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Applied Industrial Energy and Environmental Management
John Wiley and Sons Ltd, Oct 2008, Pages: 452
Contents
About the Authors
Preface
Introductory Chapter: Framework for Energy and Environmental
Management in Industry
1 Introduction
2 Energy Use by Industrial Operations
3 Environmental Impacts of Industrial Operations
4 End Use Energy Efficiency
5 Efficiency of Using Raw Materials
6 Global Energy Policy Framework
7 Energy and Environmental Policies
7.1 Integrated Pollution Prevention and Control (IPPC)
7.2 Energy Markets Deregulation and Liberalization
7.3 Consumers Choice in the Liberalized Energy Market
7.4 Emissions Trading
7.5 Compulsory Energy Efficiency Programs
7.5.1 ENCON Program in Thailand
7.6 Voluntary Programs
7.6.1 Eco-Management and Audit Scheme (EMAS)
8 Industries Self-Motivation for Effective Energy and Environmental Performance
9 Environmentally Responsible Investing
10 Where to Look for Energy and Environmental Performance Improvements
11 Bibliography
Part I: Energy and Environmental Management System in Industry (EEMS)
1 Introducing the Energy and Environmental Management System
1.1 Introduction
1.2 Definition of terms
1.2.1 System
1.2.2 Management
1.2.3 Performance
1.2.4 Information
1.2.5 Performance Indicators
1.2.6 Knowledge
1.2.7 Management System
1.2.8 Environmental Impacts
1.2.9 Energy Performance
1.2.10 Environmental Performance
1.2.11 Performance of Materials Use
1.2.12 Environmental Management
1.2.13 Energy Management
1.3 Energy and Environmental Management System
1.4 Objectives of Energy and Environmental Management
1.5 Dynamics of Energy and Environmental Management
1.6 Human Aspects of Energy and Environmental Management
1.6.1 Change
1.6.2 Aspects of Change
1.6.3 Barriers to Overcome
1.6.4 Unawareness of Opportunities
1.6.5 De-motivating Aspects
1.6.6 Motivating People
1.6.7 Providing Leadership
1.6.8 Top Managements Visible Commitment to EEM
1.6.9 Decisions to be Made
1.6.10 Visibility
1.6.11 Working with People Towards a Successful EEMS Project
1.6.11.1 Managers
1.6.11.2 Employees
1.7 Initiating Training, Awareness and Motivation Programs
1.7.1 Management
1.7.2 Technical Managers and Supervisors
1.7.3 Awareness and Motivation for all Employees
1.8 Bibliography
2 The Energy and Environmental Management Concept
2.1 Introduction
2.2 Interactions between Energy and Production
2.3 Energy Cost Centers
2.4 Assigning Responsibilities for Energy and Environmental Performance
2.5 Performance Measurement System
2.5.1 Metrics
2.5.2 Measurement Data Sources
2.5.3 Data Handling Procedures
2.5.4 Data Verification
2.5.5 Measurement Frequency
2.5.6 Supporting Infrastructure
2.5.7 Raw Material Performance Indicators
2.5.8 Energy Performance Indicators
2.5.9 Data Adequacy
2.5.10 Performance Targets
2.5.11 Environmental Performance Indicators
2.5.11.1 Integrated Pollution Prevention Control
2.5.11.2 Eco-Management and Audit Scheme
2.5.11.3 Environmental Management Standard ISO 14000
2.5.11.4 Emissions Trading
2.5.11.5 Global Reporting Initiative
2.6 Effective Use of Energy and Environmental Performance Indicators
2.7 Concept of Energy and Environmental Management System
2.8 Context of Energy and Environmental Management
2.8.1 External Context
2.8.2 Internal Context
2.8.3 Factors that Influence Energy and Environmental Performance
2.9 Bibliography
3 Relationship between Energy Use and Production Volume
3.1 Introduction
3.2 Energy/Production Relationship by Design
3.3 Energy/Production Relationship by Standard Operational Procedure
3.4 Presenting the Dynamics of the Energy/Production Relationship by Scatter Diagram
3.5 Interpretation of Energy/Production Data Pattern on the Scatter Diagram
3.6 Statistical Methods for Energy/Production Variability Analysis
3.6.1 Regression Analyses
3.6.2 Correlation Analyses
3.7 Meaning and Use of the Regression Line in Energy Performance Evaluation
3.7.1 Quantifying and Understanding Energy/Production Variability
3.7.2 Fixed and Variable Energy Consumption
3.7.3 Specific Energy Consumption
3.8 Summary of Presenting and Analyzing the Energy/Production Relationship
3.9 Bibliography
4 Evaluating the Performance of Energy and Environmental Management Practice
4.1 Evaluation of Past Performance
4.2 Energy and Environmental Auditing
4.2.1 Scope of Energy Audit
4.2.2 Scope of Environmental Audit
4.3 Evaluating Organizational Aspects
4.3.1 Qualitative Evaluation
4.3.2 Quantitative Evaluation
4.4 Evaluating Operational Aspects
4.4.1 Planning and Preparation for Data Collection
4.4.2 Data Collection on Energy Consumption
4.4.3 Data Collection on Production Processes
4.4.4 Specification of Major Utilities and End-Use Equipment
4.4.5 Data Collection on Environmental Impacts
4.4.6 Assessing On-Site Metering and Control Equipment
4.4.7 Measurement Plan
4.4.8 Timing
4.4.9 Records and Note Keeping
4.4.10 Instrumentation
4.4.11 Calculations
4.4.12 Economic and Financial Analysis
4.4.13 Presentation of Audit Results
4.5 Setting a Baseline for Monitoring Performance Improvements
4.6 Setting Initial Targets for Performance Improvement
4.6.1 Setting Targets at the Companys Level
4.6.2 Setting Targets on ECC Level
4.6.3 Targets for Different Products
4.7 Monitoring Energy and Environmental Performance
4.8 Verifying Performance Improvements CUSUM Technique
4.9 Moving Toward Targets Process of Change
4.10 Bibliography
5 Implementation of the Energy and Environmental Management System
5.1 Introduction
5.2 Phases of EEMS Implementation Process
5.3 Preparation and Planning
5.3.1 Energy and Environmental Policy
5.3.2 Assigning Management Responsibilities for Energy and Environment
5.3.3 EEMS Organization
5.4 Implementation Plan
5.4.1 Initiate Awareness and Training Programs
5.4.1.1 Awareness and Motivation
5.4.1.2 Training
5.4.2 Installation of Performance Measurement System
5.4.3 Target Setting
5.5 EEMS Operation
5.5.1 Performance Data Interpretation
5.5.1.1 Evaluation of Operational Practice
5.6 Learning Through EEMS Operation
5.6.1 Learning Cycle
5.6.2 Learning through Peoples Performance Evaluation
5.7 Continuity and Communication
5.8 Integration of EEMS with Business Management System
6 Energy and Environmental Management as a Driver for Integrated Performance Management
6.1 Introduction
6.2 Integrated Performance Management in Operations
6.3 Strategic Aspects of Performance Management
6.3.1 Identifying External Factors Influencing Performance
6.3.1.1 Identifying Technological Changes
6.3.2 Organizational Fragmentation
6.3.2.1 Data Fragmentation
6.4 Integrated Performance Measurement System
6.4.1 Knowledge Discovery
6.5 Integrated Performance Management
6.6 Conclusion
6.7 Bibliography
Part II: Engineering Aspects of Industrial Energy Management
1 Introduction to Industrial Energy Systems
1.1 Introduction
1.2 Industrial Energy Systems Analysis
2 Industrial Steam System
2.1 System Description
2.1.1 Boilers
2.1.2 Steam Distribution System
2.1.3 Steam End-users
2.1.4 Condensate Return System
2.2 System Performance Definition
2.2.1 The Cost of Steam
2.3 Principles of Performance Analysis
2.3.1 Performance Improvement Opportunities
2.3.2 Example 1: Steam System Energy Performance Analysis
2.4 Analysis of Boiler Performance
2.4.1 Direct (Input/Output) Method
2.4.2 Indirect (Heat Losses) Method
2.4.2.1 Heat Energy Loss due to Flue Gas
2.4.2.2 Heat Energy Loss due to Chemically Incomplete Combustion
2.4.2.3 Heat Energy Loss due to Mechanically Incomplete Combustion
2.4.2.4 Heat Energy Loss due to Radiation
2.4.2.5 Heat Energy Loss due to Slag
2.4.2.6 Heat Energy Loss due to Blow-down
2.4.2.7 Summary of Indirect Boiler Efficiency Determination
2.4.3 Preparing a Measurement Plan for Boiler Performance Analysis
2.5 Factors Influencing Boiler Performance
2.5.1 Boiler Load
2.5.2 Boiler Design
2.5.3 Fouling of Heat Transfer Surfaces
2.5.3.1 Gas-side Fouling
2.5.3.2 Water-side Fouling
2.5.4 Boiler Operation Controls
2.5.5 Water Quality
2.6 Opportunities for Boiler Performance Improvement
2.6.1 Combustion Efficiency Improvement
2.6.2 Load Scheduling
2.6.3 Waste Heat Recovery Techniques
2.6.3.1 Heat Recovery from Flue Gas
2.6.3.2 Combustion Air Pre-Heating System
2.6.3.3 Heat Recovery from Boiler Blow-down
2.6.4 BoilerWater Treatment Improvement
2.6.5 Boiler Control System Improvement
2.7 Software for Boiler Performance Analysis
2.7.1 Software 4: FUELS, COMBUSTION AND ENVIRONMENTAL IMPACTS
2.7.2 Software 5: THERMODYNAMIC PROPERTIES OFWATER AND STEAM
2.7.3 Software 7: EFFICIENCY OF STEAM BOILERS
2.7.4 Software 9: THE HEAT EXCHANGERS OPERATING POINT DETERMINATION
2.7.5 Example 2: Boiler Efficiency Improvement
2.7.5.1 Facility Description
2.7.5.2 Steam Generation and Fuel Consumption
2.7.5.3 Measurements, Technical Calculations and Analysis
2.7.5.4 Best Operation Practice
2.7.5.5 Efficiency Calculation Based on Measured Values
2.7.5.6 Summary of Performance Improvement Measures (PIMs)
2.8 Boiler Performance Monitoring
2.8.1 Values to be Monitored
2.9 Steam Distribution and Condensate Return System
2.9.1 Steam Distribution System Performance Analysis
2.9.2 Influencing Factors on Steam Distribution System Performance
2.9.2.1 Steam Leaks
2.9.2.2 Insulation
2.10 Condensate Return System
2.10.1 Flash Steam Recovery
2.10.2 Performance Improvement Opportunities
2.10.3 Software 8 STEAM SYSTEM INSULATION
2.10.4 Example 3: Steam and Condensate System Insulation Improvements
2.10.5 Performance Monitoring of Steam Distribution and Condensate Return System
2.11 Environmental Impacts
2.11.1 Ambient Air Pollution
2.11.2 Water Pollution
2.11.3 Carbon Emission Factors
2.11.4 Example 4: Practical Calculation of Carbon Emission Reduction
2.12 Bibliography
3 Industrial Electric Power System
3.1 Introduction
3.2 Description of Industrial Electric Power Systems
3.3 Basic Terms
3.3.1 Active and Reactive Power and Power Factor 286
3.3.2 Load Diagram
3.3.3 Peak Demand
3.3.4 Power and Energy
3.3.5 Load Factor
3.3.6 Quality of Power Supply
3.4 Tariff System
3.5 Main Components of Industrial Electric Power Systems
3.5.1 Transformers
3.5.2 Cables
3.5.3 Electric Motors
3.6 Performance Assessment of Industrial Electric Power Systems
3.7 Performance Improvement Opportunities
3.7.1 Load Management
3.7.2 Demand Control
3.7.2.1 Example 1: Demand Control by Stand-by Diesel Generators
3.7.2.2 Example 2: Relation between Load Factor, Demand Charges and Total Electricity Costs
3.7.3 Power Factor Correction
3.7.3.1 Example 3: Power Factor Correction from 0.6 to 0.9
3.7.4 Electric Motor Drives
3.7.4.1 Variable Speed Drives (VSD)
3.7.4.2 Correct Operational Procedure
3.7.4.3 Example 4: Comparison of Fan Operations with Constant and Variable Speed Control
3.8 Maintenance Considerations
3.9 Performance Monitoring
3.9.1 Power Quality Indicators
3.9.2 Electric Motor Drives Maintenance Needs Indicators
3.9.3 Electric Motor Drives Operational Practice Indicators
3.10 Environmental Impacts
3.10.1 Polychlorinated Biphenyls (PCBs)
3.11 Bibliography
4 Compressed Air System
4.1 System Description
4.1.1 Compressors
4.1.2 Air Pressure
4.1.3 Air Receiver
4.1.4 Water Removal
4.1.5 PipeWork
4.1.6 Ventilation of Compressor Room
4.2 Performance Analysis
4.2.1 Compressors Performance Graph
4.2.2 Measurements
4.2.2.1 Power
4.2.2.2 Pressure
4.2.2.3 Flow Rates
4.2.2.4 Temperature
4.2.2.5 Compressed Air Leakage Determination
4.3 Performance Improvement Opportunities
4.3.1 Operation and Maintenance
4.3.2 Control Systems
4.3.2.1 Compressors
4.3.2.2 Control of Compressed Air Quality Standard
4.3.2.3 CoolingWater Quality Control
4.3.3 Performance Improvement Measures
4.3.3.1 Compressed Air Leakage Reduction
4.3.3.2 Control System
4.3.3.3 Discharge Pressure
4.3.3.4 Waste Heat Recovery
4.4 Performance Monitoring
4.4.1 Values to be Monitored
4.5 Example: Detailed Energy Audit of Compressed Air System
4.5.1 System Inspection, Testing and Fault Finding
4.5.1.1 Activities before the Plants Shut-down
4.5.1.2 Air Leak Test (during Shut-down)
4.5.1.3 Average Power of Compressor
4.5.1.4 Air Leak Test of Distribution Network (Non-Production Period)
4.5.1.5 Pressure Drop
4.5.1.6 Ventilation of Compressor Room
4.5.1.7 Recommendations
4.5.1.8 Expected Energy Savings
4.6 Example: Comparison of Load/Unload and Pump-up Tests
4.6.1 Load/Unload Test
4.6.2 Pump-up Test
4.7 Bibliography
5 Refrigeration System
5.1 Description of System
5.1.1 Principles of Operation
5.1.1.1 Vapor-Compression Refrigeration
5.1.1.2 Vapor-Absorption Refrigeration
5.2 Performance Definitions
5.2.1 Factors Affecting Performance
5.2.1.1 Evaporating Temperature
5.2.1.2 Condenser Temperature
5.2.1.3 Compressor Isentropic Efficiency
5.2.1.4 Auxiliary Power
5.2.1.5 Cooling Loads
5.2.1.6 Part-Load Operation
5.3 Performance Analysis
5.4 Performance Improvement Opportunities
5.4.1 Maintenance
5.4.2 Control System
5.4.3 Operational Procedures
5.5 Performance Monitoring
5.5.1 Values to be Monitored
5.5.2 Software 11: Refrigeration Systems Analysis (Vapor-Compression Cycles)
5.5.3 Software 10: Cooling Towers Calculation
5.6 Example: Improvement of ChilledWater System Operation
5.6.1 Basic Data on ChilledWater System
5.6.2 As Built Scheme of ChilledWater System
5.6.3 Data Collection, Measurement and Analysis
5.6.4 Performance Improvement Measures (PIM)
5.6.5 Cost Benefit Analysis
5.7 Bibliography
6 Industrial Cogeneration
6.1 System Description
6.2 Principles of Operation
6.3 Types of Industrial Cogeneration Plants
6.3.1 Advantages and Disadvantages of Each System
6.3.2 Thermally-Activated Technologies
6.4 Operational Modes of Cogeneration Systems
6.5 Performance Definition
6.6 Factors Influencing Performance
6.6.1 Load of Cogeneration Plant
6.6.2 Load Duration Curve
6.7 Economic Aspects of Cogeneration as a Performance Improvement Measure
6.7.1 Capital Cost
6.7.2 Operating and Maintenance Costs
6.7.3 Overall Economics of Cogeneration Projects
6.8 Performance Assessment
6.9 Performance Monitoring and Improvement
6.10 Environmental Impacts 415
6.11 Case Study: Drying Kiln (Gas Turbine Operation Philosophy Improvement)
6.11.1 Facts
6.11.2 Description of Kiln
6.11.3 Objectives of Analysis
6.11.4 Measurement, Technical Calculation and Analysis
6.11.5 Energy Performance Improvements
6.11.6 Environmental Impact
6.12 Bibliography
Part III: Toolbox Fundamentals for Analysis and Calculation of Energy and Environmental Performance
Index
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