INDUSTRIAL

ENERGY ENGINEERING

Industrial Energy

EngineeringINDUSTRIAL

ENERGY ENGINEERING

C4SMarch 27, 2008

INDUSTRIAL

ENERGY ENGINEERING

Motivation

$

INDUSTRIAL

ENERGY ENGINEERING

U.S. Natural Gas Wellhead Price

0

2

4

6

8

10

12Ja

n-7

6

Ja

n-7

9

Ja

n-8

2

Ja

n-8

5

Ja

n-8

8

Ja

n-9

1

Ja

n-9

4

Ja

n-9

7

Ja

n-0

0

Ja

n-0

3

Ja

n-0

6

Do

lla

rs p

er

tho

us

an

d c

ub

ic f

ee

t

1976 Price$ 1.57 in 2007 dollars

Current Price

$ 6.46/mcf June 2007

Wellhead Price, Real Dollars

Source: EIA

INDUSTRIAL

ENERGY ENGINEERING

Cost per KWH

0.0400

0.0410

0.0420

0.0430

0.0440

0.0450

0.0460

0.0470

0.0480

0.0490

0.0500

0.0510

0.0520

0.0530

0.0540

0.0550

JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND

$ p

er K

WH

1998 20001999 2004200320022001 2005

Electricity Price

Existing Manufacturing Processes were

designed using this price

$ .045/kwh

Ohio AEP Price to Plant, Actual Rates $0.061/kwh2007

INDUSTRIAL

ENERGY ENGINEERING

40

21

18

812

0%

20%

40%

60%

80%

100%

1

Profit

SG&A

Direct Labor

Energy

Raw Material ($)

Components of Revenue

Components of Product Sale Price

INDUSTRIAL

ENERGY ENGINEERING

Energy Operating Costs

Monthly Service on Capital Expenditure

A BC

20081998

1988

Cost Minimization and Energy Impacts

INDUSTRIAL

ENERGY ENGINEERING

Energy Engineering Services

1. Energy Assessment2. Targeted Evaluation3. Energy Program Audit 4. Greenhouse Gas

Scorecard

INDUSTRIAL

ENERGY ENGINEERING

INDUSTRIAL

ENERGY ENGINEERING

Target Stack Temperature

0

200

400

600

800

1000

1200

1400

1 2 3 4 5 6 7 8 9 10Price Natural Gas ($/mcf)

Sta

ck T

em

pera

ture

(F

)

1968

1990

2007

Economical heat recovery temperature = 400 oF

INDUSTRIAL

ENERGY ENGINEERING

Rolling Annual Cost for Natural Gas

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

$400,000

$450,000

Jan-

06

Mar

-06

May

-06

Jul-0

6

Sep-0

6

Nov-0

6

Jan-

07

Mar

-07

May

-07

Jul-0

7

Sep-0

7

Nov-0

7

$/Y

ear

$100,000 Cost Increase

Overall Plant Natural Gas Consumption

0

5,000

10,000

15,000

20,000

25,000

30,000

Average mcf

Month

Co

nsu

mp

tio

n (

MC

F/m

o)

Stage I: Utility Bill Analysis

INDUSTRIAL

ENERGY ENGINEERING

Paint MCF DW MCF Resin MCF

J 9,608 848 12,740F 11,766 1,105 15,071M 8,834 773 13,202A 6,325 413 12,231M 3,533 240 10,311J 2,167 71 9,799J 1,054 3 7,213A 1,218 3 8,608S 1,262 3 8,309O 2,817 80 9,445N 5,729 404 11,836D 7,668 637 12,819

annual avg 61,981 4580 131,584

Paint Consumption

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

J F M A M J J A S O N D

MC

F/m

on

th

Resin Plant Consumption

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

J F M A M J J A S O N D

MC

F/m

on

th

DW Warehouse Consumption

0

200

400

600

800

1000

1200

J F M A M J J A S O N D

MC

F/m

on

th

Stage II: Production Operation Comparison

Energy Intensity = E /$ revenue

INDUSTRIAL

ENERGY ENGINEERING

Quantification of Top Users

Tunnel Kiln

Bickley RH

Bickley Bell

Drying Rooms

260 feet

70

fe

et

Ipsen RH

60

fe

et

Boiler 46%

21%

3%

21%

Ipsen or Bickley

Room Heaters9% winter

Major Users of Natural Gas

Tunnel Kiln

Bickley Bell Kiln

Ipsen RH Kiln

Bickley RH Kiln (not operating)

Boiler

Fired Room Heaters

Spray Dryer

INDUSTRIAL

ENERGY ENGINEERING

Operating

HP Name plate

Voltage (three phase) Efficiency

Power Factor

Full Load Amps

Percent Loaded when

operatingOperating

AmpsOperating Kilowatts

Time Operating

(%)

Time Operating

(Hours/ month) KWH/month

BR2MCC (SWG-050003: CKT-050003)HEX-423 Fulton Control Panel 452-MCCBR2 480 85% 70% 0 80% 0 0 100% 730 0HEX-046000 Fulton Oil Heater 452-MCCBR2 40 480 85% 68% 62 80% 50 28 100% 730 20502PMP-475 WFE Marley Cooling Water Pump Mid452-MCCBR2 40 480 85% 70% 60 55% 33 19 100% 730 14095PMP-474 WFE Marley Cooling Water Pump North452-MCCBR2 40 480 85% 70% 60 60% 36 21 100% 730 15376PMP-473 WFE Marley Cooling Water Pump South452-MCCBR2 25 480 85% 70% 38 80% 30 18 0% 0 0HEX-421 Marley Cooling Tower Fan 452-MCCBR2 40 480 85% 70% 60 20% 12 7 100% 730 5125 BR2MCC 55099Building 402 (SWG-050073:CKT-050004)FAN- BAC Cooling Tower Fan 40 480 85% 70% 60 13% 8 5 90% 657 2998PMP-424 BAC Cooling Tower Pump 40 480 85% 70% 60 60% 36 21 100% 730 15376PMP-447 BAC Cooling Tower Pump 40 480 85% 70% 60 60% 36 21 0% 0 0

Building 402 18375OFFICE

HVAC Supply 25 480 85% 70% 38 80% 30 18 100% 730 12814Recirculation HVAC 25 480 85% 70% 38 80% 30 18 100% 730 12814Chillers 192 480 85% 70% 290 80% 232 135 25% 182.5 24648Other and Small 30 480 85% 70% 45 80% 36 21 100% 730 15376

Office 65652Electrical Room #2

PMP-214 Cooling Tower Recirc Pump 208-MCC1 40 240 85% 70% 121 80% 97 28 100% 730 20502FAN-207 Cooling Tower Blower 208-MCC1 15 240 85% 70% 45 80% 36 11 100% 730 7688PMP-201 Silverson Pump 208-MCC1 25 240 85% 70% 75 80% 60 18 0% 0 0PMP-023022 Wastewater Transfer Pump 208-MCC1 15 240 85% 70% 45 80% 36 11 10% 73 769FAN-207201 Blower Vacuum Spent 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-202213 Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-203255 Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 40% 292 3075PMP-101138 Filter Press Feed Pump west 208-MCC2 15 240 85% 70% 45 80% 36 11 10% 73 769PMP-101434 Filter Press Feed Pump east 208-MCC2 15 240 85% 70% 45 80% 36 11 10% 73 769PMP-233242 S.R.S. Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 20% 146 1538PMP-233243 S.R.S. Vacuum Pump 208-MCC2 15 240 85% 70% 45 80% 36 11 20% 146 1538PMP-259 Coolant Recirc Pump 208-MCC2 10 240 85% 70% 30 80% 24 7 80% 584 4100FAN-020100 SRO Vent Fan 208-MCC3 10 240 85% 70% 30 80% 24 7 100% 730 5125Misc Small 208 Misc Small and other 208 100 240 85% 70% 302 80% 242 70 80% 584 41004

Electrical Room #2 93027Electrical Room #4PMP-040220 R2 Vacuum Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040420 R4/R5 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041021 R10 Vacuum Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040720 R7 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041120 R11 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-040320 R3 Vacuum Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-040120 R1 Vacuum Pump 448-MCC1 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041001 R10 Agitator 448-MCC1 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041622 R10 Booster Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-041601 R16 Agitator 448-MCC1 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041620 R16 Vacuum Pump 448-MCC1 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-471 Transfer Pump 448-MCC1 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041621 Recirc Pump 448-MCC1 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-040820 R8 Vacuum Pump 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-048022 R8 Vacuum Booster Pump 448-MCC2 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-045020 Incrosoft Loading Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-041326 WFE Hot Oil Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-132 Fatty Alcohol Unload Pump 448-MCC2 25 480 85% 70% 38 80% 30 18 40% 292 5125PMP-041325 WFE Vacuum Pump 448-MCC2 15 480 85% 70% 23 80% 18 11 40% 292 3075AGT-041401 R14 Agitator 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041420 R14 Vacuum Pump 448-MCC2 20 480 85% 70% 30 80% 24 14 40% 292 4100AGT-103 Agitator Tank 112 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075PMP-149 Pastillation Bag Blower 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-127 South Pastillation Chiller Feed 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075CLR-105 South Pastillation Chiller 448-MCC3 75 480 85% 70% 113 80% 91 53 40% 292 15376AGT-104 Agitator Tank 113 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075AGT-419 R15 Agitator 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-041520 R15 Vacuum Pump 448-MCC3 20 480 85% 70% 30 80% 24 14 40% 292 4100PMP-041522 R15 Vacuum Booster 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-147 Pastillation #2 Bag Blower 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050PMP-468 Transfer Pump Newark Tanks 448-MCC3 10 480 85% 70% 15 80% 12 7 40% 292 2050AGT-426 Pastillation Flaker Storage Tank 448-MCC3 15 480 85% 70% 23 80% 18 11 40% 292 3075

Stage III: Individual Process Listing and Analysis

•What are the top 100 Electrical Users? Quantify

•What are the top 20 Natural Gas Users? Quantify

INDUSTRIAL

ENERGY ENGINEERING

Stage IV: Alignment of Energy Use And Production

INDUSTRIAL

ENERGY ENGINEERING

Energy Alignment

1.1 MMBTU/hr$96,000/yr

Nitrogen Carrier Gas and VOC700 scfm5% O294% N2

1.1 MM BTU/hr1000 oF

Quench Air, Secondary800 scfm

600 oF

Combustion Air300 scfm

Heated Combustion Air

1800 scfm0.9 MMBTU/hr @600 F

Heat Lost 0.2 MM BTU/hr

INDUSTRIAL

ENERGY ENGINEERING

Energy Engineering Analysis

Input Natural Gas 4,000,000 BTU/hr for two rooms

Stack Losses 2,20,000 BTU/hr

Recirculation System and other Losses 475,000 BTU/hr

Transferred to Drying Rooms 975,000 BTU/hr

As Found Conditions BTU/hr Percent

Energy Input (natural gas) 4,000,000 100

Stack Losses 2,200,000 55%Boiler Shell Losses 350,000 9%Steam Piping Losses 475,000 12%Energy Delivered to Drying Room 975,000 24%Room Wall Losses 120,000 3%Infiltration Losses 180,000 5%Energy Transferred to Trays 500,000 13%Energy Transferred to Product 175,000 4%

Indirect Heating System Analysis

Steam

INDUSTRIAL

ENERGY ENGINEERING

Energy Recovery

Soaking Pits and

Reheat Furnace Steel

Natural Gas

Combustion Air

Preheat

Air

Steel at Rolling Temp

Hot Stack Gas

Recuperator

Waste Heat Boiler

Cool Stack Gas

Steam Water

Natural Gas

INDUSTRIAL

ENERGY ENGINEERING

Cost Effectiveness Ranking

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

$0 $20,000 $40,000 $60,000 $80,000 $100,000

Implementation Costs

Na

tura

l G

as

Sa

ve

d (

mc

f/y

r)Drying Room New Heating System

$17.5/mcf

$12.5/mcf

$ 8/mcf$ 6/mcf

ProductionPrioritization

$10/mcf

Boiler Replacement

Bickley Bell Kiln Retrofit

Not Cost Effective

Drying Room Cycling

Cost Effective

Action Plan for Energy Reduction