Energy Management
Opportunities
Reduce Energy Intensity and
Carbon Emissions by Changing the
Way You Use Energy
This document was specifically prepared to aid Tech Resources’ clients that wish to inform their customers about available
energy management solution options that these customers may wish to consider. Any other use of this material (in whole or in
part) is not allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.
© 2009 Tech Resources, Inc.
Energy Management
 Mike Carter
 Mark Farrell
© 2009 Tech Resources, Inc.
2
Energy Management Benefits
 Bottom line cost savings today!
• Energy
• Maintenance
 Reduced noise levels
 Better indoor air quality
 Reduced air emissions
© 2009 Tech Resources, Inc.
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Energy Management Opportunities









Basics
Energy Management
Insulation
HVAC
Lighting
Heating Systems
Motors
Transformers
Compressed Air
© 2009 Tech Resources, Inc.
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Energy Efficiency Basics
 Power versus Energy
• Kilowatt (kW) is a measure of power, like the
speedometer of your car that records the
rate at which miles are traveled.

A bigger engine is required to travel at a faster rate.
 Peak power demand is usually measured as an average
over a 15-minute period.
– Spikes and surges from motor startup and other short-term
anomalies have little influence on peak demand.
• Kilowatt-hour (kWh) is a measure of energy/load
consumption—similar to the odometer on your car
which measures miles traveled.
© 2009 Tech Resources, Inc.
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Energy Efficiency Basics
 Power versus Energy (cont’d)
• Energy Cost = Energy Consumption x Unit Cost =
kWh x $/kWh

A 113-Watt four-lamp light fixture costs about $66 annually
when operating 16 hr/day (113 W x 5,840 hr x $0.10/kWh ÷
1,000 W/kW)
• Motor power (kW) = Horsepower x 0.746/efficiency
A 10 HP motor = 10 HP x 0.746/0.90 = 8.3 kW
 A 10 HP motor costs about $4,850 annually (8.3 kW x 5,840 hr
x $0.10/kWh) when operating 16 hr/day

• Pay the price for improved energy efficiency!

The operating cost over the lifetime of a motor or light fixture
can far exceed the original purchase price.
© 2009 Tech Resources, Inc.
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Energy Basics
 Load Factor
• Ratio of average load over peak load
• LF = kWAvg/kWP = kWh/hrs  kWP
 Assume 30-day billing




(30 x 24 hrs = 720 hrs)
10,000 kWh load
21 kW peak
LF = 10,000/720  21 kW
LF = 66%
© 2009 Tech Resources, Inc.
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Energy Basics
 Peak Demand Curtailment
• Separate loads into three categories:

Life, health, and safety-driven
 Mission critical
 Non-critical
• Start by considering curtailment of non-critical loads

Non-safety lighting
 HVAC
• Consider installing sub-metering to identify high
intensity loads
© 2009 Tech Resources, Inc.
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Energy Basics
 Power Factor
• Real/active power (kW) does real work
• Reactive power (kVAR) bound up in magnetic fields
• Apparent power (kVA) must be supplied by utility to
accommodate reactive component
PF = kW/kVA
kVA2 = kW2 + kVAR2
(kVA)² = (kW)² + (kVAR)²
= (75)² + (75)² = 11,250
Apparent Power = 11,250 = 106 kVA
Then: Power Factor = kW/kVA = 75/106 = 70.8%
© 2009 Tech Resources, Inc.
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Energy Basics
 Power Factor
• Add capacitance to correct power factor
• Does not change demand (kW) or save much
energy (kWh)
© 2009 Tech Resources, Inc.
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Energy Basics
 Carbon Footprint
• Metric tons (2,205 lbs or 19,550 ft3) of CO2
 Natural
Gas - 12 lbs CO2/ccf
 Electricity - 0.95 lbs CO2/kWh
 Carbon = CO2  3.67 (100 tons CO2 = 27 tons C)
– Pine trees can absorb roughly 1 metric ton of carbon per
acre per year
• Direct emissions from company-owned stacks
• Indirect emissions from travel
© 2009 Tech Resources, Inc.
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Corporate Energy Management
 Key Components of Energy Management
• Commitment by upper level management
• Clearly stated goals on energy efficiency, waste
•
•
•
reduction, and sustainability
Delegation of responsibility and accountability to the
appropriate personnel
Sustained tracking and assessment of energy use and
technology application
Continuous investigation of potential energy reduction
projects
© 2009 Tech Resources, Inc.
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Corporate Energy Management
 Energy Information Systems
• Measure and Evaluate

Knowledge is power
– “If you can't measure it, you can't manage it!"

Access to real-time energy consumption/demand and cost data
across multiple plants and facilities
• Plan

Benchmark
– Against yourself
– Against similar facilities

Prioritize solutions
• Implement
© 2009 Tech Resources, Inc.
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Insulation
 Insulation has diminishing returns
• R-value is resistance to heat flow (additive)

R-7 + R-21 = R-28 (4 times R-7, and 75% better than R-7)
 R-7 + R-49 = R-56 (8 times R-7, but only 12% better than R-28!)
• U-value is conductance of heat; inverse of R-value
U(R-7) = 1/7 = 0.143
 U(R-56) = 1/56 = 0.018 (87% less than R-7)
 U(R-21) = 1/21 = 0.048  U(R-28) = 1/28 = 0.036 (75% less than R-7)

Insulating Value
U-Value (Btu/ft.2 °F hr)
0.300
R-3.5
0.250
0.200
R-7
0.150
0.100
R-14
R-28
0.050
R-56
0.000
0
5
10
15
20
25
30
R-Value
© 2009 Tech Resources, Inc.
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35
40
45
50
55
60
Insulation
 Insulate steam pipes with at least ½" insulation
• For a 350°F process steam pipe, savings are $5,000 for 2"
•
dia. and $10,000 for 4" dia. pipe
Diminishing returns for insulation
thickness > ½"
Type
Fiberglass
2.2-3.1
Vermiculite/perlite
2.4-2.8
Polystyrene
4.0-5.0
Polyurethane
Polyisocyanurate
© 2009 Tech Resources, Inc.
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R-value per inch
6.0
6.0-7.1
HVAC
Implementation
Load (kWh)
Peak (kW)
Temperature Setback

Economizers

Heat/Energy Recovery Ventilators/Wheels

Chiller Water Temperature


New HVAC Equipment


Geothermal Heat Pump

Air Doors/Curtains

© 2009 Tech Resources, Inc.
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
HVAC
 Temperature Setback/Setforward
• Save 3% per °F per 24 hrs
• 72°F  68°F (4°F) for 12 hrs
saves 6%
 Economizers Bring in Cool Outside Air
• Typical 2 to 5 year payback for economizers
• Most appropriate for large systems
•
(>5 tons in West and >11 tons in Midwest)
Not very effective in high humidity climates
© 2009 Tech Resources, Inc.
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HVAC
 Heat Recovery Ventilators
• Can recover about 60% to 70% of heat in exiting air
• A solution to ASHRAE 62 IAQ requirements
Photo source: George Retseck Illustrations
© 2009 Tech Resources, Inc.
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HVAC
 Energy/Enthalpy/Desiccant Wheels
• Can recover about 70% to 80% of the energy in the
exiting air and deliver that energy to the incoming air.

Desiccant wheels are most cost effective in climates with
extreme winters or summers, and where fuel costs are high.
• In mild climates, the cost of the additional electricity
consumed by the system fans and drum motor may
exceed the energy savings from not having to condition
the supply air.
© 2009 Tech Resources, Inc.
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HVAC
 Narrow Your Chiller Water Temperature Set Points
• Typical conditions are chilled water temperature of 42°F
and condensing water temperature of 80°F to 85°F.

2% savings per °F that chilled water temperature is raised
 5°F to 10°F increase is possible; more may cause damage and
reduce cooling capacity (ton rating)
• Efficiency benefits from lowering condensing water
temperature are offset by increased fan and pump
operation, along with reduced cooling capacity.

Variable Frequency Drives (VFDs) and oversizing the cooling
tower can help

The larger the system, the greater the net energy savings
© 2009 Tech Resources, Inc.
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HVAC
 Upgrade Older HVAC (10 to 15 years)
• Chillers: 0.8 kW/ton  0.5 kW/ton (37% less!)
• Unitary rooftop: 1.5 kW/ton  1.2 kW/ton (20% less!)
 Geothermal or Water-Source Heat
Pump
• Roughly 30% savings compared to
•
AC/Boiler or AC/Furnace
combination
Geothermal requires higher capital
investment and requires significant
amounts of real estate
 New construction accommodates
verticals and pond loop
© 2009 Tech Resources, Inc.
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HVAC
 Use Air Doors/Curtains
• A door 14 feet wide and 11feet high, indoor
temperature of 70°F, outdoor temperature of
20°F, zero wind velocity, loses 600,000
Btu/h at a cost of roughly $7 per hour
•
•
•
•
Any wind at all triples the loss!
Air door recovers 75% of heat loss
1 to 2 year payback possible ($3,500 cap. + $100 op.)
Exhaust fans (negative pressure) and wind tunnel
effect are problems
© 2009 Tech Resources, Inc.
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Lighting
Implementation
Load
(kWh)
Peak
(kW)
Replace T12 with T8 or T5


Replace Metal Halide with T8 or T5HO


Replace Incandescent with CFL


© 2009 Tech Resources, Inc.
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Lighting
 Replace existing T12 fluorescent lamps with T8 fluorescent lamps (up
to 30% savings).
Four-lamp T12 versus T8 Fixtures
Lamp Type
Fixture
Watts
Fixture
Lumens
LPW
F32T12
148
9,120
62
F32T8
113
10,600
94
 No magnetic ballasts for new installations sold or manufactured after
March 2005.
 More stringent magnetic ballast performance requirements after July
2009.
 No magnetic ballasts manufactured for replacement after June 2010.
© 2009 Tech Resources, Inc.
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Lighting
 Super T8 lamps, with high-efficiency ballasts, are high lumen (>3,000
versus 2,850 std.) and extended life (>24,000 versus 20,000 hrs std.)
products.
 Only saves energy when combined with a lower ballast factor ballast.
Type
Initial
Lumens
Initial
Watts
Ballast
Factor
Fixture
Lumens
Fixture
Watts
T8
2,950
33
0.85
2,496
28
Super T8
3,200
34
0.78
2,496
26
 Group relamping recommended at 60% to 80% of rated life.
• Every 2 to 3 years for 20,000 hour fluorescents
• Can be 30% to 40% cheaper to group relamp due to labor savings
© 2009 Tech Resources, Inc.
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Lighting
 Metal Halide (MH) versus Fluorescent for Highbay
• Probe start (PS) MH with low lumen maintenance (<65%) is best target for
replacement

The lumen maintenance of metal halides can decrease to 45% during its
lifetime, whereas fluorescents maintain 90% to 95% in optimal conditions.
• Compare 320 W PS MH with 20,000 EOL lumens and six F32T8 with
18,000 EOL lumens at 220 system watts
• Lumen output of fluorescents declines with heat/cold
 Compact Fluorescent Lighting (CFL)
• You get the same or more light output (lumens) with a
75% energy reduction and over six times the rated life!
• Energy savings far outweigh difference in lamp price
• Use reflector flood CFLs in recessed can lights
• Issue of mercury content can be addressed
© 2009 Tech Resources, Inc.
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Heating Systems
Implementation
Load (Btu)
Load (kWh)
Peak (kW)
Waste Heat Absorption Chillers


Industrial Heat Pumps for Drying/Heating

Radio Frequency/Microwave Drying/Heating

Gas Burner Air:Fuel Ratio

Modern Gas Burners/Controls

Steam Traps

Stack Heat Recovery

Infrared Booster Heaters


Induction Process Heating
© 2009 Tech Resources, Inc.
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Heating Systems
 Measuring Boiler Efficiency
• Fuel-to-steam efficiency is the best efficiency metric

Boiler output (Btu)/boiler input (Btu)
 Accounts for both combustion and thermal efficiency, radiation, and
convection losses
• Efficiency mainly influenced by boiler design

Number of passes more important than add-on (turbulator)
 Burner/boiler compatibility (accounts for geometry, heat transfer, and so on)
 Burner controls (independent control of fuel and air is best)
 Heating surface (square feet/boiler HP; 5 ft2/HP is desired)
• Other factors

Flue gas temperature directly correlates with efficiency
 Fuel hydrogen/carbon ratio (fuel oil > natural gas)
 Excess air (10% to 12%)
 Ambient temperature (every 40°F ~ 1% efficiency change)
© 2009 Tech Resources, Inc.
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Heating Systems
 Proper Boiler Air:Fuel Ratio
Combustion Efficiency of Natural Gas
Excess %
Temp. ° F (Flue-Comb.)
Air
Oxy
200°F
600° F
9.5
2.0
85.4%
76.0%
28.1
4.0
84.7%
74.0%
81.6
6.0
82.8%
68.2%
• Efficiency improvements
82.8%  85.4% = 2.6%
 68.2%  76.0% = 7.8%

© 2009 Tech Resources, Inc.
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Heating Systems
 Upgrade to Modern Burners
•
•
•
•
•
•
•
•
•
•
Motor-controlled flue gas recirculation dampers
Swirl vanes
Turbulence enhancement
Premixing chambers
Leak-tight modulating air dampers
Tangential diluent injection
Rotating concentric blade air registers
Fuel atomizers
Venturi tube air registers
Tapered burner tiles with baffles
© 2009 Tech Resources, Inc.
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Heating Systems
 Use Electronic Burner Controls (typical savings)
• Linkless burners have no backlash (1%)
• Increased turndown (5%)

Burner on/off cycles and their associated cold air purges also
will be reduced
• A second PID control (10%)

Some electronic fuel:air ratio controls have two internal
proportional–integral–derivative (PID) modulation circuits.
 If a plant does not run continuously then this second PID
control’s setpoint can be used to switch the boiler to a lower
steam pressure or hot water temperature during periods of
reduced activity.
• Adaptive oxygen trim (2% to 3%)

Large boilers only (>$100,000 fuel per year)
© 2009 Tech Resources, Inc.
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Heating Systems
 Use Electronic Burner Controls (cont’d)
• Fan speed control

With mechanical cam control and with basic electronic fuel:air
ratio controls, processors sacrifice combustion efficiency at
low fire to achieve an improvement in burner turn-down.
 By adding fan speed control, burner turn-down can be
increased without compromising efficiency, and additional fuel
savings can be achieved.
• Boiler sequencing (lead/lag) control and
communication software

Boiler sequencing control enables the plant operator to achieve
better utilization and additional energy savings are possible.
© 2009 Tech Resources, Inc.
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Heating Systems
 Fix Broken Steam Traps
• One 1/8" diameter stuck-open steam trap
orifice on a large boiler can cost $1,000 (15
psig) to $5,000 (140 psig) per year in increased
natural gas consumption
• 1 lb/hr ~ 1,000 Btu/hr
 There are Several Ways to Test Steam Traps
• Plugged traps are cool while operating and leaking traps are
hot. Use a non-contact, infrared thermometer.
• In acoustic testing, an inspector listens for the variances in the
acoustic patterns of working or failed traps.
• The electronic procedure typically involves touching the trap
on the downstream side with the instrument’s contact probe
and adjusting the sensitivity to better hear the flow.
© 2009 Tech Resources, Inc.
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Heating Systems
 Stack Heat Recovery
• Each 40°F reduction in stack
temperature results in a 1%
improvement in efficiency.

Preheating combustion air
 A 200°F air preheat saves 5%
• Best applications >900°F stack temperature

1,000°F  800°F results in 5% savings
• Recuperators, regenerators, and heat exchangers
 Infrared Booster Heaters
• Reduces curing times of coatings by 25% to 40%
• Best in conjunction with convection and for
thin simple shapes
© 2009 Tech Resources, Inc.
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Heating Systems
 Absorption Chillers
• Fueled by waste heat but high
capital costs
• Best for high peak demand
charges, CFC or HCFC
environmental concerns, waste
heat temperature >270°F and
>500 tons capacity
• Yazaki Energy Systems (Plano, TX) and Thermax
(Piscataway, NJ) claim to have low temperature (185°F
to 203°F) absorption chillers (20 to 30 ton max
capacity)
© 2009 Tech Resources, Inc.
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Heating Systems
 Industrial Heat Pumps
Process
Key Enabler
Applications
Separation
Reduced column pressure enables distillation
at low temperatures
Propane/propylene,
butane/butylenes
Concentration
Low (<50°F) temperature lift results in gentle
evaporation cycle
Beer, sugar solutions, milk and
whey, juice, steep water, syrup
and radioactive waste.
Drying
Upper temperature limit; Slow dry time desired;
Continuous operation
Lumber and paper
Dehumidification
High temperature air used for drying; Slow dry
time desired
Brick, ceramics
Space Heating
Higher thermal efficiency than other furnaces
Shop, warehouse
© 2009 Tech Resources, Inc.
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Heating Systems
 Radio Frequency/Microwave
Process
Key Enabler
Applications
Pre-drying
Selective heating (water only) to avoid product
damage; Speed
Fiberglass packaging and mats;
Dyed yarn spools; Ceramic
fiberboard, powder, and extrusions
Post-drying
(20%->8%)
Low final moisture content; Uniform (small
temperature gradient) heating; No surface
crust
Foods such as cookies, potato
chips, and pasta; Dry pet foods;
Polyurethane foam
Tempering
Volumetric heating; Speed
Frozen meats; Room temperature
bacon; Chocolate
Cooking
Reduce drip loss (water, fat, nutrients, and
flavor)
Sausage, bacon
Curing
Uniform heating; Precise temperature control;
Speed
Adhesives for wood and laminates
© 2009 Tech Resources, Inc.
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Heating Systems
 Induction
Process
Key Enabler
Applications
Metallurgical processing
(Hardening, Tempering,
Annealing)
Selective heating; Speed;
In-line continuous process
Gear teeth; Cutting blades;
Pulleys; Axles; Camshafts;
Galvanized sheet
Preheating prior to deformation
(Forging; Swaging; Upsetting;
Bending; and Piercing)
Reduced scale formation;
Speed
Turbine engine blades; Billets; Mill
rolling of slabs and strips
Melting
Speed; Flexibility
Steel; Iron; Copper alloys;
Aluminum; Zinc
Brazing and Soldering
Localized heating; Precise
temperature control and
uniformity
Dissimilar materials; Carbide tips;
Turbine blades; Eyeglass frames
© 2009 Tech Resources, Inc.
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Motors and Transformers
Implementation
Load
(kWh)
Replace motors

Use variable speed drives

Right size the motor

Disconnect unused transformers

© 2009 Tech Resources, Inc.
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Peak
(kW)


Motors
 Repair or Replace Motors
• Replace motors <40 HP
• Replace if cost of rewind >65% of new motor
• Replace motors last rewound before 1980
 Variable Speed Drives/Adjustable Speed Drives
• Best for variable torque loads often found in variable flow
•
•
•
applications (pumps, fans, and blowers) and greater than
2,000 hours operation
Horsepower varies as the cube of speed/flow
Cut speed/flow by 50%, you cut energy consumption by
nearly 90%! (0.5 x 0.5 x 0.5 = 0.125)
Converts 60 Hz to 120 to 400 Hz in pulse width modulation

Pulse-width modulation most common
 Current-source inverter used for 100+ HP motors
© 2009 Tech Resources, Inc.
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Motors
 Right Size the Motor

• Motor efficiency plummets at <40% rated load
Premium Efficiency Motors
• Good motor efficiency varies
from about 85%
( 1 HP) to 95% (>75 HP)
• NEMA Premium Efficiency
motors are 1% to 3% basis
points more efficient than
baseline (EPACT 1992)
© 2009 Tech Resources, Inc.
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Transformers
 Transformer Losses
• Remove power from unused transformers
 No load losses (NL)

Caused by the magnetizing current
to energize the core

Do not vary according to the loading
on the transformer

<0.5% of rating (for example,
roughly 125 watts on a 50 kVA
transformer)
 Full load losses (FL)

Heat losses, or I²R losses, in the
winding materials

Roughly 5x NL losses (600 watts on a 50 kVA transformer)
• High-Efficiency Transformer

Paying a little more upfront ($400 to $4,000) leads to long term
savings (>$20,000 for a 1500 kVA transformer)
© 2009 Tech Resources, Inc.
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Compressed Air
Implementation
Load
(kWh)
Only use when there is no other option

Fix leaks

Right size

Use variable speed compressor motor drives

Peak
(kW)

Implement heat recovery
Use two-stage, lubricated or centrifugal
© 2009 Tech Resources, Inc.
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

Compressed Air
 Compressed Air energy cost for 6,000 hrs
at $0.10/kWh = $125/CFM
• At 4 CFM/HP, a 250 HP compressor costs about $125,000 annually
 Only use compressed air when it is absolutely
necessary!
• If possible, switch to motors, mechanical actuators, and other means
to accomplish the same function
 Leaks often account for 20% to 30% of compressor
output
• A 1/32" leak in a 90 psi compressed air system would cost
approximately $185 annually
© 2009 Tech Resources, Inc.
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Compressed Air
 Compressors operate at highest efficiency at full load
or off
• Optimum controls results in big savings
• For example, at 50% full-load flow, kW input varies from 51% to 83%.
Percent kW Input at Operating Capacity
for Lubricant-Injected Rotary Screw
% FullLoad Flow
Load/No-load
(5 gal/cfm)
Modulation
Variable
Displace
Variable
Speed
90%
95%
97%
92%
91%
80%
92%
95%
83%
81%
70%
85%
90%
78%
71%
60%
78%
85%
68%
61%
50%
72%
83%
63%
51%
40%
63%
80%
60%
42%
Source: Improving Compressed Air System Performance: A Sourcebook for Industry, DOE
© 2009 Tech Resources, Inc.
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Compressed Air
 Variable speed is best applied to compressors that
operate primarily as trim units, or as single units with
loads below 75% to 80% demand
• Below 85% loading, variable displacement units
become less efficient than variable speed, and are
very poor at loads below 50%
 Reducing system pressure by 10 psi saves 8% to 10%
 Use ¾" diameter hose for >3 HP tools or >50' lengths
© 2009 Tech Resources, Inc.
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Compressed Air
 Heat Recovery
• Air-cooled compressors offer recovery efficiencies of
80% to 90%

Ambient atmospheric air is heated by passing it across the
system’s aftercooler and lubricant cooler.
 As a rule, approximately 50,000 British thermal units per hour
(Btuh) of energy is available for each 100 cfm of capacity (at
full-load).
 Air temperatures of 30°F to 40°F above the cooling air inlet
temperature can be obtained.
 Space heating or water heating.
• Water-cooled compressors offer recovery efficiencies of
50% to 60% for space heating only.

Limited to 130°F
© 2009 Tech Resources, Inc.
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Compressed Air
 Reciprocating air cooled compressor has lowest first cost, but is
inefficient
 Spend a little more for a two-stage unit and achieve better efficiency
 Lubricated compressors are often more efficient than a similar nonlubricated unit, but they contribute oil content to the system and may
impact the compressor air quality
Air Compressor Efficiency Benchmarks
Reciprocal
Rotary Screw
Centrifugal
Air
cooled
Water
cooled
Water
cooled
Lubricated
Lubricated
Nonlube
Units
SingleStage
SingleStage
TwoStage
SingleStage
Two-Stage
TwoStage
BHP per 100
CFM
26-32
25
19-22
23-26
20-22
20-26
22-27
kW per 100
CFM
22-27
21
16-18
19-22
17-18
17-22
18-22
© 2009 Tech Resources, Inc.
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<250 HP
Questline
 Go to www.questline.com
 Provided by:
Tech Resources
2025 Riverside Drive
Columbus, OH 43221
800-824-0488
mcarter@questline.com

This document was specifically prepared to aid Tech Resources’ clients that wish to inform their customers about available
energy efficient options that these customers may wish to consider. Any other use of this material (in whole or in part) is not
allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.
© 2009 Tech Resources, Inc.
49
What’s Next?
If you would like more information about the four strategies to increase cash flow,
contact your local Manufacturing Extension Partner.
Arizona Manufacturing Extension Partnership
California Manufacturing Technology Consulting
Maryland Technology Extension Service
Montana Manufacturing Extension Center
The Oklahoma Manufacturing Alliance
Rhode Island Manufacturing Extension Services
South Carolina Manufacturing Extension Partnership
Texas Manufacturing Assistance Center
University of Tennessee Center for Industrial Services
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Extension Partnerships and their
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© 2009 Tech Resources, Inc.
West Virginia Manufacturing Extension Partnership
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