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 transm
itted 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
0
1
2
3
4
5
6
7
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-14
BTU x 10
6
per TON of Melt
MONTH
Melt Energy Intensity
A Good SUSTAINED Trend
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Sustainable Energy Efficiency
Fuel Group
Energy Source
Pounds
of CO
2
Per
Million BTU
Coal
Bituminous
and
Anthracite Coal
Lignite Coal
205.3
215.07
Natural Gas
Natural Gas
Propane
117.1
139.2
Nuclear
Nuclear
0.0
Renewable ( non
-
Biomass)
Solar (PV)
Geothermal
Hydro
Wind
0.0
16.6
0.0
0.0
Biomass
Landfill gas
Sludge Waste
Wood
waste solids
115.1
199.5
195.0
Note
:
1 Million BTU = 0.293 MWh
1 MWh =3.412 Million BTU
Source:
http://cta.ornl.gov/bedb/biopow
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.
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Industry Data
Ferrous Metal Foundry Info (NAICS Code 33151)
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Industry Data
Estimated Metal Casting Energy Use by Metal Type
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Industry Data
Estimated Metal Casting Energy Use by Energy Type
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Industry Data
Estimated Metal Casting Energy Use by Process Type
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;
www.eia.gov/forecasts/aeo
~12%
The really BIG Picture…..
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Perspective…..
>
383 Trillion BTUs =
>
E
quivalent to the reactors on 1,439 James
Madison Class ballistic missile nuclear subs
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Total Gas Intensity (kBtu/sqft, annual basis): 1,183.64
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
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Total Electric
Intensity (kWh/sqft, annual basis):
262.73
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:
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Manufacturing Energy
–
FOUNDRIES (NAICS 3315)
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2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Energy Use per TON for Various Processes
-
STEEL
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2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Foundry Energy Consumption
Energy
Use
per
POUND
for
Various Processes
-
ALUMINUM
Isothermal
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 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
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
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
For foundries, the
transformation
is focused on MELTING
>
The
e
nergy 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
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
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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
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
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 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
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
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 ~ rpm
3
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Motors and Variable Frequency Drives (VFD’s)
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
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
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Boilers / Furnaces / Combustion
Balance Air and Fuel
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Boilers / Furnaces / Combustion
>
Understand Losses
>
Each 40
⁰
F
decrease in stack temperature
results in a 1% increase in efficiency
>
Preheat Combustion Air
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Involve Everyone
o
n the Plant Team
in
Energy Efficiency
:
>
Product Design
>
Purchasing
>
Finance
>
Operators
>
Maintenance
>
Plant
Engineering
>
Energy Teams
>
Utility Account Managers
Copyright ©
2013,
North Carolina Advanced Energy Corporation. All rights reserved.
Energy Prospecting
Remember Renewable Energy Opportunities
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
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
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
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
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
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.
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
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:
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
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
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
U
sing 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
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
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.
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.
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
1
st
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. 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
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}
mstowe@advancedenergy.org
Energy Efficiency in Foundries and Melting
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