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Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Copyright © 2013 North Carolina Advanced Energy Corporation. All rights.

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Presentation on theme: "Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Copyright © 2013 North Carolina Advanced Energy Corporation. All rights."— Presentation transcript:

1 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

2 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Introduction Energy Efficiency in Foundries and Melting

3 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:

4 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:

5 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Sustainable Energy Efficiency A Good SUSTAINED Trend

6 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Sustainable Energy Efficiency Fuel GroupEnergy SourcePounds of CO 2 Per Million BTU CoalBituminous and Anthracite Coal Lignite Coal Natural Gas Propane Nuclear 0.0 Renewable ( non- Biomass) Solar (PV) Geothermal Hydro Wind BiomassLandfill gas Sludge Waste Wood waste solids Note: 1 Million BTU = MWh 1 MWh =3.412 Million BTU Source: er/Carbon_Dioxide_Uncontroll ed_Emission_Factors.pdf CO 2 Emissions by Electrical Power Generation Type Depending on your utility electrical generation mix, you can determine your electrical consumption CO 2 footprint.

7 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Industry Data Ferrous Metal Foundry Info (NAICS Code 33151)

8 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Industry Data Estimated Metal Casting Energy Use by Metal Type

9 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Industry Data Estimated Metal Casting Energy Use by Energy Type

10 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Industry Data Estimated Metal Casting Energy Use by Process Type

11 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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; ~12% The really BIG Picture…..

12 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Perspective….. > 383 Trillion BTUs = > Equivalent to the reactors on 1,439 James Madison Class ballistic missile nuclear subs

13 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Total Gas Intensity (kBtu/sqft, annual basis): 1, Average Gas Consumption per Establishment (kBtu): 206,894,400 Average 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

14 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Total Electric Intensity (kWh/sqft, annual basis): Average Electric Consumption per Establishment (kWh): 45,923,890 Average 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:

15 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Manufacturing Energy – FOUNDRIES (NAICS 3315)

16 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Energy Use per TON for Various Processes - STEEL

17 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Foundry Energy Consumption Energy Use per POUND for Various Processes - ALUMINUM Isothermal

18 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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 BTUs 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

19 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

20 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

21 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

22 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Demand Side Management

23 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Waste Heat Recovery > From Melting > From Holding > From Boilers > From Combustion > From Compression

24 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

25 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

26 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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 VFDs > 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

27 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Motors and Variable Frequency Drives (VFDs) > 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 > VFDs on properly selected motors can result is dramatic savings Horsepower is proportional to speed (rpm) CUBED HP ~ rpm 3

28 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Motors and Variable Frequency Drives (VFDs)

29 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Motors and Variable Frequency Drives (VFDs) > 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

30 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Boilers / Furnaces / Combustion Balance Air and Fuel

31 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Boilers / Furnaces / Combustion > Understand Losses > Each 40 F decrease in stack temperature results in a 1% increase in efficiency > Preheat Combustion Air

32 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Involve Everyone on the Plant Team in Energy Efficiency: > Product Design > Purchasing > Finance > Operators > Maintenance > Plant Engineering > Energy Teams > Utility Account Managers

33 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Energy Prospecting Remember Renewable Energy Opportunities

34 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

35 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

36 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

37 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Teamwork Infrastructure > Take delivery at the primary voltage > The Utility can bid and turn key install: Substations Transformers Switchgear Main Feeder lines to Furnaces

38 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

39 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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.

40 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Teamwork Other Energy Efficiency Programs > ISO – 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

41 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Teamwork To Find the Best Available Energy Efficient Solution Vendors Consultants Utilities Foundries working together with:

42 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

43 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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

44 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

45 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Ingersoll Rand Mocksville NC Case Study - Teamwork Equipment Vendor-Best Technology Induction Melting - Benefits > Re duced Emissions– Lower CO 2 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

46 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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.

47 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. 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.

48 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

49 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Training Opportunity 1 st Annual Electrotechnologies Seminar Oct , 2013, The Conrad Hotel, Indianapolis, IN > There are two tracks: Track ONE: Electrotechnologies for Drying, Curing, and Finishing Track TWO: Electrotechnologies for Processing Metals

50 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

51 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

52 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Contributors Michael P. Looby District Manager, Southeast USA Baskar Vairamohan, CEM Senior Project Engineer George Bowyer VP Operations W. Roger Paules, Jr., PE, CEM Program Manager | Energy Utilization

53 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Sources INFORMATION SOURCES: > Advanced Energy: > Advanced Energy Motor Info: > 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 > Dibalog > Duke Energy

54 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Sources INFORMATION SOURCES (continued): > Duke Energy Smart $aver® Incentive Program > Energy Footprints by NAICS Codes www1.eere.energy.gov/manufacturing/pdfs/mfg_footprint_2012.pdf > Energy Star > Electric Power Research Institute (EPRI) Melting Technologies for Aluminum and other Non-ferrous metals – EPRI Technical Commentary – Product Id: , 2000 Induction and Cupola Melting: A cost comparison model: CR , CMP – Report No 89-4, 1989 Efficient Electric Technologies for Industrial Heating, product Id – , 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: , May 2001

55 Copyright © 2013, North Carolina Advanced Energy Corporation. All rights reserved. Sources INFORMATION SOURCES (continued): > Industrial Heating Equipment Association (IHEA) > Inductotherm > ISO – Energy Management System > Powerit Solutions > Superior Energy Performance Overview > Superior Energy Performance Demonstration > Theoretical/Best Practice Energy Use in Metalcasting Operations J.F. Schifo, J.T. Radia, KERAMIDA Environmental, Inc., Indianapolis, IN, 2004

56 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


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