TEES/ESL Industrial Energy Technology Conference IETC 2006 May 9-12, 2006 New Orleans, Louisiana, USA Printed from e-media with permission by: Curran Associates, Inc. 57 Morehouse Lane Red Hook, NY 12571 www.proceedings.com ISBN: 978-1-60423-444-2 Some format issues inherent in the e-media version may also appear in this print version.
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TEES/ESL Industrial Energy Technology Conference 2006 TABLE OF CONTENTS AMERICAN CHEMISTRY COUNCIL AWARD WINNERS Baytown Energy Project... 1 John R. Porter Reduction of Utility Usage in a Glyphosate Intermediate (GI) Unit... 2 Michael L. Sander Deer Park Chemical Plant received ACC award for energy efficiency program... 3 Steve Moon, Eva Heyman Managing Energy Efficiency Improvement... 7 Joe Almaguer DISASTER RECOVERY AND ENERGY: LESSONS LEARNED FROM 2005 Advancing Equipment Reliability via a Natural Disaster, Opportunities for Thinking Outside the Box... 9 Robert Stephens ENERGY USE ANALYSIS TOOLS A Case Study in Developing Process Unit Energy Metrics... 10 Joseph L. Davis Jr., Bob Van Atta Quantifying Energy Savings from Lean Manufacturing Productivity Increases... 12 John Seryak, Gary Epstein, Mark D Antonio Thermal and Economic Analyses of Energy Saving by Enclosing Gas Turbine Combustor Section... 20 Xianchang Li, Ting Wang, Benjamin Day FACILITIES & EQUIPMENT IMPROVEMENTS Optimization of Industrial Refrigeration Plants: Including a Case Study at Stonyfield Farm Yogurt... 29 Mark D Antonio, Satyen Moray, Brian McCowan, Gary Epstein,Lisa Drake, Randal Dixon Direct-Contact Process Water Heating... 40 Mark R. Hamann Upgrade Your Lighting & Open the Door to Energy Savings... 47 John K. Houcek Roof Coating Procedures and their Productivity Gains... 48 John Bonaby, Diane Schaub
FLUID HANDLING SYSTEMS Taking Another Look at Pumping Systems: Opportunities Go Well Beyond Just Energy Savings... 49 Vestal Tutterow, Trey Walters Redesigning Process Cooling Systems In The Plastics Industry... 57 Glen R Anderson The Many Faces Of A Compressed Air Audit... 62 Henry L. Kemp Effects of Limited Product Line Audits... 68 Henry L. Kemp Industrial Ventilation Statistics Confirm Energy Savings Opportunity... 75 Ales Litomisky INDUSTRIAL ENERGY MODELING: WHAT IS THE STATE OF THE ART? CIMS: An Integrated US-Canadian Model... 86 John Nyboer Distributed Energy: Modeling Penetration in Industrial Sector over the Long-Term... 87 Lorna Greening Detailed Modeling of Industrial Energy Use and Greenhouse Gas Emissions in an Integrated Assessment Model of Long-term Global Change... 88 Paramita Sinha, Marshall Wise, Steven Smith Integrating Empirical Measures of Energy Efficiency Into An Energy Modeling Framework... 100 Gale Boyd MEASURING THE RESULTS Designing and Implementing Monitoring Based Energy Cost Reduction Programs... 101 Andrew S. McMullan, Bruce L. Pretty, David Hart Audits and Implementation of Plant Wide Energy Management and Reporting Systems... 106 James E. Robinson, David Moore Real-Time Demand Side Energy Management... 116 Annelize Victor, Michael Brodkorb Industrial Energy Management: Doing More With Less... 121 Jason Sheppard, Anthony Tisot NATIONAL ENERGY EFFICIENCY PROGRAM INITIATIVES U.S. Department of Energy (DOE) Industrial Programs and Their Impacts... 125 Steven A. Weakley, Joseph M. Roop Energy Efficiency Opportunities in the Stone and Asphalt Industry... 133 Satyen Moray, Nathan Throop, John Seryak, Chris Schmidt,Chris Fisher, Mark D Antonio The Role of Emerging Technologies in Improving Energy Efficiency: Examples from the Food Processing Industry... 146 Robert Bruce Lung, Eric Masanet, Aimee McKane
Combined Heat And Power: Connecting The Gap Between Markets And Utility Interconnection And Tariff Practices (Part I)... 161 Susanne Brooks, Brent Elswick, R. Neal Elliott STEAM SYSTEMS Steam Pressure Reduction, Opportunities, And Issues... 170 Jan Berry, Bob Griffin, Anthony L. Wright The Enbridge Steam Saver Program Steam Boiler Plant Efficiency-Update To Year End, 2005... 180 Bob Griffin, Daniel Johnson STRATEGIES FOR IMPLEMENTATION Energy Cost Control Strategies: What Do Large Energy Consumers Do, and Why?... 197 Christopher Russell Creating an Energy Strategy that Delivers Cost Savings while Optimizing Asset Utilization... 201 Allan Sears Reaping Energy Savings From Petroleum Refining... 211 Alan Deng, Ron Cascone Energy And Environmental Footprinting... 214 David Severson, Christian Whitaker, Fred James Lost Opportunities in Industrial Energy Efficiency: New Production, Lean Manufacturing and Lean Energy... 218 John Seryak, Gary Epstein, Mark D Antonio TEAMWORK FOR ENERGY MANAGEMENT Energy Workforce Training, Future Need, and Projections... 225 S. Midturi, S. B. Pidugu Multi-Site Energy Reduction Through Teamwork... 230 Thomas R. Theising Status Of North American Energy Markets... 233 R Neal Elliott Driving Energy Performance with Energy Management Teams... 239 Meredith Younghein, Walt Tunnessen TECHNICAL SOLUTIONS FOR EMISSION REDUCTIONS Final Flue Gas Cleaning (FFGC)... 246 Daniel H. Stinger, Mario H. Romero Cost Assessment of CO2 Sequestration by Mineral Carbonation... 262 Frank E. Yeboah, Tuncel M. Yegulalp, Harmohindar Singh Developing Solutions for the Energy and Environmental Challenge... 267 Andrew McMullan Plant-Wide NOx Reduction Strategies... 273 C. Baukal, D. Waibel, T. Webster
UNDERSTANDING MOTOR APPLICATIONS Unusual ASD Motor Conversions in a Carpet Yarn Plant... 285 Michael Brown, William Meffert Unwinding the Spin on Variable Speed Drive Air Compressors... 292 Chris E. Beals Replacing Motors, Counting Savings: Results From A 100 Motor Study... 302 Nicole M. Kaufman Author Index