Energy Efficiency Solutions Series
Introduction
Despite making up almost one-fifth of global energy consumption, industrial heat processes are often overlooked in the effort to reduce costs and emissions. Fortunately, by modernizing your industrial heating and steam systems with energy-efficient solutions, you can optimize the performance of your equipment while substantially reducing energy costs and emissions.
With efficient energy solutions for your industrial heat processes, you can save on operational costs and improve sustainability efforts at the same time. Not only will you be using cleaner energy sources, but also benefit from increased safety, reliability, productivity and lower maintenance fees all year round!
EFFICIENCY SOLUTIONS FOR INDUSTRIAL HEAT APPLICATIONS
There are a number of ways process heating, steam and thermal energy systems can be made more efficient UNIDO’s training and industrial heat capacity building programmers are divided into three broad areas:?
Process heat optimization
While thermal energy may be created and concentrated in a boiler, or a furnace, it’s critical to remember that industrial heat processes are part of a broader system. In some cases an industrial plant may involve various industrial heat systems, some require steam and others may be powered by gas for example. To achieve the best results in terms of energy efficiency, industry managers must consider the whole heat process system rather than just the individual components. Understanding the current operations and energy needs as well as the management of the industrial heat system is the first step toward systemically optimizing an entire heat process. This means measuring and assessing how much energy is currently used in each stage of a particular process and in the system as a whole.?
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Opportunities for process heat optimization include:
Improving the efficiency of combustion (burners) and other heat generating equipment by controlling the air-fuel ratio and eliminating air leakages into directives furnaces. Regular maintenance of furnaces and heating systems to increase heat transfer from heat source to process load. Reducing heat losses through effective insulation of piping and related transfer equipment which helps to trap and conserve heat, as well as the implementation of systemized procedures for regular maintenance. Recover and reuse waste heat through various technologies and equipment. Where possible automate process measurements and controls. Identify and set appropriate operating temperatures to avoid overheating and waste heat. Avoid non-productive loads and idle periods where heat is being used.?
Steam systems optimization
Steam is widely used in the industrial sector for a multitude of processes which require heating, stripping, drying and cleaning among many other applications.
While steam is among the most efficient and cost-effective heating sources available, data from industry shows that average steam energy usage in industry could be as much as 35-40 per cent of the entire onsite energy consumption. Therefore, it is very important to optimize steam systems and minimize their operating?
There is a huge array of opportunities for efficiency in steam systems which can uncover dramatic financial savings. In addition to the process heat optimization opportunities mentioned in the previous section, steam system specific optimization opportunities include:?