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U.S. DEPARTMENT OF Energy Efficiency & ENERGY Renewable Energy ADVANCED MANUFACTURING OFFICE Improving Process Heating System Performance A Sourcebook for Industry Third Edition U.S. Department of Energy Energy Efficiency and Renewable Energy Bringing you a prosperous future where energy is clean, abundant, reliable, and affordable Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.” ACKNOWLEDGEMENTS Improving Process Heating System Performance: A Sourcebook for Industry is a development of the U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) and the Industrial Heating Equipment Association (IHEA). The AMO and IHEA undertook this project as part of an series of sourcebook publications developed by AMO on energy-consuming industrial systems, and opportunities to improve performance. Other topics in this series include compressed air systems, pumping systems, fan systems, steam systems, and motors and drives. The U.S. DOE, IHEA, Lawrence Berkeley National Laboratory, and Resource Dynamics Corporation wish to thank the following individuals for their input to this third edition: David Boone, Alabama Power Company Joe Cresko, US Department of Energy Dan Curry, Selas Heat Technology Robert De Saro, Energy Research Company Marc Glasser, Rolled Alloys Leslie Muck, Industrial Heating Equipment Association Sachin Nimbalkar, Oak Ridge National Laboratory Bill Orthwein, US Department of Energy William Pasley, Southern Company Ernesto Perez, Nutec Bickley Paul Sheaffer, Lawrence Berkeley National Laboratory Perry Stephens, Duke Energy We also wish to thank the following individuals for their review and/or input to this and previous editions: B.J. Bernard, Surface Combustion; Tony Carignano, PCT Engineered Systems; Elliott Davis, Selas Heat; Ken Dulaney, EPRI; Brian Kelly, Elster; Tim O'Neal, Selas Heat Technology; Wayne Pettyjohn, Georgia Power; Bruno Purnode, Owens Corning; Steve Sikirica, US Department of Energy; Michael Stowe, Advanced Energy; Arvind Thekdi, E3M, Inc.; Craig Tiras, Gaumer Process; Baskar Vairamohan, EPRI; Devin Wachowiak, Rolled Alloys; and Carsten Weinhold, SCHOTT North America. Third Edition, 2015 Prepared for the United States Department of Energy Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office By Lawrence Berkeley National Laboratory, Berkeley, California Resource Dynamics Corporation, McLean, Virginia In cooperation with the Industrial Heating Equipment Association, Taylor Mill, Kentucky IMPROVING COMPRESSED AIR SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY FOREWORD The DOE Office of Energy Efficiency and Renewable Energy (EERE)’s Advanced Manufacturing Office works with industry, small business, universities, and other stakeholders to identify and invest in energy efficient technologies. Reducing energy consumption through investment in advanced technologies and practices can enhance American manufacturing competitiveness. The industrial sector is responsible for about one-third of all U.S. primary energy use, and the associated greenhouse gas (GHG) emissions. The U.S. industrial base is diverse, with about two-thirds of the end-use energy consumed by the energy intensive industries including chemicals, forest products, petroleum refining, iron and steel, glass, aluminum, metal-casting foundries and cement. Beyond the large energy consumers, there are a wide range of energy dependent industries whose products and operations are significantly impacted by energy. Of all manufacturing operations, process heating consumes more energy in the U.S. than any other manufacturing system – more than 7,000 Trillion Btu (TBtu), or approximately 61% of manufacturing onsite energy use annually. Opportunities to reduce the energy demand for process heat include more efficient heat generation, system design to reduce losses prior to heat use, and alternative manufacturing processes that require less heat to produce the same material. This Sourcebook outlines opportunities for energy and performance improvements in process heating systems, and is intended to help the reader identify improvement opportunities in their own facilities. This Sourcebook is not a substitute for a rigorous engineering-based assessment and evaluation of the technical and economic potential of any process heating improvement. This Guidebook is also intended to serve as a companion to other resources and sources of information, such as: • The DOE 2015 Quadrennial Technology Review (QTR) Technology Assessments on Process Heating and Waste Heat Recovery, as well as other Technology Assessments that can provide insights into state-of-the-art and emerging opportunities to improve process heat utilization and production efficiencies. • AMO’s Steam System Modeling Tool (SSMT), available at http://energy.gov/eere/amo/software-tools. This tool help users survey and assess their steam system equipment, perform heat balances, quantify heat losses, and identify potential energy efficiency upgrades. • Fact sheets, technical analyses, roadmaps and other resources that can be found by searching on the AMO “Information Resources” webpage. These and other resources that can help the reader find more information can be found in Section 7 of this Sourcebook – “Where to Find Help.” IMPROVING COMPRESSED AIR SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY CONTENTS QUICK START GUIDE SECTION 1: PROCESS HEATING SYSTEM BASICS OVERVIEW ..................................................................................................................................................................................................... 3 EFFICIENCY AND ENERGY INTENSITY OPPORTUNITIES .............................................................................................................................................. 3 SYSTEMS APPROACH........................................................................................................................................................................................ 4 BASIC PROCESS HEATING OPERATIONS ............................................................................................................................................................... 5 COMMON TYPES OF PROCESS HEATING SYSTEMS AND EQUIPMENT .......................................................................................................................... 8 SECTION 2: PERFORMANCE IMPROVING OPPORTUNITIES - FUEL-BASED SYSTEMS FUEL-BASED PROCESS HEATING EQUIPMENT CLASSIFICATION ............................................................................................................................... 14 EFFICIENCY OPPORTUNITIES FOR FUEL-BASED PROCESS HEATING SYSTEMS .............................................................................................................. 18 TYPES OF ELECTRIC-BASED PROCESS HEATING SYSTEMS – DIRECT AND INDIRECT ...................................................................................................... 25 SECTION 3: PERFORMANCE IMPROVING OPPORTUNITIES - ELECTRIC-BASED SYSTEMS ARC FURNACES......................................................................................................................................................................................... 26 ELECTRIC INFRARED PROCESSING ............................................................................................................................................................ 28 ELECTRON-BEAM PROCESSING ................................................................................................................................................................ 32 INDUCTION HEATING AND MELTING ....................................................................................................................................................... 34 LASER PROCESSING .................................................................................................................................................................................. 36 MICROWAVE PROCESSING ...................................................................................................................................................................... 37 PLASMA PROCESSING (ARC AND NONTRANSFERRED ARC) ..................................................................................................................... 39 RADIO-FREQUENCY PROCESSING ............................................................................................................................................................ 40 RESISTANCE HEATING AND MELTING ...................................................................................................................................................... 40
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