Five Ways to Improve Energy Efficiency

The five ways in which improved energy efficiency can be achieved within plant processes are highlighted below and will be discussed in detail in this book  

In reality, steam generated in the boiler house is distributed through an extensive network of steam pipelines to end users. The losses in steam distribution can be 10-20% of fuel fired in boilers. Hence, the net boiler efficiency could be 10-20% lower from the user s point of view. 

The operation performance gaps are mainly caused by operation variability. Two kinds of operation variability are common in the industry. The hrst is the so-called operation inconsistency, which is mainly caused by different operation policy and practices applied due to different experience from operators. The second operation inefficiency refers to the kind of operation that is consistent but nonoptimal. This occurs when there are no tools available to indicate to the shift operators the optimal method to run the process and equipment when conditions of feeds and product yields vary. 

Once operational gaps are identified, assessment methods (Chapters 5-8 for energy operation. Chapters 12 and 13 for process operation, and Chapter 16 for utility system operation) are then applied to identify root causes— potential causes include inefficient process operation, insufficient maintenance, inadequate operating practices, procedures, and control, inefficient energy system design, and outdated technology. Assessment results are translated into specific corrective actions to achieve targets via either manual adjustments, the best practices, or by automatic control systems. Finally, the results are tracked to measure the improvements and benefits achieved. 

Once specific process units have been identified for improved heat integration, pinch technology can be applied to efficiently screen potential modification options, which is explained in Chapter 9. Practical assessment (Chapter 10) is required, which considers not only the value and cost of improved heat recovery but also the impact in terms of operating flexibility, especially with respect to start-up, shutdown, maintenance, control, and safety. 

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