Plant Wide Assessment of Energy Usage Utilizing SitEModelling as a Tool for Optimizing Energy Consumption
The Evonik Degussa Corporation is the global market leader in the specialty chemicals industry. Innovative products and system solutions make an indispensable contribution to our customers' success. We refer to this as "creating essentials". In fiscal 2004, Degussa's 45,000 employees worldwide generated sales of 11.2 billion euros and operating profits (EBIT) of 965 million euros. Evonik Degussa Corporation has performed a plant wide energy usage assessment at the Mapleton, Illinois facility, which consumed 1,182,330 MMBTU in 2003. The purpose of this study was to identify opportunities for improvement regarding the plant’s utility requirements specific to their operation. The production is based mainly on natural gas usage for steam, process heating and hydrogen production. The current high price for natural gas in the US is not very competitive compared to other countries. Therefore, all efforts must be taken to minimize the utility consumption in order to maximize market position and minimize fixed cost increases due to the rising costs of energy. The main objective of this plant wide assessment was to use a methodology called Site Energy Modelling (SitE Modelling) to identify areas of potential improvement for energy savings, either in implementing a single process change or in changing the way different processes interact with each other. The overall goal was to achieve energy savings of more than 10% compared to the 2003 energy figures of the Mapleton site. The final savings breakdown is provided below: - 4.1% savings for steam generation and delivery These savings were accomplished through better control schemes, more constant and optimized loading of the boilers and increased boiler efficiency through an advanced control schemes. - 1.6% savings for plant chemical processing These saving were accomplished through optimized processing heating efficiency and batch recipes, as well as an optimized production schedule to help equalize the boiler load (e.g. steam consumption).
- Research Organization:
- Evonik Degussa Corporation
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- DOE Contract Number:
- FG36-06GO16016
- OSTI ID:
- 927050
- Report Number(s):
- DOE/GO/16016-1; TRN: US200816%%959
- Country of Publication:
- United States
- Language:
- English
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