Energy Efficiency and Conservation in Metal Industries

Description

This book provides a deep insight into the energy usage in the energy intensive metal industry and the methodology for efficiency assessment. Various methodologies for energy audits are described, along with concept-level analysis for minimum energy design. Apart from the technical and engineering analysis, the book also describes management aspects such as energy management systems and financial, environmental and social analysis leading to the development of a comprehensive plan for implementation of energy efficiency and conservation in industries. Barriers to investment in energy efficiency and conservation are discussed, based on review of global and Indian case studies. FEATURES: Details fundamental principles driving energy consumption in an industrial set-up backed with illustrative examples Explains various alternative methods for discovery of energy efficiency and conservation projects. Focusses on metal-producing and -processing facilities with an emphasis on environmental quality Supports maximum digitalization of energy audit assessment and report preparation processes Includes global case studies and tutorials at the end of the corresponding chapters This book is useful for researchers, professionals and graduate students in thermodynamics, manufacturing, thermal engineering, energy engineering, energy efficiency and energy processes, especially in the metal industry. Cover Half Title Title Copyright Dedication Contents Preface Acknowledgments Authors Chapter 1 Energy Efficiency and Conservation 1.1 Historical Perspective 1.2 Metal Industries: Local and Global Perspectives 1.3 Energy Conservation Global Imperatives 1.4 Energy Efficiency and Conservation: Future Trends and Scope 1.5 Energy Efficiency and Conservation Activities: Metal Industries 1.5.1 Energy Efficiency, Conservation and Processes of Steel Plants from an Indian Perspective 1.5.2 Discussion and Analysis 1.6 Conclusion References Websites Chapter 2 EE&C Policy Considerations 2.1 Energy, Environment, Economy and Society 2.1.1 United We Progress, Divided We Regress 2.1.2 Social Evolution with Energy, Environment and Economy 2.2 EE&C and Sustainable Development 2.2.1 Energy Trilemma 2.2.2 Challenges before Metal Industries 2.2.3 Overcoming Challenges before Metal Industries 2.3 International Agreements and Protocols 2.3.1 Local to Global and Global to Local 2.3.2 Objectives and Purposes of Selected Agreements and Protocols 2.3.3 Countries’ Preparedness 2.4 National Policy Drivers 2.4.1 Think Globally and Act Locally 2.4.2 Some Points to Ponder While Considering a Regulatory Framework 2.4.2.1 Subsidy vs. Directives 2.4.2.2 Protection vs. Competition 2.4.2.3 Negotiations vs. Restrictions 2.4.2.4 Green Primary Metal Production vs. Recycling 2.4.2.5 Total vs. Per Capita 2.5 EE&C Policy Considerations: Tips on the Top 2.5.1 EE&C Policy Needs to be Technology Savvy 2.5.2 EE&C Policy Needs to be Pragmatic 2.5.3 EE&C Policy Needs to be Coherent 2.5.4 EE&C Policy Needs to be Short­/Medium­/ Long­Term 2.5.5 EE&C Policy Needs to be Evolving Yet Binding 2.5.6 Suggestive Flow Chart for Preparation of an Effective Policy for EE&C in Metal Industries 2.6 Concluding Remarks on EE&C Policy References Websites Chapter 3 Energy Efficiency and Conservation Technologies 3.1 Introduction 3.2 Thermodynamics and EE 3.3 Going Beyond Thermodynamic Efficiency 3.4 Motor Systems 3.4.1 Existing Motors 3.4.2 Motor Alignment 3.4.3 Sizing of Motors 3.4.4 Use the Most Efficient Motor 3.4.5 Maintenance Issues 3.4.6 Variable­Speed Drives 3.4.7 Motor Characteristics 3.4.8 Power Factor 3.4.9 Motor Efficiency and Field Test for Determining Efficiency 3.4.10 No Load Test 3.5 Electric Furnace Systems 3.5.1 Dust Vacuum Equipment 3.5.2 Continuous Foundry Equipment 3.5.3 Heating Furnace 3.6 Furnace Systems 3.7 EE&C in (Chemical) Unit Operations 3.7.1 EE&C in (Chemical) Unit Operations in I&S Industries 3.7.1.1 EE&C in (Chemical) Unit Operations in I&S Industries: Blast Furnace 3.7.1.2 EE&C in (Chemical) Unit Operations in I&S Industries: Sponge Iron Plant 3.7.1.3 EE&C in (Chemical) Unit Operations in I&S Industries: Hot Strip Mill (HSM) 3.7.2 EE&C in (Chemical) Unit Operations in the Aluminum Industry 3.7.3 EE&C in (Chemical) Unit Operations in the Aluminum Industry: Captive Renewable Power Plants 3.7.4 EE&C in (Chemical) Unit Operations in the Copper Industry 3.8 EE&C in WHR, CHP and Other Utilities 3.9 Conclusion References Websites Chapter 4 Metal Manufacturing Processes and Energy Systems 4.1 Generic Characteristics of Metals and Metal Industries 4.2 Ferrous and Non­Ferrous Metallurgy 4.2.1 Types of Metals 4.2.1.1 Types of Metals: Ferrous 4.2.1.2 Types of Metals: Aluminum 4.2.1.3 Types of Metals: Silver 4.2.1.4 Types of Metals: Copper 4.2.2 Common Applications of Metals 4.2.2.1 Common Applications of Iron and Steel: Cast Iron 4.2.2.2 Common Applications of Aluminum 4.2.2.3 Common Applications of Silver 4.2.2.4 Common Applications of Copper 4.3 Energy Systems in Metal Industries 4.3.1 Generic Use of Energy 4.3.2 Process Energy Systems 4.4 Smelting and Refining 4.4.1 Ferrous Metal Industries 4.4.1.1 Iron and Steel: Integrated Steel Plant 4.4.1.2 Mini Steel Plant 4.4.2 Non­Ferrous Metal Industries 4.4.2.1 Aluminum Manufacturing Process Energy System 4.4.2.2 Silver Manufacturing Process Energy System 4.4.2.3 Copper Manufacturing Process Energy System 4.5 Energy and Mass Balance 4.5.1 Digitization of the Steel Making Process and Incorporation of the Circular Economy for Energy Efficiency 4.5.2 Energy Requirements in Aluminum Production 4.5.3 Energy Requirements in Copper Production 4.6 Conclusions with Some Energy­Saving Potential in Metal Industries 4.6.1 Energy Consumption Patterns in a Forging Industry 4.6.2 Energy Conservation Measures in a Forging Industry 4.6.3 Three Types of Energy­Saving Potential in Metal Industries References Websites Chapter 5 Energy Audits in Metal Industries 5.1 Introduction 5.2 Energy Audits in Metal Industries 5.3 Preliminary Energy Audits 5.4 Investment Grade Energy Audits (IGEA), a.k.a. Detail Energy Audits 5.5 Virtual Energy Audits 5.6 Process Synthesis­Minimum Energy Approach 5.7 Tools for Energy Audits 5.8 Instrumentation 5.9 Software Applications 5.10 Energy Audits in Ferrous and Non­Ferrous Industries 5.11 Performance Achievements and Trade (PAT) Cycles of India Iron and Steel Projections and Achievements until 2030 5.12 Energy­Saving Potential in Indian Metal Industries 5.12.1 Short­Term Energy­Saving Proposals 5.12.2 Medium­Term Energy­Saving Proposals 5.12.3 Long­Term Energy­Saving Proposals 5.13 Case Studies for Classified Metal Industries 5.14 Conclusion References Chapter 6 Implementation of Energy Efficiency and Conservation Projects 6.1 Introduction 6.2 Energy Service Companies in Metallurgical Industries 6.3 Objective of ESCOs 6.3.1 Energy Performance Contracts (EPCs) 6.3.2 Energy Saving 6.3.3 Technical Support 6.3.4 Monitoring and Maintenance 6.4 Progress of the ESCO Industry in India 6.4.1 Energy Conservation by Energy Source in India 6.4.2 Start of Financing to Energy Efficiency Projects by Financial Institutions 6.4.3 Start of ESCO Projects 6.5 ESCO Projects in Developed and Developing Countries 6.6 Actions of the Industrial Sector to ESCO Business 6.6.1 Financial Models through Which ESCOs Operate 6.6.2 Guaranteed Savings Model 6.6.3 Shared Savings Model 6.7 Risk Analysis 6.7.1 Technical Risk 6.7.1.1 Engineering Design 6.7.1.2 Implementation 6.7.1.3 Operation and Maintenance (O&M) 6.7.2 Commercial Risk 6.7.2.1 Procurement 6.7.2.2 Counterparty Risk 6.7.3 Financial Risk 6.7.3.1 Expected Return 6.7.3.2 Financing Structure 6.7.4 Risk Perception and Mitigation 6.8 Barriers to Implementing ESCOs in Promoting Energy Efficiency 6.8.1 Institutional Barriers 6.8.2 Financial and Economic Barriers 6.8.3 Knowledge and Information Barriers 6.9 Conclusion References Websites Chapter 7 Energy Management and Monitoring Systems 7.1 Introduction 7.2 Objectives of Energy Management and Monitoring Systems 7.3 Benchmarking and Energy Performance 7.3.1 Plant Energy Performance 7.3.2 Production Factor 7.3.3 Reference Year Equivalent Energy Use 7.3.4 Optimizing the Input Energy Requirements 7.3.5 Fuel and Energy Substitution 7.4 Key Elements of Monitoring and Targeting Systems 7.4.1 Principles for Monitoring, Targeting and Reporting 7.5 Energy Analytics with Application of AI and IoT 7.5.1 Plant Level 7.5.2 Plant Departmental Level 7.5.3 System Objective Level 7.5.4 Equipment Level 7.6 Energy Management Information Systems and ISO 50001 7.7 Application of AI in Metal Industries and Its Improvement 7.7.1 Industrial Applications in the Metal Industries of Fuzzy Logic and Neural Networks 7.7.1.1 Galvanizing and Coating Lines 7.7.1.2 Coke­Oven Batteries 7.7.1.3 Cold Rolling 7.7.1.4 Refining and Continuous Casting of Steel 7.8 Conclusion References Websites Chapter 8 Sustainability in Metal Industries 8.1 Introduction 8.2 Regional Perspectives Analysis: Comparison to Global and Regional (e.g. ASEAN) Best Practices 8.3 Lessons from COVID­19 8.3.1 Takeaways from COVID­19 Lessons 8.4 Economic, Environmental and Social Sustainability 8.4.1 Advances in Sustainability and ESG Reporting of Metal Industries 8.5 Circular Economy 8.6 Extended Producer Responsibility 8.7 Development Pathway 8.8 Conclusion References Index