Energy Management and Efficiency for the Process Industries

Alan P. Rossiter is President of Rossiter & Associates, a process improvement consulting company specializing in industrial energy efficiency. Clients include ExxonMobil, Natural Resources Canada, Syncrude Canada, ConocoPhillips, Sasol, LyondellBasell,Valero, and Hess. He has more than 30 years of process engineering and management experience and more than 60 publications including three books. He has a PhD in chemical engineering from the University of Cambridge, is a chartered engineer (UK) and a registered professional engineer (Texas), and was the 2010 Chair of the South Texas Section of the AIChE. Beth P. Jones was for several years the worldwide energy manager for LyondellBasell Industries, after positions in process engineering management and optimization. She retired in 2013 to enjoy new expat adventures and then an invitation to work on this book, her first, with Alan. She has a BS in Chemical Engineering from Oklahoma State University and is a Certified Energy Manager.

Foreword ix
by The Honorable Charles D. McConnell

Preface xi

Acknowledgments xv

Contributors xvii

Units of Measure xix

Section 1 Energy Management Programs 1

1 Energy Management in Practice 3
Beth P. Jones

2 The Dow chemical Company: Energy Management Case Study 25
Joe A. Almaguer

3 Eastman Chemical’s Energy Management Program: When Good is Not Enough 37
Sharon L. Nolen

4 General Mills’ Energy Management Success Story 48
Graham Thorsteinson

5 Energy Benchmarking 56
Mark Eggleston

6 Energy Management Standards 66
Kathey Ferland, Paul E. Scheihing, and Graziella F. Siciliano

7 Protecting The Environment and Influencing Energy Performance Within Process Industries 81
Elizabeth Dutrow

Section 2 Energy Management Technologies 93

8 The Technologies of Industrial Energy Efficiency 95
Alan P. Rossiter

Equipment 105

9 Energy Efficiency in Furnaces and Boilers 107
Bala S. Devakottai

10 Enhanced Heat Transfer and Energy Efficiency 128
Thomas Lestina

11 Heat Exchanger Cleaning Methods 139
Joe L. Davis

12 Monitoring of Heat Exchanger Fouling and Cleaning Analysis 143
Bruce L. Pretty and Celestina (Tina) Akinradewo

13 Successful Implementation of a Sustainable Steam Trap Management Program 164
Jonathan P. Walter and James R. Risko

14 Managing Steam Leaks 179
Alan P. Rossiter

15 Rotating Equipment: Centrifugal Pumps and Fans 186
Glenn T. Cunningham

16 Industrial Insulation 207
Mike Carlson

Utility Systems 217

17 Heat, Power, and The Price of Steam 219
Alan P. Rossiter and Joe L. Davis

18 Balancing Steam Headers and Managing Steam/Power System Operations 230
Alan P. Rossiter and Ven V. Venkatesan

19 Real-Time Optimization of Steam and Power Systems 242
R. Tyler Reitmeier

20 Fuel Gas Management and Energy Efficiency in Oil Refineries 251
Joe L. Davis

21 Refrigeration, Chillers, and Cooling water 260
William (Bill) Turpish

22 Compressed Air System Efficiency 277
Joe Ghislain

23 Lighting Systems 290
Bruce Bremer

24 Heating, Ventilation, and Air-Conditioning Systems 300
Bruce Bremer

Process 311

25 Identifying Process Improvements For Energy Efficiency 313
Alan P. Rossiter and Joe L. Davis

26 Pinch Analysis and Process Heat Integration 326
Alan P. Rossiter

27 Energy Management Key Performance Indicators (EnPIs) and Energy Dashboards 349
Jon S. Towslee

Index 361