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Energy Management for Pretreatment Operators: Getting Started

Learn how to evaluate and optimize energy consumption in pretreatment operations, including understanding bills, surveying equipment, energy savings strategies, common inefficiencies, and best practices. Attend upcoming workshops for practical insights.

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Energy Management for Pretreatment Operators: Getting Started

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  1. Energy Management for Pretreatment Operators

  2. Getting Started?

  3. Evaluate Your Consumption • Review energy bills • actual use, demand, power factors, surcharges, number of meters… • Map energy use & costs over time • monthly, weekly, daily…. • Look for trends • seasonal trends, diurnal cycles, special events, changes in production rates…..

  4. Understanding your Bills • Actual Use: actual power draw • Demand Charges: highest 15 minute draw, maximum transmission requirements • Power Factor (Reactive Power): energizing current for certain equipment • Fuel/Green Power Surcharge • Other miscellaneous trackers and charges

  5. Survey Equipment and Facilities • List equipment: motors, compressors, heated tanks, boilers, lights, spray guns, vents, chillers.. • Note characteristics: size, age, load, condition….. • Look at use: what time of day, how long, what process, well matched…. • Building: windows, HVAC, doors, insulation…. • Evaluate water use

  6. Survey WW Operations • Best TSS range for treatment • Minimum DO for best operations • Minimum velocity to achieve goal • Equipment (motors, pumps, tanks, VFDs) • Monitoring & recording • Regulatory requirements

  7. Energy Savings from Dissolved Oxygen Management

  8. Opportunities for Improvement • Reduced load through water conservation • Decrease operating hours/off peak usage • Wastewater treatment practices • Use gravity flow instead of pumps • Equipment size, type, condition

  9. Optimize Motors • High efficiency motors • Proper size (70-90% load) • Use variable frequency drives • Proper pulley drive alignment & non-slip belts • Decrease idle time • Replace rather than rewind

  10. See the System, Not just the Component

  11. Designed for different function • Partially closed discharge valve • Discharge bypass line that stays open • Multiple parallel pumps with the same number always running • Noise at the pump (or elsewhere in system) • Excessive maintenance costs Signs of Inefficiencies

  12. Boilers and Steam Systems • Insulate condensate return pipes & reservoir • Inspect & repair steam traps • Use exhaust heat to preheat make-up water or combustion air • Proper maintenance • Fire/water tubes cleaned? • Fuel air ratio properly adjusted?

  13. Steam Wasted from Leaking Traps @ 100psi, 80% boiler efficiencySource: Energy Management Handbook-Fifth Edition

  14. Compressed Air Systems • Monitor and repair leaks • Evaluate how & where it is used • Deliver only where needed • Store in accumulator tanks • Run only during production hours • Use the lowest operating pressure possible • Fresh air intake • Harvest waste heat and use elsewhere • Minimize air loss during condensate release

  15. Example: Energy Loss from Leaks • 8,760 hours of operation • 10 leaks, 1/16” • 90 psi • Energy loss= 36,646 kWh/yr • Cost ($0.06/kWh) = $2,200/yr

  16. Lighting Systems • Use energy efficient lamps, ballasts and fixtures • Install fixtures at the proper height • Use task lighting • Use the proper light levels • Use occupancy sensors

  17. Example: Savings from Motion Sensor (33% savings) • 25 fixtures, F96, T12, 60W • 8,760 hrs = 30,222 kWh/yr • Energy cost = $0.06/kWh • Lighting cost = $1,813/yr • 2,920 hrs = 10,074 kWh/yr • Savings = $604/yr

  18. Ventilation & Dust Collection • Vent to outside air only as needed • Minimize the volume of air vented • Use fans only during production • Filter and return ventilation air during heating season • Preheat return air in an air-exchanger • Use variable speed drive

  19. Chillers & Cooling Towers • Use variable speed drive controls on fans and pumps • Use energy efficient fan and pump motors • Consider raising the chiller water temperature • Harvest heat for use elsewhere

  20. Best Practices Workshops • Motors • Fans • Pumps • Compressors • Lighting • Steam • Process Heating • HVAC • Sustainability • http://www.mep.purdue.edu/events/default.aspx#ees

  21. Upcoming Events • Fan Workshop • June 11, 201008:00AM-04:00PM Vincennes Univ. 850 College Ave. JASPER, IN 47546 • Steam System • June 22, 201008:00AM-04:00PM Vincennes Univ. JASPER, IN 47546 • June 23, 201008:00AM-04:00PM 6640 Intech Blvd. • Indpls, IN 46268

  22. Guidebook for Public Utilities • Intended for Water and Waste Water Utilities • Energy Management documentation • Project identification and prioritization • Developing a systematic approach http://www.epa.gov/region1/eco/energy/pdfs/guidebook_si_energymanagement.pdf

  23. Questions, Comments, Need Help? Ethan Rogers Manager EES 317-275-6817 earogers@purdue.edu

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