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Combustion, Cooling & Energy Conservation
Workshop
Combustion, Cooling & Energy Conservation
Workshop
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
Purpose
Help you• Save money• Reduce energy use • Reduce pollutant emissions
From your combustion, heating, and cooling operations
Combustion, Cooling & Energy Conservation Workshop
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
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
Program• 8:15 am Opening Session• 10:00 am -Coffee Break • 10:30 am Breakout Sessions• 11:30 am -Lunch• 1:00 pm Breakout Sessions• 2:00 pm -Break• 2:15 pm Panel – Energy Analysis• 3:30 pm Closing Remarks• 3:35 pm Tours
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
EPA’s Commitment to Energy Conservation & Municipal Energy
Challenge
Susan Studlien, Director
Office of Environmental Stewardship
EPA Region 1
Combustion, Cooling & Energy Conservation Workshop
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
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
The Strategic Energy Management Process
Roy Crystal
Environmental Scientist
Assistance & Pollution Prevention Office
EPA Region 1
The Strategic Energy Management Aproach:How to
Reduce Energy Use, Cost, and Air Pollution
Roy CrystalU.S. EPA – Region 1
Combustion WorkshopCambridge, MA
June 27, 2007
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
Strategic Energy Management Produces Superior Results
1. Reduce Demand – Energy Efficiency– Management, Operations, and Maintenance– Upgrade Technology
2. 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
3. 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.
STEP 1:
Reduce Demand through Energy Efficiency
Based on successful practices of ENERGY STAR partners, EPA has identified the key components for a successful energy management program
Components of a Successful Energy Management Program
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
EPA has extensively studied the status quo in building energy performance
Technology alone does not guarantee performance - management is critical
Weak Correlation: Code vs. Simulated EUI
y = 0.0021x
R2 = 0.1321
-20.0%
-10.0%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
0 20 40 60 80 100 120
Energy Star Score (based on National Average Occupancy)
% E
lect
rici
ty S
avi
ng
s re
lati
ve t
o c
od
e
Source: NBI, California Board for Energy Efficiency, EPA
California Office Buildings Buildings 20% better than code can have an energy performance score ranging from 1-100.
Not sending rightmarket signal.
• You can’t manage what you don’t measure!
• Until recently, a standardized, comparable metric of whole building energy performance did not exist.
• EPA’s Energy Performance Rating System developed to meet this need.
Do You Know How Your Facilities Perform?
Fuel Efficiency Rating: MPG
Is 10 MPG high or low for an automobile?
EPA Energy Performance Rating
Is 65.7 kBtu/sf/yr high or low for a building?
Performance Rating Systems
Common knowledge.
Even many building experts
don’t know.
Building Energy UseHighest Lowest
Nu
mb
er
of B
uild
ings
1001 25 50 75Benchmark Score
The rating system overlays a 1 to 100 scale over national census data, which gives
relative meaning to energy use
National Energy Performance Rating
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
Eligible Building Types
Hotels
Schools
Office Buildings Courthouse
Hospitals
Medical Offices
DormitoriesGrocery Stores
Warehouses
Time
Tune up LightingLoad
Reductions
Fan and Motor
Systems
PlantUpgrades
Focus on Sizing, Operations and Control
RO
I
Planning Improvements:The Five-Stage Approach
STEP 2:
Clean Up Supply through:Proper sizing
Combined Heat and Power
On and Off Site Renewable Energy
• 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
Oversized Equipment is a Major Source of Inefficiency
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
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.
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.
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
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
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
Opacity Problems & Particulate Emissions - Mystic Station, Everett, MA
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
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
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
It’s not only about saving money!
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.
Contact Us
U.S. EPA – Region 1
Roy Crystal
Assistance & Pollution Prevention Unit
Crystal.Roy@epa.gov, 617-918-1745
Shubhada Kambli
Energy Team
Kambli.Shubhada@epa.gov, 617-918-1584
1-888-STAR-YES
www.energystar.gov
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
Tools and Resources Available from EPA’s 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
Supporting the Development of Combined Heat and Power Projects
Felicia A. RuizProgram ManagerCombustion, Cooling, & Energy Conservation WorkshopBoston, MassachusettsJune 27, 2007
EPA and Clean EnergyEPA 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.
• EPA’s 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.
EPA’s Voluntary Clean Energy ProgramsEPA’s Voluntary Clean Energy Programs
The Benefits of CHP 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
• 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 multiplefuel types
EPA Combined Heat and Power PartnershipEPA Combined Heat and Power Partnership
Project ResourcesProject Resources
• Procurement Guides
• CHP Emissions Calculator
• Funding & Incentives Database
• Analyses of CHP potential in strategic markets - ethanol, hotels/casinos, wastewater treatment, and data centers
Technical Assistance for Candidate SitesTechnical 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
Public Recognition 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%.
For More Information or to Join CHPPFor More Information or to Join CHPP
Felicia A. RuizCombined Heat and Power PartnershipU.S. Environmental Protection Agency
ruiz.felicia@epa.govph.: (202) 343-9129 fax: (202) 343-2208
www.epa.gov/chp
Combustion, Cooling & Energy Conservation Workshop
Combustion, Cooling & Energy Conservation Workshop
Assessing & Improving Efficiency of Steam Systems
William Orthwein
Project Manager
U.S. Department of Energy
National Energy Technology Laboratory
Industrial Technologies Program Energy savings Environmental quality
Yield improvement/ Resource conservation
Economic viability
Energy security
Targeting the largest opportunity to save energyin the United States
Industry35%
Transportation28%
Commercial17%Residential
20%
2001 Energy Use
Delivering Technology Solutions
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
Note: Does not include off-site losses
U.S. Manufacturing Energy Use by Type
of System (%)
Process Heating
38%
Steam 35%
Other4%Electrochemical - 2%
ProcessCooling
1%
Motor Systems
12%
Facilities 8%
Replicating Assessment Savings
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.
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
New Steam Tool Now Available:Steam 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
Industry Uses LOTS Of Steam!!% Total Energy To Produce Steam
45%
84%
50%
30%
23%
5%
2%
1%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Weighted Average
Forest Products
Chemicals
Petroleum Refining
Steel
Glass
Metal Casting
Aluminum
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
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
Six SSAT Worksheets• Input
• Model
• Projects Input
• Projects Model
• Results
• User Calculations
Problem:
12% or 180 of the plants 1,500steam traps were failing andwasting steam.
Rohm and Haas, Kentucky
Benefits:
• $500,000 saved annually• Carbon emissions reduced by 2,000 tons/yr.• Payback averages 22 days/steam trap replaced
Solution:Replaced all failed steam traps and instituted regular inspection and maintenance program.
One Example: ROHM AND HAAS
3E-PlusMain Menu
3E-Plus Cost of Energy
Input Screen
3E-Plus Cost of Energy
Output Screen
One Example: GEORGIA PACIFICPlywood Plant in Madison, Georgia
• Goal: Reduce dependence on purchased fuel
• Determined optimal insulation thickness (NAIMA’s 3E Plus)
• Insulated several steam lines leading to plywood dryers and installed new traps
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!
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
Combustion, Cooling & Energy Conservation Workshop
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