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Process Heating: Open Tanks

Introduction The total heat loss from the top of open tanks can be determined by summing heat loss through convection, radiation and evaporation. These losses can be reduced by adding floats to the surface. Two methods for estimating energy savings from adding floats are presented. The first is an analytical method based on heat transfer equations. This method is incorporated into the easy-to-use HeatSim software available from the UDIAC. The second method is based on experimental results published by a manufacturer of floats. Both methods give similar results.

Uncovered hot tank with evaporation losses and hot tank with floats to reduce heat and moisture losses. Determining Energy Savings by Adding Floats: Analytical Method The total heat loss from the top of an open tank can be determined by summing heat loss through convection, radiation and evaporation. The value of the convection coefficient, h, for free convection from the top of a hot surface can be estimated by calculating the conductivity, k, kinematic viscosity, nu, Prandl number, pr, and Raleigh number, Ra, for the appropriate film temperature, tf, then using the appropriate relation for the Nusselt number, Nu, depending on whether the flow is laminar or turbulent. The method is summarized below: define input variables l = length of tank w = width of tank ta = temp of air tw = temp of water rh = rel hum of air 'calc props tf = (ta + tw) / 2 nu = (13.90552 + 0.09424 * tf) * 10 ^ -6 'm2/s

k = (23.9886 + 0.0782 * tf) * 10 ^ -3 'W/mK pr = 0.716956 - 0.000228 * tf leq = (l * w) / (2 * (l + w)) 'm 'calc convection heat loss ra = (9.8 * (tw - ta) * (leq ^ 3) * pr) / ((tf + 273) * nu ^ 2) If ra < 10 ^ 7 Then h = k * 0.54 * ra ^ 0.25 / leq 'W/m2K Else h = k * 0.15 * ra ^ 0.33333333 / leq 'W/m2K End If qconv = h * (l * w) * (tw - ta) 'W The method for calculating radiation heat loss, assuming the emissivity of water is 0.96, is summarized as follows: 'calc radiation heat loss sb = 5.67 * 10 ^ -8 W/m2K4 qrad = 0.96 * sb * (l * w) * ((tw + 273) ^ 4 - (ta + 273) ^ 4) 'W The mass transfer coefficient, hm, can be estimated from the convection coefficient, h. The mass of water evaporated, mw, can then be calculated based on the relative humidity of the air, rh, specific volume of the water vapor in the air, vgta, and specific volume of the water vapor at the water surface, vgtw. The heat loss through evaporation, qevap, is the product of the water loss and the enthalpy of evaporation, hfg, at the water temperature. The method is shown below. Dab = 0.26 * 10 ^ -4 'm2/s vgtw = Exp(5.285152 - 0.06458115 * tw + 0.000172321 * tw ^ 2) 'm3/kg vgta = Exp(5.285152 - 0.06458115 * ta + 0.000172321 * ta ^ 2) 'm3/kg hm = h * Dab * (nu / (pr * Dab)) ^ 0.3333333 / k 'm/s mw = hm * (l * w) * ((1 / vgtw) - (rh / vgta)) * 3600 'kg/h hfg = 2503.863 - 2.43774 * tw qevap = mw * hfg * 1000 / 3600 'W To estimate heat loss when the surface is covered with floats, we estimate the fraction of surface area covered by floats based on the geometry of the floats. We assume that heat loss from the uncovered area is the same as without floats. We assume no evaporative heat loss for the covered area. We then use an iterative energy-balance method to determine the temperature of the top of the floats. We use this temperature to calculate the convection and radiation heat loss from the top of the floats. Energy savings from using floats is the difference between the heat loss of the open tank and the tank with floats.

HeatSim This method is encoded into the easy-to-use HeatSim software available from the UDIAC. Determining Energy Savings by Adding Floats: Experimental Method Experimental data from a float manufacturer showing energy loss and percent savings from open tanks are shown below.

Heat and liquid loss savings


Open surface
Average Surface Temperature oC Energy consumption Kwh/h Percentage energy saving Evaporation litres/mh Percentage evaporation saving

1 layer 38mm balls 50 90 75% 1.67 87% 70 1.31 71% 0.41 91% 50 0.60 65% 0.14 90% 1.61 2.70

2 layers 38mm balls 90 2.04 81% 1.28 90% 70 0.76 76% 0.38 92% 50 0.51 70% 0.13 91%

90 10.73 -

70 4.61 -

13.05 4.97 1.45 -

Test Tank Dimensions = 600mm(W) x 1850mm(L) x 1000mm(H).

Source: Euro-Matic Plastics Inc., www.euro-matic.com/hollow.html Comparison of HeatSim and Experimental Results We compared the energy and liquid losses estimated by HeatSim to the experimental results shown above for 70 C water and one layer of 38 mm balls (Euro-Matic Plastics Inc., www.euro-matic.com/hollow.html). To do so, we estimated that the ambient air temperature was 50 F, ambient air relative humidity was 50%, and thermal resistance of the balls was 3 hr-ft2-F/Btu-in. The HeatSim input and output screens are shown below.

Comparison of results is as follows:


Experimental Results Open Tank Energy loss (kW) Liquid loss (kg/h) With Balls Energy loss (kW) Liquid loss (kg/h) Percent Reduction Energy loss Liquid loss A = 0.6 m x 1.85 m = 1.11 m2 4.61 5.52 1.31 0.46 0.72 0.92 HeatSim Results 4.05 4.90 0.97 1.00 0.76 0.80

These results indicate that HeatSims estimates of energy and liquid loss are slightly conservative, but are certainly close enough for estimating savings. Some of the deviation between HeatSim and experimental results may be attributed to the difference between the ambient conditions in the experiment, which were not published, and the ambient conditions assumed in the HeatSim simulation. Properties of Insulating Floats Cost of floats varies widely depending on the type (ball or interlocking float) and material. Material properties are listed below: MATERIAL SPECIFICATION AND CHEMICAL RESISTANCE
Polypropylene (PP) Able to withstand continuous working temperatures of up to 110C (230F). Suitable for contact with most chemicals used in the metal treatment industry. High Density Polyethylene (HDPE) - Suitable for working conditions up to 80C (176F). HDPE is recommended for all external applications due to its enhanced resistance to freezing conditions. Black, Ultra Violet stabilising additives prevent the degrading effects of sunlight. HDPE is also recommended for demineralised water and Chromic acid applications. PVDF - This material offers significant increases in operating temperatures up to 160C (320F) providing resistance to many aggressive chemicals where alternative plastics would fall.

Source: Euro-Matic Plastics Inc., www.euro-matic.com/hollow.html Specifications and Cost Specifications for two types of floats are shown below. Propylene Balls and Saucers from Plating Specialists (859-441-9500) Balls; D = 1.5 inch; 74 balls/ft2; $102/1,000 balls Saucers; D = 1.5 inch; 74 saucers/ft2; $75/1,000 saucers Polypropylene Hexagonal Floats from Burlington International (800-659-5506) Floats; R = 0.164 h-ft2-F/Btu; D = 100 mm; 10 floats/ft2; $1870/1,000 floats; coverage = 95%; reduction in fluid loss = 70%; reduction in heat loss = 80% Based on these specifications, costs range from about $3 /ft 2 for polypropylene balls to $18 /ft2 for interlocking floats with better coverage. Two manufacturers are listed below: Euro-Matic Plastics Inc 2201 Stantonburg Road Wilson NC 27893 Tel: + 1 252 293 0060 Fax: + 1 252 293 0099 e-mail: euromaticltd@simflex.com www.euro-matic.com/hollow.html

Burlingham International 1032 West 18th Street Costa Mesa, CA 92627-4556 1-800-659-5506 Example Recommendations

AR x: Insulate Hot Water Tank with Insulation Floats


Annual Savings Resource CO2 (lb) Natural Gas 112.1 mmBtu 12,600 Dollars $572 Capital $1,870 Project Cost Other Total None $1,870 Simple Payback 39 months

Analysis An open-aired water tank is located in the steel yard. Steel bar stock is dipped in the tank to bring it above ambient temperature before it is shear cut. A natural gas fired U-tube boiler heats the tank. We measured the temperature of the tank water to be about 140 F. The top of the water tank is uncovered, and looses considerable amounts of heat and water to the atmosphere. In the past, hollow plastic balls, or wiffle balls, were used to provide insulation. Burlingham International makes a hexagonal shaped float for such purposes. According to the manufacturer, the floats spread out and arrange themselves to cover approximately 95% of the tank surface area. Recommendation We recommend purchasing insulation floats for the hot water tank. Insulation floats would insulate the water tank, while allowing the bar stock to dip into the tank. Estimated Savings The total heat loss can be determined by calculating the heat loss through convection and radiation, plus the heat loss through evaporation. We assume the combined resistance (R) value for radiation and convection is about 0.61 hr-ft 2-F/Btu (Energy Engineering, Mitchell). The heat loss due to convection and radiation can be determined using the following equation: Q = A / R x (T) Where Q is the heat loss rate, A is the surface area of the tank, R is the restive value, and T is the difference between water temperature and outside air temperature. We measured the surface of the tank to be 4 feet by 25 feet. According to facility engineering personnel, the water tank is heated only during first shift, except when it may freeze. To estimate savings from insulating the tank during first shift, we assumed that from February through November, the tank is heated from 7 AM until 3 PM. Using Typical Meteorological Year data for Dayton, Ohio (TMY2, National Renewable Energy Laboratory), the average temperature during these hours from February through November is about 65 F. Thus, the heat loss rate for the open tank for the 303 days from February through November would be about: (25 feet x 4 feet) / 0.61 hour-feet2-F/Btu x (140 65) F = 12,295 Btu/hour 12,295 Btu/hr x 8 hrs/dy x 303 dys/year / (1,000,000 Btu/ 1 mmBtu) = 29.8 mmBtu/year

According to manufacturer specifications, the floats have a thermal conductivity of 0.22 W per meter-K, and a thickness of inches. Thus, resistance of the insulation floats is about: [0.25 /12 ft] / [0.22 W/m-K x 3.415 Btu/h-W x (1 m / 3.28 ft) x 5/9 K/F] = 0.164 h-ft2-F/Btu The total thermal resistance would be about (0.61 + 0.16) hr-ft2-F/Btu = 0.77 hr-ft2-F/Btu According to the manufacturer, the hexagonal floats only cover 95% of the surface area. Thus, the heat loss rate with the floats would be about: (25 feet x 4 feet) / 0.61 hour-feet2-F/Btu x (140 65) F x 5% = 615 Btu/hour (25 feet x 4 feet) / 0.77 hour-feet2-F/Btu x (140 65) F x 95% = 9,253 Btu/hour 615 Btu/hour + 9,253 Btu/hour = 9,868 Btu/hour 9,868 Btu/hr x 8 hrs/dy x 303 dys/year / (1,000,000 Btu/ 1 mmBtu) = 23.9 mmBtu/year We assumed that during December and January, the tank was heated for 24 hours. Using TMY2 data, we found the typical average temperature during December and January to be about 28 F. We will use 32 F for the average our December and January calculations for ease and to be conservative. The chart below shows the heat loss rates using the method shown above.
Period Feb-Nov Jan, Dec Rvalue hr-ft2-F/Btu 0.61 0.77 0.61 0.77 Twater F 140 140 140 140 Tair F 65 65 32 32 Hours/Period Q hr mmBtu/year 2,424 29.8 2,424 23.9 1,488 26.3 1,488 21.1

Thus, the heat loss savings due to convection and radiation would be about: (29.8 23.9) mmBtu/year + (26.3 21.1) mmBtu/year = 11.1 mmBtu/year In addition to the savings from convection and radiation, there would also be savings from reduction in evaporation. This can be determined using the following set of equations: Q = m x hfg Where, m is the mass flow rate (kg/s), and hfg is the heat of evaporation (kj/kg). m = hmass x A x (,s - ,o)

Where hmass is the mass transfer coefficient (m/s), A is the area (m 2), ,s is the density of vapor near the surface (kg/m3), and ,o is the density of vapor in the air (kg/m3). hmass = Sh x D / L Where Sh is the Sherwood number, D is the mass diffusivity (m 2/s), and L is the characteristic length, found by dividing the area of the open surface by the perimeter. Sh = 0.15 x (Gr x Sc)1/3 Where Gr is the Graschoff number, and Sc is the Schmidtt number Sc = / D Where is the viscosity (m2/s). Gr = g x (o - s) x L3/( x 2) Where g is the acceleration due to gravity (m/s 2), o is sum of the vapor and air density in the environment, s is the sum or the vapor and air density near the water, and is the average of o and s. D = (1.87 x 10-10) x T2.072 / P Where T is the average temperature between the water and the air, and P is the pressure of the air. To obtain density, viscosity, and heat of vaporization values for air and vapor, standard thermodynamic charts were consulted. (Fundamentals of Classical Thermodynamics, Van Wylen & Sonntag). From February through November, the average temperature was 65 F (291 K, 18 C). The temperature of the tank water was 140 F (333 K, 60 C). Assuming an atmospheric pressure of 1 atm, the mass diffusivity was about: (1.87 x 10-10) x ((291 + 333)/2)2.072 / 1 = 2.75 x 10-5 m2/s The viscosity of the average air temperature was about 1.69 x 10 -5 m2/s, thus, the Schmidt number is about: 1.69 x 10-5 m2/s / 2.75 x 10-5 m2/s = 0.6145 The characteristic length of the tank would be about: 100 ft2 x (1 m/ 3.28 ft)2 / (25 ft + 25 ft + 4 ft + 4 ft) x (1 m/ 3.28 ft) = 0.573 m

The density of air and vapor near the water is about 1.196 kg/m 3, and in the environment it is about 1.239 kg/m3, and the average of these values is 1.218 kg/m 3. The acceleration due to gravity is 9.8 m/s2. Thus, the Graschoff number is about: 9. 8 m/s2 x (1.239 - 1.196) kg/m3 x (0.573 m)3 / (1.218 kg/m3 x (1.69 x 10-5 m2/s)2) = 2.28 x 108 Therefore, the Sherwood number would be about: 0.15 x [(2.28 x 108) x 0.6145]1/3 = 77.9 And the mass transfer coefficient would be about: 77.9 x (2.75 x 10-5 m2/s) / 0.573 m = 0.00374 m/s The densities of vapor near the water surface and in the environment are about 0.13 and 0.0155 kg/m3, respectively. Thus, the mass flow rate would be about: 0.00374 m/s x (25 ft x 4 ft x (1 m/ 3.28 ft)2) x (0.13 0.0155) kg/m3 = 0.004 kg/s The heat of evaporation is about 2,358 kJ per kg, thus, the heat loss rate due to evaporation would be about: 0.004 kg/s x 2,358 kJ/kg x 3,415 Btu/hr / (kJ/s) = 32,210 Btu/hr As noted above, the tank would be in operation for 8 hours per day, 303 days per year. According to manufacturer field tests, the floats prevent 70% of the evaporation from a tank. Thus, gas savings would be about: 32,210 Btu/hr x 8 hours/day x 303 days/year x 70% x (1 mmBtu/1,000,000 Btu) = 54.7mmBtu/year Similar calculations can be done for the period of December and January, and values are shown in the table below:

Variable Units Value Twater K 333 Tout K 273 Tave K 303 pv,s kg/m3 0.13 pv,o kg/m3 0.00485 pa,s kg/m3 1.066 pa,o kg/m3 1.342 ps kg/m3 1.196 po kg/m3 1.346 Diffusivity m2/s 2.59 x 10^-5 Viscosity m2/s 1.60 x 10^-5 Characteristic Length m 0.573 Graschoff # 8.5 x 108 Schmit # 0.6178 Sherman # 121 hmass m/s 0.00547 mv kg/s 0.00636 Qrate Btu/hour 51,212 hours hours/year 1,488 Qsavings mmBtu/year 53.3

Thus, the annual heat loss savings from evaporation would be about: 54.7 mmBtu/year + 53.3 mmBtu/year = 108 mmBtu/year The total heat loss savings from installing insulator floats would be about: 11.1 mmBtu/year + 108 mmBtu/year = 119.1 mmBtu/year 119.1 mmBtu/year x $5.10 /mmBtu = $607 /year Estimated Implementation Cost We measured the hot water tank to be about 4 wide by 25 long. According to the manufacturer, ten 100 mm hexagonal floats cover one square foot. Thus, the number of hexagonal floats needed would be about: 10 floats/ft2 x (25 ft x 4 ft) = 1,000 floats. According to the manufacturer, an order of 1,000 floats would cost about $1.87 per float. Thus, total capital cost would be about: $1.87 /float x 1,000 floats = $1,870 According to the manufacturer, the floats will self organize when placed in the tank, thus there is not associated labor cost with installation. Estimated Simple Payback $1,870 / $607 /year x 12 months = 37 months

Contact Burlingham International 1032 West 18th Street Costa Mesa, CA 92627-4556 1-800-659-5506 burlint@worldnet.att.net

AR x: Insulate Hot Tanks with Polypropylene Balls


Natural Gas Electrical Demand Electrical Energy Total Analysis There are four open-aired hot liquid tanks in the plant, the cadmium soak cleaner, cadmium electroclean, hot water rinse, and quench furnace tanks, as shown in the photos below. Annual Savings Resource CO2 (lb) Dollars 24 mmBtu 2,712 $281 0.4 kW $38 1,787 4,110 $59 6,822 $378 Project Cost Capital Other Total Simple Payback

$200

None

$200

6 months

Cadmium soak and electroclean

Hot water rinse

Quench furnace The tanks are steam-heated, with the exception of the quench furnace, which is heated by electrical resistance heaters. The liquid temperatures range from 130 F to 330 F. We measured plant air temperature to be about 78 F. The tops of the uncovered tanks loose heat and water to the plant atmosphere. The chromium hot dip tanks are already covered with floating polypropylene balls in order to reduce toxins in the air, as shown below.

Chromium hot dip tank with polypropylene balls Recommendation We recommend insulating all hot open-aired liquid tanks to prevent heat loss through convection, radiation, and evaporation. This will reduce the energy required to heat the tanks. Estimated Savings The total heat loss can be determined by summing heat loss through convection, radiation and evaporation. Convection and Radiation

We assume the combined resistance (R) value for radiation and convection is about 0.61 hr-ft2-F/Btu (Energy Engineering, Mitchell). The heat loss due to convection and radiation can be determined using the following equation: Q = A / R x (T) Where Q is the heat loss rate, A is the surface area of the tank, R is the restive value, and T is the difference between water temperature and outside air temperature. We measured the cadmium soak cleaner to be four feet by three feet, with a liquid temperature of about 132 F. Thus, heat loss due to convection and radiation is currently about: (4 feet x 3 feet) / 0.61 hour-feet2-F/Btu x (132 78) F = 1,062 Btu/hour We could not find manufacturer information on the conductivity of the polypropylene balls. Thus, we assume the resistance is the same as other insulating floats we are familiar with which have a resistance of about 0.164 h-ft 2-F/Btu. If so, the total thermal resistance with floats would be about (0.61 + 0.16) hr-ft2-F/Btu = 0.77 hr-ft2-F/Btu Assuming the balls cover 90% of the surface area, the heat loss rate with the floats would be about: (4 feet x 3 feet) / 0.61 hour-feet2-F/Btu x (132 78) F x 10% = 106 Btu/hour (4 feet x 3 feet) / 0.77 hour-feet2-F/Btu x (132 78) F x 90% = 842 Btu/hour 106 Btu/hour + 842 Btu/hour = 948 Btu/hour According to management, the tanks are heated about 12 hours per day, 7 days per week, 50 weeks per year. Thus, the energy savings from reducing convection and radiation would be about: (1,062 - 948) Btu/hr x 12 hrs/dy x 7 dys/week x 50 weeks/year / (1,000,000 Btu/ 1 mmBtu) = 0.5 mmBtu/year Evaporation In addition to the savings from convection and radiation, there would also be savings from reducing evaporation. This can be determined using the following set of equations: Q = m x hfg Where, m is the mass flow rate (kg/s), and hfg is the heat of evaporation (kj/kg). m = hmass x A x (,s - ,o)

Where hmass is the mass transfer coefficient (m/s), A is the area (m 2), ,s is the density of vapor near the surface (kg/m3), and ,o is the density of vapor in the air (kg/m3). hmass = Sh x D / L Where Sh is the Sherwood number, D is the mass diffusivity (m 2/s), and L is the characteristic length, found by dividing the area of the open surface by the perimeter. Sh = 0.15 x (Gr x Sc)1/3 Where Gr is the Graschoff number, and Sc is the Schmidtt number Sc = / D Where is the viscosity (m2/s). Gr = g x (o - s) x L3/( x 2) Where g is the acceleration due to gravity (m/s 2), o is sum of the vapor and air density in the environment, s is the sum or the vapor and air density near the water, and is the average of o and s. D = (1.87 x 10-10) x T2.072 / P Where T is the average temperature between the water and the air, and P is the pressure of the air. To obtain density, viscosity, and heat of vaporization values for air and vapor, standard thermodynamic charts were consulted. (Fundamentals of Classical Thermodynamics, Van Wylen & Sonntag). We measure the liquid temperature of the cadmium soak cleaner and the air to be about 329 K and 298 K, respectively. Assuming an atmospheric pressure of 1 atm, the mass diffusivity was about: (1.87 x 10-10) x ((298 + 329)/2)2.072 / 1 = 2.78 x 10-5 m2/s The viscosity of the average air temperature was about 1.69 x 10 -5 m2/s, thus, the Schmidt number is about: (1.69 x 10-5 m2/s) / (2.78 x 10-5 m2/s) = 0.61 The characteristic length of the tank would be about: (4 x 3) ft2 x (1 m/ 3.28 ft)2 / (4 ft + 4 ft + 3 ft + 3 ft) x (1 m/ 3.28 ft) = 0.33 m

The density of air and vapor near the water is about 1.174 kg/m 3, and in the environment it is about 1.204 kg/m3, and the average of these values is 1.218 kg/m 3. The acceleration due to gravity is 9.8 m/s2. Thus, the Graschoff number is about: 9. 8 m/s2 x (1.204 - 1.174) kg/m3 x (0.33 m)3 / (1.189 kg/m3 x (1.69 x 10-5 m2/s)2) = 0.31 x 108 Therefore, the Sherwood number would be about: 0.15 x [(0.31 x 108) x 0.61]1/3 = 40 And the mass transfer coefficient would be about: 40 x (2.78 x 10-5 m2/s) / 0.33 m = 0.0034 m/s The densities of vapor near the water surface and in the environment are about 0.11 and 0.0231 kg/m3, respectively. Thus, the mass flow rate would be about: 0.0034 m/s x (4 ft x 3 ft x (1 m/ 3.28 ft)2) x (0.11 0.0231) kg/m3 = 0.00033 kg/s The heat of evaporation is about 2,358 kJ per kg, thus, the heat loss rate due to evaporation would be about: 0.00033 kg/s x 2,358 kJ/kg x 3,415 Btu/hr / (kJ/s) = 2,654 Btu/hr As noted above, the tank would be in operation for 12 hours per day, seven days per week, 50 weeks per year. We estimate that the polypropylene balls would prevent 60% of the evaporation from a tank. Thus, gas savings would be about: 2,654 Btu/hr x 12 hrs/dy x 7 dys/wk x 50 wks/yr x 60% x (1 mmBtu/1,000,000 Btu) = 6.7 mmBtu/year Total Savings Similarly, we can calculate gas savings for the other open-aired hot liquid tanks, as shown in the table below.
Liquid Temperature (F) 132 135 185 333 Convective & Radiative Savings (Btu/hour) 198.7 209.7 196.8 469.1 1,074.3 Evaporation Savings Total Savings (Btu/hour) (mmBtu/year) 1,576.7 7.2 1,580.2 7.5 839.2 4.4 987.4 6.1 4,983.5 25.2

Tank Cadmium Soak Cleaner Cadmium Electroclean Hot Water Rinse Quench Furnace Total

Area (ft2) 12 12 6 6

Assuming that the steam generator is about 80% efficient, the natural gas savings would be about: (7.2 + 7.5 + 4.4) mmBtu/year / 80% = 24 mmBtu/year 24 mmBtu/year x $11.71 /mmBtu = $281 /year

The reduction in CO2 emissions would be about: 24 mmBtu x 10 ccf/mmBtu x 11.3 lbs CO2 /ccf = 2,712 lbs CO2/year The electrical demand savings would be about: (469.1 + 987.4) Btu/hour x 0.000293 kWh/ 1 Btu = 0.4 kW 0.4 kW x 12 months/year x $8.00 /kW-month = $38 /year The electrical energy savings would be about: 6.1 mmBtu/year x 0.000293 kWh/1 Btu = 1,787 kWh/year 1,787 kWh/year x $0.033 /kWh = $59 /year The reduction in CO2 emissions would be about: 1,787 kWh/year x 2.3 lbs CO2 /kWh = 4,110 lbs CO2/year Thus, the total savings would be about: $281 /year + $38 /year + $59 /year = $378 /year The total reduction in CO2 emissions would be about: 2,712 lbs CO2/year + 4,110 lbs CO2/year = 6,822 lbs CO2/year Estimated Implementation Cost According to the manufacturer, 74 1.5-inch polypropylene saucers will cover one square foot, for the cost of $75 per 1,000 balls. Thus, the number of polypropylene balls needed would be about:

Tank Cadmium Soak Cleaner Cadmium Electroclean Hot Water Rinse Quench Furnace Total

Area (ft2) 12 12 6 6

Balls 888 888 444 444 2,664

Cost ($) $67 $67 $33 $33 $200

Estimated Simple Payback $200 / $378 /year x 12 months = 6 months

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