Energy Management and Efficiency for the Process Industries

Provides a unique overview of energy management for the process industries

• Provides an overall approach to energy management and places the technical issues that drive energy efficiency in context
• Combines the perspectives of freewheeling consultants and corporate insiders
• In two sections, the book provides the organizational framework (Section 1) within which the technical aspects of energy management, described in Section 2, can be most effectively executed
• Includes success stories from three very different companies that have achieved excellence in their energy management efforts
• Covers energy management, including the role of the energy manager, designing and implementing energy management programs, energy benchmarking, reporting, and energy management systems
• Technical topics cover efficiency improvement opportunities in a wide range of utility systems and process equipment types, as well as techniques to improve process design and operation

Foreword ix
by The Honorable Charles D. McConnell

Preface xi

Acknowledgments xv

Contributors xvii

Units of Measure xix

Section 1 Energy Management Programs 1

1 Energy Management in Practice 3
Beth P. Jones

2 The Dow chemical Company: Energy Management Case Study 25
Joe A. Almaguer

3 Eastman Chemical’s Energy Management Program: When Good is Not Enough 37
Sharon L. Nolen

4 General Mills’ Energy Management Success Story 48
Graham Thorsteinson

5 Energy Benchmarking 56
Mark Eggleston

6 Energy Management Standards 66
Kathey Ferland, Paul E. Scheihing, and Graziella F. Siciliano

7 Protecting The Environment and Influencing Energy Performance Within Process Industries 81
Elizabeth Dutrow

Section 2 Energy Management Technologies 93

8 The Technologies of Industrial Energy Efficiency 95
Alan P. Rossiter

Equipment 105

9 Energy Efficiency in Furnaces and Boilers 107
Bala S. Devakottai

10 Enhanced Heat Transfer and Energy Efficiency 128
Thomas Lestina

11 Heat Exchanger Cleaning Methods 139
Joe L. Davis

12 Monitoring of Heat Exchanger Fouling and Cleaning Analysis 143
Bruce L. Pretty and Celestina (Tina) Akinradewo

13 Successful Implementation of a Sustainable Steam Trap Management Program 164
Jonathan P. Walter and James R. Risko

14 Managing Steam Leaks 179
Alan P. Rossiter

15 Rotating Equipment: Centrifugal Pumps and Fans 186
Glenn T. Cunningham

16 Industrial Insulation 207
Mike Carlson

Utility Systems 217

17 Heat, Power, and The Price of Steam 219
Alan P. Rossiter and Joe L. Davis

18 Balancing Steam Headers and Managing Steam/Power System Operations 230
Alan P. Rossiter and Ven V. Venkatesan

19 Real-Time Optimization of Steam and Power Systems 242
R. Tyler Reitmeier

20 Fuel Gas Management and Energy Efficiency in Oil Refineries 251
Joe L. Davis

21 Refrigeration, Chillers, and Cooling water 260
William (Bill) Turpish

22 Compressed Air System Efficiency 277
Joe Ghislain

23 Lighting Systems 290
Bruce Bremer

24 Heating, Ventilation, and Air-Conditioning Systems 300
Bruce Bremer

Process 311

25 Identifying Process Improvements For Energy Efficiency 313
Alan P. Rossiter and Joe L. Davis

26 Pinch Analysis and Process Heat Integration 326
Alan P. Rossiter

27 Energy Management Key Performance Indicators (EnPIs) and Energy Dashboards 349
Jon S. Towslee

Index 361

"This book is a “go-to” source for industrial energy management programmes." (Heat Processing, 1 April 2015)

Alan P. Rossiter is President of Rossiter & Associates, a process improvement consulting company specializing in industrial energy efficiency. Clients include ExxonMobil, Natural Resources Canada, Syncrude Canada, ConocoPhillips, Sasol, LyondellBasell,Valero, and Hess. He has more than 30 years of process engineering and management experience and more than 60 publications including three books. He has a PhD in chemical engineering from the University of Cambridge, is a chartered engineer (UK) and a registered professional engineer (Texas), and was the 2010 Chair of the South Texas Section of the AIChE.

Beth P. Jones was for several years the worldwide energy manager for LyondellBasell Industries, after positions in process engineering management and optimization. She retired in 2013 to enjoy new expat adventures and then an invitation to work on this book, her first, with Alan. She has a BS in Chemical Engineering from Oklahoma State University and is a Certified Energy Manager.

LAYS OUTTHE UNDERLYING MANAGEMENT ANDTECHNICAL ISSUES THAT DRIVE SUCCESSFUL INDUSTRIAL ENERGY MANAGEMENT PROGRAMS

With a Foreword by The Honorable Charles D. McConnell, former Assistant Secretary of Energy

Energy efficiency is highly visible in industry in the US and around the world. Many engineers and managers are assigned energy management roles at some point in their careers, but few have a clear understanding of either the scope of the opportunity or the available methodologies to capture savings.

Energy Management and Efficiency for the Process Industries is a "go-to" source for engineers and managers who are designing and implementing policies and programs for energy management and energy efficiency. It introduces a framework for an industrial energy management program, provides illustrations, and discusses the basic principles that lead to robust and sustainable improvements in energy performance.

Through contributions from leading experts in diverse fields, Energy Management and Efficiency for the Process Industries provides a unique overview of industrial energy management informed by the technologies and issues that drive energy efficiency in the process industries.

Divided into two sections, the book provides both management and technical recommendations. The management section offers guidance on how to design and implement energy management programs, with advice on the organizational design, human interaction, and technical aspects of energy management. Management topics include program goal setting, benchmarking, strategies, priorities, tools, the roles of energy management personnel, and case studies from three successful energy programs.

The second section deals with more traditional engineering—the technical aspects of significant process equipment and systems, seen through the lens of energy efficiency as well as process requirements. Technical experts provide advice on proven options for understanding and enhancing the energy efficiency of the plant systems and equipment items with the highest impact on process energy efficiency success.