ENERGY CONTAINMENT Recovery if waste heat from process operations can contribute to overall energy efficiency.

The flue gases from boilers and furnaces and other units which would depend on combustion provide excellent opportunities for heat recovery. Depending on the flue gas temperatures, the exhaust heat can be used to raise steam or to preheat the air to the boiler. An example of such a system is shown in figure 3.1 where an ammonia reformer heater is designed to conserve fuel by using a steam generator and an air preheater to recover heat from the stack gas. Energy in the from of heat is available at a variety of sources in industrial operations, many of which are not normally derived from primary heat sources. Such sources include electric motors, crushing and grinding operations, air compressors, and air thickening and drying processes. These units require cooling in order to maintain proper operation. The heat from these systems can be collected and transferred to some appropriate use such as space heating.

An example of this type of heat recovery is shown in figure 3.2. all of the energy supplied to the motor in electrical from is ultimately transformed into heat, and nearly all of it is available to heat buildings or for domestic water or mine air heating.

An interesting example of this type approach occurred in a large manufacturing firm in california. This firm faced the curtailment of natural gas boiler fuel. By reviewing the entire plant operation, it was noticed that there were several multi-stage, 5000 hp air compressors air temperature from 350 F to 70 F. This water was discharged to a cooling tower. A study was undertaken to determine how much natural gas boiler fuel could be eliminated by heat recovery from the air compressors. The result indicated that a substantial savings could be achieved and a detail design program was initiated.

Another pontential source of waste heat recovery is the exhaust air which must be rejected from industrial operations in order to maintain health and safety standarts of ventilation. If the reject air has been subjected to heating and cooling processes, it represents an energy loss inasmuch as the make up air must be modified to meet the interior conditions. One way to reduce this waste is through the used of recovery wheels which operate in a similiar fashion to the rotary air recuperator described above. Both heat and moisture can be transferred with these systems. The heat pipe is gaining wider acceptance for speciallized and demanding heat transfer applications. The transfer of energy between incoming and out going air can be accomplishet by banks of these devices. A refriggerant and a capillary wick are permanently scaled inside a metal tube setting up a liquid to vapor circulation path. Thermal energy applied to either end of the pipe causes the refrigerant to vaporize. The refrigerant vapor then travels to the other end of the pipe where thermal energy is removed. This causes the vapor to condense into liquid again and the condensed liquid then flows back to the opposite end through the capillary wick. These units promise to be highly efficient, require minimal maintance, and could be useful in a variety of heat recovery operations.

More efficent equipment. Ligthing is an area where large savings can accrue from the installation of more efficient equipment, particularly in the commercial sector. Equipment is available which is appropriate for both new construction and for retrofit applications. Certain substitutions can be made without ballast changes (replacing mercury vapor street lamps with high pressure sodium), but most of the improved devices require new luminaires and ballasts. One interesting point about the new equipment it is generally so efficient that the old wiring has ample capacity, less current is required. In an actual installation in sourthern california, two lighting configurations were considered to provide 540 lux illumination in a manufacturing plant having 4300 m. The first configuration used a conventional array of 3 2 tube, 96 inch high output fluorescent luminaires to provide illumination over a 25 foot lenght of the building. A total of 269 luminairies was required, with a connected load of 71 kw and an initial cost of 16000 exclusive of the distribution panel.

The second configuration used 400 watt high pressure sodium lamps placed 25 feet apart so that one high pressure sodium luminaire replaced there fluorescent luminaires. This system had a connected load of 40 kw, required 90 luminaires, and had an initial cost of 30000. The electricity saving alone led to a three- year payout for the high pressure sodium lamps based on two shift operation. When the added savings due to longer life, fewer lamps to clean and maintain, and lower losses are considered, the payout period is even higher. At the beginning of discussion, it was sugessted that a basic approach to energy management was the concept of task energy use, or energy where and when needed. Microwave heating is one of the best examples of this approach, since the energy is deposited in the material to be heated and losses from the oven are reduced. Microwave techniques are only now beginning to find use in industry, and as the benefits become better known, the usage will increase. A study was made to find a replacement for a gas fired drying oven used in the processing of agricultural feed additives. Lests were made using a microwave oven, an electric resistance heat oven, and a solar oven. The relative drying time using these three energy forms was in the ratio of 1:10:100. Not only was the microwave process the fastest, but it led to considerable energy savings and improved product quality.

CONCLUSIONS Energy is ubiquitios because it permeates every aspect of human endeavor. At first glance, the diversity of energy end uses is so great as to defy any attempt at classification of syinthesis, however, in attemping to use energy resources more efficiently to extend and prolong exiting supplies and to bring the benefits of low cost energy to greater share of the worlds populations, certain fundamental principle may be identified. These provide a starting point for initiating energy management effort in any activity.