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SYNOPSIS
Energy Management and Process Heating is used by all major industries to heat materials in manufacturing of items used by consumers and industries. It is one of the most important areas of energy use and it offers attractive and cost effective methods of energy savings and green house gas emission reduction for all industrial sectors. Process heating systems include all commonly used heating equipment such as heaters, furnaces, ovens, boilers, dryers, melters etc. For a typical industrial plant energy used for process heating represents a large percentage of the total energy used in the plant – sometime as high as 70% of the total plant energy use.
Process heating involves raising temperature of solids, liquids or gases in fired or unfired heating equipment. The heating processes are used to soften, melt, evaporate the materials, and may promote chemical reactions, molecular rearrangements, breakdown of molecules etc. for the materials being heated. The materials processed include metals such as steel and aluminium, and non-metals such as glass, cement, rubber, plastic, petroleum products and ceramics. Heat required in process heating equipment is obtained from fuels such as natural gas, fuel oil, coal etc., electricity, steam or other energy sources.
This workshop is designed to offer insights into process heating, basics of heat generation through combustion of commonly used fuels, performing a heat balance for a heating system, description of burners and their application, and overview of electrical heating systems and steam or fluid heating systems with associated controls. Additional topics include heat transfer and its optimization in process heating systems, reduction of combustion generated emissions, and controls to maximize energy efficiency. The workshop schedule includes discussion and examples of practical and cost effective measures of improving energy efficiency for all areas of energy use or losses for a heating system.
The course introduces attendees to PHAST, the Process Heating Assessment and Survey Tool developed for the US Department of Energy (DOE), available at no cost to users. The attendees are guided through the tool and its hands-on use to analyze and improve the performance of existing systems.
WHAT YOU WILL LEARN
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Role of process heating in industrial plants
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Energy foot-print for industrial plants
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Description of energy systems and their role in efficiency improvement
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Process heating systems characteristics and components
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Areas of energy saving opportunities for process heating systems
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Process heating systems used in the industries
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Fuels, electricity and steam
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Efficient combustion
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Concept of available heat and efficiency
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Heat balance for process heating equipment
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Burner types and efficient operation
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Burner and combustion controls application
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Heat transfer in furnaces, heater, boilers, ovens etc.
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Fluid dynamics and pressure controls
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Environmental issues associated with combustion system
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Electrical and Steam heating systems
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Types of systems and their use in industries
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Pros and cons of electrical and steam systems vs. fuel fired systems
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Instruction to PHAST (Process Heating Assessment and Survey Tool)
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Important features of PHAST
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Areas of energy savings
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Identification of areas of potential energy savings
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Energy reduction measures for different areas of a system
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Energy savings analysis and estimated savings
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Economics – cost and payback estimates
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Waste heat management
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Waste heat sources and their characteristics
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Methods of waste heat recycling and recovery
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Waste heat recovery systems and selection criteria
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Electrical power generation using waste heat
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Data collection – measurements for use in PHAST
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Required data and data collection sheets
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Instruments and their use for data collection
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Introduction to standards and guidance document
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Energy assessment or audit procedure
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ASME EA-1 - 2009 Energy Assessment for Process Heating Systems
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ASME EA-1G - 2010 Guidance for EA – 1 Energy Assessment for Process Heating Systems
ABOUT THE EENP
The Energy Efficiency National Partnership (EENP) is a voluntary programme that seeks to help companies improve their energy efficiency by encouraging them to put in place energy efficiency programmes at the organisational level to reduce energy wastage and improve energy efficiency.
ACCREDITATION
Pending accreditation with the Professional Engineers Board's for Continuing Professional Development Programme for Engineers in Singapore.
ABOUT THE SPEAKER
Dr. Arvind Thekdi has over 40 years of experience in research, development, design of industrial process heating equipment and waste heat recovery systems for all major industries. He has developed and delivered training programs in the area of process heating, and has offered them for the US Department of Energy, utility companies and private industries in many countries. Dr. Thekdi has also developed several software tools such as Process Heating Assessment and Survey Tool (PHAST), NOx Emission Reduction Tool, Combined Heat and Power (CHP) Application tool for the US and other countries. These tools are used to increase efficient use of energy in process heating applications while reducing Green House Gas (GHG) emissions. He has trained over 100 experts who provide energy assessment services for process heating systems in various US industries. Dr. Thekdi has personally conducted energy assessments at more than 50 plants world-wide. During the last 10 years he has been very active in energy efficiency and Green House Gas (NOx, CO2 etc.) emission reduction activities in USA, Canada, China, India, Egypt and South American countries. He has served as a co-chair and has been responsible for preparing draft of the energy assessment standards developed under the American society of Mechanical Engineers (ASME) and ANSI. While working for three furnace companies during his career, he has worked on a number of R&D programs related to development and commercialization of innovative heating furnaces, heat recovery systems and modeling of systems to reduce energy use, improve productivity and product quality. He has 15 US and foreign patents and contributed to several books and magazines, and published several papers on the subject.
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