EPA-650/2-75-032-d
August 1975
Environmental Protection Technology Series
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EPA-650/2-75-032-d
ENERGY CONSUMPTION
FUEL UTILIZATION
AND CONSERVATION IN INDUSTRY
by
John T. Reding and Burchard P. Shepherd
Dow Chemical, U.S.A.
Texas Division
Freeport, Texas 77541
Contract No. 68-02-1329, Task 14
Program Element No. 1AB013
ROAP No. 21ADE-010
EPA Project Officer: Irvin A. Jefcoat
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, North Carolina 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, D. C. 20460
August 1975
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EPA REVIEW NOTICE
This report has been reviewed by the National Environmental Research
Center - Research Triangle Park . Office of Research and Development,
EPA, and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendation for use.
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environ-
"mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development and applica-
tion of environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These series are:
1. ENVIRONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVIRONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-
poitit sources of pollution. This work provides the new or improved
technology required for the control and treatment of pollution sources
to meet environmental quality standards.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
Publication No. EPA-650/2-75-032-d
11
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CONTENTS
Page
EPA Review Notice ii
List of Tables iv
Sections
I Conclusions 1
II Recommendations 4
III Introduction 5
IV Fuel Utilization and Conservation in Industry 7
V Bibliography 36
VI Glossary of Abbreviations 38
VII Appendix 39
111
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TABLES
No. Page
1 Fuel Utilization in the Six Biggest Fuel
Consuming Industries by Industry and Operation 8
2 Fuel Utilization in the Six Biggest Fuel
Consuming Industries by Unit Operation 12
3 Heat Rejection in the Six Biggest Fuel
Consuming Industries 15
4 Energy Conservation in the Six Biggest
Fuel Consuming Industries 18
5 Fuel Utilization by Operation in the Chemical
Industry 2O
6 Fuel Utilization by Process and Operation
in the Chemical Industry 21
7 Energy Conservation in the Chemical Industry 24
8 Energy Conservation in the Primary Metals
Industry 26
9 Energy Conservation in the Petroleum Industry 29
1O Energy Conservation in the Paper Industry 31
11 Energy Conservation in the Stone-Clay-Glass-
Concrete Industry 33
12 Energy Conservation in the Food Industry 34
13 Production Volume, Fuel Usage, and Economic
Importance of Energy in the Six Biggest
Fuel Consuming Industries 35
IV
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SECTION I
CONCLUSIONS
Annual fuel utilization in the six largest fuel consuming
industrial sectors in the early 197O's is characterized as
follows:1
• Chemical industry usage2 1160 ± 12O x 1012 kcal
• Primary metals industry
usage 1310 ± 13O x 1012 kcal
• Petroleum industry usage 766 ± 8O x 101 2 kcal
• Paper industry usage 645 ± 65 x 1012 kcal
• Stone-clay-glass-concrete
industry usage 365 ± 40 x 1012 kcal
• Food industry usage 323 ± 3O x 1012 kcal
• Total for the six sectors 4569 ± 50O x 1012 kcal*
Annual fuel utilization by unit operation in the six industrial
sectors is characterized as follows:
• Direct heating of process
streams 178O ± 40O x 1012 kcal
• Compression 340 ± 10O x 1012 kcal
• Distillation 300 ± 100 x 1012 kcal
• Electrolysis 34O ± 5O x 1012 kcal
• Evaporation 165 ± 3O x 1012 kcal
• Drying 27O ± 5O x 1012 kcal
*This amounts to 25 to 3O percent of the total ener,gy con-
sumption in the United States.
-------
• Cooking, sterilizing,
and digestion 185 ± 30 x 1012 kcal
• Feedstock 490 ± 50 x 1012 kcal
• Other or unaccounted for 699 x 1O12 kcal
• Total 4569 ± 5OO x 1012 kcal
Purchased electricity is valued at 2500 kcal/kWh throughout
this report.
2 Process fuel utilization - 670 x 1012 kcal
Feedstock fuel utilization - 49O x 1O12 kcal
Annual fuel utilization by type of fuel is characterized as
follows:
• Purchased electricity 813 ± 80 x 1012 kcal
• Coal 853 ± 85 x 1012 kcal
• Petroleum 701 ± 70 x 1012 kcal
• Natural gas 1602 ± 160 x 1012 kcal
• Other 600 ± 60 x 1012 kcal
• Total 4569 ± 500 x 1012 kcal
Level of annual heat rejection from process is characterized
as follows:
• Radiation, convection
conduction, other 410 ± 150 x 1012 kcal
• Below 100°C 1420 ± 3OO x 1012 kcal
• From 100°C to 250°C 728 z 200 x 1O12 kcal
• From 250°C to 800°C 557 ± 150 x 1012 kcal
• From 800°C to 1800°C 254 ± 100 x 1012 kcal
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Energy conservation efforts should be capable of decreasing
annual energy usage in the short run (less than 5 years) as
follows:
• Chemical industry 187 x 1012 kcal
• Primary metals industry 208 x 1012 kcal
• Petroleum industry 130 x 1012 kcal
• Paper industry 170 x 1012 kcal
• Stone-clay-glass-
concrete industry 37 x 1012 kcal
• Food industry 36 x 1O12 kcal
• Total 774 x 1012 kcal
Energy conservation approaches should be capable of decreasing
annual energy usage in the short run (less than 5 years) as
follows:
• Waste utilization 86 x 1012 kcal
• Maintenance and insulation 19O x 1O12 kcal
• Operation modification 68 x 1012 kcal
• Design modification 215 x 1012 kcal
• Process integration 139 x 1012 kcal
• Process modification 72 x 1012 kcal
• Market modification 4 x 1O12 kcal
• Total 774 x 1012 kcal
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SECTION II
RECOMMENDATIONS
The use of recommended energy conservation approaches is
grossly estimated to reduce short term annual fuel con-
sumption in the six biggest energy consuming industries
by 774 x 1012 kcal. It would appear worthwhile to look
in more detail at these conservation approaches with the
goal of answering the following questions:
• What are the shortcomings in the present energy
conservation techniques?
• How can the conservation techniques be improved?
• What are the costs, success odds, and possible
impact of research on conservation techniques?
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SECTION III
INTRODUCTION
Purpose
The purpose of this task is to prepare a tabular summary of
fuel utilization by industry, process, and unit operation for
the six biggest energy consuming industrial categories. These
industries include chemicals, primary metals, petroleum, paper,
stone-clay-glass-concrete, and food.
Scope
This report presents tables containing estimates of the
following:
• Fuel utilization in the six biggest fuel consuming
industries by industry, process, and unit operation.
• Level of heat rejection in the six biggest fuel
consuming industries.
• Short term effects of applying recommended conser-
vation approaches.
General Background
The National Academy of Engineering (NAE) has been com-
missioned by the Environmental Protection Agency (EPA) to
conduct a comprehensive assessment of the current status
and future prospects of sulfur oxides control methods and
strategies. The agreement between the EPA and the NAE states
explicitly that special data collection projects may be
required to provide the NAE panel with the background
necessary for viewing all aspects of the problem in per-
spective. Three reports (EPA-650/2-75-032-a, EPA-650/2-75-
O32-b, and EPA-650/2-75-O32-c) were written by the authors
of this report as one segment of the data collection project
associated with the NAE assessment. The three reports
presented information on energy utilization by operation in
a number of processes in the six biggest energy using
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industrial groups. They also gave information on level of
rejected heat and the possible effects of energy con-
servation approaches for the process covered. The present
report presents more information on fuel utilization, level
of rejected heat, and probable short term effects of using
recommended conservation approaches in the six biggest
energy using industrial groups.
6
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SECTION IV
FUEL UTILIZATION AND CONSERVATION IN INDUSTRY
The annual fuel utilization in the six biggest fuel consuming
industries by industry and operation is shown in Table I.
The largest fuel user is primary metals (1310 ± 130 x 1012
kcal). Next is the chemical industry (116O ± 120 x 1012
kcal). However, 42 percent of this energy is for feedstock
material. Third is the petroleum industry (766 ± 80 x 1012
kcal). Fourth is the paper industry (645 ± 65 x 1012 kcal)
while fifth is the stone-clay-glass-concrete industry (365 ±
40 x 1012 kcal) and sixth the food industry (323 ± 30 x
1012 kcal). The above quantities value purchased electricity
at the fuel value required to generate the electricity
(2500 kcal per kWh). The estimates apply for the years 1971,
1972, or 1973 depending on the industry.
Table 1 indicates that purchased electricity accounts for
17-18 percent of the energy usage, coal for 18-19 percent,
petroleum for 15-16 percent, natural gas for 35 percent, and
other fuels for 13 percent.
Table 2 shows the fuel utilization in the six biggest fuel
consuming industries by unit operation. Direct heating of
process streams by fuel combustion or electricity is the
largest energy user with an estimated annual usage of 1780 ±
400 x 1012 kcal. Other listed operations are compression
with 340 ± 10O x 1012 kcal, distillation with 30O ± 100 x
1012 kcal, electrolysis with 340 ± 50 x 1012 kcal,
evaporation with 165 ± 3O x 1012 kcal, drying with 270 ± 50 x
1012 kcal, cooking or digestion with 185 ± 30 x 1012 kcal,
feedstock with 490 ± 50 x 1012 kcal, and other with 699 x
1012 kcal.
Table 3 shows the level of heat rejection in the six biggest
fuel consuming industries. Radiation, convection, conduction,
and other losses account for 410 ± 150 x 1O12 kcal per year.
The estimated heat rejected at a temperature below 10O°C is
1420 ± 300 x 1012 kcal per year. The estimate at a
temperature between 10O°C and 25O°C is 728 ± 20O x 1O12 kcal
per year. At 250°C to 800°C the estimate is 557 ± 150 x 1012
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Table 1. FUEL UTILIZATION IN THE SIX BIGGEST FUEL
CONSUMING INDUSTRIES BY INDUSTRY AND
OPERATION
Industry (or process)
and operation
Fuel Used (1O12 kcal/year)
Chemical
Direct heating
Compression
Distillation
Electrolysis
Evaporation
Drying
Other
Feedstock
Purch.
Elect.
at fuel
value
(2500
kcal per
kWh)
1OO
55
15
Coal Petroleum
Nat.
Gas
Other
Total
365
Total
i
200
65
395
125
480
140 ±
190 ±
1OO ±
9O ±
65 ±
10 ±
75
49O ±
40
50
50
20
20
5
50
20 1160 ±120
for the year 1973
Direct heating of process streams only. Energy used to
generate utility steam is alloted to the unit operation
where the steam is used. If the steam directly enters
into the process stream then heat required for its
generation is included under direct heating.
Purch. Nat.
Elect. Coal Petroleum Gas
Other
Total
Primary metals
Steel
Coking
Agglomeration
Blast furnace
Steel making
Casting, soaking
Primary rolling
Reheating
Rolling mills
Heat treatment
Other
Sub-total
4
40
8
26
11
7
70
20
350
6
22
16
6
65
2
10
10
4
3
10
1OO
555
46
4
10
9
12
24
51
13
43
166
78 ± 8
32 ± 5
373 ± 35
68 ± 7
50 ± 15
8 ± I
74 ± 20
26 ± i5
33 ± 10
125
867 ± 90
8
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Table 1. (continued)
Purch. Nat.
Elect. Coal Petroleum Gas Other Total
Aluminum
Digestion & Evap. 4 15 19 ± 5
Calcining 8 8 ± 2
Electrolysis ISO5 156 165 ± 2O
Melting, heat treat- 1 6 7 ± 2
ing
Sub-total 155 15 29 199 ± 2O
Other metal processes 65 70 4 1O5 244
Total 32O 625 65 3OO 1310 ±13O
3 For the year 1972
4 3O x 1012 kcal of the coal is used to produce oils, tar, and
coke breeze not returned to the steel process.
5 Fuel value of purchased and self-generated electricity using
a conversion factor of 250O kcal/kWh. Approximately 5O$ of
the electricity generated for aluminum reduction is from
hydroelectric plants. However, because the extensive inter-
connection of U.S. electric utilities permits the ready ex-
change of power between regions, aluminum production must be
regarded as a load on the entire electricity grid. Therefore,
the typical utility fuel value of 25OO kcal per kWh is used
to calculate fuel consumption.
6 Fuel value of carbon electrodes consumed in electrolysis
reaction.
Purch. Nat.
Elect. Coal Petroleum Gas Other8 Total
Petroleum
Petroleum refining
Crude distillation 17O ± 3O
Cracking & fractionation 23O ± 5O
Reforming & fractionation 8O ± 2O
Alkylation & fractionation 5O ± 1O
Asphalt plant 25 ± LO
Coking & fractionation 20 ± 5
Other operations 166
Sub-total 53 3 6O 275 35O8 741 ± 7O
Other processes 25 ± 1O
Total 766 ± 8O
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Table 1. (continued)
7 For the year 1971.
8 Other - refinery gas = 253 x 1O12 kcal; petroleum coke =
8O x 1012 kcal; acid sludge = 7 x 1O12 kcal; purchased steam
= 1O x 1012 kcal.
Purch. Nat.
Elect. Coal Petroleum Gas
Other
Paper
Kraft process
Digester & washer
Liquor evaporation
Pulp & paper drying
Lime regeneration
Other operations
Other paper making processes
Other sectors of paper industry
Total
90
60
110
155
230
10
Total
75 ± 15
40 ± 1O
1OO ± 2O
20 ± 5
140 ± 30
22O ± 4O
50 ± 10
645 ± 65
9 For the year 1972.
10 Other - bark and wood = 40 x 1O12 kcal; black liquor =
19O x 1012 kcal.
Purch.
Elect.
Stone-clay-glass-concrete
Cement
Kiln 5
Other 22
11
Sub-total
Glass
Melting
Annealing
Other
Sub-total
27
12
1
2
Coal Petroleum
42
2
44
16
1
17
Nat.
Gas
54
2
56
15
60
Other
Total
117 ± 10
27 ± 3
144 ± 15
63 ± 10
7 ± 1
9 ± 1
79 ± 10
11
For the year 1972.
10
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Table 1. (continued)
Brick & clay tile
Ready-mixed concrete
Lime
Other
Total
Food12
Meat packing
Fluid milk
Canned fruits & veg
Frozen fruits & veg
Animal feeds
Bread, cake,
related products
Beet sugar
Malt beverage
Wet corn milling
Soy bean oil
Other
Total
Purch.
Elect.
2
! 2
2
12
Coal
3
X
10
7
Nat.
Petroleum Gas Other Total
2
11
1
1
20
X
9
60
27 ±
13 ±
22 ±
80
4
2
3
60
8
8
3
5
4
5
1
6
2
4
44
65
4
1
35
3
4
205
11
7
12
90
35
36
162
27 ±
13 ±
22 ±
80
365 ±
26 ±
20 ±
15 ±
13 ±
19 ±
18 ±
21 ±
17 ±
18 ±
14 ±
142
4
2
3
40
5
4
3
3
4
4
4
4
4
3
323 ± 30
Totals
12
For the year 1971.
813
853
701
1602
6OO 4,569 ±5OO
11
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Table 2. FUEL UTILIZATION IN THE SIX
BIGGEST FUEL CONSUMING INDUSTRIES
BY UNIT OPERATION
Type and Amount of Energy (1O12 kcal/year)
Operation & Purch.
Industry Elect. Coal Petroleum Gas Other Total
Direct heating
Chemical 140 ± 40
Primary metals 75 55O 5O 225 9OO ± 150
Petroleum
refining 45O ± 100
Paper 2O
Stone-clay-
glass-conc. 25O ± 5O
Food 20
1780 ± 4OO
Compression
Chemical 120 190 ± 5O
Primary metals 1O
Petroleum 70 ± 30
Paper
Stone-clay-
glass-conc.
Food 6O 7O ± 3O
340 ± 1OO
Distillation
Chemical 1OO ±50
Primary metals
Petroleum 2OO ±75
Paper
Stone-clay-
glass-conc.
Food __-"__
3OO ± 1OO
12
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Table 2. (continued)
Type and Amount of Energy (1O12 kcal/year)
Operation & Purch.
Industry Elect. Coal Petroleum Gas Other Total
Electrolysis
Chemical 55 90 ± 2O
Primary metals 200 25O ± 50
Petroleum
Stone-clay-
glass-conc.
Food
340 ± 50
Evaporation
Chemical 65 ± 20
Primary metals 20
Petroleum
Paper 50 ± 10
Stone-clay-
glass-conc.
Food 30
165 ± 30
Drying
Chemical 1°
Primary metals 10
Petroleum
Paper 2OO ± 40
Stone-clay-
glass-conc. 2O
Food 30
270 ± 50
Cooking
(digesting)
Chemical
Primary metals 10
Petroleum
13
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Table 2. (continued)
Operation &
Industry
Paper
Stone-clay-
glass-conc.
Food
Feedstock
Chemical
Other or
unaccounted
for
Chemical
Primary metals
Petroleum
Paper
Stone-clay-
glass-conc.
Food
GRAND TOTAL
Type and Amount of Energy (1012 kcal/year)
Purch.
Elect. Coal Petroleum Gas Other Total
365
125
125
50 ± 10
185 ± 30
490 ± 50
75
110
46
250
95
123
699
813
853
701 1602 600 4569 ± 50O
14
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Table 3. HEAT REJECTION IN THE SIX BIGGEST
FUEL CONSUMING INDUSTRIES
Rejected Heat (1012 kcal/yr)'
Chemical
Chlorine/caustic soda
Ethylene/propylene
Ammonia
Ethylbenzene/styrene
Carbon black
Sodium carbonate (syn.)
Oxygen/nitrogen
Cumene
Phenol/acetone
Other
Total
Primary Metals
Steel
Aluminum
Other
Total
Petroleum
Paper
Stone-clay-glass-conc,
Cement
Glass
Other
Total
Radiation,
Convection,
Conduction,
Other
10
5
8
0.3
0.5
) 0.5
0.3
X
X
25
50
75
30
30
Below
100°C
64
38
29
6
X
9
43
1
2
158
350
20
95
100
100°-
250°C
13
20
35
7
8
4
37
1
2
73
2OO
10O
20
3O
250°- 800°-
800°C 1800°C
X
10
10
X
X
X
X
X
X
20
40
150 200
5 20
10 20
135
80
50
215
250
350
150
125
190
165
175
30
240
30
25
25
20
15
20
10
3
10
55
22
40
9
5
14
20
7O
0.3
(I)2
x
(0.3)
(1)
180
30
65
25
80
55
23
117
14
15
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Table 3. (continued)
Industry (or Process)
and Operation
Food
GRAND TOTAL
Radiation,
Convection,
Conduction,
Other
15
410 ±
150
Below 100°- 250°- 800°-
100°C 250°C 800°C 1800°C
200
1420 ±
300
40
728 ±
200
30
557 ±
150
254 ±
100
Heat
Used for
Reactions
(1012 kcal/yr)
1 The rejected heat includes heat rejected in generating purchased and self-
generated electricity for the process.
Exothermic reactions.
16
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kcal per year, and the estimate at 8OO°C to 18OO°C is 254 ±
100 x 1O1 kcal per year.
Table 4 shows the estimated short term (less than 5 years)
effect of applying recommended conservation approaches to
the six big fuel consuming industries. Research and
development on new processes, on increasing product yields,
or on other areas might yield even more beneficial effects
on fuel utilization. This conservation approach was not
included in this analysis because the effects of research
and development efforts are very difficult to estimate. The
estimated effect of applying conservation approaches other
than research and development is to decrease annual fuel
usage by 774 x 1012 kcal. The order of effectiveness of
conservation approaches is design modification, maintenance
and insulation, process integration, waste utilization,
process modification, operation modification, and market
modification.
Tables 5 and 6 show more detailed information on fuel
utilization by unit operation and process in the chemical
industry. Processes accounting for approximately 48 percent
of the total chemical process (non-feedstock) energy usage
are analyzed in Table 6. The total chemical industry energy
consumption by operation (Table 5) was estimated using the
analyzed process information plus published information on
total energy usage in the chemical industry. Feedstock
coverage in analyzed processes was much more complete.
Approximately 77 percent of published total feedstock con-
sumption was accounted for in the chemical processes which
were analyzed in Table 6.
Tables 7, 8, 9, 10, 11, and 12 show more detailed information
on energy conservation in the six big energy consuming
industries. Table 13 gives information on production volume,
fuel usage and the economic importance of energy in the six
big fuel using industries.
17
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Table 4. ENERGY CONSERVATION IN THE SIX BIGGEST
FUEL CONSUMING INDUSTRIES
Industry
Chemical
Primary
Metals
Petroleum
Paper
Conservation Approach
Waste utilization
Maintenance and insulation
Market modification
Operation modification
Design modification
Process integration
Total
Waste utilization
Process integration
Process modification
Design modification
Maintenance and insulation
Operation modification
Total
Process integration
Design modification
Maintenance and insulation
Waste utilization
Operation modification
Total
Process integration
Marketing modification
Process modification
Design modification
Waste utilization
Maintenance and insulation
Total
Estimated
Fuel Savings
(1012 Tccal/yr)
14
50
1
24
78
20
Industry
Energy Usage
(1012 kcal/yr)
187
35
13
36
66
30
28
208
32
40
40
8
16
136
68
3
15
5
29
50
170
670
1310
766
645
18
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Table 4. (continued)
Industry
Stone-clay-
glass-conc.
Food
Conservation Approach
Process modification
Maintenance and insulation
Design modification
Total
Maintenance and insulation
Process integration
Design modification
Total
Estimated
Fuel Savings
(1012 kcal/vr)
21
10
37
Industry
Energy Usage
(1012 kcal/vr)
365
GRAND TOTAL
10
6
IP
36
774
323
4569
1 Process energy only. This does not include feedstock energy usage.
19
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Table 5. FUEL UTILIZATION BY OPERATION
IN THE CHEMICAL INDUSTRY
Operation
Direct heating
Compression
Distillation
Electrolysis
Evaporation
Drying
Feedstock
Other
Total
Energy Consumption
Processes Analyzed
(1012 kcal/year)1
106 ± 15
99 ± 25
2O ± 5
63 ± 10
27 ± 4
4 ± 1
413 ± 50
All Chemical
Processes
(1012 kcal/year)1
140 ± 40
190 ± 50
100 ± 50
90 ± 20
65 ± 20
10 ± 5
490 ± 50
75
732 ± 75
1160 ± 120
1 For the year 1973
20
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Table 6. FUEL UTILIZATION BY PROCESS AND OPERATION
IN THE CHEMICAL INDUSTRY
Fuel Usage (1012 kcal/Year)x
Process and Purchased
Operation Electricity
Chlorine/
Caustic Soda
Electrolysis 33
Compression 4
Evaporation
Other
37
Ethylene/
Propylene
Direct heating5
Compression 3
Distillation
Feedstock x
3
Ammonia
Compression 7
Direct heating5
Feedstock x
7
Ethylbenzene/
Styrene
Direct heating
Distillation [1]
Feedstock x
1
Petroleum Natural
f2 Coal Products Gas
[sum of three]= 29
[ " ]= 3
[ " ]= 26
_L " ]= 4
10 3 50
[sum of three]= 49
[ " ]= 38
[ •' ]= 6
XX X
46 I6 886
[sum of three]= 2O
[ " ]= 41
XX X
5 56
[sum of three]= 5
[ ]= 7
XX X
1 0.3 11
21
Feedstock Total
x 63
x 7
x 26
x 4
100
x 49
x 41
x 6
2724 272
2724 368
x 27
x 41
877 87
877 155
x 5.5
x 7.5
228 22
22 35
± 10
± 2
± 5
± 10
± 10
± 8
± 2
± 30
± 40
± 5
± 8
± 10
± 16
± 1
± 2
± 4
± 4
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Table 6. (continued)
Fuel Usage (1012 kcal/Year)1
Process and Purchased
Operation Electricity2
Carbon Black
Direct heating
Drying
Feedstock x
Sodium
Carbonate10
Compression —
Drying
Distillation
Direct heating
Oxygen/
Nitrogen
Compression 19.5
Cumene
Process
Feedstock x
X
Phenol/
Acetone11
Distillation
Other 0.4
0.4
Total 68
Petroleum Natural
Coal Products Gas Feedstock
9
1
xx x 259
10 259
[sum of three ]= 3 x
[ " ]= 3 x
[ •• ]= 3 x
[ » ]= 2.5
3 1 7.5 x
0.3 0.3 0.4 x
0.3 0.3 1.5 x
xx x 8.58
0.3 0.3 1.5 8.5
[sum of three]= 3.7 x
[•']=! x
1 0.3 3.4 x
18 11 223 378
Total
9 ±
1
25 ±
35 ±
3 ±
3 ±
3 ±
2.5 ±
11.5 ±
20.5 ±
2.1 ±
8.5 ±
10.6 ±
3.7 ±
1.4 ±
5.1 ±
2
5
5
1
1
1
1
2
2
0.5
2
1
1
0.5
0.5
NOTE: Footnotes on following page.
22
-------
Table 6. (continued)
For the year 1973.
2 Fuel value of purchased electricity using a conversion factor
of 2500 kcalAWh-
3 Approximately 55% of the propylene produced in 1973 was a by-
product of ethylene production.
4 89 x 1O12 kcal as ethane, 95 x IQi2 kcal as propane, 87 x 1012
kcal as naphtha.
5 Direct heating includes heating of steam which enters into the
process stream.
6 Considerable gaseous by-products are produced in the ethylene
process which can be used as fuel. They are not credited to
the ethylene process in this analysis. Their 1973 fuel value
was 55 x 1012 kcal.
7 Natural gas feedstock.
8 Benzene feedstock.
9 22.5 x 1012 kcal as oil, 2.5 x 1012 kcal as natural gas.
10 Synthetic sodium carbonate only. Approximately 5O$ of the
U.S. production in 1973 was synthetic.
11 The cumene oxidation process only. This process accounted
for approximately 87$ of the U.S. production of cumene in
1973.
23
-------
Table 7. ENERGY CONSERVATION IN THE
CHEMICAL INDUSTRY
Conservation Technique
Waste Utilization
Estimated
Fuel Savings
(1012 kcal/Yr)
a. Recover the fuel value of wasted
by-product in chlorine process.
Assume that 5O$ is now being
wasted.
b. Increase burning of other wasted
by-products.
Insulation and Maintenance
Improve maintenance and insulation
of steam systems. This should re-
duce steam usage by 15 to 2O%.
Operation Modification
a. Operate electroysis cells at
lower current densities.
b. Closely control excess air to
furnaces.
10
50
10
c. Closely control the reflux on
distillation colums.
Design Modification
a. Increase waste heat recovery
from hot streams such as furnace
stack gases or hot process streams.
b. Design distillation columns
to operate at a lower reflux.
c. Convert the chlorine cells using
graphite anodes (approximately 50$)
to metal anodes.
50
10
8
24
-------
Table 7. (continued)
Conservation Technique
d. Replace inefficient compressors
and motors with more efficient
equipment.
5. Process Integration
Increase efforts to co-produce steam
and electricity.
6. Market Modification
Substitute 50% NaOH in half of the
applications now using 100$ NaOH.
Total
Estimated
Fuel Savings
(1012 kcal/Yr)
10
20
187
Total chemical industry process fuel usage ~ 67O x 1012 kcal/
year.
25
-------
Table 8. ENERGY CONSERVATION IN THE
PRIMARY METALS INDUSTRY
Conservation Approach
1. Waste Utilization
a. Use 25% of the presently un-
accounted for blast furnace gas
as fuel.
b. Increase domestic recycle of
scrap steel. Decrease exports by
3 x 1O6 tons per year (~40$ of
exports in 1972).
c. Increase old scrap recycle of
aluminum from approximately 5%
of aluminum production to 10$.
2. Process Integration
Co-produce electricity and steam.
If 50% of the process steam generated
in manufacturing steel were co-
produced with electricity, approxi-
mately 7 x 1012 kcal of electricity
could be generated using an extra
8 x 1O12 kcal of fuel. This amount
of electricity typically requires
21 x 1012 kcal of fuel for its
generation.
Estimated
Fuel Savings
(1012 kcal/Yr)
15
10
Process Modification
a. Replace the open hearth process
for producing steel with the basic
oxygen process. Assume that one-
half of the open hearth portion of
steel production (26% in 1972) is
replaced with the basic oxygen
process.
10
13
26
-------
Table 8. (continued)
Conservation Approach
b.
c.
Increase the use of continuous
casting in the steel industry
from 6$ of raw steel cast in 1972
to 50$ of raw steel cast.
Increase the ratio of iron-ore
pellets to sinter in the blast
furnace charge. Reduce sinter
charge to 20$ of the total charge.
Estimated
Fuel Savings
(IP12 kcal/Yr)
15
d.
Use Alcoa's newly developed
aluminum process to produce
the U.S. aluminum production.
of
4. Design Modification
a. Increase waste heat recovery by
charging hot sinter, pellets, and
coke into the blast furnace.
Assume that 30$ of the heat from
these materials can be salvaged.
b. Preheat combustion air supplied
to sinter and pellet furnaces.
Assume that 25$ of the heat from
hot stack gases can be recovered.
c. Increase the air blast temperature
to 11OO°C and the top gas absolute
pressure to 210 kN per m2 in the
blast furnace on 50$ of the
furnaces. Coke savings of 2O$ on
the charged furnace can be achieved,
d. Assume that the off-gases from 50$
of the basic oxygen furnaces are
used for their fuel and sensible
heat.
27
9
35
-------
Table 8. (continued)
Conservation Approach
e. Improve heat recuperators in open
hearth furnaces, soaking pits,
reheat furnaces, and heat treating
furnaces.
f. Reduce electrolyte resistance in
aluminum electrolysis cells by
closer electrode spacing or
modifying bath composition.
Operation Modification
a. Operate aluminum electrolysis cells
at 2O$ lower current density.
b. Closely control depth of aluminum
pad, the distance between anode
and cathode, and bath composition.
Maintenance and Insulation
Improve maintenance and insulation of
steam systems in all primary metals
processes. This should result in
savings of 10 to 2O$ in steam usage.
Total
Estimated
Fuel Savings
(1012 Tccal/Yr)
8
20
30
2O8
Total primary metals energy usage ~ 131O ± 130 x 1012 kcal/yr,
28
-------
Table 9. ENERGY CONSERVATION IN THE
PETROLEUM INDUSTRY
Conservation Approach
Process Integration
Co-produce electricity and process
steam. At present only 1O to 15$ of
process steam production is combined
with electric generation. Assume
that this can be increased to 50$.
Then an additional 17 x 1O12 "kcal of
electricity could be generated using
19 x 1012 kcal of fuel. Utilities
typically require 51 x 1O kcal of
fuel to generate this quantity of
electricity.
Design Modification
Estimated
Fuel Savings
(1012 kcal/Yr)
32
a. Increase heat recuperation from
furnaces. Assume that air pre-
heaters which will decrease fuel
consumption 15^ are installed on
an additional 25% of industry
furnaces.
b. Increase heat interchange between
process streams,
c. Increase use of turbines to re-
cover mechanical energy from
high pressure process streams.
d. Design distillation columns to
require lower reflux.
Maintenance and Insulation
Improve maintenance and insulation on
steam systems. This should reduce steam
consumption by 15 to 2O%.
29
16
8
8
8
40
-------
Table 9. (continued)
Estimated
Fuel Savings
Conservation Approach (1012 kcal/Yr)
4. Waste Utilization
8
Increase the use of flue gas from
catalytic crackers as fuel.
5. Operation Modification
Closely control steam stripping 16
operations, use of H2 in desulfuri-
zation operations, use of excess air
in furnaces, and reflux in fraction-
ation operations.
Total 136
Total petroleum industry fuel usage ~ 766 ± 80 x 1012 kcal,
30
-------
Table 10. ENERGY CONSERVATION IN THE
PAPER INDUSTRY
Conservation Approach
Estimated
Fuel Savings
LO12 kcal/Yr)
Process Integration
a. Co-produce electricity and 6O
process steam. At present
approximately 2O to 25% of the
possible steam-electricity co-
production possibilities are being
exercised. If this were increased
to 5O$, an additional 30 x 1O12
kcal of electricity could be gener-
ated using an additional 33 x 1012
kcal of fuel. A typical utility
would require 9O x 1O12 Tccal of
fuel to generate this quantity of
electricity.
b. The movement toward integrated pulp 8
and paper mills should be continued
because of the expenditure of 0.85 x
106 Tccal/ton of pulp dried in non-
integrated mills. Assume that
production from integrated mills
increases from the present 6O$ of
the total to 75$ of the total.
Process Modification
Use paper-forming processes which require 15
less fuel for drying in 25$ of the mills
(Thermo Electron's Lodding K-Former
process).
Waste Utilization
a. Increase waste paper recycle from
the present level of 19$ o:f
produced paper to 21% of produced
paper.
31
-------
Table 10. (continued)
Conservation Approach
b. Increase use of process wastes as
fuel from the present level of
230 x 1012 kcal to 25O x 103 "
kcal.
Estimated
Fuel Savings
(1012 kcal/Yr)
20
•a 2
Design Modification
Continue replacement of batch di-
gesters with continuous digesters.
Assume that the continuous digester
production increases from its present
of the total to 75$.
Maintenance and Insulation
Improved maintenance and insulation
of steam systems should result in a
10$ decrease in steam usage.
Market Modification
Substitute unbleached paper for
bleached paper in 15% of the present
bleached paper market.
Total
50
170
1 2
Total paper industry energy usage ~ 645 ± 65 x 10 kcal/yr.
32
-------
Table 11. ENERGY CONSERVATION IN THE STONE-CLAY-
GLASS-CONCRETE INDUSTRY
Estimated fuel
savings
Conservation Approach (1O12 kcal/year)
1. Process modification
a. Convert 25 percent of the present 12
wet process cement production to
the dry process using a suspension
preheater system.
b. Convert 25 percent of the present 6
dry process cement production using
a long kiln to the dry process
using a suspension preheater.
c. Enrich combustion air with oxygen 3
on 50 percent of the glass furnaces.
Use agglomerated feed in 5O percent
of the glass furnaces.
2. Design modification
Continue trend to larger glass furnaces 6
in which radiation losses are less and
heat recuperation is more feasible.
3. Maintenance and insulation
Improve maintenance of insulation and 1O
increase insulation in cement kilns and
and glass melting furnaces.
Total 37
stone-clay-glass-concrete energy usage
-365 ± 40 x 1012 kcal/year
33
-------
Table 12. ENERGY CONSERVATION IN THE FOOD INDUSTRY
Conservation Approach
Maintenance and insulation
Improved maintenance and insulation
of steam systems should decrease
steam consumption by 2O percent.
Process integration
Co-produce electricity along with
process steam. Assume that 25
percent of the steam production is
combined with electricity production.
Then approximately 3 x 1O12 kcal of
electricity could be produced using
3.3 x 1O12 kcal of fuel. A typical
utility would use 9 x 1012 kcal to
produce the 3 x 1O12 kcal of
electricity.
Design modifications
a. Increase the use of high tempera-
ture, short time pasteurization
equipment in the milk process.
b. Replace batch canning operations
with continuous operations.
c. Use baking ovens with air agitation.
d. Use a more efficient evaporation
system in the beet sugar process.
e. Increase use of heat recuperation
in many processes.
f. Use more efficient cooling equipment
Estimated fuel
savings
(101 kcal/year)
10
20
Total
food industry fuel use ~323 ± 3O x
kcal/year
34
10
12
36
-------
Table 13. PRODUCTION VOLUME, FUEL USAGE, AND ECONOMIC
IMPORTANCE OF ENERGY IN THE SIX BIGGEST
FUEL CONSUMING INDUSTRIES
Fuel Usage
industry Production
(or process) (109
Chemical
Chlorine &
caustic soda
Ethylene +
propylene
Ammonia
Ethylbenzene
+ styrene
Carbon black
Sodium carbo-
nate3
Oxygen
Total industry
Primary metals
Steel
Aluminum
Total industry
Petroleum
Paper
Stone-clay-glass-
concrete
Cement
Glass
Total industry
kg /year)
19
f\
12 2
14
6
1.6
3.53
14.5
X
83.5
3.7
X
610
56
73
16
X
Purchased
and self
generated
electricity
70
3
10
8
X
X
95
37
15
77
24
6
23
19
19
20
Steam
(for
heating
or
mechanical
drive)
30
46
29
55
X
78
5
43
20
10
15
34
74
X
X
5
Direct
firing
X
51
60
37
10O
22
X
20
65
13
61
60
3
81
81
75
Economic importance
of energy
kcal used
$ of value added
2OO , OOO
XXX
Jl
2OO , OOO4
XXX
130, OOO4
14O , OOO
40 , OOO
35,OOO
40 , 000
14O , OOO
5O,OOO
90 , 000
25 , OOO
40 , 000
30
65
Does not include feedstock.
1O, OOO
Food :
1 Process fuel only.
2 Includes only propylene manufactured as a dry product of the ethylene
process. This is approximately 55 percent of the U.S. production.
3 Synthetic sodium carbonate only.
4 Includes feestock energy
35
-------
SECTION V
BIBLIOGRAPHY
Brantley, F. E., Iron and Steel. In: Minerals Yearbook 1972.
Schreck, A. E. (ed.). Washington, B.C., U. S. Government
Printing Office, 1974. _!: 641-666.
Bravard, J. C., H. B. Flora, and C. Portal. Energy Expendi-
tures Associated with the Production and Recycle of Metals.
Oak Ridge National Laboratory, Oak Ridge, Tennessee. Publi-
cation Number ORNL-NSF-EP-24. November 1972. 87 p.
Brown, B. C., Cement. In: Minerals Yearbook 1972. Schreck,
A. E. (ed.). Washington, B.C., U. S. Government Printing
Office. j.:247-288.
Energy Consumption in Manufacturing. Myers, J. G. (ed.)
Cambridge, Massachusetts, Ballinger Publishing Company, 1974.
610 p.
Garrett, H. M., and J. A. Murray. Improving Kiln, Thermal
Efficiency-Besign and Operation Considerations, Part 1.
Rock Products. .7J7: 74-77, 124, May 1974.
Industrial Energy Study of Selected Food Industries. Bevelop-
ment Planning and Research Associates, Inc., Manhattan, Kansas.
Contract Number 14-O1-OOO1-1652. July 1974.
Norbom, H. R., Wet or Bry Process Kiln for Your New Installation?
Rock Products. _77_: 92-98, 100, May 1974.
Patterns of Energy Consumption in the United States. U. S.
Government Printing Office. Washington, B.C. Stock Number
4106-0034. January 1972. 250 p.
Reding, J. T., and B. P. Shepherd. Energy Consumption: Paper,
Stone/Clay/Glass/Concrete, and Food Industries. EPA, Research
Triangle Park, N. C. Publication Number EPA-650/2-75-032-C.
April 1975. 54 p.
Reding, J. T., and B. P. Shepherd. Energy Consumption: The
Chemical Industry. EPA, Research Triangle Park, N. C. Publica-
tion Number EPA-650/2-75-032-a. April 1975. 64 p.
36
-------
Bibliography (continued)
Reding, J. T., and B. P. Shepherd. Energy Consumption. The
Primary Metals and Petroleum Industries. EPA, Research
Triangle Park, N. C. Publication Number EPA-650/2-75-O32-b.
April 1975. 53 p.
Saxton, J. C., M. P. Kramer, D. L. Robertson, M. A. Fortune,
N. E. Leggett and R. G. Capell. Data Base for the Industrial
Energy Study of the Industrial Chemicals Group. Department
of Commerce, Washington, D.C. Publication Number PB-237-845.
September 1974. 242 p.
Shaw, R. W. The Impact of Energy Shortages on the Iron and
Steel Industries. Booz, Allen and Hamilton, Inc. Bethesada,
Maryland. Contract Number 14-01-0001-1657. August 1974.
Sheridan, E. T., Coke and Coal Chemicals. In: Minerals Year-
book 1972. Schreck, A. E. (ed.). Washington, D.C., U. S.
Government Printing Office, 1974. _1:427-460.
Study of Effectiveness of Industrial Fuel Utilization.
Gyftopoulos, E. P. (director). Thermo Electron Corporation,
Waltham, Massachusetts. Report Number TE 5357-71-74.
January 1974. 12O p.
Study of Process Energy Requirements in the Food Industry.
New York, American Gas Association, Inc.
Study of Process Energy Requirements in the Glass Industry.
New York, American Gas Association, Inc.
Study of Process Energy Requirements in the Iron and Steel
Industry. New York, American Gas Association, Inc. 69 p.
Study of Process Energy Requirements in the Non-Ferrous Metals
Industry. New York, American Gas Association, Inc. 69 p.
Study of Process Energy Requirements in the Paper and Pulp
Industry. New York, American Gas Association, Inc. 29 p.
Zaffarano, R. F. and S. O. Wood, Jr. Carbon Black. In:
Minerals Yearbook 1972, Schreck, A. E. (ed.). Washington,
D.C., U. S. Government Printing Office, 1974. J.: 237-246.
37
-------
SECTION VI
GLOSSARY OF ABBREVIATIONS
cone. - concrete
elect. - electricity
kcal - kilo calories
kg - kilogram
kN - kilonewton
kWh - kilowatt hour
m - meter
purch. - purchased
syn. - synthetic
yr. - year
38
-------
SECTION VII
APPENDIX
ENERGY CONSERVATION APPROACHES
Design modification - This term includes design changes in
equipment or process.
Insulation - This term implies that a review of the economics
of additional insulation is needed.
Maintenance - This term implies that the economics of
additional maintenance effort needs review.
Process integration - This term relates to the best use of
steam by using the same steam in more than one process
or to the optimization of the steam-electricity produc-
tion ratio. It also covers the combination of two or
more processes within one plant.
Research and development - This term relates to the improve-
ment of processes by future discoveries.
Operation modification - This term includes changes in
operating procedures or practices that do not require a
design change.
Market modification - This term relates to the substitution
of a low energy consumption product for a high energy
consumption product.
Process modification - This term relates to a change in a
process due to a change in process feedstock, raw
materials, or process route.
Waste utilization - This term relates to the use of fuel
value of waste process streams or to the recycling of
used materials.
39
-------
TECHNICAL REPORT
(Please read Instructions on the reverse
DATA
before completing)
I REPORT NO
EPA-650/2-75-032-d
3 RECIPIENT'S ACCESSION-NO.
4 TITLE ANOSUBTITLE
Energy Consumption: Fuel Utilization and
Conservation in Industry
S REPORT DATE
September 1975
6 PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO
John T. Reding and Burchard P. Shepherd
9 PERFORMING ORGANIZATION NAME AND ADDRESS
Dow Chemical, U.S.A.
Texas Division
Freeport, Texas 77541
10 PROGRAM ELEMENT NO.
1AB013: ROAP 21ADE-010
11 CONTRACT/GRANT NO.
68-02-1329, Task 14
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 4-6/75
14. SPONSORING AGENCY CODE
15 SUPPLEMENTARY NOTES
16 ABSTRACT,^ reporf gives results of a study of fuel utilization and energy conservation
for the six biggest energy consuming industrial groups: chemicals, primary metals,
petroleum, paper, stone/clay/glass/concrete, and food. Total annual fuel usage in
these industries in the early 1970s was 4569 + or - 500 x 10 to the 12th power kcal.
Purchased electricity (valued at 2500 kcal per kWh) accounts for 17-18% of the energy
use, coal for 18-19%, petroleum for 15-16%, natural gas for 35%, and other fuels for
13%. Unit operations accounting for energy use include direct heating (39%), com-
pression (7-8%), distillation (6-7%), electrolysis (7-8%), evaporation (3-4%), drying
(6%), cooking or digestion (4%), feedstock (10-11%), and other (15-16%). Approximately
800 x 10 to the 12th power kcal per year of energy is rejected in these industries at a
temperature above 250 C. Intense efforts at waste heat recovery should eventually
allow use of most of this rather high level heat. In the short term, use of a variety
of conservation approaches should reduce annual fuel use in the big six industrial
groups by 774 x 10 to the 12th power kcal below the level without conservation.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c COSATI Field/Group
Air Pollution
Fuels
Fuel Consumption
Energy
Conservation
Industries
Heat Recovery
Chemical Industry
Metal Industry
Petroleum Industry
Paper Industry
Glass Industry
Concretes
Food Industry
Air Pollution Control
Stationary Sources
Primary Metals Industry
Stone Industry
Clay Industry
13B
2 ID
07A
11F
11L
11B
05C 13C
2QM. 13A 06H
3 DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21 NO OF PAGES
44
2O SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
40
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