CORNING, HARRODSBURG ENERGY REDUCTION INITIATIVES
ENERGY SAVINGS HISTORY 2008 - Established Energy Management Team Year kwh(eq) $ ‘ 08 159, 000 7, 300 ‘ 09 3, 750, 000 178, 000 ‘ 10 8, 680, 000 442, 000 ‘ 11 7, 620, 000 404, 606 ‘ 12 4, 530, 000 223, 300
SOME ENERGY SAVING PROJECTS $ ITEM KWH REDUCTION -HEATED PULSE AIR 290, 000 FOR BAG HOUSE -N 2 COMP TURNDOWN 760, 000 -FREE COOLING 1, 380, 000 -LIGHTING RETROFIT 460, 000 -ALL TANKS SAME PA 1, 820, 000 -SHUT DOWN N 2 COMP 4, 050, 000 -ADJUST BOILER SETPTS 760, 000 -BATCH DUST FAN 240, 000 -HI-EFF CHILLER 610, 000 -HI-EFF DRYER 130, 000 41, 800 75, 900 25, 300 100, 100 222, 800 41, 800 13, 200 33, 600 7, 100 FUTURE -ENERGY RECOVERY 22, 600 @ $6/MCF 1, 135, 000 KWH(eq) 3, 763, 000 FT 3 NG 16, 000
ENERGY RECOVERY How much energy can we recover, how much will it cost, and how much will it save? Using waste energy to produce steam
TEST UNIT Fan outlet gate Fan Stea m E Heat Exchanger D C Water Outlet Isolation gate Inlet Isolation gate B Main duct slide gate Floor above melter A Melter
OBJECTIVES and KEY LEARNINGS OBJECTIVES – Prove that we can utilize energy in the melter exhaust without negative impact on melting - Determine the impact of scale - Establish relationship between gas flow rate and performance LEARNINGS - We can do this with no negative impact - Scale formation will be an issue - Performance appears to be related to flow rate - Getting all the energy to the HX is going to be a challenge
OBJECTIVES and KEY LEARNINGS OBJECTIVES – Prove that we can utilize energy in the melter exhaust without negative impact on melting - Determine the impact of scale - Establish relationship between gas flow rate and performance LEARNINGS - We can do this with no negative impact - Scale formation will be an issue - Performance is related to flow rate - Getting all the energy to the HX is going to be a challenge
How much steam do we need? Recently, during the coldest days, the York. Shipley and the 2 Claytons were operating at 50%, 38%, and 52% respectively. That’s 150, 133, and 182 bhp or a total of about 15 million BTU/hr. We should be able to reclaim be about 5 million BTU/hr. Replacing the plant’s 18 steam heaters (during cold weather, consume nearly 4, 500, 000 BTU/hr), would reduce peak demand to 10. 5 million BTU/hr. In the winter we would have to augment with the boilers. However, in an average year, we could leave the boilers shut down for about 8 ½ months.
HEAT RECOVERY SUMMARY Total available steam energy up to 132 bhp At 132 bhp the gas reduction would be 37, 600 MCF/yr. At $6. 00/MCF, savings would be $225, 000/yr Estimated cost- $85, 000/unit or $595, 000 for 7 units Simple Payback – 2. 6 yrs. Current gas price is near the historical low. The 2009 peak was over $15/MCF. At that price, savings = $564, 000/yr and simple payback = 1. 05 yrs or about 13 months.
Motors, Compressors and Fans NITROGEN Generator capacity of 55, 000 scfh was based on nitrogen consumption when it was ordered. Since then, numerous process improvements have led to significant reductions in consumption to less than 35, 000 scfh. So we were venting 17, 000 scfh to atmosphere. However, by turning the compressor down to the point where it becomes unstable and then back up to maintain an acceptable safety margin (about 40, 000 scfh), the compressor power dropped by 166 kw. (166 kw)(730 hrs/mo)($. o 6/kwh)=$7270/month or about $87, 000 per year. Cost to implement - “zero”
Motors, Compressors and Fans OXYGEN A similar compressor turn down on the oxygen generator yielded savings of about $94, 000 per year. Cost to implement – “zero” POLLUTION ABATEMENT We have two systems, each capable of carrying about ¾ of the total possible plant load. During periods of light load, we can use a x-connect to send all exhaust into either bag house. During extended “light load” conditions this saves over $9, 000/month or $110, 000/yr. Cost to install X-connect: $63, 000 Simple payback: 7 months
Corning’s Global Energy Management Group Corning Incorporated recoups ~70% of what it pays to NYSERDA (New York State Energy Reduction Development Agency) via grants for energy reduction projects. Corning dedicates significant amounts of time and resources to complete grant applications and monitor progress. Many companies lack the resources required to submit grant applications and execute major energy reduction projects but still must pay NYSERDA fees.
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