| LIFT Chemical Roadmap |
| Barriers/ Chalenges |
Potential energy Savings or Environmental Improvement |
Short Term R&D Current to 5 year from today |
Mid Term R&D from 5 to 15 year from today |
Long Term R&D greater than 15 years from today |
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| Reduce Energy required by compressed air systems |
Approximately $5000/plant-year or 669,000 MMBtu state-wide |
Training in leak detection and Air Handling SystemsDesign new overall distribution system |
Build and Install new distribution system and proper preventive maintenance |
New compressed air technology with higher efficiency pumps |
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| Reduce NOX in combustion |
Efficiency currently 70-85% can be improved and NOX may be eliminated--reduction
of NOX statewide more than 2,000 Tons/year, energy savings 1,750,000 MMBtu |
Models of Oxy-fuel systems being studied Footnote (1) |
Large Oxy-fuel systems being demonstrated and prototypedRetrofit of most existing boiler and combustor with higher efficiency
burners and/or oxy-fuel |
New burners and boilers 95% efficient with little NOX emmissions |
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| Use CHP to reduce electrical system demand and share power with distributed
systems |
Potentially CHP can save each plant about $100,000 annually or statewide
more than 10,000,000 MMBtu |
Convert existing systems to used waste heat with Turbine/Generator Systems |
For Plants with excess steam generation capacity--run existing boilers
at maximum output and use back-pressure turbine to lower the process load |
Develop new techniques for combined heat/power including fuel cells |
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| Improve existing steam systems to use steam more efficiently and size
new and replacement systems properly |
As much as $10,000 per plant per year and 1,500,000 MMBtu |
Steam leak maintenance training including steam traps Footnote (2)Install adequate insulation on boilers and piping Footnote (2) |
Development of newer (more efficient) steam traps and the use of back-pressure
turbines |
Design and change of custom steam systems totally computer controlled
and maintained |
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| Use and savings of Energy Efficient Motors, Variable Speed Drives and
more efficient lighting |
Generally, savings are a function of the number of motors used in the
plant and can effect both energy cost and demand. Up to 750,000 MMBtu statewide
savings at the source |
Training of the benefits and cost saving potential for using energy
efficient motors and vaiable speed drives Footnote (3) Start replacing single
speed drives and standard energy efficient motors as the wearout
Footnote (3) |
New Chemical plants and additions to existing chemical plants add Energy
efficient motors and variable speed drives to improve energy efficiency.
Additionally, chemical companies start replacing lights with the most efficient
avaialable |
Practically all chemical plants in the state using variable speed drives
and energy efficient motors |
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| Work to improve peak load and power factor by the chemical companies |
Load sheading and power factor improvement will both lower the utility
bills and improve the peak demand requirements in the state Footnote (4) |
Goal shall be for each chemical plant to improve power factor to 0.80
(about 80% complete, currently) and reduce peak power requirements by 50
kW (savings per plant estimated at $10,000/yr. |
Goal shall be for each chemical plant to improve Power factor to 0.85
and reduce peak demand by 100 kW from today. Savings estimated at $20,000/yr. |
Goal shall be for each chemical plant to improve Power factor to 0.90
and reduce peak demand by 150 kW from today. Savings estimated at $30,000/yr. |
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| Improve energy efficiency and energy use of process furnaces |
Potential savings could be as high as 45,000,000 MMBtu state wide |
Perform head and mass balance to increase the inlet air temperature and
and reduce fuel consuption by using waste heat from other sources |
Goal is to reduce all waste heat to the atmosphere to less than 300F.
Other waste heat recovered using advanced techniques. |
Goal is to reduce All waste heat to the atmosphere to less than 250F. |
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| Footnote (1) |
CARBO Ceramics, Inc. of New Iberia (working with the state IAC and LIFT),
is developing an Oxy-fuel system for at least one of their rotary kiln units. |
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| Footnote (2) |
Louisiana Industries of the Future Teams [LIFT] sponsored a three day
steam training seminar (with Laboratory) for Chemical LIFT Members in October
2002 |
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| Footnote (3) |
Louisiana Industries of the Future Teams [LIFT] sent to all Chemical
LIFT Members the Motor Master 3.0+ (developed by Office of Industrial Technologies,
US DOE) and Energy Star program in August 2002 |
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| Footnote (4) |
Louisiana Industries of the Future Teams [LIFT] sent to all the chemical
companies a summary sheet on Power Factor improvement and load sheading
in September 2002 |
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