Process heating assessments using DOE's manufacturing energy assessment software for utility reduction (MEASUR) tool suite

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Abstract

Process heating is the most energy-intensive manufacturing process for most sectors of industry. To quantify energy savings from various energy conservation measures, the Department of Energy (DOE) sponsored the development of the Process Heating Assessment and Survey Tool (PHAST) and similar tools for other industrial systems in the early 2000s. It has been used extensively in the Save Energy Now Program's Energy Savings Assessments and the Better Plants Program's In-Plant Trainings. Since the initial development of the legacy tools, both computer operating systems and software development have evolved significantly. Thus, DOE has invested in the modernization of PHAST and other legacy software tools to create the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool suite. MEASUR offers a collection of software tools that can aid manufacturing facilities in improving the efficiency of energy systems and equipment (specifically pumps, fans, steam, and process heating) and in conducting “Energy Treasure Hunts”. Eventually, the tool will also add compressed air and process cooling systems. The Process Heating Assessment (PHA) module of MEASUR is an upgrade of the PHAST tool. PHA provides the means to model fuel-fired, steam-based, and electric process heating systems, covering process heating for most industrial plants in manufacturing sector. It also includes several key upgrades, including the ability to consider multi-component charge loads and account for several different areas of energy losses. The new tool includes a comprehensive flue gas calculator to quantify available heat and heat loss for various gaseous, liquid, and solid fuels and new heat loss calculators. It generates a report and a dynamic Sankey diagram to show the energy consumption in various areas of energy use. MEASUR has significantly improved the user experience by adopting a modern software design. This paper details the structure and workflow of PHA and presents a real-world case study to demonstrate energy savings quantification and MEASUR's outstanding reporting capabilities.

Original languageEnglish
Title of host publicationProceedings of the Iron and Steel Technology Conference, AISTech 2020
PublisherIron and Steel Society
Pages1665-1679
Number of pages15
ISBN (Electronic)9781935117872
DOIs
StatePublished - 2020
EventAISTech 2020 Iron and Steel Technology Conference - Cleveland, United States
Duration: Aug 31 2020Sep 3 2020

Publication series

NameAISTech - Iron and Steel Technology Conference Proceedings
Volume3
ISSN (Print)1551-6997

Conference

ConferenceAISTech 2020 Iron and Steel Technology Conference
Country/TerritoryUnited States
CityCleveland
Period08/31/2009/3/20

Funding

This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Keywords

  • Electrotechnology
  • Heat balance
  • Industrial energy efficiency
  • Process heating
  • Waste heat recovery

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