Industrial Ventilation Best P B t Practices ti Training Seminar

John Steinhoff, P.E. Principal EnVise LLC

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608-663-3751 jsteinhoff@envise.net

Goals d Obj ti G l and Objectives

Reveal the Mysteries Associated with y Industrial Ventilation Provide Clear Definitions of Systems, Costs and Applications Identify Short and Long-Term Cost Saving Opportunities Define Best Practices Approach to Optimizing Industrial Ventilation Systems

Energy Efficient Ventilation

Energy C t E Costs and Opportunities O t iti

Winter Heating: Direct-Fired Make Up Air Unit

Electric Fan Costs $0.42 10%

Total Cost: $4.20/Hour

10,000 CFM Unit Operating 1,600 Hours/Year Eau Claire, WI

Natural Gas Costs C t $3.78 90%

Gas @ $8.00/MMBTU, 97% Efficient., 65F Set Point

Winter Heating: Unit Heater f S for Space Heat

Electric Fan Costs $0.47 $0 47 9%

Total Cost: $5.36/Hour $5 36/Hour

10,000 CFM Unit Operating 1,600 Hours/Year Eau Claire, WI

Gas @ $8.00/MMBTU, 75% Efficient., 65F Set Point

Natural Gas Costs $4.89 91%

Winter Heating: Indirect- Fired Unit Make-Up Air Unit

Electric Cost $0.47 8%

Total Cost: $5.70/Hour

10,000 CFM Unit Operating 1,600 Hours/Year Eau Claire, WI

Gas Cost $5.23 92%

Gas @ $8.00/MMBTU, 70% Efficient., 65F Set Point

Summer H ti S Heating:
Up-Blast Roof Exhauster

Industrial Wall Propeller Fans

Total Cost: Up-Blast Exhauster Approximately $0.10 per Hour Wall Fan Exhausters Approximately $0.09 per Hour

Based on 10,000 CFM of Exhaust Air and $0.07 Electric Rate

Energy Efficient Ventilation V til ti

Ventilation Systems

Objectives of Maintaining Adequate Levels of Ventilation

Control Maximum Levels of Contaminants p Maintain Space Comfort Improve Process Quality Increase Production Rates Meet or Exceed Environmental Code and Safety Requirements Minimize Energy Use!

Ventilation S t V til ti System Elements El t

Exhaust Systems Makeup Air Systems MAUs Recirculation Systems with Filters Contaminant Collection Systems Contaminant Dilution Systems Contaminant Conversion Systems Heat Recovery Systems Energy Optimization Design Controls Manual and Automatic

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Heat Recovery Systems

Makeup Air Unit

80 F
Recirculation System S

95-120 F Reclaim Ceiling AIR HEAT

Summer Winter Air

PROCESS

PROCESS

PROCESS

65 F

FA AN

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Ventilation S t V til ti System Components C t

Controls

Location of Distribution Points

Duct System y Connecting Fan to Distribution Points

Fans & MAU s MAUs

System Component C t Installation and Annual Operating Costs C t

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Negatively U B l N ti l UnBalanced B ildi d Buildings All of the Air Exhausted is Replaced with Outside Air All Outside Air Does NOT Come Through Controlled Make-Up Air Units The Ventilation Changes Each Times Doors Are Opened or Closed Ventilation Is Out Of Control!

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Impacts of Negative Air Ventilation

Increased Heating and Ventilation Costs Uncontrolled Work Area Temperatures Unstable Process Operation Possible Increased load on Ventilation Fans Decreased Exhaust CFM for All Exhausts

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Impacts of Negative Air Ventilation (continued)

Increased Building Moisture Penetration Unsafe Outside Door Operation Increased Heating Load on Space Heating Equipment Back draft of Flue Gases from Unit Heaters into building

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Impact Of P iti I t Positive U b l Unbalance

Required for Specific Areas
Control Contamination From Entering Area Paint Rooms Food Processing

Too M h P iti Ai i E T Much Positive Air is Expensive! i !

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Effective Summer V til ti Eff ti S Ventilation

Install Enough Air Inlets to Maintain Low Static Pressure Across Exhaust Fans If Ventilation Air is Supplied Mechanically, Duct Air Closer to Work Surfaces Install C Controls Linked to S Space Temperature or Process Operations to Control Ventilation and/or Make Up Air Operation Make-Up

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Concept of Ventilation Effectiveness Placing exhaust systems and outside air systems in the best location and position to remove the highest concentration of contamination as possible with the least volume of air flow

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Ventilation Effectiveness K K Reference Examples

Compare the Layout of Exhaust Fans and MAUs in Buildings with the Layouts Shown in the Following Slid th F ll i Slides This Will Give You an Estimate of the K Values of those Systems Smaller K Values Indicate Higher Ventilation Effectiveness Higher Effectiveness = Lower CFM & Cost
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Examples: K=8 K 8 Low Effectiveness

EXH FAN MAU or OA INTAKE

PROCESS S

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Effectiveness Improvement: K=5

EXH FAN

MAU or OA INTAKE

PR ROCESS

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Effectiveness Improvement: K=3

CFM R d F S Reqd For Same C t i ti R Contamination Removal A l Approx 1/3 Of CFM Wh When K 8 K=8
MAU or OA INTAKE MAU or OA INTAKE

EXH FAN

PROC CESS

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Capturing Contaminates: Capturing Effectiveness Reduced to K=0.5

MAU or OA INTAKE EXH FAN MAU or OA INTAKE

PROCE ESS

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Energy Efficient Ventilation V til ti

Best B t Practices Discussion Di i

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Effective and Efficient Plant Designs

1. Place E h 1 Pl Exhaust Pi k t Pickups N Near th the Contamination Source 2. 2 Place Air Supply Outlets Near the Worker 3. Allow Use of MAU Blower and Ductwork Year Around 4. Provide Controls to Reduce the CFM Flow to Match the Contamination Demand

Reduce Ventilation Operating Costs

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Demand Ventilation D d V til ti

Most Fixed Rate Ventilation Systems are Sized to Meet 70% 90% f the Maximum V til ti R t M t 70%-90% of th M i Ventilation Rate
The Control for these Systems is Usually a Manual On or OFF Decision

For A System Sized to Meet 80% of Peak Requirements:

When The Contamination Generation Exceeds the 80% Level The Ventilation Rate is too Low and Contaminants Build Up When The Contamination Generation is Below the 80% Level The Ventilation Rate is too High and Operating Costs are Higher than Required

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Demand Control Ventilation System Components

Variable Volume MAU VFDs: Provide Fan Speed Control Operator Training and Instructions Ensures Proper and On-Going Operation

Manual or Automatic Control With A Programmable Logic Control (PLC) Unit U it

Process Operation Sensors

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Demand Control System

Multi-Zone Control Components
EXH FAN (100 - 25%) VFD 50% MAU 50%

CELL - 1 OFF
PR ROCESS

CELL - 2 ON
PR ROCESS

CELL - 3 ON
PR ROCESS

CELL - 4 OFF
PR ROCESS

Mini-Plc

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Diagram of Ventilation System with No Demand Control

CONT TAMINATE PRODUCT E TION RATE E
FIXED VENTILATION CFM & COST 100%

80% 60% 40% 20%

Contamination Demand

HRS DURING THE WINTER SEASON

FIXED VENTILA D ATION CFM & COST M

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Demand Control Optimizes Energy Savings

100%
C CONTAMINAT PRODUCT TE TION RATE

SAVINGS VENTIL LATION CF FM 80% 60%

40% 20%

HRS DURING THE WINTER SEASON

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Energy Efficient Ventilation V til ti

Dust Collection Systems

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Overview of Dust Collection Systems

Benefits System Types Definitions Applications Design Considerations y System Costs Limitations

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Cost Comparison (Dust Collection vs. Ventilation Dilution)

10,000 cfm Eau Claire Wisconsin Operating 1,600 hrs/yr Direct Fired Make-up Air Unit = $4.60/hr Dust Collection System = .15 kWh x $0.07/kWh = $1.05/hr 77% Difference in Operating Cost

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Cartridge T C t id Type P Permanent t

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Cartridge T C t id Type P t bl Portable

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Definitions D fi iti
Dust consists of tiny solid particles carried by air currents capable of remaining in suspension CFM Cubic feet per minute of air flow (standard vs. actual) Air Velocity- Speed of dust being moved through various components of a system in units of feet/minute A/C Ratio air to surface ratio is airflow though the filtration system in cfm divided by the total amount of filter media in sq. feet. American Conference of Governmental and Industrial Hygienists (ACGIH) Micron A unit of length equal to one millionth of a meter

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Relative Sizes of Common Air Contaminants

Contaminant Gas Molecules Oil Smokes Dusts Human Hair Heavy Industrial Dust Size (microns) 0.0001 0.1 10 100 1000

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Application C A li ti Considerations id ti
Provide Adequate Not Excessive Ventilation Minimize Distance f Mi i i Di t from D t P d ti t H d Dust Production to Hood Use Gravitational Forces Design to Maintain Minimum System Velocities g y Minimize Pressure Drops Maximize Containment Provide Even Airflow at Hood Faces Choose the Best Filter Media Design with Safety in Mind (Prevent Explosions and Fire) Design Maintenance and Monitoring into System Operation
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Dust Collection - Source Capture Ventilation Air Return

Return Air

Dust Collector

Process s

Process s

Process s

Source Capture Hoods

Fan

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Applications Where Dust Control Systems DO NOT Work

Combustion Gases Specific Gas Streams that Removal Systems Cannot Handle General Rule: Contaminants less than 0.01 0 01 Microns are NOT Good Candidates

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Safety S f t
Explosions -Potential measured as Kst, or p , the rate of pressure rise
Install Explosion Vents as Required (outside and away f from the building) )

Fire Install spark suppression and detection systems at duct inlets

Suppression Systems include water, chemical and inert gas Diversion Systems utilizes abort gates to divert air stream outside
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Energy Efficient Ventilation V til ti

Closing Comments and Additional Resources

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Recommended Ventilation Design Plan

Total Pl t V til ti Evaluation T t l Plant Ventilation E l ti Clearly Define Ventilation Problems Perform Feasibility Study Considering Proposed Improvements g Develop Budget Cost Estimates for Each Item Estimate Energy Costs and Savings Work with Companies that have system experience Maximize the availability of incentives Focus on Energy

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Wisconsins Focus on Energy Program

Presented by:

Nate Altfeather
Focus on Energy Industrial Program

Focus Mission
Improve energy efficiency in Wisconsin by supporting customer energy efficiency projects that ffi i j t th t g p otherwise would not get completed.

Focus on Energy
A Part of the Solution

This is Your program

Funding comes from your rates
(average is 1.2% of rates)

Why it works:
Rate payer can choose to pay either.. $2500+ per kW for new power plants $500 to free up an existing kW through improved efficiency

Energy Efficiency - A Solution

1.

Reducing future utility rate increases g y

Energy efficiency New power plant <$400 per kW >$2,500 per kW

2.

Business survival
Businesses have saved 20%+ of energy costs through higher efficiency to improve profitiability and infrustructure.

3.

Global climate change

Increasing efficiency is the most cost effective solution by far

How does it work?

Prescriptive/Direct Incentives P i ti /Di t I ti Custom Incentives Technical Support Information & Education

Prescriptive (mail-in) Incentives

Can be applied for after p j pp project is complete p Simply attach invoice and mail in with completed application.
Lighting Compressed air studies Compressed air leak detection VSD Air compressors Premium Efficient Motors VFD pump / fan p p Boiler / Chiller tune-up EE Repulper Rotors EE burner inserts Steam Trap Survey/Repair Boiler Combustion Mngmt*

Custom Grants
Must be approved BEFORE project begins Must work with a F.O.E. energy advisor
Up to 6 / kWh and $200 / kW (on first year savings) Up to 60 / therm (on first year savings) For projects with payback between 1.5 and 4 years Up to 30% of project cost paid for (many projects reach 30%) Cap of $250,000 per project; $500,000 per company per year

Feasibility Study Grants

help you quantify savings opportunities Up to 50% of study cost, max of $7,500 (larger Up cost grants possible for larger studies) Prescriptive incenti es available for Prescripti e incentives a ailable compressed air studies Metering projects may qualify

Grants are Easy and Quick

Easy - grant application paperwork is minimal and energy advisor is there to assist with application process process. Quick - response usually within 10 days of submission (larger grants require large review period)

Technical Support Service

Identify and quantify energy efficiency projects Expert third-party review of proposals Grant application assistance Develop an energy management plan or team Find suppliers for equipment or services Tool Lending Library

Technical Support
Practical Energy Management Tool
Establish & enhance Energy Management gy g Teams Best Practice sa gs est at o too s est act ce savings estimation tools Energy Management program tools

Best Practice Classes

Practical Energy Management Compressed Air Systems Refrigeration Ventilation Steam Systems Lighting Pumping Systems Fan Systems
To register, go to:

www.focusonenergy.com gy

Best Practice Guidebooks

Energy Guidebooks
Pulp & Paper Metalcasting Plastics Dairy/Food Processing Water/Waste water

Management Best Practices Technical Best Practices Developed by industry experts

Summary
Grants up to 30% of project costs! p p j Most grants approved in less than 10 business days from submission Cap - $250,000 per project $500,000 per tax ID annual limit Technical and study support y pp Energy management team support

Part of the Solution

We W can help you h l be a part of the solution. For your company and your community
Nate Altfeather 608-277-2949 altfeathern@saic.com
800-762-7077 800 62 0 www.focusonenergy.com

Focus on Energy

Best Practice Story Mercury Marine

Centralized Compressed Air System
Savings
9.2 million kWh 1.1 MW trimmed 135,000 therms 6,900 tons CO2 reduced

Economics
$1,850,000 project cost $541,000 energy savings $60,000 Focus grant 3.4 year payback on energy 2.6 year payback with other savings $2.7 illi $2 7 million power plant savings l t i

Emerging Technology Story Nestle USA

Condensing Stack Economizer
Savings
142,000 therms 826 tons CO2 reduced

Economics
$340,000 project cost $111,000 energy savings $40,400 Focus grant 3.1 year payback