Combustion, Cooling

1
Combustion, Cooling Energy Conservation
Workshop

2
Combustion, Cooling Energy Conservation Workshop

• Purpose
• Help you
• Save money
• Reduce energy use
• Reduce pollutant emissions
• From your combustion, heating, and cooling
  operations

3
Combustion, Cooling Energy Conservation Workshop

• 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

4
Combustion, Cooling Energy Conservation Workshop

• Program
• 815 am Opening Session
• 1000 am -Coffee Break
• 1030 am Breakout Sessions
• 1130 am -Lunch
• 100 pm Breakout Sessions
• 200 pm -Break
• 215 pm Panel Energy Analysis
• 330 pm Closing Remarks
• 335 pm Tours

5
Combustion, Cooling Energy Conservation Workshop

• EPAs Commitment to Energy Conservation
  Municipal Energy Challenge
• Susan Studlien, Director
• Office of Environmental Stewardship
• EPA Region 1

6
Combustion, Cooling Energy Conservation Workshop

• State Energy Policy Changes to Encourage Energy
  Conservation Combined Heat Power
• David Cash
• Assistant Secretary for Policy
• Massachusetts Executive Office of Energy
  Environmental Affairs

7
Combustion, Cooling Energy Conservation Workshop

• The Strategic Energy Management Process
• Roy Crystal
• Environmental Scientist
• Assistance Pollution Prevention Office
• EPA Region 1

8

The Strategic Energy Management Aproach How to
Reduce Energy Use, Cost, and Air Pollution
Roy CrystalU.S. EPA Region 1Combustion
WorkshopCambridge, MAJune 27, 2007
9
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

10
Strategic Energy Management Produces Superior
Results

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

11
STEP 1

• Reduce Demand through Energy Efficiency

12
Components of a Successful Energy Management
Program

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

13
EPA has extensively studied the status quo in
building energy performance

• 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

14
Technology alone does not guarantee performance -
management is critical
California Office Buildings
Buildings 20 better than code can have an energy
performance score ranging from 1-100. Not
sending right market signal.
Source NBI, California Board for Energy
Efficiency, EPA
15
Do You Know How Your Facilities Perform?

• You cant manage what you dont measure!
• Until recently, a standardized, comparable metric
  of whole building energy performance did not
  exist.
• EPAs Energy Performance Rating System developed
  to meet this need.

16
Performance Rating Systems
Is 65.7 kBtu/sf/yr high or low for a building?
Even many building experts dont know.
EPA Energy Performance Rating
Fuel Efficiency Rating MPG
Is 10 MPG high or low for an automobile?
Common knowledge.
17
National Energy Performance Rating

• The rating system overlays a 1 to 100 scale over
  national census data, which gives relative
  meaning to energy use

Number of Buildings
Building Energy Use
Highest
Lowest
18
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
19
Eligible Building Types
Office Buildings
Courthouse
Hotels
Schools
Medical Offices
Hospitals
Grocery Stores
Dormitories
Warehouses
20
Planning ImprovementsThe Five-Stage Approach
Focus on Sizing, Operations and Control
ROI
Plant Upgrades
Fan and Motor Systems
Load Reductions
Tune up
Lighting
Time
21
STEP 2

• Clean Up Supply through
• Proper sizing
• Combined Heat and Power
• On and Off Site Renewable Energy

22
Oversized Equipment is a Major Source of
Inefficiency

• 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

23
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

24
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.

25
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.

26
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

27
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

28
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

29
Opacity Problems Particulate Emissions - Mystic
Station, Everett, MA
30
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

31
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

32
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
• Its not only about saving money!

33
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.

34
Contact Us
U.S. EPA Region 1 Roy Crystal Assistance Pollution Prevention Unit Crystal.Roy_at_epa.gov, 617-918-1745 Shubhada Kambli Energy Team Kambli.Shubhada_at_epa.gov, 617-918-1584
1-888-STAR-YES www.energystar.gov
35
Combustion, Cooling Energy Conservation Workshop

• Tools and Resources Available from EPAs
  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

36
Supporting the Development of Combined Heat and
Power Projects

• Felicia A. Ruiz
• Program Manager
• Combustion, Cooling, Energy Conservation
  Workshop
• Boston, Massachusetts
• June 27, 2007

37
EPA 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.
• EPAs 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.

38
EPAs Voluntary Clean Energy Programs
39
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

40
EPA Combined Heat and Power Partnership

• 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
  multiple
• fuel types

41
Project Resources

• Procurement Guides
• CHP Emissions Calculator
• Funding Incentives Database
• Analyses of CHP potential in strategic markets -
  ethanol, hotels/casinos, wastewater treatment,
  and data centers

42
Technical 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

43
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.

44
For More Information or to Join CHPP
Felicia A. Ruiz Combined Heat and Power
Partnership U.S. Environmental Protection
Agency ruiz.felicia_at_epa.gov ph. [phone]
fax [phone] www.epa.gov/chp
45
Combustion, Cooling Energy Conservation Workshop

• Assessing Improving Efficiency of Steam Systems
  
• William Orthwein
• Project Manager
• U.S. Department of Energy
• National Energy Technology Laboratory

46
Industrial Technologies Program

• Energy savings
• Environmental quality
• Yield improvement/ Resource conservation
• Economic viability
• Energy security

GOALS
47
Delivering Technology Solutions
48
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

Other4
Facilities 8
Electrochemical - 2
ProcessCooling1
U.S. Manufacturing Energy Use by Type of System
()
Steam 35
Motor Systems 12
Process Heating 38
Note Does not include off-site losses
49
Replicating Assessment Savings
50
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.

51
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

52
New Steam Tool Now AvailableSteam 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

53
Industry Uses LOTS Of Steam!!
Total Energy To Produce Steam
54
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

55
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

56
Six SSAT Worksheets

• Input
• Model
• Projects Input
• Projects Model
• Results
• User Calculations

57
One Example ROHM AND HAAS

Rohm and Haas, Kentucky
Problem 12 or 180 of the plants 1,500 steam
traps were failing and wasting steam.
Solution Replaced all failed steam traps and
instituted regular inspection and maintenance
program.

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

58
3E-PlusMain Menu
59
3E-Plus Cost of Energy

• Input Screen

60
3E-Plus Cost of Energy

• Output Screen

61
One Example GEORGIA PACIFIC

• Plywood Plant in Madison, Georgia
• Goal Reduce dependence on purchased fuel
• Determined optimal insulation thickness (NAIMAs
  3E Plus)
• Insulated several steam lines leading to plywood
  dryers and installed new traps

62
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!

63
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
64
Combustion, Cooling Energy Conservation Workshop

• Breakout Sessions
• Session 1A - RDR 1-3 (upstairs)
• Assessing Industrial Energy Conservation Options
• Session 1B Auditorium
• Assessing Institutional, Commercial, and
  Municipal Energy Conservation Options