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Process Heating Assessment and Survey Tool (PHAST)

Prepared By Dr. Arvind Thekdi, E3M, Inc. For Industrial Technologies program (ITP) Energy Efficiency and Renewable Energy (EERE) Office The U. S. Department of Energy. Process Heating Assessment and Survey Tool (PHAST). Use of PHAST. PHAST can be used to:

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Process Heating Assessment and Survey Tool (PHAST)

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  1. Prepared By Dr. Arvind Thekdi, E3M, Inc. For Industrial Technologies program (ITP) Energy Efficiency and Renewable Energy (EERE) Office The U. S. Department of Energy Process Heating Assessment and Survey Tool (PHAST)

  2. Use of PHAST PHAST can be used to: • Estimate annual energy use and energy cost for process heating equipment such as furnaces, ovens, heaters, kilns, boilers etc. in an industrial plant • Perform detail heat balance and energy use analysis that identifies areas of energy use and energy losses for a furnace or a boiler • Perform “what-if” analysis for possible energy reduction and efficiency improvements through changes in operation, maintenance and retrofits of components/systems

  3. PHAST 2.0 • PHAST 2.0 is designed for use with U.S. – English units and International units (MKS) of measurements. • It allows use of local country currency value for energy cost calculations. • PHAST 2.0 can be used with Microsoft Windows 2000/XP/Vista operating systems. • Some of the additional features include: • A heat balance report that includes “static” Sankey Diagram showing energy use in key components of the process heating system • A report that contains values of actual data used in PHAST • Energy cost values in local country currency as well as in US dollars. • Greater flexibility of use and user input capabilities

  4. PHAST – Access and Requirements Access and installation - PHAST version 2.0 • The tool can be installed by 1) using a setup CD or 2) downloaded from the U. S. Department of Energy web site. • See next slide for details . System Requirement: • A PC running Windows 2000 /Windows XP/ Windows Vista with latest service pack • At least 200MB free space in hard disk • A processor (preferably Pentium) 133 MHz or faster. • A monitor supporting resolution of at least 1024 x 768. • A mouse or compatible tracking device. • An optical drive. • Microsoft Office 2000 or higher with MS Access 2000 or higher • Acrobat PDF Reader

  5. PHAST – Where to Get It? Download it from http://www1.eere.energy.gov/industry/bestpractices/software.html The download package includes • Installation instructions • User manual • Useful calculators • Data collection forms • PHAST 2.0 program

  6. Caution for Users of PHAST Version 1 • Before running the setup of PHAST 2.0, the user MUST install the patch for PHAST 1.1.2, if PHAST 1.1.2 is installed on the machine where PHAST 2.0 is to be installed. • Note: you do not need to install the patch if PHAST 1.1.2 is not installed previously on the computer). • Instructions for installation of the patch for PHAST 1.1.2 (previous version of PHAST) are given on the download site for PHAST 2.0

  7. Gateway to PHAST

  8. Major Sections of PHAST

  9. Data Collection Forms Plant and Equipment Survey

  10. Data Collection Forms Heat Balance

  11. Technical Information Support

  12. Unit Converter

  13. CO2 Emission Factors

  14. Glossary – Process Heating Terms

  15. Calculators This section includes a number of calculators that allow analysis of following conditions. • Energy use with alternate energy supply (fuel firing vs. electric heating) • Effect of excess air and use of preheated air on energy savings • Effect of use of oxygen enriched air or oxy-fuel system on energy savings. • Flow calculations for orifice type flow meters in gas – air lines.

  16. Plant Equipment Information This section is used to survey process heating equipment used in a plant • Company and plant information • Details of type and unit cost of energy • Information for process heating equipment and their use pattern • Information for auxiliary equipment associated with each process heating equipment • Comments related to each equipment surveyed.

  17. Plant Equipment InformationReport This report is used to select high energy use equipment for detail assessment – heat balance and analysis of energy saving measures.

  18. Plant Equipment InformationReport The report gives following information – data: • Description of the plant and product, country and currency, and contact information for the assessment team leader. • Types of energy used (fuels, electricity and steam), their heating values and unit cost. • Estimate of annual energy use as fuel, electricity and steam for each process heating equipment surveyed. • Estimated annual cost of energy (heat and electricity) for the process heating equipment included in the survey. The cost is given in local currency and U.S. dollars. • A pie-chart showing relative energy cost for the heating devices and their percentage energy use • Documentation of comments or other information provided by the assessment team.

  19. Heat Balance Section • This section is used to enter data collected during the assessment. • Data is collected by using appropriate sources including site measurements • Data is collected and entered for the following categories of energy use-loss • Load – charge material (solid, liquid or gas) • Material handling - fixtures, conveyor etc. • Furnace atmosphere – if used. • Openings – fixed and variable such as door openings. • Water cooling, if used • Other heat losses from the system • Heat storage • Flue gas losses for fuel fired system and system losses for steam-electric heating

  20. Heat Balance ReportCurrent Operation

  21. Heat Balance ReportComparison – Current and Modified Operation

  22. Energy Supply and Use – Losses Fuel Fired System

  23. Energy Supply and Use – Losses Steam and Electric Heated Systems

  24. Report Selection Report Selection section allows access to the following reports • Plant Summary – Equipment energy use and cost report for equipment surveyed • Furnace analysis – heat balance for the equipment assessed. • Furnace summary – Energy supply and use or losses in the form of a “static” Sankey Diagram. • Input Data – complete record of data entered in all forms

  25. Report - Data Input

  26. Export – Import Data • This section is used to transfer data between users of PHAST program • All data entered for the use of PHAST can be saved as a .mdb file that can be transmitted to other users of PHAST electronically. • The receiver can import the file to PHAST provided the receiver uses the same version (PHAST 2.0) of PHAST. • A word of caution! • Some organizations do not allow receiving and sending .mdb file electronically. In such case it may be necessary to zip the file and transfer it as a zip file.

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