New Methodology of Assessing Wasted Energy in Industrial Sector: Assessing Industrial Systems contribution to Thermal Pollution 

Abstract

Thermal Pollution represents “the release into the environment of substances that are innocuous themselves but at a temperature higher than the ambient altering the physical characteristics of the air or water with which they mix” (Science Dictionary). The quantity of the heated air dumped in the atmosphere is intrinsically related to efficiency of industrial systems, processes and industries. Increasing efficiencies of industrial systems, processes and industries will directly reduce the thermal pollution. In other words, all energy savings obtained by increasing energy efficiency of industrial systems and processes (IS&P) represents avoided Thermal Pollution. To date, studies of energetic performances of industrial systems and industries have lagged behind those used in the commercial and institutional sectors due to: Variability and complexity of IS&P, Variability of material and environmental conditions, The absence of a large population of comparable data required for a regression-based approach that would enable the normalization of material and environmental conditions, and thus allow for a useful comparison of energy performance at the process level. The reluctance of industrial firms to share data on industrial processes that is often considered proprietary. Paper proposes: an energetic assessment of Thermal Pollution by using a new rating system model describing the energy efficiency of any industrial equipment, system drive or process independent of a comparison with other processes. Comparative element across an industrial sector that is traditionally used, is replaced with a theoretical goal. The rating is then solely based on how close the true energy consumption within an industrial process gets to that ideal state. Proposed methodology splits energy consumption in 2 (two) specific components: Ideal energy (EIdeal) and Energy at Risk (E@R) – that represents actually the Thermal Pollution (Th.P). By considering these two energy types Benchmark Energy Factor (BEF) can be defined. The (BEF) will enable a new approach towards energy efficiency in the industrial sector and help level the playing field for energy management reducing the waste energy and therefore Thermal Pollution. It will be demonstrated that Energy at Risk (Thermal Pollution) variation is embedded in (BEF). Once Energy at Risk (E@R) is known, it will be logical proceeding with benchmarking plants, industrial systems or/and processes assessing their capability of managing E@R (waste energy or Th.P) by focusing on in-situ testing and making educated decision towards reducing wasted heat and thermal pollution. Case studies on proposed methodology are presented at the level of equipments, industrial system drives, plants, processes, and industries. The methodology of determining the magnitude of thermal pollution is applied to a typical national industrial system by using conservation potential obtainable when Integrated Industrial System Drives (IISD) are to be used. The scope of this paper is to uncover Th.P. as new pollutant that can be included in EPA Clean Air Act making available to consultants, designers, end-users, utility programs and environmental organizations reliable criteria of reducing thermal pollution of the existing or new industrial systems or plants as part of the climate change mitigation.

Novel method of benchmarking energetic efficiency of industrial systems

“…Waste energy or E@R is 45 % of the input energy (power) [6] . Input power P used represents actual electric power P Electric used by SIC to accomplish the required task P ideal .…”

“…E@R represents the difference between 2 E Ideal energy values can be dependent of specific variables [6] like: material, environmental conditions, personnel, equipment condition, thermal insulation condition, transportation, lighting, etc. In this case E Ideal is re-evaluated it will be increased to a new value named essential energy E Essential , this value replacing ideal values of energy E Ideal in (1) resulting in adjustment of BEF value.…”

Benchmarking Industrial Systems Using Energy at Risk and Benchmark Energy Factor Concepts

“…From a measurement and verification (M&V) perspective, due to complexity of industrial systems the fundamental equation used to calculate energy savings (ES) is often related to the term for "+/-Adjustments" [12]: ES = E consumptin, before -E consumption, after +/-Adjustments (6) As IPMVP states, "adjustments are derived from identifiable physical facts". These variables are mentioned in Note 3 and Chapter IV where it has been demonstrated how they influence BEF values via E Essential [7] - [9] By using proposed concepts of ideal energy E Ideal and Energy at Risk (E@R) approach no further adjustments are necessary because fundamentally these adjustments are embedded in the ideal energy model and established through the BEF.…”

“…While the ultimate target of these initiatives is reduction of power/energy losses at the time of measurement, their magnitude ( Power savings are currently obtained by maximizing overall efficiency given by (1) in Figure 1. Waste energy or E@R is 45 % of the input energy (power) [6] With reference to figure 1, when electric power is ISD input the used power P used represents the actual electric power P Electric used by ISD to accomplish the required task P ideal . Total Losses of a typical ISD can be expressed as:…”