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Energy Analysis and Diagnostics in Wood Manufacturing Industry Graduate Theses, Dissertations, and Problem Reports 2002 Energy analysis and diagnostics in wood manufacturing industry Amol Anant Mate West Virginia University Follow this and additional works at: https://researchrepository.wvu.edu/etd Recommended Citation Mate, Amol Anant, "Energy analysis and diagnostics in wood manufacturing industry" (2002). Graduate Theses, Dissertations, and Problem Reports. 1270. https://researchrepository.wvu.edu/etd/1270 This Thesis is protected by copyright and/or related rights. It has been brought to you by the The Research Repository @ WVU with permission from the rights-holder(s). You are free to use this Thesis in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you must obtain permission from the rights-holder(s) directly, unless additional rights are indicated by a Creative Commons license in the record and/ or on the work itself. This Thesis has been accepted for inclusion in WVU Graduate Theses, Dissertations, and Problem Reports collection by an authorized administrator of The Research Repository @ WVU. For more information, please contact [email protected]. Energy Analysis and Diagnostics in Wood Manufacturing Industry Amol Mate Thesis submitted to the College of Engineering and Mineral Resources at West Virginia University in partial fulfillment of the requirements for the degree of Master of Science in Industrial Engineering B.Gopalakrishnan, Ph.D., Chair Ralph Plummer, Ph.D. Bruce Anderson, Ph.D. Department of Industrial and Management Systems Engineering Morgantown, West Virginia 2002 Keywords: Energy Assessment, Wood Manufacturing Industry, Sensitivity Analysis, Motor Downsizing, Demand Reduction, Motor Master + Abstract Energy Analysis and Diagnostics in Wood Manufacturing Industry Amol Mate Energy conservation is the need of the hour. It is a continuous process that requires consistent efforts for identifying potential areas for conservation, formulation of proposals and implementing the same. Energy is the most critical resource today. Gap between demand and supply of energy will be continuously widening in the years to come. Scarcity of fuels, insufficiency in energy systems and ever rising cost of energy, lead to energy crisis, alarming for energy conservation. In the above context, there is certainly a need for more research and diagnostics in the different industrial sectors, especially in those where much of the efforts have not been concentrated in the past. Wood manufacturing (SIC 24 manufacturing facilities) is definitely one of those industries where more research efforts are required. It would be extremely beneficial if more energy analysis and research is done in SIC 24. This thesis and research work is concerned with the energy analysis and diagnostics in wood manufacturing industry in West Virginia. This work involves actually conducting site assessments at several lumber and wood manufacturing plants in West Virginia. Using the collected data, we determined energy conservation opportunities and made recommendations. It is important that manufacturers understand the potential for these assessment recommendations with respect to the parameters governing them. Research emphasis is on the demand side management. We found that demand charge plays a crucial role in the total energy charges for this industry. An exhaustive utility bill analysis was performed followed by a sensitivity analysis for demand reduction. Instantaneous motor load test are carried out to determine the load factor of the motors using a digital stroboscope. After motors are identified as suitable candidates for downsizing, an extensive analysis of the motor replacement decision is performed using the Motor Master + software. It is found from the research work that the SIC 24 is indeed heavily oversized for the application. There is tremendous potential for downsizing the motors to their appropriate size in this sector. It is certain that this downsizing will result in the tremendous demand savings as well impact the total energy bill. This work will definitely help the wood industry reduce its production and energy cost and obtain good profits in this ailing economy. ACKNOWLEDGEMENTS I would like to wholeheartedly thank my advisor Dr. B. Gopalakrishnan for his continued support, guidance and encouragement during the course of this research work. I also wish to thank Dr. Ralph Plummer and Dr. B. Anderson, my committee members, for their advice and support. Above all, I wish to thank god and my parents for their constant support and blessings and enabling my success and happiness in all my pursuits and endeavors in life. iii Table of Contents ABSTRACT............................................................................................................................ II ACKNOWLEDGEMENTS .................................................................................................III INTRODUCTION................................................................................................................... 1 1.1 ENERGY ........................................................................................................................... 1 1.2 ENERGY MANAGEMENT................................................................................................... 2 1.3 INDUSTRIAL ENERGY CONSERVATION .............................................................................. 3 1.4 CORPORATE VIEWPOINT .................................................................................................. 6 1.5 IMPORTANCE OF WOOD INDUSTRY .................................................................................. 8 1.5.1 Definition ......................................................................................................................... 8 1.5.2 The manufacturing operations ......................................................................................... 8 1.5.3 Process ............................................................................................................................. 8 1.5.4 Introduction to the lumber and wood products industry................................................ 10 1.6 ECONOMIC PROFILE AND TRENDS OF THE LUMBER AND WOOD PRODUCTS INDUSTRY .. 10 1.6.1 Annual Production ......................................................................................................... 10 1.6.2 Value of Shipments........................................................................................................ 11 1.6.3 Labor Productivity ......................................................................................................... 11 1.7 ENERGY USE IN FOREST AND WOOD PRODUCTS INDUSTRY ........................................... 12 1.7.1 Energy Use by Fuel........................................................................................................ 12 1.7.2 Energy Expenditures...................................................................................................... 13 1.7.3 Technologies and Equipment......................................................................................... 13 1.7.4 Energy management activities ....................................................................................... 14 1.8 WOOD INDUSTRY IN WEST VIRGINIA............................................................................. 15 1.9 NEED FOR RESEARCH..................................................................................................... 16 1.10 ENERGY RESEARCH IN WEST VIRGINIA........................................................................ 16 1.11 RESEARCH OBJECTIVES ................................................................................................ 18 1.12 CONCLUSIONS.............................................................................................................. 18 LITERATURE REVIEW .................................................................................................... 20 2.1 ENERGY ANALYSIS IN FOREST PRODUCTS INDUSTRY..................................................... 20 2.2 ENERGY TECHNOLOGY RESEARCH AND DEVELOPMENT................................................ 22 2.3 WOOD MANUFACTURING INDUSTRY............................................................................... 25 2.4 CONCLUSION.................................................................................................................. 26 UTILITY BILL ANALYSIS................................................................................................ 27 3.1 DATA COLLECTION........................................................................................................ 27 3.2 ELECTRIC COST DISTRIBUTION...................................................................................... 27 3.2.1 Sample Calculation ........................................................................................................ 28 3.2.2 Load Factor Sample Calculation.................................................................................... 31 3.3 POWER FACTOR ............................................................................................................. 31 3.3.1 Power Factor Improvement............................................................................................ 33 3.3.2 General Considerations for Power Factor Improvements.............................................. 34 iv 3.3.3 Power factor at facility A..............................................................................................
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