Texas Industries of the Future November 20, 2013

Transcription

1 For Texas Industries of the Future November 20, 2013 Bob Bessette, President Council of Industrial Boiler Owners

2 CIBO is dedicated to ensuring that non-utility industrial, commercial and institutional energy producers and users can continue to provide safe, cost-effective and reliable energy to sustain a strong and globally competitive economy. 2

3 CIBO represents the interests of America s non-utility energy producers and users. It is the organization of choice for accurate information and advocacy to achieve safe and cost-effective solutions for industrial energy, technology and environmental issues. CIBO activities are designed to: Provide for the focused exchange of accurate technical information among organizational members, government and the public concerning policies, laws and regulations that impact industrial energy systems. Provide a forum for the continued education of organizational members, and the broader industrial energy community on advances in technology and operations to improve the reliability, costeffectiveness and environmentally safe production and use of energy. 3

4 Tune-ups and Energy Assessments for Boiler MACT & GACTCompliance. Area Source Boilers MMBtu/hr. or more March 21, 2014 Major Source Boilers 0.3 TBtu/Yr. or more (approximately 34 MMBtu/hr.) January 31, 2016

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6 For small units, gas 1 units, and metal process furnaces, it is technologically and economically infeasible to measure emissions and prescribe controls. Dioxin/furan emissions are below measureable levels for all subcategories. EPA believes that tune-ups will allow boilers to operate more efficiently, minimizing HAP emissions and saving fuel. They are GACT in the area source rule.

7 Inspect the burner, clean or replace any components of the burner as necessary (there are allowances for certain types of units to delay until next shutdown); Inspect the flame pattern, adjust the burner as necessary to optimize the flame pattern. Inspect system controlling the air-to-fuel ratio, ensure it is correctly calibrated and functioning properly (there are allowances for certain types of units to delay until next shutdown)

8 Optimize total emissions of CO, consistent with the manufacturer s specifications and with any NOX requirement to which the unit is subject; Measure effluent CO in ppmvd and %O2, before and after the adjustments are made. Measurements may be taken using a portable CO analyzer; and Maintain on-site and submit, if requested, an annual report with CO/O2 measurements, any corrective actions, annual fuel use.

9 Unit Limited use; Light liquid or gas 1 or gas 2 unit <5 MMBtu/hr; unit with automatic O2 trim system Gas 1 and light liquid units >5 and <10 MMBtu/hr; gas 2 and heavy liquid units <10 MMBtu/hr Units >10 MMBtu/hr Tune-up Frequency Every 5 years Every 2 years Annual If existing unit not operating on required date of tune-up, conduct tune-up within 30 days of startup. No initial tune up for new units; the first annual, biennial, or 5-year tune-up must be no later than 13 months, 25 months, or 61 months, respectively, after the initial startup.

10 EPA has utilized the Department of Energy (DOE) to develop a boiler tuning guidance document < > < l > Given the diversity of the boiler population: The guide is inherently more generalized rather than specific in nature Each facility will need to tailor the guide to conform to the installed boilers and boiler combustion control systems.

11 Tuning must be done in a safe manner by trained, experienced, technically competent personnel familiar with the boiler being tuned and the control system. Before tuning commences: Find the original design specification sheets for the Boiler Develop written procedures that contain boiler and emission limit data Evaluate where to sample fluegas Find a home for the steam at high loads Assign roles & responsibilities Vet the tuners and get a firm price with costs for additional work/hours

12 During the tuning: Tune across the boilers design firing range Check minimum fire for stability,repeatability and percent of full load Check fluegas combustible/co and O2 levels at each load point Evaluate economizer/air heater performance Check flame pattern/bed depth/ grate condition as appropriate Insure FGR, if used, is operating properly Make sure the tuning is consistent with emissions limits and record emissions as needed For liquid fuels confirm gun is properly assembled with clean correctly oriented tips Confirm liquid fuel atomization system operating properly

13 First, Cause and Effect with Combustion Performance

14 After the tuning: Confirm all data properly recorded and regulatory requirements met Move boiler through operating range to confirm system responds without issues Obtain tuning data from tuner, in rough draft form, before tuner leaves site

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16 What must be assessed? Boiler System(s) Means boiler and associated equipment Feed water system Combustion air system Fuel System (including burners) Blowdown system Combustion control systems Steam systems Condensate return systems

17 Assess boiler and process heater systems and systems using energy from onsite boilers and process heaters (% of total energy production that must be evaluated varies based on size) Review facility s energy management practices Recommend improvements and cost-effective energy savings measures Report outlining measures, cost, benefits, and payback period

18 BOILER SYSTEM Feed water Steam Systems Combustion Air Fuel Combustion Controls Blowdown Steam Systems

19 BOILER SYSTEM What is Boiler System boundary? Feed water Steam Systems Combustion Air Fuel Combustion Controls Blowdown I interpret as above boundary (not official interpretation) BOILER SYSTEM Steam Systems Feed water Steam Systems Combustion Air Fuel Combustion Controls Blowdown Steam Systems

20 What must be assessed? Boiler System(s) Process Heater(s) Energy use system(s) accounting for at least 20% of the energy (e.g., steam, process heat, hot water, or electricity) production Energy Use System includes systems that use energy provided by boiler or process heater Process heating Compressed air systems Machine drive (motors, pumps, fans) Process cooling Facility heating, ventilation, and air-conditioning systems Hot water systems Building envelop Lighting OR other systems that use steam, hot water, process heat, or electricity provided by affect boiler or process heater. Only include systems using energy clearly produced by affected boilers and process heaters

21 ENERGY USE SYSTEM Process Heating Heat Exchangers Heat Tracing Columns Insulation Etc. Compressed Air Plant Air Instrument Air Etc. Machine Drives Motors Pumps Fans Turbines Etc. Process Cooling Chilled Water Glycol Refrigerant River Water Loops Etc. Facility HVAC Heating Ventilation Air Conditioning Hot Water Systems Heat Exchangers Insulation Etc. Building Envelop Insulation Windows Etc. Lighting LED CFL Ballasts Etc. Other Inert Gases Turbine Generators?

22 BOILER SYSTEM Feed water Steam Systems Combustion Air Fuel Combustion Controls Blowdown Purchased Power Assess 100% of Boiler System(s) Steam Systems ENERGY USE SYSTEM Assess 20% of Energy Systems Don t include purchased power Process Heating Heat Exchangers Heat Tracing Columns Insulation Etc. Compressed Air Plant Air Instrument Air Etc. Machine Drives Motors Pumps Fans Turbines Etc. Process Cooling Chilled Water Glycol Refrigerant River Water Loops Etc. Facility HVAC Heating Ventilation Air Conditioning Building Envelop Insulation Windows Etc. Lighting LED CFL Ballasts Etc. Other Inert Gases Turbine Generators Hot Water Systems Heat Exchangers Insulation Etc.

23 Total Combined Heat Input Capacity Max Number of Technical Hours On Site Percentage of energy production to be evaluated <0.3 TBtu/yr 8 50% 0.3 to 1.0 TBtu/yr >1.0 TBtu/yr 24 for the first 1 TBtu and 8 for every additional 1 TBtu 24 33% 20% Note - 1 TBtu/yr is about 115 MMBtu/hr for 8760 hours.

24 On-site Assessment Hours T Btu/year Multiply above numbers by 115 to get MMBTU/hr Definition says to not exceed the above hours, but may go longer. No specified minimum

25 Someone who has demonstrated capabilities to evaluate energy savings opportunities for steam generation and major energy using systems, including, but not limited to: Boiler combustion management Boiler thermal energy recovery, including Conventional feed water economizer Conventional combustion air preheater, and Condensing economizer. Boiler blowdown thermal energy recovery Primary energy resource selection, including Fuel (primary energy source) switching, and Applied steam energy vs direct-fired energy vs electricity Insulation issues Steam trap and steam leak management Condensate recovery Steam end-use management

26 Capabilities and knowledge includes, but is not limited to: Background, experience, and recognized abilities to perform the assessment activities, data analysis, and report preparation. Familiarity with operating and maintenance practices for steam or process heating systems Additional potential steam system improvement opportunities including improving steam turbine operations and reducing steam demand Additional process heating system opportunities including effective utilization of waste heat and use of proper process heating methods. Boiler-steam turbine cogeneration systems Industry specific steam end-use systems.

27 No certification required Only demonstrated capabilities Can be done in house No brief case required

28 Energy Conservation Measures Implemented to improve the energy efficiency of the boiler or facility Cost Effective A measure with <2 year payback Must develop list of all cost effective energy conservation measures

29 Visual inspection of boiler or process heater system Operating characteristics, specifications, procedures, constraints Inventory of major energy use systems Architectural/Engineering plans, O&M procedures/logs, fuel usage Energy Management practices

30 Include a signed certification that the energy assessment was complete with your Notification of Compliance Status (NoCS). NoCS is due 60 days after compliance date It does NOT say Include results of assessment Include final report of assessment Include list of cost effective energy conservation measures

31 Can use an energy assessment performed after January 1, 2008 It is okay to make modifications to an old assessment to fit MACT requirements Major Source - Must be complete before January 31, Area Source Must be complete before March 21, 2014

32 If you have an Energy Management Program that is COMPATIBLE with ISO you DO NOT have to perform a one-time energy assessment.

33 ISO Energy Management System Model EPA Energy Management Overview c=guidelines.guidelines_index

34 Are worth doing Typically pay for themselves Resulting investments usually low risk However, they are not free Marginal facility is worried about paying bills, not doing projects with a short payback period.

35 Before onsite visit Operating area receives questionnaire. They list Utilities used Consumption Metered? Calculated? Assumed? Known opportunities Known problems Procedures Drawings Constraints Energy Assessor(s) review information Familiarization Look for obvious (to someone with an energy hat) opportunities Heat integration Control valves operating <50% downstream of pump Etc.

36 During onsite visit Field walk down Leaks Missing Insulation Condensate to ditch PRV blowing through Faulty steam traps Etc. Operating area describes process (flow diagrams) Brainstorm energy savings opportunities VFD instead of control valves Heat integration Metering Lighting Eliminate heating then cooling (or vice versa) Heat Exchanger effectiveness Etc.

37 After onsite visit Estimate cost and benefit of brainstormed ideas Start off with back of napkin quality Increase estimate quality if project has potential Present good projects to operating area Typically further refinement is needed to list No, you can t do that because That will work but savings won t be that high because Refine estimates and place qualifying projects in the capital project hopper to be chosen when it makes good financial sense.

38 An energy audit that identifies several cost effective energy conservation measures should feel like a success. Company will save money in the long run Profits increase However, that long list now feels like a liability. Will EPA/State ever ask to see your list? You don t have to submit it but will they ask for it when you do a construction permit? Can it fall into the hands of NGO? Will they demand to see if a public comment period ever comes up for your facility? Confidential information (energy costs, energy:product) What if you never do a single identified project?

39 MACT does not specify the quality of the list Low quality estimate will likely show low cost and high savings Back of napkin energy savings are usually fairly easy & accurate but capital cost can be +/- 100% for complex projects. High quality estimates are expensive to obtain We should be able to throw out high risk solutions Shutdown a pump so others can run more efficiently Now you don t have an operating spare Use less steam and heat product to low end of specification Now you have more off quality product How long is the list valid?

40 While brainstorming during an energy assessment Be reasonable If you wouldn t do it (too risky), don t write it down Recognize that there probably are some improvements that can and should be done I wouldn t want to tell Agency that my assessment found nothing. Estimating Apply appropriate contingencies based on quality of estimate Reporting Any item listed as a Cost Effective Energy Conservation Measure needs to be a feasible project. Don t have it listed and be forced to tell Agency you really can t do it

41 Robert D. (Bob) Bessette President Council of Industrial Boiler Owners (CIBO) 6801 Kennedy Road, Suite 102 Warrenton, VA Telephone: