Maryland Energy Administration

Industrial Energy Efficiency

With the rise in natural gas prices the U.S. Department of Energy's Office of Industrial Technologies has listed suggestions for industry to save natural gas consumption. These tips do not require expensive new equipment nor are they complicated. The DOE suggests companies get worker participation for wide success. A plant-wide energy assessment can be arranged through the DOE's Best Practices Program.

Save Your Company Natural Gas with the Following Tips

Equipment Up-keep

• Inspect and recalibrate thermocouples in furnaces for more accurate zone temperature measuring and increased furnace efficiency.
• Install removable insulation on uninsulated valves, pipes, and fittings to reduce losses in the process heat distribution system.
• Inspect and repair steam distribution systems leaks. Some possible areas of leaks include piping, valves, process equipment, steam traps, flanges, and seals.
• Clean strainers located upstream of steam traps regularly. This prevents excessive particle accumulation which can accelerate the need for steam trap repair or replacement.

Facility Awareness

• Measure and manage plant ventilation with an economizer to optimize outside air use. Warped or worn outside air dampers should be replaced.
• Relook your gas contract for possible term renegotiations. This could result in you obtaining lower rates with your utility providers.

Operations

• Minimize surplus combustion air by tuning damper settings on boiler draft fans, installing over-fire draft control systems, sealing doors, etc. Excess air in the combustion chamber contributes to heat loss via flue gas escape.
• Lower the water temperature in boilers to reduce short-cycle loss, as well as convective and radiant heat loss.
• Prevent scale accumulation in boiler feedwater tubes with effective operation of water treatment systems.
• Rework the schedules of processing operations. For example, lessen the frequency of mixed and/or partial loads to reduce delays and reheat requirements.