



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


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


Energy Prospecting

Demand Side Management


Energy Prospecting

Waste Heat Recovery

>From Melting

>From Holding

>From Boilers

>From Combustion

>From Compression


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


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


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


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


Energy Prospecting



Energy Prospecting


>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


Energy Prospecting

Boilers / Furnaces / Combustion

Balance Air and Fuel


Energy Prospecting

Boilers / Furnaces / Combustion >Understand Losses

>Each 40⁰ F decrease in stack temperature results in a 1% increase in efficiency

>Preheat Combustion Air


Energy Prospecting

Involve Everyone on the Plant Team in Energy Efficiency:

>Product Design

>Purchasing

>Finance

>Operators

>Maintenance

>Plant Engineering

>Energy Teams

>Utility Account Managers


Energy Prospecting

Remember Renewable Energy Opportunities


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


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


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


Teamwork

Infrastructure

>Take delivery at the primary voltage

>The Utility can bid and turn key install:

Substations

Transformers

Switchgear

Main Feeder lines to Furnaces


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


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.


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


Teamwork

To Find the Best Available Energy Efficient Solution

Vendors

ConsultantsUtilities

Foundries working together with:


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



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


Ingersoll Rand Mocksville NC


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


Ingersoll Rand Mocksville NC


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



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.


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.


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


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


Wrap Up

Review Our Topics: Sustainable Energy Efficiency



ENDURING TRANSFORMATION with an ever increasing OUTPUT per

unit of INPUT


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


Contributors

Michael P. LoobyDistrict Manager,

Southeast USA

Baskar Vairamohan, CEMSenior Project EngineerGeorge Bowyer

VP Operations

W. Roger Paules, Jr., PE, CEMProgram Manager | Energy

Utilization


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


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


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


Questions

ENDURING TRANSFORMATION with an ever increasing OUTPUT

per unit of INPUT

Michael Stowe(919) 857 – 9043 {desk}(919) 904 – 0279 {cell}

[email protected]

Energy Efficiency in Foundries and Melting

copyright © 2013, north carolina advanced energy corporation. all rights reserved. copyright ©...

Documents

energy type slide

introduction energy

energy prospecting combing

metal casting energy

eia energy intensity

party energy use datasets

metal type slide

process type slide