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.

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    • 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


-------
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

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        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)
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