EPA-650/2-75-032-d August 1975 Environmental Protection Technology Series ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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? ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- |