Join ITP in the Effort to Save Energy Now!
Take advantage of the unique opportunity to have your manufacturing facility evaluated by an energy efficiency expert! Applications for the first round of Energy Savings Assessments are now being accepted through December 20. As a primary goal of ITP's Save Energy Now initiative, ITP will conduct Energy Savings Assessments at 200 energy-intensive plants. At each plant assessed, an expert will identify immediate efficiency measures to help companies optimize steam and process heating systems, improve productivity, and save energy and costs.
Aluminum Operations Benefit from New Heater Design
Natural gas-fired reverberatory melting furnaces are the workhorses of the aluminum industry, generating high throughput, and low operating and maintenance costs. However, these radiant heat furnaces have poor thermal efficiency, high metal oxidation rates, are spatially intensive, and generate emissions. With ITP support, Apogee Technology, Inc. has developed the Isothermal Melting (ITM) technology, an innovative technology that uses high heat flux-direct immersion electric resistance heaters. Benefits include excellent metal quality, highly efficiency operations, reduced emissions, and significantly reduced plant floor space requirements. The first commercial-scale ITM at the Aleris International facility in Newport, OH, is demonstrating specific melt energy performance of 614 Btu/lb with under 0.5% melt loss in pilot scale operation. Energy cost savings of $261,000/year are predicted, with annual energy savings of 53.1 billion Btu for a 5,000lb/hr unit.
Predictive Process Design Capability Optimizes Steel Tubing Production
The Timken Company is applying research results from an ITP-sponsored project to enhance manufacturing processes and performance of seamless mechanical steel tubing, saving 0.8 billion Btu annually, and and nearly $1.5 million per year in operating costs. The Controlled Thermo-Mechanical Processing of Tubes and Pipes (CTMP) enables consistent products to be made with targeted structure and properties while minimizing time and energy inputs. Metallurgical, thermal, and deformation studies are integrated into a tube optimization model (TOM) to identify a target specification and produce recipes for steel microstructures. In addition, manufacturers can use the Virtual Pilot Plant, a PC-based optimization of the process, to create a variety of desired tube products. This system improves product quality, consistency, and productivity, while reducing scrap and rework, natural gas consumption, and emissions. It also enables manufacturers to conduct process studies without interrupting production. Read the full report (PDF 5.7 MB).
New Refractories for Black Liquor Gasification Complete One Year of Service
Black liquor gasification technology has the potential to convert energy-intensive pulp and paper mills from consumers into producers of energy. Gasification of black liquor is superior to conventional black liquor recovery treatment; it improves energy efficiency of the process; generates syngas, which can be converted to fuels, power, or chemicals; and emits fewer emissions and wastewater. However, the challenging environment of the gasifiers, with combined-cycle cogeneration of steam and electricity, requires improved materials, including the refractory liners of gasifier vessels. Now, ITP has partnered with industry to create corrosion resistant, spinel refractory materials that will better withstand the challenging environment of the gasifiers. New spinel refractory panels were installed at Weyerhaeuser Company's New Bern, NC, mill in October 2004, and after one year of continuous performance, showed excellent corrosion and spallation resistance, and did not require replacement. These improved materials can help accelerate the implementation of gasification technology. Read about the project.
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ITP offers technical publications, software tools, and other resources to help you address your company's industrial energy needs. Here are the latest products from ITP.
New Steam Technical Brief Tackles Pressure Reduction Issues
Steam production uses more energy in U.S. industry than any other system, therefore, efficiency is crucial to cutting energy costs. BestPractices has just added a new technical resource to its library of publications designed to help you optimize your industrial steam system. A BestPractices Steam Technical Brief, Steam Pressure Reduction: Opportunities and Issues (PDF 1.2 MB) identifies typical causes of boiler and steam system losses, and methods of achieving energy and cost-saving benefits. View this and other BestPractices technical publications.
Chilled Water System Analysis Software Tool Update Available Now
Is your chilled water system operating at peak efficiency? Use the Chilled Water System Analysis Tool (CWSAT) Version 2.1 to find out! CWSAT is a free software tool to help you determine energy consumption and costs of a chilled water system, examine the energy and economic impact of various operating scenarios, and quantify potential cost and energy savings. More information and to download.
Cement Manufacturer Saves $$ With Help from MotorMaster+
Properly fitted industrial motors can greatly improve system performance and reduce energy consumption. At the CEMEX cement plant in Davenport, CA, existing motors were evaluated using DOE's MotorMaster+ software tool, identifying 13 worn and inefficient motors on multiple cement blowers and silo pumps. Plant personnel replaced the motors with efficient, totally enclosed, fan-cooled motors. As a result, the plant is realizing annual energy savings of approximately 2.1 million kWh, annual cost savings of $168,000, and maintenance costs savings of $30,000. Read the Performance Spotlight.
Visit the ITP Web site for more BestPractices technical publications, software tools, and case studies to help you improve efficiency, productivity, and the bottom line.
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ITP awards cost-shared funding for R&D and plant assessment projects through a competitive merit review process.
Apply Now for Solicitations
ITP offers competitive solicitations to encourage industry partners to participate in cost-shared research and development projects. Check the Solicitations web page for three R&D funding opportunities currently available through the Industrial Assessment Centers, Innovative Energy Systems, and Chemicals Industry of the Future. And, prior to applying for solicitations, remember to first register with Grants.gov. This will streamline your application process!
To learn more about project opportunities, visit ITP's solicitation page.
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