Efficiency April 2006 Prepared fr! Prepared "y! Energy and En#irn$ental Analysis% Inc& www.eea-inc.com 'ead(uarters )est *ast +ffice 1655 N. Fort Myer Drive, Suite 600 12011 NE First Street, Suite 210 Arlinton, !irinia 2220" #ellevue, $as%inton "&005 'el( )*0+, 52&-1"00 'el( )-25, 6&&-01-1 Fa.( )*0+, 52&-5106 Fa.( )-25, 6&&-01&0 The Gas Company E,ecuti#e -u$$ary '%is wor/0a0er 1escri2es si. calculators t%at will allow t%e Sout%ern 3ali4ornia 5as 3om0any )'%e 5as 3om0any, account e.ecutives an1 ot%er sta44 to estimate annual as savins 4or in1ustrial customers a00lyin 4or incentive 4un1s 4or %eat recovery un1er t%e #usiness Enery E44iciency 6rorams )#EE6,. '%ese calculators are as 4ollows( 7.yen Enric%ment Moisture 8e1uction $all 9osses Aluminum 3%are 6re%eat Steel 3%are 6re%eat. Furnace Fi.ture 8e0lacement :n1ustrial 0rocess %eatin consumes a sini4icant amount o4 natural as in 3ali4ornia an1 t%rou%out t%e ;nite1 States. $%ile t%e e44iciency o4 many in1ustrial %eatin systems suc% as 4urnaces, ovens, an1 /ilns %ave 2een im0rove1 over time, t%ere are still sini4icant o00ortunities remainin 4or im0rovin t%e e44iciency o4 t%ese systems. EEA i B-REP-06-599-13 The Gas Company .AB/E +F *+0.E0.- Page E.ecutive Summary ..................................................................................................................................... i 1. 7verview................................................................................................................................................. 1 2. Annual 5as ;se....................................................................................................................................... + +. 5as Savins 3alculations.........................................................................................................................- +.1 7.yen Enric%ment.................................................................................................................. - +.2 Moisture 8e1uction.................................................................................................................. 6 +.+ $all 9osses ...........................................................................................................................10 +.- Aluminum 3%are 6re%eat Enery Savins 3alculator...........................................................12 +.5 Steel 3%are 6re%eat...............................................................................................................16 +.6 Fi.ture $ei%t 8e1uction.......................................................................................................1" A00en1i. A Furnace Availa2le <eat 3alculation........................................................................................1 A00en1i. # $all <eat 9oss 3alculations....................................................................................................1 A00en1i. 3( Assume1 5as 3om0osition.....................................................................................................1 EEA iii B-REP-06-599-13 The Gas Company /I-. +F .AB/E- Page 'a2le 1. 7.yen Enric%ment 3alculator......................................................................................................- 'a2le 2. Moisture 8e1uction 3alculation....................................................................................................& 'a2le +. Furnace $all 9oss Savins 3alculator :n0ut=7ut0ut 'a2le.........................................................11 'a2le -. Aluminum 6re%eat 3alculator......................................................................................................1- 'a2le 5. Steel 3%are 6re%eat 3alculator...................................................................................................1* 'a2le 6. Fi.ture $ei%t 8e1uction............................................................................................................20 'a2le *. S0eci4ic <eat o4 Materials ;se1 in Fi.ture 9oss 8e1uction 3alculator.......................................22 'a2le &. Assume1 5as 3om0osition............................................................................................................1 /I-. +F FI12RE- Page Fiure 1. San/ey Enery Diaram 4or 5eneric 6rocess <eater ..................................................................2 Fiure 2. 7.yen Enric%e1 #urner Sc%ematic.............................................................................................- Fiure +. <i% E44iciency 3entri4ue Mec%anical Dewaterin 6ress...........................................................* Fiure -. Furnace $all 9osses...................................................................................................................10 Fiure 5. Aluminum Stac/ Melter.............................................................................................................1+ Fiure 6. Steel 3%are 0re%eat in Steel 8e%eat Furnace Ac%ieve1 2y E.ten1in t%e <eatin >one..........16 Fiure *. A1vance1 9i%twei%t 3ar2on Fi2er 8ein4orce1 3ar2on Furnace Fi.ture.................................1" Fiure &. Availa2le <eat 4or Stoic%iometric Natural 5as 3om2ustion as a Function o4 Flue 5as 'em0erature.................................................................................................................................... 2 Fiure ". <eat 3ontent o4 Air as Function o4 'em0erature..........................................................................+ Fiure 10. Sim0li4ie1 Diaram o4 <eat 9oss 4rom E.ternal Sur4ace o4 6rocess <eater ..............................1 EEA iv B-REP-06-599-13 The Gas Company 1& +#er#ie3 '%is wor/0a0er 1escri2es si. calculators t%at will allow t%e Sout%ern 3ali4ornia 5as 3om0any )'%e 5as 3om0any, account e.ecutives an1 ot%er sta44 to estimate annual as savins 4or in1ustrial customers a00lyin 4or incentive 4un1s 4or %eat recovery un1er t%e #usiness Enery E44iciency 6rorams )#EE6,. '%ese calculators are as 4ollows( 7.yen Enric%ment Moisture 8e1uction $all 9osses Aluminum 3%are 6re%eat Steel 3%are 6re%eat. Furnace Fi.ture 8e0lacement :n1ustrial 0rocess %eatin consumes a sini4icant amount o4 natural as in 3ali4ornia an1 t%rou%out t%e ;nite1 States. $%ile t%e e44iciency o4 many in1ustrial %eatin systems suc% as 4urnaces, ovens, an1 /ilns %ave 2een im0rove1 over time, t%ere are still sini4icant o00ortunities remainin 4or im0rovin t%e e44iciency o4 t%ese systems. 'o illustrate t%e o00ortunities 4or enery savins, consi1er t%e San/ey 1iaram s%own in Fiure 1. As in1icate1, t%e %eat t%at oes into an in1ustrial 0rocess ty0ically leaves t%e 0rocess as 4ollows( Flue as Moist com0onent accounts 4or %eat re?uire1 to va0ori@e water 0ro1uce1 1urin com2ustion, Dry com0onent accounts 4or %eat carrie1 away 2y %ot 4lue ases )a4ter water %as 2een va0ori@e1, $all losses 70enin losses 3onveyor losses )inclu1es 4i.tures in 2atc% or continuous 4urnaces, <eat storae )2atc% o0erations only, <eat to loa1 )use4ul %eat, EEA 1 B-REP-06-599-13 The Gas Company Source !or"h American Com#us"ion $an%#oo&' 3 r% E%i"ion' (o) 1' 19*6 Figure 1& -an4ey Energy 5iagra$ fr 1eneric Prcess 'eater 8e4errin to Fiure 1, any %eat t%at leaves t%e 0rocess %eater, ot%er t%an t%e use4ul %eat to t%e loa1, re0resents lost enery t%at re1uces overall e44iciency. '%is wor/0a0er s0eci4ically a11resses enery e44iciency im0rovements t%at can 2e accom0lis%e1 t%rou% t%e 4ollowin enery e44iciency measures( :ncreasin t%e o.yen content o4 com2ustion air 2y usin o.yen or enric%e1 air com2ustion A re1uces 4lue loss 2y re1ucin t%e volume an1 associate1 %eat containe1 in t%e %ot nitroen in t%e 4lue. '%e %i%er t%e 0ercentae o4 o.yen t%at t%ere is in t%e com2ustion BairC t%e lower will 2e t%e volume o4 nitroen t%at ets %eate1 an1 e.%auste1 2y t%e 0rocess. 8e1ucin wall %eat losses A #y re1ucin t%e tem0erature o4 e.ternal 4urnace walls t%rou% t%e use o4 2etter insulatin materials an1 elimination o4 a0s an1 %ot s0ots, t%e %eat lost t%rou% t%e walls can 2e re1uce1. 6re%eatin t%e loa1 )eit%er aluminum or steel, usin 4lue as enery A 3%are 0re%eatin ca0tures some o4 t%e waste %eat in t%e 4lue as an1 trans4ers it to t%e incomin 0ro1uct stream. 8e0lacin 4urnaces 4i.tures )e.., /iln 4urniture, wit% lower t%ermal mass materials A re1uces t%e conveyor an1 4i.ture losses. 8e1ucin t%e moisture o4 t%e loa1 0rior to 0rocessin A A sini4icant amount o4 %eat is re?uire1 to remove 0ro1uct moisture wit%in a 0rocess %eater. 8e1ucin t%e moisture content EEA + B-REP-06-599-13 The Gas Company o4 t%e 4ee1stoc/ 2e4ore it enters t%e 4urnace can sini4icantly re1uce t%e %eat re?uire1 to 0rocess t%e 4ee1stoc/ to its 4inal out0ut con1itions. #ecause t%e in0ut enery must matc% t%e sum o4 all o4 t%e out0ut enery streams A use4ul or waste4ul A re1ucin any o4 t%e losses 1escri2e1 a2ove will re1uce t%e in0ut enery re?uirements accor1in to s0eci4ic relations%i0s o4 tem0erature, mass-4low, %eat ca0acities )air, com2ustion 0ro1ucts, 4ee1stoc/, 4i.tures,, an1 %eat trans4er. '%ese relations%i0s are im2e11e1 into t%e si. savins calculators 1escri2e1 in t%is wor/0a0er to 4acilitate t%e consistent an1 correct enery savins estimation un1er #EE6 an1 ot%er e44iciency incentive 0rorams currently 2ein im0lemente1. '%e calculators re?uire a limite1 num2er o4 in0uts Annual Fuel 2se A '%e estimate1 consum0tion o4 natural as 2y t%e 2aseline 0rocess %eater )4urnace, oven, /iln, etc., :n a recent 12-mont% 0erio1 )t%erms=year,. Flue 1as .e$perature A '%e tem0erature o4 t%e 4lue ases e.itin t%e 0rocess 2e4ore an1 a4ter im0lementation o4 t%e e44iciency measure. +,ygen *ncentratin in Flue 1as A '%e 0ercentae o4 o.yen in t%e 4lue as measure1 on a 1ry 2asis. )'%is value is assume1 to remain constant 2e4ore an1 a4ter im0lementation o4 e44iciency measure., *$"ustin Air .e$perature A '%e tem0erature o4 t%e com2ustion air 2e4ore an1 a4ter im0lementation o4 t%e e44iciency measure. Furnace Prduct and Fi,ture .6er$al *6aracteristics 7 For c%are 0re%eatin an1 moisture re1uction, t%e c%are tem0erature, an1 =or moisture content must 2e /nown. A$"ient r -tarting *nditins fr Fuel% Air% and -ecndary Prducts A t%e startin tem0erature 4or com2ustion air, 4urnace c%are 0ro1ucts must 2e s0eci4ie1. 2& Annual 1as 2se '%e 2aseline annual 4uel use 2y an in1ivi1ual 0rocess %eater wit%in a 4acility is rarely measure1 1irectly 2ecause, ty0ically, t%ere is no su2-meterin o4 in1ivi1ual e?ui0ment, Dust t%e main as meter 4or t%e 4acility as a w%ole. 'o 0rovi1e a stan1ar1i@e1 estimate o4 t%e 2aseline annual 4uel use, '%e 5as 3om0any %as 1evelo0e1 an E.cel 2ase1 ,oa% Ba)ance Too)- 1 '%e tool allows t%e user to i1enti4y an1 c%aracteri@e t%e as-usin e?ui0ment wit%in t%e 4acility. '%e tool t%en allocates t%e metere1 4acility consum0tion amon t%e e?ui0ment i1enti4ie1 wit%in t%e 4acility. '%e assum0tions an1 e?uations use1 in t%e 9oa1 #alance 'ool are 1ocumente1 in its wor/0a0er 2 . 1 E.cel 2ase1 0roram, ,oa% Ba)ance Too) .ver 1/-0)s' 2 ,oa% Ba)ance Too)' 1or&paper, Enery an1 Environmental Analysis, :nc. A0ril 2006. EEA 3 B-REP-06-599-13 The Gas Company 3& 1as -a#ings *alculatins '%e natural as consum0tion an1 savins calculations are in t%e E.cel 2ase1 2urnace Savin3s 1or&#oo&. '%ere are si. calculators in t%is wor/2oo/( 7.yen Enric%ment Moisture 8e1uction $all 9osses Aluminum 3%are 6re%eat Steel 3%are 6re%eat. Furnace Fi.ture 8e0lacement 3&1 +,ygen Enric6$ent $%en natural as is 2urne1, o.yen in t%e com2ustion air c%emically com2ines wit% %y1roen an1 car2on in t%e 4uel to 4orm water an1 car2on 1io.i1e, releasin %eat in t%e 0rocess. Air is com0ose1 o4 a00ro.imately 21E o.yen, *&E nitroen, an1 1E various ot%er ases. Durin air-4uel com2ustion, t%e c%emically inert nitroen 1ilutes t%e reactive o.yen an1 carries away some o4 t%e enery in t%e %ot com2ustion e.%aust as. An increase in o.yen in t%e com2ustion air can re1uce t%e enery loss in t%e e.%aust ases an1 increase %eatin system e44iciency. 7.yen enric%e1 com2ustion is 0rimarily use1 in t%e lass meltin in1ustry, 2ut %as a00lication as well to metals meltin an1 %eatin, 0ul0 an1 0a0er, c%emicals 0rocessin, an1 0etroleum re4inin.. + Fiure 2 s%ows a sc%ematic re0resentation o4 an o.yen enric%e1 2urner. Figure 2& +,ygen Enric6ed Burner -c6e$atic 8 '%e in0uts an1 t%e results 4or t%e 40y3en Enrichmen" Ca)cu)a"or are s%own in a one-0ae ta2le, 'a2le 1. ;ser in0uts are in 2lue on t%e w%ite 4iel1s, t%e ray 4iel1s re0resent interme1iate calculations, t%e 4inal annual as savins value is s%own at t%e 2ottom o4 t%e ta2le in t%e 1ar/ 2lue 4iel1. .a"le 1& +,ygen Enric6$ent *alculatr + 7.yen-Enric%e1 3om2ustion,C Ener3y Tips 5 Process $ea"in3' !o-3, ;.S. D7E, Enery E44iciency an1 8enewa2le Enery, Se0tem2er 2005. - 6#i%- EEA 7 B-REP-06-599-13 The Gas Company Standard Air Enriched Air 1 Connected load (MBtuh) 5,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%!85 & '(ui)alent $ull load hours (hrs/yr) !,001 5 *nnual gas use (therms/yr) "00,0"0 ! O+ygen in Com,ustion *ir (-) 21- &5- .lue gas temp% (.) 2,000 2,000 8 .urnace *)aila,le /eat - &5%0 !5%& 0 1as sa)ings (-) Base "1- 10 2e3 1as 4se (therms/year) Base 20!,50" 11 93,527 12 1as 5ate (6/therm) 60%05 13 $88,851 Annual Dollar Savings Annual Savings ($/ear! "asSavings (ther#s/ear! E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions and *+gen ,atio Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings Scenario -ara#eter '%e calculator re?uires only t%ree in0uts to c%aracteri@e t%e 1uty cycle an1 annual as consum0tion, an1 two in0uts to 1escri2e t%e 2e4ore an1 a4ter 4urnace )0rocess, o0eration. '%e calculations 1etermine t%e 4uel use, 4lue as, an1 0re%eat air enery to 1e4ine 2e4ore an1 a4ter availa2le %eat to t%e 0rocess. 5 '%e unit savins are t%en a00lie1 to t%e annual consum0tion to 1etermine t%e annual as savins. E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 1. :n0ut( E?ui0ment ratin or connecte1 loa1 )M#tu%, is 0rovi1e1 2y t%e customer )4or screenin 0ur0oses, t%is in4ormation may 2e availa2le 4or customers usin t%e MAS 1ata2ase. 2. :n0ut( E?ui0ment usae rate )%ours=year, -- to 2e ta/en 4rom t%e ,oa% Ba)ance Too) +. :n0ut( E?ui0ment loa1 4actor in use )0ercent , A to 2e ta/en 4rom t%e ,oa% Ba)ance Too) -. 3alc( E?uivalent 4ull loa1 %ours F )9ine 2, . )9ine +,. 5 All o4 t%e relations%i0s an1 t%ermo1ynamic calculations were containe1 in a 0reliminary calculation s0rea1s%eet t%at was 1evelo0e1 an1 0rovi1e1 to '%e 5as 3om0any 2y Dr. Arvin1 '%e/1i, E3+M 3om0any. Dr. '%e/1i also 0rovi1e1 t%e 2ac/-u0 relations%i0s. EEA 5 B-REP-06-599-13 The Gas Company 5. 3alc.( Annual as consum0tion F )9ine -, . )9ine 1, . M#tu=t%erm conversion 2urnace Con%i"ions an% 40y3en Ra"io 6. 7.yen in com2ustion air E -- '%e concentration o4 o.yen in stan1ar1 air is a00ro.imately 21E. '%is is use1 as t%e startin value 4or t%is calculator. '%e 0ercentae o4 o.yen in t%e enric%e1 air stream is entere1 in t%e last column. *. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut. &. 3alc.( Availa2le <eat to t%e 6rocess )0ercent, A '%is e?uals t%e total %eat o4 com2ustion minus t%e sensi2le an1 latent %eat containe1 in t%e 4lue ases. :n t%is calculator t%e e44ect o4 e.cess air is inore1. )'%e Dusti4ication an1 1ocumentation o4 t%is calculation are 0rovi1e1 in Appendi, A&9 Gas Savin3s Ra"e an% Annua) Gas Savin3s ". 3alc.( 5as Savins 6ercent A t%e 1i44erence o4 2aseline as use )5, an1 new as use )10, 1ivi1e1 2y 2aseline as use. )5,. 10. 3alc.( )5, ol1 as use . )&, ol1 availa2le %eat = )&, new availa2le %eat 11. 3alc.( Annual 5as Savins 1ue to e44iciency measure A t%is is t%e 0rimary out0ut o4 t%e calculation 2ase1 on 2aseline as use minus as use a4ter im0lementation o4 t%e e44iciency measure. Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 12. :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 1+. 3alc.( )12, as rate . )11, as savins. :n t%e e.am0le s%own a2ove in 'a2le 1, a 5,000 M#tu% 4urnace availa2le &*60 %ours=year wit% a 6&.5E loa1 4actor consumes +00,0+0 t%erms=year usin air 4or com2ustion. 7.yen enric%ment to -5E air is t%e 0ro0ose1 e44iciency measure. Flue as tem0erature is 2000 FI t%is is assume1 to 2e a con1ition o4 t%e 4urnace t%at remains unc%ane1. '%e re1uction in t%e volume o4 nitroen in t%e 4lue as results in t%e availa2le %eat to t%e 4urnace increasin 4rom -5.0E to 65.-E. '%is c%ane will result in a +1E enery savins, 4or t%e same 0ro1uction, or "+,52* t%erms=year. '%e customer will save G&&,&51 0er year in as costs 2ase1 on an averae as rate o4 G0."5=t%erm. 3&2 :isture Reductin '%e se0aration o4 water 4rom a 4ee1stoc/ or 0ro1uct is a common, o4ten enery-intensive, 4unction in many in1ustrial manu4acturin 0rocesses. '%ermal 1ewaterin in t%e 4urnace re?uires a2out 1,000 #tu=l2 o4 water t%at nee1s to 2e remove1. :4 t%e 4urnace 4ee1stoc/ can 2e 1ewatere1 mec%anically or 2y some ot%er means suc% as air 1ryin, t%en t%e ?uantity o4 enery nee1e1 wit%in t%e 4urnace or oven can 2e re1uce1 sini4icantly. Dewaterin a00lications are 4oun1 in a variety o4 in1ustries inclu1in 0ul0 an1 0a0er, 4oo1 0rocessin, ariculture, c%emicals, an1 minin. Fiure + s%ows a sc%ematic o4 a %i% e44iciency mec%anical 1ewaterin 0ress. EEA 6 B-REP-06-599-13 The Gas Company Figure 3& 'ig6 Efficiency *entrifuge :ec6anical 5e3atering Press 6 'a2le 2 s%ows t%e moisture re1uction calculation. '%e calculator measures t%e enery savins 1ue to lowerin t%e moisture 0ercentae o4 t%e 4ee1stoc/ enterin t%e 0rocess 2ase1 on t%e ca0acity an1 1uty cycle o4 t%e 0rocess, an1 t%e 4urnace o0eratin con1itions. '%e calculator assumes t%at t%e moisture remove1 is 4ree water, i.e., not c%emically 2oun1 to t%e 4ee1stoc/ as in calcinin, an1 t%at t%e 4inal 0ro1uct moisture re?uirements are 2elow t%e in0ut con1itions. 6 Joto2u/i :n1ustries 3o., 9t1, 1i:ar% Press, 0ro1uct 1escri0tion. EEA ; B-REP-06-599-13 The Gas Company .a"le 2& :isture Reductin *alculatin .aseline E//icienc 0easure 1 Connected load (MBtuh) 2,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%&5 & '(ui)alent $ull load hours (hrs/yr) &,000 5 *nnual gas use (therms/yr) 80,000 ! .lue gas temp% (.) !00 O+ygen in .lue gas (- dry ,asis) " 8 '+cess air (-) 15%5! 0 Com,ustion air temp% (.) 100 10 *)aila,le /eat to the .urnace 8%&& 11 7otal 3eight (l,s/hr) 5,000 5,000 12 Moisture content (-) "0 20 1" 8ater Content (#,s/hr) 1,500 1,000 1& 7emperature at .urnace 'ntrance (.) 100 150 15 1as sa)ings (-) Base &&- 1! 2e3 1as 4se (therms/year) Base &5,1"0 17 31,872 18 1as 5ate (6/therm) 60%05 19 $33,123 Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings Scenario -ara#eter (harge 0aterial 4eight and 0oisture (onditions Annual Dollar Savings Annual Savings ($/ear! "asSavings (ther#s/ear! E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions '%e calculation ste0s corres0on1in to t%e line num2ers on t%e ta2le are 1escri2e1 2elow. E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 9ines 1-5 are t%e same 4or all calculations in t%is wor/2oo/, so are omitte1 4rom t%e 1iscussion %ere. 2urnace Con%i"ions 6. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut A t%e same 4or 2ot% 2e4ore an1 EEA * B-REP-06-599-13 The Gas Company a4ter e44iciency measure. '%e %i%er t%e 4lue as tem0erature is t%e %i%er will 2e t%e enery savins 4rom an e?uivalent volume o4 water removal. *. :n0ut( 7.yen 0ercent in t%e 4lue as )E 1ry 2asis, A a customer su00lie1 in0ut. &. 3alc.( E.cess air is a 4unction o4 7.yen in t%e e.%aust )9ine *,. '%is is 4unction is a 0olynomial curve 4it to t%e out0ut o4 a com2ustion e?uili2rium mo1el. * ". :n0ut( 3om2ustion air tem0erature A ty0ically %i%er t%an am2ient tem0erature 1ue to 0ic/ o4 %eat 4rom t%e 2lower motor. 10. 3alc.( Availa2le <eat to t%e 6rocess )0ercent, A '%is e?uals t%e total %eat o4 com2ustion minus t%e sensi2le an1 latent %eat containe1 in t%e 4lue ases. :n t%is calculator t%e e44ect o4 e.cess air is inore1. )'%e Dusti4ication an1 1ocumentation o4 t%is calculation are 0rovi1e1 in Appendi, A&9 Char3e <a"eria) 1ei3h" an% <ois"ure Con%i"ions 11. :n0ut( 'otal wei%t )l2s=%our, A total wei%t o4 t%e c%are in0ut to t%e 0rocess, assume1 to 2e t%e same 2e4ore an1 a4ter moisture removal. 12. :n0ut( Moisture content )E, A t%e 2asis 4or t%e enery savins 4or t%e 0rocess. 1+. 3alc.( $ater content )l2s=%r, A 'otal wei%t )11, times )12, moisture 0ercent 1-. :n0ut( 'em0erature at 4urnace entrance A '%e in0ut tem0erature o4 t%e 0ro1uct enterin t%e 4urnace. Drier 0ro1uct may 2e %otter 1e0en1in on moisture removal 0rocess use1. Gas Savin3s Ra"e an% Annua) Gas Savin3s 15. 3alc.( 5as Savins 6ercent A 3alc.( 5as savins )1*, = :nitial 5as use )5, 16. 3alc.( New as use )t%erms=year, A 3alc.( :nitial 5as ;se )5, - 5as savins )1*, 1*. 3alc.( Annual 5as Savins 1ue to e44iciency measure A '%e 1i44erence in t%e %eat re?uire1 to %eat an1 va0ori@e t%e water in t%e 4ee1stoc/ 1ivi1e1 2y t%e 4urnace availa2le %eat. '%is is t%e 0rimary out0ut o4 t%e calculation tool. Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 1&. :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 1". 3alc.( )1&, as rate . )1*, as savins. '%e calculation s%own in 'a2le 2 s%ows t%e natural as savins w%ere t%e incomin 4ee1stoc/ moisture is re1uce1 4rom +0E to 20E 2e4ore enterin t%e 0rocess. '%e e?ui0ment %as a 2,000 M#tu% connecte1 loa1 an1 its 1uty cycle is e?ual to -,000 EF9<. '%e 0rocess %as a 600 F 4lue as tem0erature an1 a measure1 +E 72 )1ry 2asis, in t%e 4lue as. '%e availa2le %eat to t%e 4urnace is *&.-E. '%e 4ull loa1 0ro1uct in0ut is 5,000 l2s=%our. 8e1ucin t%e moisture 0ercentae as s%own re1uces t%e moisture t%at must 2e remove1 t%ermally 2y t%e 4urnace 2y 500 l2s=%r. '%is c%ane results in a --E enery savins or +-,&*0 t%erms=year wit% a as cost savins to t%e customer o4 t G++,126. * Arvin1 '%e/1i, 0rivate communication, +="=06. EEA 9 B-REP-06-599-13 The Gas Company 3&3 )all /sses <eat is lost t%rou% t%e 4urnace walls 1urin 0ro1uction. '%ese losses are cause1 2y t%e con1uction o4 %eat t%rou% t%e walls, roo4, an1 4loor o4 t%e %eatin 1evice, as s%own in Fiure -. 7nce t%at %eat reac%es t%e outer s/in o4 t%e 4urnace an1 ra1iates to t%e surroun1in area or is carrie1 away 2y air currents, it must 2e re0lace1 2y an e?ual amount ta/en 4rom t%e com2ustion ases. '%is 0rocess continues as lon as t%e 4urnace is at an elevate1 tem0erature. & Figure 8& Furnace )all /sses 'a2le + s%ows t%e one-0ae in0ut=out0ut ta2le 4or t%e =a)) )osses savin3s ca)cu)a"or. .'%e 2asis 4or t%e calculations are 1escri2e1 A00en1i. # $all <eat 9oss 3alculations. & 6mprovin3 Process $ea"in3 Sys"em Per>ormance A Source#oo& >or 6n%us"ry, ;.S. De0artment o4 Enery an1 :n1ustrial <eatin E?ui0ment Association EEA 10 B-REP-06-599-13 The Gas Company .a"le 3& Furnace )all /ss -a#ings *alculatr Input;+utput .a"le .aseline E//icienc 0easure 1 Connected load (MBtuh) 8,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%!85 & '(ui)alent $ull load hours (hrs/yr) !,000 5 *nnual gas use (therms/yr) &80,000 ! .lue gas temp% (.) 000 - O+ygen in $lue gases 5 8 '+cess air (-) 20%&0 0 *m,ient temperature (.) 5 5 10 Com,ustion air temp% (.) 100 11 9ur$ace area ($t:2) 1,50 1,50 12 8all 9ur$ace temperature (.) 250 1&5 1" /eat #oss ;Btu/(hr%$t:2)< &1 1!" 1& 1as sa)ings (-) Base 8- 15 2e3 1as 4se (therms/year) Base &&0,!&! 13 39,351 1 1as 5ate (6/therm) 60%05 18 $37,383 E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions Scenario -ara#eter )urnace 4all Area and 5e#%erature Annual Dollar Savings Annual Savings ($/ear! "asSavings (ther#s/ear! Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings '%e calculation ste0s corres0on1in to t%e line num2ers on t%e ta2le are 1escri2e1 2elow. E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 9ines 1-5 are t%e same 4or all calculations in t%is wor/2oo/. 2urnace Con%i"ions 6. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut A t%e same 4or 2ot% 2e4ore an1 a4ter e44iciency measure. *. :n0ut( 7.yen 0ercent in t%e 4lue as )E 1ry 2asis, A a customer su00lie1 in0ut. EEA 11 B-REP-06-599-13 The Gas Company &. 3alc.( E.cess air is a 4unction o4 7.yen in t%e e.%aust )9ine *,. '%is is 4unction is a 0olynomial curve 4it to t%e out0ut o4 a com2ustion e?uili2rium mo1el. ". :n0ut( Am2ient air tem0erature A 0art o4 t%e calculation o4 %eat loss 4rom t%e wall. 10. :n0ut( 3om2ustion air tem0erature A ty0ically %i%er t%an am2ient tem0erature 1ue to 0ic/ o4 %eat 4rom t%e 2lower motor. 2urnace 1a)) Area an% Tempera"ure 11. :n0ut( Sur4ace area o4 t%e 4urnace )s?.4t., A #ase1 on t%e lent%, %ei%t, an1 wi1t% o4 t%e 4urnace. 12. :n0ut( $all sur4ace tem0erature A t%e re1uction in tem0erature 4rom t%e 2aseline to t%e e44iciency case is t%e 2asis 4or t%e savins. 1+. 3alc.( <eat loss )#tu=s?.4t., A Estimate1 %eat loss 0er s?uare 4oot 2ase1 on t%e 1i44erence 2etween t%e 4urnace sur4ace tem0erature an1 am2ient con1itions )see Appendi, B9 Gas Savin3s Ra"e an% Annua) Gas Savin3s 1-. 3alc.( 5as Savins 6ercent A 3alc.( 5as savins )16, = :nitial 5as use )5, 15. 3alc.( New as use )t%erms=year, A 3alc.( :nitial 5as ;se )5, - 5as savins )16, 16. 3alc.( Annual 5as Savins 1ue to e44iciency measure A <eat loss 1i44erence . sur4ace area . EF9< )see A00en1i. 3, Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 1*. :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 1&. 3alc.( )1*, as rate . )16, as savins. :n t%e e.am0le s%own a2ove in 'a2le +, t%e 4urnace insulation is to 2e re2uilt so t%at averae wall tem0erature 1urin o0eration will 1ro0 4rom 250 to 1-5 F. 5iven t%e 4urnace ca0acity an1 1uty cycle s%own, t%e annual savins are +","5- t%erms re0resentin an &E savins. 3&8 Alu$inu$ *6arge Pre6eat Energy -a#ings *alculatr $%ere 0ermitte1 2y system con4iuration, 0re%eatin t%e 0ro1uct c%are can also 2e a 4easi2le e44iciency im0rovement. Muc% li/e com2ustion air 0re%eatin, t%is 4orm o4 enery trans4er to an u0stream mass can re1uce 4uel use. Aluminum melters can use stac/ c%arin o4 scra0 or 0re%eatin c%am2ers 4or inots an1 sows. :n t%ese systems, aluminum scra0 is c%are1 t%rou% an incline1 rate at t%e to0 o4 t%e 4urnace t%at serves as t%e stac/ 4or e.%austin 4lue ases. '%is con4iuration allows t%e c%are to 2e 0re%eate1 t%ere2y re1ucin ca0turin a11itional enery 4rom t%e %i% tem0erature 4lue ases re?uire1 4or t%e melt @one. '%ese 4urnaces are ca0a2le o4 meltin aluminum 4or as little as 1,000 #tu=l2. '%e aluminum 0re%eat calculator 1e4ines t%e enery savins attri2uta2le to t%e increase in aluminum c%are tem0erature. " '%e calculator is s%own in 'a2le -& " :4 t%e aluminum tem0eratures are not /nown, 2ut t%e c%ane in 4lue as tem0erature is /nown, t%e savins can 2e calculate1 usin t%e E44icient 3om2ustion 3alculation in t%e <eat 8ecovery $or/2oo/. EEA 1+ B-REP-06-599-13 The Gas Company Therma) Pro%uc" So)u"ions Figure 5& Alu$inu$ -tac4 :elter '%e calculation ste0s corres0on1in to t%e line num2ers on t%e ta2le are 1escri2e1 2elow. E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 9ines 1-5 are t%e same 4or all calculations in t%is wor/2oo/. 6. :n0ut( Annual 0ro1uction )tons=year, A customer su00lie1 in0ut on tons o4 molten aluminum 0ro1uce1 2y t%e 4urnace. *. 3alc.( Enery use )#tu=l2 Aluminum, A annual enery consum0tion )5, 1ivi1e1 2y annual 0ro1uction )6, wit% unit conversion 4rom t%erms to #tus an1 tons to l2s. 2urnace Con%i"ions &. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut A t%e same 4or 2ot% 2e4ore an1 a4ter e44iciency measure. ". :n0ut( 3om2ustion air tem0erature A ty0ically %i%er t%an am2ient tem0erature 1ue to 0ic/ o4 %eat 4rom t%e 2lower motor. 10. :n0ut( 7.yen 0ercent in t%e 4lue as )E 1ry 2asis, A a customer su00lie1 in0ut. 11. 3alc.( E.cess air is a 4unction o4 7.yen in t%e e.%aust )9ine 10,. '%is is 4unction is a 0olynomial curve 4it to t%e out0ut o4 a com2ustion e?uili2rium mo1el. 12. 3alc.( Availa2le <eat to t%e Furnace )0ercent, A '%is e?uals t%e total %eat o4 com2ustion minus t%e sensi2le an1 latent %eat containe1 in t%e 4lue ases. :n t%is calculator t%e e44ect o4 e.cess air is inore1. )'%e Dusti4ication an1 1ocumentation o4 t%is calculation are 0rovi1e1 in Appendi, A&9 EEA 13 B-REP-06-599-13 The Gas Company .a"le 8& Alu$inu$ Pre6eat *alculatr .aseline E//icienc 0easure 1 Connected load (MBtuh) 1&,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%01" & '(ui)alent $ull load hours (hrs/yr) 8,000 5 *nnual gas use (therms/yr) 1,120,000 ! *nnual production (tons/yr) &0,000 'nergy 4se (Btu/l, *l) 1&00 8 .lue gas temp $rom $urnace .) 1&50 0 Com,ustion air temp%(.) 100 10 O2 in $lue gas (- dry ,asis) "%00 11 '+cess air (-) 15%5! 12 .urnace *)aila,le /eat - 5&%55 1" Charge =nitial temp (.) 100 00 1& .inal Molten *luminum temp% (.) 1"50 1"50 15 /eat re(uired $or *luminum (Btu/l,) &88%! "&&%& 1! /eat in other losses (Btu/l,) 25%1 25%1 1 7otal net heat re(uired (Btu/l,) !"% !10%5 18 1ross heat input re(uired (Btu/l,) 1&00%0 11"5%! 10 1as sa)ings (-) Base 18%0- 20 2e3 1as 4se (therms/year) Base 008,50 21 211,193 22 1as 5ate (6/therm) 60%05 23 $222,918 Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings Scenario -ara#eter Annual Savings ($/ear! "asSavings (ther#s/ear! E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions Alu#inu# 6n%ut and *ut%ut (onditions Annual Dollar Savings EEA 17 B-REP-06-599-13 The Gas Company A)uminum 6npu" an% 4u"pu" Con%i"ions 1+. :n0ut( 3%are initial tem0erature A #aseline tem0erature o4 t%e aluminum c%are1 to t%e melter, a customer su00lie1 in0ut. 1-. :n0ut( 3%are 0re%eat tem0erature A '%e sueste1 c%are 0re%eat 4or t%e e44iciency measure, a customer su00lie1 in0ut. 15. :n0ut( Final molten aluminum tem0erature )F, A t%e tem0erature o4 t%e molten aluminum leavin t%e 4urnace, a customer su00lie1 in0ut. 16. 3alc.( <eat re?uire1 4or t%e aluminum )#tu=l2, A t%is calculation inclu1es t%e %eat re?uire1 to raise t%e aluminum to melt tem0erature, t%e %eat re?uire1 4or t%e 0%ase c%ane 4rom soli1 to li?ui1, an1 t%e %eat re?uire1 to raise t%e molten aluminum to its 4inal tem0erature. '%is calculation re?uires t%e s0eci4ic %eat o4 soli1 aluminum 4rom am2ient to meltin tem0erature, a00ro.imately 1225 o F, t%e %eat o4 4usion, an1 t%e s0eci4ic %eat o4 molten aluminum 4rom 1225 o F to its 4inal tem0erature. 1*. 3alc.( <eat in ot%er losses )#tu=l2, A t%is calculate1 value is t%e 1i44erence 2etween t%e availa2le %eat to t%e 4urnace an1 t%e %eat containe1 in t%e 4inal 0ro1uct. '%ese losses inclu1e losses 4rom t%e walls, o0enins, conveyors an1 4i.tures, an1 %eat store1 in t%e 4urnace. :t is assume1 4or t%is calculation t%at t%ese ot%er losses remain t%e same, a reasona2le assum0tion i4 t%e c%are 0re%eat is use1 to 1ecrease enery use rat%er t%an to increase t%e t%rou%0ut o4 t%e 4urnace. 1&. 3alc.( 'otal net %eat to t%e 4urnace )#tu=l2, A t%is calculate1 value e?uals t%e sum o4 t%e %eat re?uire1 4or t%e 0ro1uct an1 t%e ot%er losses, or as 0reviously 1e4ine1 t%e availa2le %eat to t%e 4urnace. 1". 3alc.( 5ross %eat to re?uire1 )#tu=l2, A net %eat re?uire1 )1&, 1ivi1e1 2y availa2le %eat E )12, = 100. Gas Savin3s Ra"e an% Annua) Gas Savin3s 20. 3alc.( 5as Savins 6ercent A 3alc.( '%e 1i44erence 2etween 2aseline an1 e44iciency measure ross %eats )line 1", = 2aseline ross %eat )1", 21. 3alc.( New as use )t%erms=year, A 3alc.( )1 A as savins E )20,, . 2aseline as use )5, 22. 3alc.( Annual 5as Savins 1ue to e44iciency measure A #aseline as use )5, minus new as use )20,. Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 2+. :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 2-. 3alc.( 5as savins )22, . 5as rate )2+,. '%e savins calculation s%own a2ove in 'a2le - is 2ase1 on a 1-,000 M#tu% 4urnace wit% a 1uty cycle e?ual to &,000 EF9<. '%e 4urnace 0ro1uces -0,000 tons=year o4 molten aluminum wit% an averae enery use o4 1-00 #tu=l2. '%e 4urnace o0erates wit% 15.65E e.cess air )calculate1 4rom +E o.yen in t%e e.%aust on a 1ry 2asis, an1 %as a 4lue as tem0erature )2e4ore any c%are 0re%eatin, o4 1-50 F. '%e resultin availa2le %eat to t%e 4urnace is 5-.55E. #y raisin t%e c%are tem0erature 4rom 100-*00 F, t%e averae enery re?uire1 is re1uce1 to 11+6 #tu=l2, an 1&."E savins in enery consum0tion. Annual enery savins o4 211,-"+ t%erms translate to a G200,"1& re1uction in as costs to t%e customer. EEA 15 B-REP-06-599-13 The Gas Company 3&5 -teel *6arge Pre6eat Steel c%are 0re%eatin is conce0tually similar to aluminum 0re%eatin only t%e steel a00lication involves steel re%eat rat%er t%an meltin. Fiure 6 s%ows %ow c%are 0re%eat can 2e ac%ieve1 1irectly 2y e.ten1in t%e %eatin @one in a continuous steel re%eat 4urnace. '%e steel c%are %eatin calculator is s%own in 'a2le 5& '%e only conce0tual 1i44erences 2etween t%is calculator an1 t%e aluminum 0re%eat calculator is t%at t%ere is no meltin in t%e steel 4urnaceI t%ere4ore, only t%e s0eci4ic %eats o4 t%e soli1 material nee1 to 2e consi1ere1 an1 t%e steel calculator also inclu1es com2ustion air 0re%eat t%at is u0stream o4 t%e 0ro1uct %eatin. Figure 6& -teel *6arge pre6eat in -teel Re6eat Furnace Ac6ie#ed "y E,tending t6e 'eating <ne 10 10 Arvin1 '%e/1i, BEnery E44iciency :m0rovement 700ortunities in 6rocess <eatin 4or t%e Forin :n1ustry,C F:A Forin 3linic, Fe2ruary &K", 2005. EEA 16 B-REP-06-599-13 The Gas Company .a"le 5& -teel *6arge Pre6eat *alculatr .aseline E//icienc 0easure 1 Connected load (MBtuh) 15,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%!85 & '(ui)alent $ull load hours (hrs/yr) !,000 5 *nnual gas use (therms/yr) 000,000 ! *nnual production (tons/yr) !0,000 'nergy 4se (Btu/l, steel) 50 8 .lue gas temp $rom $urnace (.) 1!00 1322 0 *irpreheat temp% (.) 00 722 10 Current O2 in $lue gases (-) "%00 3722 11 '+cess air (-) 15%5! 15%5! 12 .urnace *)aila,le /eat (-) !&%20 !&%20 1" Charge =nitial temp (.) 80 00 1& .inal steel temp% (.) 2100 2100 15 /eat in steel at $inal temperature (Btu/l,) ""0%8! 2"%8! 1! /eat in other losses (Btu/l,) 150%!" 150%!" 1 7otal net heat re(uired (Btu/l,) &81%&0 "88%&0 18 /eat (gross) input re(uired (Btu/l,) 50%00 !05%1& 10 1as sa)ings (-) Base 10%"- 20 2e3 1as 4se (therms/year) Base 2!,1!& 21 173,833 22 1as 5ate (6/therm) 60%05 23 $135,111 Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings Scenario -ara#eter Annual Dollar Savings Annual Savings ($/ear! "asSavings (ther#s/ear! E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions Steel 6n%ut and *ut%ut (onditions '%e calculation ste0s corres0on1in to t%e line num2ers on t%e ta2le are 1escri2e1 2elow. EEA 1; B-REP-06-599-13 The Gas Company E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 9ines 1-5 are t%e same 4or all calculations in t%is wor/2oo/. 6. :n0ut( Annual 0ro1uction )tons=year, A customer su00lie1 in0ut on tons o4 %eate1 steel 0ro1uce1 2y t%e 4urnace. *. 3alc.( Enery use )#tu=l2 steel, A annual enery consum0tion )5, 1ivi1e1 2y annual 0ro1uction )6, wit% unit conversion 4rom t%erms to #tus an1 tons to l2s. 2urnace Con%i"ions &. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut A t%e same 4or 2ot% 2e4ore an1 a4ter e44iciency measure. ". :n0ut( 3om2ustion air tem0erature A may inclu1e com2ustion air 0re%eat. 10. :n0ut( 7.yen 0ercent in t%e 4lue as )E 1ry 2asis, A a customer su00lie1 in0ut. 11. 3alc.( E.cess air is a 4unction o4 7.yen in t%e e.%aust )9ine 10,. '%is is 4unction is a 0olynomial curve 4it to t%e out0ut o4 a com2ustion e?uili2rium mo1el. 12. 3alc.( Availa2le <eat to t%e Furnace )0ercent, A '%is e?uals t%e total %eat o4 com2ustion minus t%e sensi2le an1 latent %eat containe1 in t%e 4lue ases. :n t%is calculator t%e e44ect o4 e.cess air is inore1. )'%e Dusti4ication an1 1ocumentation o4 t%is calculation are 0rovi1e1 in Appendi, A&9 S"ee) 6npu" an% 4u"pu" Con%i"ions 1+. :n0ut( 3%are initial tem0erature A customer su00lie1 in0ut concernin t%e tem0erature o4 t%e steel c%are1 to t%e 4urnace. 1-. :n0ut( 3%are 0re%eat tem0erature A '%is in0ut 1escri2es t%e 0re%eat to 2e ac%ieve1 2y t%e enery e44iciency measure an1 is t%e 2asis 4or t%e savins. )Note( s%oul1 2e less t%an 1-00 o F., 15. :n0ut( Final steel tem0erature )F, A t%e tem0erature o4 t%e steel 0ro1uct leavin t%e 4urnace, a customer su00lie1 in0ut. )Note( s%oul1 2e reater t%an 1*00 o F., 16. 3alc.( <eat re?uire1 4or t%e steel )#tu=l2, A t%is calculation inclu1es t%e %eat re?uire1 to raise t%e steel to its 4inal tem0erature. '%is calculation re?uires t%e mean s0eci4ic %eat o4 steel 4rom initial c%are tem0erature to its 4inal e.it tem0erature. 1*. 3alc.( <eat in ot%er losses )#tu=l2, A t%is calculate1 value is t%e 1i44erence 2etween t%e availa2le %eat to t%e 4urnace an1 t%e %eat containe1 in t%e 4inal 0ro1uct. '%ese losses inclu1e losses 4rom t%e walls, o0enins, conveyors an1 4i.tures, an1 %eat store1 in t%e 4urnace. :t is assume1 4or t%is calculation t%at t%ese ot%er losses remain t%e sameI a reasona2le assum0tion i4 t%e c%are 0re%eat is use1 to 1ecrease enery use rat%er t%an to increase t%e t%rou%0ut o4 t%e 4urnace. 1&. 3alc.( 'otal net %eat to t%e 4urnace )#tu=l2, A t%is calculate1 value e?uals t%e sum o4 t%e %eat re?uire1 4or t%e 0ro1uct an1 t%e ot%er losses, or as 0reviously 1e4ine1 t%e availa2le %eat to t%e 4urnace. 1". 3alc.( 5ross %eat to re?uire1 )#tu=l2, A net %eat re?uire1 )1&, 1ivi1e1 2y availa2le %eat E )12, = 100. EEA 1* B-REP-06-599-13 The Gas Company Gas Savin3s Ra"e an% Annua) Gas Savin3s 20. 3alc.( 5as Savins 6ercent A 3alc.( '%e 1i44erence 2etween 2aseline an1 e44iciency measure ross %eats )line 1", = 2aseline ross %eat )1", 21. 3alc.( New as use )t%erms=year, A 3alc.( )1 A as savins E )20,, . 2aseline as use )5, 22. 3alc.( Annual 5as Savins 1ue to e44iciency measure A #aseline as use )5, minus new as use )20,. Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 2+. :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 2-. 3alc.( 5as savins )22, . 5as rate )2+,. '%e e.am0le calculation s%own in 'a2le 5 s%ows t%e enery savins attri2uta2le to increasin t%e tem0erature o4 t%e steel c%are1 to t%e 4urnace 4rom &0 to *00 F, resultin in a 1".+E 3&6 Fi,ture )eig6t Reductin '%e 0ro1uct 2ein %eate1 in many 4urnaces must 2e carrie1 or su00orte1 2y conveyors, 4i.tures, trays, etc. '%is material must 2e %eate1 to t%e same tem0erature as t%e 0ro1uct an1 will e.it t%e 4urnace carryin t%at %eat away wit% it. 8e1ucin t%e %eat lost t%rou% 4i.tures re?uires a re1uction in t%e %eat ca0acity )mass times mean s0eci4ic %eat, o4 t%ese systems an1 materials. Fiure * s%ows an innovative e.tremely li%twei%t car2on 4i2er 4urnace 4i.ture t%at coul1 re0lace a muc% %eavier metal 4i.ture. '%e 4urnace 4i.ture %eat loss re1uction calculator is s%own in 'a2le 6. '%e enery savins are 1etermine1 2y t%e ty0e o4 4i.ture material an1 its associate1 mean s0eci4ic %eat, accesse1 2y means o4 a 1ro0-1own menu an1 loo/-u0 ta2le, t%e re1uction in t%e %eat leavin t%e 4urnace, t%e 4urnace con1itions, an1 t%e 1uty cycle. Source( Sc%un/ 5ra0%ite 'ec%noloy, 993 Figure =& Ad#anced /ig6t3eig6t *ar"n Fi"er Reinfrced *ar"n Furnace Fi,ture EEA 19 B-REP-06-599-13 The Gas Company .a"le 6& Fi,ture )eig6t Reductin .aseline E//icienc 0easure 1 Connected load (MBtuh) &,000 2 Operating time (hrs/yr) 8,!0 " #oad $actor 0%!85 & '(ui)alent $ull load hours (hrs/yr) !,000 5 *nnual gas use (therms/yr) 2&0,000 ! .lue gas temp% (.) 1,200 O+ygen in .lue gas (- dry ,asis) " 8 '+cess air (-) 15%5! 0 Com,ustion air temp% (.) 100 10 *)aila,le /eat to the .urnace !1%58 11 =nitial temp% entering $urnace (.) 100 12 .inal temp% lea)ing $urnace (.) 1,200 1" 7otal .i+ture 8eight (l,s) ",000 1,000 1& Material used $or the $i+ture > $urniture Car,on 9teel 9tainless steel 15 Mean speci$ic heat o$ the material used (Btu/l,% .) 0%1& 0%1 1! 1as sa)ings (-) Base 11- 1 2e3 1as 4se (therms/year) Base 21",0&0 18 23,251 10 1as 5ate (6/therm) 60%05 22 $21,719 Source( 3alculation met%o1oloy 0rovi1e1 2y Arvin1 '%e/1i, E+M, :nc. "as Savings ,ate and Annual "as Savings Scenario -ara#eter (hange in )i+ture 0aterial and/or 4eight Annual Dollar Savings Annual Savings ($/ear! "asSavings (ther#s/ear! E$ui%#ent &oad and Annual 'se (alculation )urnace (onditions EEA +0 B-REP-06-599-13 The Gas Company '%e calculation ste0s corres0on1in to t%e line num2ers on t%e ta2le are 1escri2e1 2elow. E8uipmen" ,oa% an% Annua) 9se Ca)cu)a"ion 5 :n4ormation 4rom t%is section is to 2e ta/en 4rom t%e 9oa1 #alance 'ool. 3ustomer su00lie1 in4ormation t%at varies 4rom t%e 9oa1 #alance 'ool re?uires a00roval. 9ines 1-5 are t%e same 4or all calculations in t%is wor/2oo/. 2urnace Con%i"ions 6. :n0ut( Flue as tem0erature A a customer su00lie1 in0ut A t%e same 4or 2ot% 2e4ore an1 a4ter e44iciency measure. *. :n0ut( 7.yen 0ercent in t%e 4lue as )E 1ry 2asis, A a customer su00lie1 in0ut. &. 3alc.( E.cess air is a 4unction o4 7.yen in t%e e.%aust )9ine *,. '%is is 4unction is a 0olynomial curve 4it to t%e out0ut o4 a com2ustion e?uili2rium mo1el. 11 ". :n0ut( 3om2ustion air tem0erature A ty0ically %i%er t%an am2ient tem0erature 1ue to 0ic/ o4 %eat 4rom t%e 2lower motor. 10. 3alc.( Availa2le <eat to t%e 6rocess )0ercent, A '%is e?uals t%e total %eat o4 com2ustion minus t%e sensi2le an1 latent %eat containe1 in t%e 4lue ases. :n t%is calculator t%e e44ect o4 e.cess air is inore1. )'%e Dusti4ication an1 1ocumentation o4 t%is calculation are 0rovi1e1 in Appendi, A&9 Char3e in 2i0"ure <a"eria) an%?or1ei3h" 11. :n0ut( :nitial tem0erature )F, A t%e tem0erature o4 t%e 4i.ture enterin t%e 4urnace, a customer in0ut. 12. :n0ut( Final tem0erature )F, A t%e tem0erature o4 t%e 4i.ture leavin t%e 4urnace, a customer in0ut. 1+. :n0ut( 'otal 4i.ture wei%t )l2s, A '%e wei%t o4 t%e 4i.tures 4or 2ot% t%e 2aseline an1 t%e enery e44iciency measure cases, a customer in0ut. 1-. :n0ut( Material use1 4or t%e 4i.ture=4urniture A t%e calculator %as a 1ro0 1own list o4 materials. '%e user selects 4rom t%is list 4or 2ot% t%e 2aseline an1 t%e e44iciency measure cases. 15. 3alc.( mean s0eci4ic %eat o4 t%e 4i.ture material A once t%e 4i.ture material is selecte1 )1-, t%e s0eci4ic %eat 4or t%at material 2etween t%e entrance )11, an1 e.it tem0eratures )12, is entere1 into t%e calculator automatically 2y means o4 a loo/-u0 ta2le, s%own in 'a2le *. Gas Savin3s Ra"e an% Annua) Gas Savin3s 16. 3alc.( 5as Savins 6ercent A 3alc.( 5as savins )1&, = :nitial 5as use )5, 1*. 3alc.( New as use )t%erms=year, A 3alc.( :nitial 5as ;se )5, - 5as savins )1&, 1&. 3alc.( Annual 5as Savins 1ue to e44iciency measure A EF9< . )e.it tem0 - initial tem0, . )$ei%t1 . 301 -$ei%t2 . 362,=Availa2le %eat to 4urnace, wit% units correcte1 to 11 Arvin1 '%e/1i, 0rivate communication, +="=06. EEA +1 B-REP-06-599-13 The Gas Company t%erms=year 4rom #tu=year Annua) Gas Cos" Savin3s .4p"iona) Ca)cu)a"ion/ 1". :n0ut( as rate )G=t%erm, A 3ustomer as rateHavoi1e1 commo1ity an1 1elivery rate. 20. 3alc.( )1", as rate . )1&, as savins. .a"le =& -pecific 'eat f :aterials 2sed in Fi,ture /ss Reductin *alculatr 0aterial S%eci/ic 8eat .tu/(l97 )7! :otes Car,on> graphite 0%21 to 0%&! $rom 200 .% to 1200 .% Car,on 9teel 0%1" to 0%1!! $rom 200 . to 2200 .% Cast =ron/=ron 0%11 Ceramics 0%2" Copper 0%1 1lass 0%1" to 0%2 $rom !0 .% to 1200 .% =nconel 0%12 Magnesium 0%2 2ic?el (2ic?el alloys) 0%1"& @latinum 0%0"! AuartB 0%2" 9ilicon car,ide 0%2" 9ilicone 0%1! 9tainless steel 0%1& to 0%2& $rom &00 .% to 1200 .% 9tone 0%2 7itanium 0%1& 7ungsten 0%0"& Cinc 0%12 Source( 3om0ile1 2y Arvin1 '%e/1i 4rom various sources inclu1in Nort% American 3om2ustion <an12oo/. Note( 9inear inter0olation use1 to et value o4 s0eci4ic %eat at a re?uire1 tem0erature w%ere a rane o4 values is iven. '%e savins calculation s%own in 'a2le 6 illustrates t%e savins t%at can 2e ac%ieve1 2y re1ucin total 4i.ture wei%t 4rom +,000 l2s to 1,000 l2s inclu1in a c%ane 4rom car2on steel to stainless steel. 5iven t%e ca0acity an1 1uty cycle o4 t%e 4urnace an1 t%e availa2le %eat o4 61.5&E, annual as savins o4 26,051 t%erms are 0ossi2le )an 11E savins over 2aseline enery consum0tion, wit% customer as cost savins o4 G2-,*-". EEA ++ B-REP-06-599-13 The Gas Company Appendi, A Furnace A#aila"le 'eat *alculatin '%e calculation o4 t%e value o4 %eat recovery 4or 0re%eatin com2ustion air is 2ase1 on t%e %eatin value o4 t%e 4uel, t%e ?uantity o4 %eat leavin t%e 0rocess in t%e 4lue ases, an1 t%e amount o4 %eat t%at can 2e 0ut 2ac/ into t%e 0rocess 2y 0re%eatin t%e com2ustion air. '%is eneral relations%i0 is 1escri2e1 in t%e e?uation 2elow( 12 /eating )alue o$ $uel D heat in $lue gases + 100- #/E F lo3er heating )alue o$ $uel E poc F )olume o$ $lue gas E air F )olume o$ com,ustion air t 2 F temperature o$ $lue gases at $urnace e+it t 2air F temperature o$ preheated com,ustion air cpm poc F mean speci$ic heat o$ $lue gases at t 2 cpm air F mean speci$ic heat o$ preheated com,ustion air at t 2air #/E D (E poc )(t 2 )(cpm poc ) #/E G (E air )(t 2air )(cpm air ) D (E poc )(t 2 )(cpm poc ) 1 > + 100- - 9a)ings F - 9a)ings F 1 > /eating )alue o$ $uel G heat in com,ustion air > heat in $lue gases #/E F lo3er heating )alue o$ $uel E poc F )olume o$ $lue gas E air F )olume o$ com,ustion air t 2 F temperature o$ $lue gases at $urnace e+it t 2air F temperature o$ preheated com,ustion air cpm poc F mean speci$ic heat o$ $lue gases at t 2 cpm air F mean speci$ic heat o$ preheated com,ustion air at t 2air #/E D (E poc )(t 2 )(cpm poc ) #/E G (E air )(t 2air )(cpm air ) D (E poc )(t 2 )(cpm poc ) 1 > + 100- #/E D (E poc )(t 2 )(cpm poc ) #/E G (E air )(t 2air )(cpm air ) D (E poc )(t 2 )(cpm poc ) 1 > + 100- - 9a)ings F - 9a)ings F 1 > /eating )alue o$ $uel G heat in com,ustion air > heat in $lue gases 'o calculate a numerical result 4or t%is eneral e?uation, one nee1s to /now 2ot% t%e com0osition o4 t%e 4uel )in or1er to 1etermine t%e stoic%iometric air to 4uel ratio an1 t%e %eatin value, an1 also t%e amount o4 e.cess air t%at is in t%e 4lue as. 74 course, t%e 4lue as tem0erature an1 t%e 1esire1 com2ustion air 0re%eat must also 2e in0ut. '%e 0ro2lem is solve1 usin 4itte1 e?uations to t%e results o4 a eneral e?uili2rium com2ustion mo1el. '%ere are t%ree e?uations t%at o into t%e 1etermination o4 Avai)a#)e $ea" "o "he Process Percen"( '%ese e?uations estimate t%e 4ollowin( 1. Availa2le %eat to t%e 0rocess 4or stoic%iometric air to 4uel ratio 2ase1 on an assume1 natural as com0osition )A00en1i. 3., F"5 - 0.025 . t2 )see varia2le 1e4initions a2ove, 2. Minus a correction 4actor 4or t%e %eat containe1 in t%e e.cess air t%at is also Boin u0 t%e 4lueC F-)-2 L 0.02 . t2,M)E.cess AirE=100, alternatively F .02 . )t2 -100, . E.cess AirE=100 )w%ere .02 #tu=sc4 is t%e averae s0eci4ic %eat o4 air an1 100 is t%e assume1 2ase com2ustion air tem0erature in 1erees F., +. 6lus a correction 4actor 4or t%e %eat t%at is containe1 in t%e "o"a) com2ustion air inclu1in t%e e.cess air 12 Com#us"ion Techno)o3y <anua)' 2our"h E%i"ion, :n1ustrial <eatin E?ui0ment Association, 1"&&, 0026*-2*0. EEA A-1 B-REP-06-599-13 The Gas Company F)-2L0.02M t2air,M)1 L E.cess AirE==100, As in )2, t%is e?uation is 2ase1 on an averae s0eci4ic %eat o4 air o4 0.02 #tu=sc4 an1 an assume1 startin 0oint o4 100 o F. -. '%e Availa2le %eat to t%e 0rocess F )1, A )2, L )+, 5. Enery savins e?uals t%e c%ane in as consum0tion 1ivi1e1 2y t%e oriinal enery consum0tion. '%e actual calculation 4or t%is value comes 4rom t%e c%ane in availa2le %eat to t%e 0rocess 0ercent 1ivi1e1 2y t%e new availa2le %eat to t%e 0rocess 0ercent. '%ese two terms are e.actly e?ual 2ecause enery consum0tion is inversely 0ro0ortional to availa2le %eat to t%e 0rocess 0ercent. '%e 4irst e?uation is 2ase1 on a 4itte1 line to t%e results o4 an e?uili2rium com2ustion mo1el o4 stoic%iometric com2ustion wit% natural as an1 *5 o F. air. '%is curve is s%own in Fiure && Availa9le 8eat ; :atural "as (o#9ustion Stoichio#etric using 75 deg7 )7 (o#9ustion Air 0- 10- 20- "0- &0- 50- !0- 0- 80- 00- !00 800 1,000 1,200 1,&00 1,!00 1,800 2,000 2,200 2,&00 )lue "as 5e#% Deg7 ) A v a i l a 9 l e
8 e a t
<
o /
8 e a t
6 n % u t Figure >& A#aila"le 'eat fr -tic6i$etric 0atural 1as *$"ustin as a Functin f Flue 1as .e$perature '%e %eat content o4 air t%at is use1 in e?uations )2, an1 )+, is 2ase1 on t%e relations%i0 s%own in Fiure ". EEA A-+ B-REP-06-599-13 The Gas Company ; 12 22 32 12 52 32 222 122 322 822 1,222 1,222 1,122 1,322 1,822 2,222 2,222 2,122 2,322 5e#%erature (Deg7 )7! 8 e a t
( o n t e n t
( . t u / s c / ! Figure 9& 'eat *ntent f Air as Functin f .e$perature '%ere are a num2er o4 sim0li4yin assum0tions an1 cavea"s 4or t%e relations%i0 in t%e calculator( '%ere are no wall losses assume1 in t%e recu0erator an1 1uctin. '%ere is no am2ient air in4iltration assume1. All o4 t%e e.cess air is assume1 to come 4rom t%e com2ustion air. Enery losses in t%e 4urnace )0rocess, itsel4 are assume1 to 2e unc%ane1 A 4urnace wall losses, ra1iation losses, etc. '%ese losses 1o not a44ect t%e value o4 t%e %eat recovery measure, 2ut may 2e o00ortunities 4or ot%er e44iciency measures. '%e calculation tool 1oes not measure t%e e44ectiveness o4 t%e 0ro0ose1 %eat recovery e?ui0ment. '%e 0er4ormance, inlet an1 outlet tem0eratures must come 4rom t%e customer or ven1or. :t is im0ortant t%at realistic values 2e entere1 4or 4lue as tem0erature an1 com2ustion air 0re%eat. '%e calculations are 2ase1 on a 4i.e1 as com0osition an1 stoic%iometric air to 4uel ratio. '%e results are relatively insensitive to assum0tions rear1in 4uel com0osition. 5oin 4rom 100E met%ane to 100E 0ro0ane only c%anes t%e availa2le %eat estimate 2y 1E. . EEA A-3 B-REP-06-599-13 The Gas Company Appendi, B )all 'eat /ss *alculatins 3onsi1er t%e 0rocess %eater s%own in Fiure 10. Durin o0eration, t%e e.ternal sur4aces o4 t%e 0rocess %eater are %ot, an1 enery is trans4erre1 to t%e surroun1in environment t%rou% t%e 0rocesses o4 con1uction, convection, an1 ra1iation. For 0ractical 0ro2lems suc% as t%e 0rocess %eater s%own in Fiure 10, enery is trans4erre1 4rom t%e %ot e.ternal soli1 sur4ace o4 t%e 0rocess %eater to t%e surroun1in air. For %eat trans4er 4rom soli1 sur4aces to a surroun1in 4lui1 suc% as air, t%e con1uction an1 convection terms are 4re?uently com2ine1 an1 e.0resse1 as 4ollows( T A h A @ 8 c c c E(uatin 1 w%ere ?c A %eat trans4er 0er unit area )#tu=%r-4t, N c A %eat trans4er rate )#tu=%r, A A sur4ace area )4t 2 , % c A %eat trans4er coe44icient, inclu1in 2ot% convection an1 con1uction )#tu=%r-4t 2 -F, O' A tem0erature 1i44erence 2etween 0rocess %eater wall an1 surroun1in air )F, Figure 10& -i$plified 5iagra$ f 'eat /ss fr$ E,ternal -urface f Prcess 'eater 8a1iation %eat trans4er 2etween two 2o1ies is 0ro0ortional t%e 1i44erence o4 t%e 4ourt% 0ower o4 t%e a2solute tem0erature o4 eac% 2o1y. <owever, to 0reserve similarities wit% t%e 4orm o4 t%e convection %eat trans4er e?uation, t%e ra1iation %eat trans4er is o4ten e.0resse1 as T A h A @ 8 r r r E(uatin 2 EEA B-1 B-REP-06-599-13 @rocess /eater Conduction Con)ection 5adiation T A h A @ 8 r r r
T A h A @ 8 c c c
The Gas Company w%ere ?r A %eat trans4er 0er unit area 1ue to ra1iation )#tu=%r-4t, N r A %eat trans4er rate )#tu=%r, % r A ra1iation %eat trans4er coe44icient )#tu=%r-4t 2 -F, '%e %eat trans4er 4rom t%e soli1 sur4aces o4 a 0rocess %eater, suc% as t%at 1e0icte1 in Fiure 10, vary 4or %ori@ontal an1 vertical sur4aces, an1 4or 1i44erence ty0es o4 materials )emissivity c%anes, w%ic% c%anes ra1iation,. '%e %eat trans4er 4rom soli1 sur4aces is also stronly 1e0en1ent on e.ternal air 4low. For e.am0le, i4 t%ere is 4orce1 convection )e.., a 4an t%at moves air across t%e 0rocess %eater,, t%e %eat trans4er rates can 2e sini4icantly %i%er com0are1 to natural convection )air movement only occurs 1ue to natural 2uoyancy e44ects t%at occur 4rom tem0erature variations o4 t%e air,. '%ere will also 2e variations in %eat trans4er across t%e e.ternal sur4ace 1ue to tem0erature variations on t%e wall )e.., t%e e.ternal sur4ace o4 t%e 4urnace roo4 may 2e %otter t%an t%e si1es,. For 0ractical 0ro2lems suc% as t%e %eat loss 4rom t%e e.ternal walls o4 0rocess %eaters, several sim0li4yin assum0tions are enerally set suc% t%at an estimate can 2e o2taine1. '%e sim0li4yin assum0tions use1 in t%is wor/0a0er inclu1e( Mo1el e.ternal 4urnace area as a vertical wall. E.clu1e t%e 4loor area o4 t%e 4urnace an1 only inclu1e t%e si1es an1 roo4 t%at are in contact wit% t%e surroun1in air. :sot%ermal wall tem0erature No 4orce1 convection ;sin t%ese sim0li4yin assum0tions, enineers %ave 1evelo0e1 em0irical %eat trans4er e?uations t%at are enerally vali1 4or a rane o4 wall tem0eratures an1 am2ient air tem0eratures. 7ne suc% em0irical e?uation 1evelo0e1 4or wall tem0eratures in t%e rane o4 a00ro.imately 1-0 to -00 o F an1 an am2ient air tem0erature o4 *5 o F is( ( ) ( ) 1 ] 1
, _
1 ] 1
+ "0 100 0&5 . 0
50 *5 16- -2 . 1 000 , 1 * . " 2 =a)) am# =a)) =a)) T T T T A @ 8 E(uatin 3 13 '%e 0rece1in e?uation re0resents a curve 4it o4 1ata 1evelo0e1 2y Dr. Arvin1 '%e/1i )see Appendi, A,. At low tem0eratures ra1iation is insini4icant relative to convection, an1 t%e %eat trans4er relations%i0 can 2e sim0li4ie1. :n t%is wor/0a0er, 4or wall tem0eratures in t%e rane o4 60 to 1-0 o F t%e 4ollowin e?uation is use1( ( )( ) am# =a)) =a)) T T T A @ 8 + 006 . 0 6 . 1 E(uatin 8 18 '%e 0rece1in two e?uations are t%e 4un1amental relations%i0s use1 in t%e 6rocess <eatin 'ool to estimate %eat loss 4rom t%e e.ternal walls o4 an oven, 4urnace, or any ot%er 0rocess %eatin system wit% %ot e.ternal sur4aces. 1+ '%e/1i, A., 0rivate communication. 1- 'rin/, $., :n1ustrial Furnaces, !olume 1, - t% E1ition, 1"51. EEA B-+ B-REP-06-599-13 The Gas Company EEA B-3 B-REP-06-599-13 The Gas Company Appendi, *! Assu$ed 1as *$psitin '%e as com0osition assume1 in t%e analysis is s%own in 'a2le && .a"le >& Assu$ed 1as *$psitin 1as *nalysis Molar Eolume - C/& 0&%1000- C2/! "%0100- C"/8 0%&200- C&/10 0%2800- CO 0%01&0- /2 0%0"25- CO2 0%100- O2 0%0100- 22 1%&100- EEA C-1 B-REP-06-599-13