Identifying Energy Savings in Industrial Plants using DOE s QuickPEP

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1 Identifying Energy Savings in Industrial Plants using DOE s QuickPEP Riyaz Papar, PE, CEM Director, Energy Assets & Optimization Hudson Technologies Company August 09, 2007

2 Introduction to Texas Industries of the Future Initiated in 2001 with Advisory Board representing Industry and Academia Located at the University of Texas, Center for Energy and Environmental Resources Funded by Department of Energy and SECO-extensive leveraging of federal resources Focus on industrial energy efficiency, providing training, tools, Active Chemical and Refining Sector Advisory Committee

3 Training, Conferences and Forums Waste Heat Recovery Workshop. Aug. 15, 2-4 pm. Baytown. Motors End User Training. Sept. 12, DFW Waste Heat to Power Conference, Sept 25, Houston Pump Systems End User Training, Late October, Houston Process Heating Systems End User Training, Oct. 31, Baytown. Texas Industrial Energy Management Forum, Nov. 1, Houston.

4 Agenda How to get the big picture in an industrial plant Basic functionality & use of the QuickPEP tool QuickPEP software demonstration Q & A Summary & Conclusions

5 Corporate Report

6 How to get the Big Picture in an Industrial Plant? Looking at the forest first Understanding the plant from an energy supply & demand perspective Different supply streams Different energy consumption (conversion) systems Puts everything down on one piece of paper Limited resources Time major constraint Available information Do you believe it?

7 US Department of Energy s QuickPEP Tool Quick Plant Energy Profiler Tool Website

8 Introduction & Background US Department of Energy (DOE) & Industry Partnerships Identifying key customer needs & how DOE can help One of the conclusions Ability to profile a plant s energy An independent, easy-to-use tool to identify energy savings opportunities in plants Led to meetings to sketch the framework of the model Specifications Software platform Significant industry participation at different levels in beta testing Originally, developed for the Chemical industry (ChemPEP) Completed development for several industries

9 Industrial Sectors in QuickPEP NAICS No. Industry 325 Chemicals 321,322 Forest Products Petroleum Refining Integrated Steel 311,312 Food and Beverage 212 Coal, Metal Ore etc Aluminum and Alumina 336 Transportation Equipment 332 Fabricated Metals 334,335 Comp. Electronics and Appl. 326 Plastics and Rubber Products EAF Steel 313,314,315,316 Textiles Cement 333 Heavy Machinery 3272 Glass and Glass Products 3315 Foundries

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11 INPUTS Plant description Utility supply data electricity, fuel & steam Energy consuming system information Scorecard responses QuickPEP Tool OUTPUTS Overall picture of plant energy use Summary of energy cost distributions Preliminary assessment & comparison Areas for energy efficiency improvement Energy cost reduction potential

12 Input Data Options Supply information Average utility information Actual utility bill information (worksheet) Energy consuming systems Typical systems for that industry selected User checked only Energy consumption (Demand) information Average distributions for that industry selected User can change the distributions User can input actual energy consumption information, if available

13 Input Data Options Energy consuming system assessment for potential energy savings opportunities Radio-button selection User can complete a detailed score-card for a system

14 Output Data Case information Annual energy purchases: Graphical & Tabulated Annual energy consumption: Graphical & Tabulated Annual potential energy savings: Graphical & Tabulated Suggested next steps w/hyperlinks for each energy system

15 Formats On screen display pdf file qpep file Output Data Options Tabulated results in energy (MMBtu) and cost ($) Graphical results can be displayed in either energy or cost units

16 QuickPEP Software Demonstration Base case Very simple average values Use default distributions Single answer scorecards Actual utility and system information Multiple fuel streams, monthly information On-site cogeneration Complete worksheets Complete scorecards

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34 QuickPEP Tool Results Establish Baselines SSST/SSAT SSST/SSAT 3E+ 3E+ QuickPEP QuickPEPTool Tool NXEAT NXEAT Identify Energy Savings PHAST PHAST PSAT PSAT Opportunities By System FSAT FSAT CHP Tool CHP Tool AirMaster+ AirMaster+ Help/References MotorMaster+ MotorMaster+ CWSAT CWSAT

35 Summary & Conclusions Use a top-down approach at an industrial plant with QuickPEP as a starting point to: Understand energy flow Identify cost impacts Identify potential energy cost reduction project areas Baseline plants at a corporate level Baseline individual systems at the plant level Monitor performance over a period of time

36 Summary & Conclusions Prioritize different energy systems based on energy savings potential and undertake an ESA on each of those systems Continue further due diligence to implement energy savings and performance improvement projects

37 Questions & Answers