IEEE Transactions on Energy Conversion, Vol. 14,No.

3, September 1999

795

Minimizing Energy Consumption in Industries by Cascade Use of Waste Energy

Naoki Hayakawa Yoshitsugu Wakazono Takeyoshi Kat0 Yasuo Suzuoki Yoichi Kaya Member, IEEE Non-member Non-member Member, IEEE Member, IEEE
Center for Integrated Research in Science and Engineering, Nagoya University Furo-cho. Chikusa-ku, Nagoya 464-01, Japan
Abstract: This paper discusses the regional energy saving potential by cascade use of waste heat in energy intensive industries, taking

into account the actual local industrial Structure in Japan. Energy flow in the industrial combinat composed of iron & steel, cement, paper & pulp and ethylene was optimized to minimize the oil consumption of steam boilers. The simulation results reveals that the local industrial structure highly influences on the energy saving potential by heat cascading. The industrial structure optimizing energy consumption was determined in consideration of spatial constraints of manufacluring plants or heat transmission loss between different plants. More than 90% reduction in oil consumption was expected by interconnection of waste heat supply and energy demand mainly between ethylene and paper & pulp industries.
Keywords: energy system, energy saving potential, heat cascading, waste heat, energy intensive industry, industrial combinat, oil consumption, spatial constraint, heat transmission loss

previous study on such an advanced heat cascading, whole energy intensive industries in Japan were assumed to be concentrated at imaginary industrial centers, referred to as "combinat", to evaluate the nation-wide energy saving potential 131. However, actual energy saving potential by heat cascading may depend on the industrial structure in each industrial area. From the above viewpoints, this paper focused on the technical feasibility of the advanced heat cascading for minimizing energy consumption in industries. First, we studied the dependence of energy saving potential by heat cascading on the local industrial structure. Second, we tried to find an industrial structure which maximizes the regional energy savings by heat cascading. Though we took a Japanese energy system as an example, the concept and methodology in this paper may be applied to any other countries with little modification.

1 . INTRODUCTION
In recent years, cascade use of heat energy, so-called "heat cascading", in the industrial sector is expected to be one of the promising measures for improving the energy efficiency of regional energy demand system [I]-[4]. Heat cascading is interpreted as conversion of waste heat energy at high temperature levels to heat demand at lower temperature levels or electricity demand in manufacturing processes of industries. Since the oil crises in 1970s, heat cascading has contributed to energy savings particularly in four major energy intensive industries, i.e. iron & steel, cement, paper & pulp and ethylene industries. The improvement of energy efficiency in the industries, however, became stagnant, because most conventional technical measures were already introduced in each of these industries. Further energy savings can therefore be brought about only by interconnection of waste heat supply and energy demand between different industries. In the authors'
PE-266-EC-0-12-1997 A paper recommended and approved by the IEEE Energy Development and Power Generation Committee of the IEEE Power Engineering Society for publication in the IEEE Transactions on Energy Conversion Manuscript submitted July 31, 1997; made available for printing December 12, 1997.

2. HEAT CASCADING MODEL

An energy flow model of manufacturing processes of four major energy intensive industries built in the authors' previous study in [3] is the basis of this study. Waste heat supply and heat demand are classified into 7 temperature levels: 5OO"c, 300"C, 200"C, ISO"c, lOO"c, 60"c, 30C. Electric energy supplied by non-utility generation is also included in the model. We assumed constant heat supply and energy demand throughout a year, taking into account the continuous production in large-scale industries. Thermal equipment included in the combinat model are condensing turbines, backpressure turbines, regenerators of steam and hot-water, regulators, heat pumps and steam boilers. The heat pumps are operated only by electric power. The boilers are fueled by heavy oil and generate 500C steam. The advanced heat cascading facilitates the interconnection of waste heat supply and energy demand between industries in forms of steam, hot-water or electricity using the above equipments. Energy balance at each temperature level in the individual industry is expressed as a constraint equation in linear formulation. We optimized the energy flows in the advanced heat cascading with a linear programming method with the oil consumption of steam boilers in the combinat as the criterion.

3. DEPENDENCE OF ENERGY SAVING POTENTIAL BY HEAT CASCADING ON LOCAL INDUSTRIAL STRUCTURE

0885-8969/99/$10.00 0 1997 IEEE

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3. I Industrial Structure in Tokai District in Japan

Fig. 1 shows the total energy consumption of the industrial sector in Japan in 1992. Four major energy intensive industries consume 65% of the total energy consumption in Japan. The data of ethylene industry are represented by those of chemical industries in this paper. Fig. 2 shows energy consumption of the major industries in Japan and Tokai district: Aichi, Gifu and Mie prefectures located between Tokyo and Osaka. The energy consumption in Japan is shown by the value divided by 50. Fig. 2 indicates the regional characteristics of industrial structure in each prefecture, i.e. iron & steel in Aichi, cement in Gifu, ethylene in Mie are dominant in the energy consumption, respectively. Fig. 3 shows (a) recoverable waste heat supply and (b) heat and electricity demand for each industry and temperature in Aichi prefecture. The energy supply and demand models in Gifu and Mie prefectures are also shown in Figs. 4 and 5, respectively. These figures are estimated on the basis of the energy flow data in industries [3]. Figs. 3 to 5 suggest that the waste heat at high temperature levels in iron & steel, paper & pulp and ethylene may meet the heat demand at medium and low temperature levels in these industries as well as electricity demand through the advanced heat cascading.

8%

Fig. I Total energy consuinption of industrial sector in Japan in 1992.

3.2 Energy Saving Potential by Heat Cascading

Fig. 6 shows simulation results of energy saving potential by heat cascading in Tokai district as case studies. The vertical axis indicates the oil consumption of steam boilers in the combinat. The simulation results reveals that the energy consumption can be reduced by 37% in Aichi, 24% in Gifu and 7 1% in Mie, respectively, by heat cascading. According to the energy flow in the optimized combinat in Mie prefecture, high temperature waste heat in the ethylene industry is effectively supplied to electricity demand in the cement industry through condensing turbines. The high energy saving potential i!i Mie prefecture may be attributed to the fact that ethylene is the dominant industry in Mie prefecture as shown in Fig. 2. On the other hand, those of Aichi and Gifu prefectures are less than that of Mie, because the share of ethylene in Aichi and Gifu is much lower than that in Mie. These discussions indicate that energy saving potential by heat cascading highly depends on the local industry structure.
4. INDUSTRIAL STRUCTURE FOR HEAT CASCADING MINIMIZING ENERGY CONSUMPTION

X1/50
Pig. 2 Energy consumption of major industries in Japan and Tokai district.

3 6000

.-

5000

1n
Aichi

...................................

0 before heat cascading

;
'

wafter heat cascading

Gifu

Mie

Fig. 6 Energy saving potential by heat cascading in Tokai district in Japan.

In the previous chapter, energy saving potential by heat cascading of waste heat in energy intensive industries was evaluated in consideration of actual local industrial structure in Japan. In this chapter, an industrial structure for heat cascading minimizing the energy consumption is investigated, assuming that an industrial combinat is formed in a newly developed site or around an existing core industry.

4.1 Relationship between Amount of Product and Plant Area

in Industry
We here assume the total area of the combinat given. In order to obtain the data on thc area of industry, we surveyed the amount of production and the area of individual manufacturing plants in energy intensive industries. Fig. 7 shows the relationship between the amount of production and

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temperature ( C ) (a) Recoverable waste heat supply ~ i 3 Recoverable waste heat supply and energy demand in ~ .

temperature ( C ) (b) Heat and electricity demand prefecture.

thylene er&pulp 1 temperature ("C) temperature ( C ) (b) Heat and electricity demand (a) Recoverable waste heat supply Fig. 4 Recoverable waste heat supply and energy demand in Gifu PrefectuE.

temperature ( C ) temperature ( C ) (b) Heat and electricity demand (a) Recoverable waste heat supply Fig. 5 Recoverable waste heat supply and energy demand in Mie Prefecture.

plant area for (a) iron & steel, (b) cement and (c) paper & pulp, respectively. Iron & steel shows a good linear relation between the plant area and the amount of production. Cement and paper & pulp also show rough linearity with some scattering. Table I shows the gradient of regression line for each industry. As for ethylene, the proportionality coefficient in Table 1 was estimated by using data of whole chemical industries including ethylene, because the data for individual

ethylene plants were not available. The whole area srorui of the combinat is given by (1) using the proportionality coefficient Ai in each industry,
sml

csi
i

=x(Ai Pi)
i

(km2h

(1)

where S and Pi are the area and the amount of production i of each industry in the combinat, respectively.

798
80

4.3 Industrial Structure in optimized combinat

Fig. 8 shows the industrial structure, the oil reduction per unit area and the oil reduction rate in the optimized combinat, when the core industry is selected as (a) iron & steel, (b) cement, (c) paper & pulp and (d) ethylene. The oil reduction rate E is defined by ( 3 ) ,
0
10 20 amount of production (Mton)

30

E = (El - E2)/ El x 100 (8).

(3)

(a) iron & steel 10 I

I

IO 20 amount of production (Mton)

(h) cement

30

20

.
6

2 4 amount of production (Mton)

(c) paper & pulp

Fig. I Relationship between amount of production and plant area.

Table 1 Proporlionality coefficients between amount of production and plant area. iron & steel 2.37

I I

cement 0.32

I paper & ptllp I I 2.60 I

ethylene 4.60

unit: km2lMton

4.2 Objective Function and Simulation Method In order to quantitatively evaluate the energy saving potential by heat cascading given the total area &m/, the following objective function is defined,
--t

Fig. 8(a) shows the structures of the optimized combinat which consists of ethylene and paper & pulp with iron & steel as the core industry. As the whole area of the combinat increases, the oil reduction per unit area also rises. The oil reduction rate reaches 100% when the whole area is less than 6 km2. This means that medium & low temperature heat and electricity demand is fully supplied by waste heat from high temperature processes in the combinat. The amount of production of each industry in the combinat with the whole area of 6 km2 corrcsponds to 1.8% for iron & steel, 2.1% for paper & pulp and 7.4% for ethylene, respectively, of the total production in Japan. The oil reduction per unit area in the optimized combinat is evaluated as 330 Tcal/km2. Fig. 9 shows an energy flow diagram in the above optimized combinat. A large amount of waste heat of an ethylene plant is mainly supplied to middle & low temperature heat and electricity demand of paper & pulp through back-pressure turbines. Waste heat of paper & pulp is reused not only in its own plant, but also those of iron & steel and ethylene. Figs. 8(b) and (c) show the structures of the optimized combinat when cement or paper & pulp industry is selected as the core industry. The above results tell that ethylene and the other industries can effectively be interconnected in thc combinat by heat cascading between the high temperature waste heat supply of ethylene and the middle & low temperature heat and electricity demand of the other industries. On the other hand, when ethylene is selected as the core industry in Fig. 8(d), the oil reduction rate becomes relatively low particularly in a larger scale combinat. However, at the whole area less than 7 km2, the oil reduction rate exceeds 90%. In these cases, ethylene again plays the key role in heat cascading as the source of high temperature waste heat supply, which is consistent with the results in Figs. 8(a) to (c).

4.4 Comparison with Actual Industrial Structure

In the previous sections, we showed that effective energy

(E1- E2)/,Srora/ (Tcalkm) Maximum, (2) savings can be realized by the advanced heat cascading with where EI and E2 are the oil consumption of steam boilers the oil reduction rate higher than about 90%. Fig. 8 shows the
in the combinat before and after heat cascading, respectively. The above objective function means the oil reduction by heat cascading per unit area of the combinat. The area of a certain industry was fixed at 3 km2 as the core industry in the combinat, while the whole area of the combinat was parametrically varied from 4 to 20 km2. The core industry was alternatively selected among four industries.
industrial structures in the optimized combinat with the core industry given. Let us compare those industrial structures in section 4.3 with the actual industrial structure of Mie prefecture, discussed in section 3.2, as an example. The share of production in Mie prefecture in Japan is 0.9% for iron & steel, 3.7% for cement, 1.1% for paper & pulp and 3.8% for ethylene, respectively, as shown in Fig. 2. These values except for

:I-h

799

1000

6 1000
oil reduction rate
. .
i.

800

800

1
t

00

oil reduction rate

80
60

c
f

600

2 400 8 'E 200

8
oil reduction per unit area

40

oil reduction per unit area

20

B
14
ethylene

8 '3 P 20 %
0

%r
h

0 16

%
1

14 12

IO
8 6 4
2 0
0

ethylene

1 n

-E 1
n

paper & pulp

r :r I
(a) core industry: iron & steel
100

5 IO 15 20 whole area of combinat (km2)

25

IO 15 20 whole area of combinat (km2)

(b) core industry: cement

25

c
4
k

1000 I

I100

oil reduction rate

EO

oil reduction rate

600

80

60

oil reduction per unit area

40

20

B B

60

'I

400

oil reduction per unit area

40

20

,g B B

N^

16 14
12

P a

0 16
14

ethylene

cement

1 TI.

108 6 4 0

F 5
2

12

IO
8

TI.

6
4
2 0

2t
0

IO 15 20 whole area of combinat (km2)

25

5 10 15 20 whole area of combinat (km2)

(d) core industry: ethylene

25

(c) core industry: paper & pulp

Fig. E Industrial structures and energy saving potential in optimized combinat by heat cascading.

cement correspond to about 1/2 of the values in the industrial =6 structure for Ston,/ km2 in Fig. 8(a). This implies that nearly optimized combinat may be constructed by the cascade use of waste heat among energy intensive industries in Mie . . prefecture. A more practical case study is now in progress, taking into account the actual geographical location of industries. As described in the Introduction, the purpose of this study is to evaluate the regional energy saving potential in a local industrial combinat rather than the nation-wide potential in Japan. Nevertheless, the discussion in this paper can be extended to the assessment of energy saving potential in the

larger area than the local industrial combinat, because of'the proportionality of industrial structure to its size.
4.5 EffectOf Heat Transmission LOSS

It is inevitable for heat cascading to transmit waste heat through pipelines between industrics, which causes dissipation of heat energy, In the previous simulations, heat transmission loss was neglected for the evaluation of energy saving potential in the ideal cases. This section deals with the influence of heat transmission loss on the energy saving potential by heat cascading.

800
dgl--( ne e

500C

200C

electricity

Ic

temperature (C) 500300200 150100 60 30 electricity ethylene 500C iron&steel 200C iron&steel electricity paper&pulp
150C

3
g
$5

S IO IS heat transmission loss factor (%)

20

(a) Industrial structure

$ 1000

paper&pulp 500C

heat pump electricity paper&pulp 200C

0;

15 heat transmission loss factor (%)

10

20

(h) Energy saving potential Fig. 10 Effect of heat transmission loss on energy saving potential. (Constant case, core industry: iron & steel, = 10 km2)

ethylene 500C

paper&pulp 100C

(c) Distance-proportional case: The loss is proportional to the distance between two industries. The distance is defined as the sum of radii of the sites of two industries, assuming that each industry in the combinat is confined in a circular area.

paper&pulp electricity

6 = 1-

(Ri+ Rj),

where Si = ZRi, Si = nRj2.

ethylene 60C iron&steel 60C Iron&steel 30C Fig. 9 Energy flow diagram in an optimized combinat. (core industry: iron & steel, .9,,o, = 6 km2) ethylene 60C

(d) Exponent case: The loss is expressed by exponent of the distance between two industries.

6 = (1 - yd)

(Ri+Rj)

The following four types of formulations of heat transmission loss factor 6 are introduced for heat transmission between two industries, i and j ( i # j ) ,with y as a parameter of the heat transmission loss. (a) Constant case: The loss is constant irrespective of the distance between two industries.

6=1-y
(b) Area-proportional case: The loss is proportional to the sum of areas of two industries.

6 = 1 - ? x (Si + Sj)

Fig. 10 shows (a) industrial structure and (b) energy saving potential in case (a) as a function of loss factor y , when iron & steel is selected as the core industry and Stmr = I O km2. Here assume the valuc of y to be less than 20% in this case, including not only the heat transmission loss to ambient, but also the additional energy to compensate for the temperature .drop associated with the heat transmission. There is a slight influence of heat transmission loss on the industrial structure. The area of paper & pulp decreases and that of cement increases as the loss factor increases. This is interpreted by the difference in energy demand characteristics in each industry. That is, in this model, paper & pulp has plenty of heat demand at middle & low temperature levels, while the energy demand of cement is only electricity as shown in Figs. 3(b) to 5(b). Thus, as the heat transmission loss increases, cement which docs not require heat transmission but conversion to electricity is introduced in the combinat rather than paper & pulp. When considerable heat transmission loss is unavoidable in the pipelines, the cascade use of waste energy converted into electricity may be

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superior to the energy cascading in the form of heat in order to enhance regional energy saving potential. Similar results were obtained in other cases than case (a). We conclude from these results that the heat transmission loss will not give a great influence to the energy saving potential in the optimized combinat, as long as the heat transmission loss is relatively low.
5. CONCLUSIONS

BIOGRAPHIES
Naoki Hayakawa (M 1990) was born in Nagoya. Japan, on September 9, 1962. He received the B.S. degree in 1985, the M.S. degree in 1987 and the P h D degree in 1991, all in Electrical Engineering, from Nagoya University, Nagoya, Japan. From 1990 to 1996 he was on the faculty of Nagoya University. Since 1996, he is an Associate Professor of Nagoya University at Center for Integrated Research in Science and Engineering.

The purpose of this paper is to investigate the potential for cascade use of waste heat among energy intensive industries: iron & steel, cement, paper & pulp and ethylene. First, regional energy saving potential by heat cascading was evaluated in the actual local industrial structure in Japan. Second, spatial constraints of industries were introduced in the combinat model to facilitate the evaluation of regional energy saving. The main results obtained in this paper are summarized as follows: (1) Energy saving potential by heat cascading highly depends on local industrial structure. (2) Cascading between high temperature waste heat supply of ethylene and middle & low temperature heat and electricity demand of paper & pulp can provide high energy saving. (3) Oil consumption of steam boilers for the energy balance in a combinat can be reduced by more than about 90% by optimizing the industrial structure. (4) Heat transmission loss will give little influence to the energy saving potential in the optimized combinat. ( 5 ) The conversion of waste energy into electricity is preferable, when considerable heat transmission loss is unavoidable. Although the a b o v e results were based upon Japanese data, we believe that the concept in this study to minimize the energy consumption by heat cascading is applicable to any other countries in the world. Further investigations are needed on the technical feasibility of the more advanced heat cascading between the industrial sector and the residential & commercial sector with low temperature heat demand. Economical feasibility based on cost-benefit analysis with costs of thermal equipments, pipelines, and other detailed engineering factors should be also examined. REFERENCES
[I] H.-M.Groscurth, R.Kiimmel and W.van.Gool, Thermodynamic Limits to Energy Optimization, Energy, Vo1.14, No.5, pp.241-258, 1989 [21 H,M.Groscurth, TH.Bmckner and R.KLimmel, Energy, Cost and Carbon Dioxide Optimization of Disaggregated, Regional Energy Supply Systems, Energy, Vo1.18, No.12, pp.1187-1205, 1993 [31 H.Nakata and Y.Kaya. Assessment of Energy Reduction Potential a1 Major Energy Intensive Industries by The Heat Combinat Model, Trans. IEE of Japan, Vol.I15-B, No 2, pp.149-155, 1995 (in Japanese) [4] A.Akisawa, R.lto and T.Kashiwagi, Effect of Cascade Use of Heat on Energy Conservation in Japan, Proceedings of Joint IEWIJSER International Conference of Energy, Economy and Environment, Osaka, pp.83-87, 1996

Yoshitsugu Wakazono (Non-member) was born in Shiga, Japan, on November 9, 1973. He entered Nagoya University in 1993. Since 1996, he is n master course student at Department of Electrical Engineering of Nagoya University, Nagoya, Japan.

Takeyoshi Kato (Non-member) was born it, Nagoya, Japan, on May 7, 1968. He received the B.S. degree in 1991, the M.S. degree in 1993 and the Ph.D. degree in 1996, all in Electrical Engineering, from Nagoya University, Nagoya, Japan. Since 1996, he is an Research Associate of Nagoya University at Center for Integrated Research in Science and Engineering.

Yasuo Suzuoki (M 1994) was horn i n Nagoya, Japan, on May 26, 1950. He rewived the B.S. degree in 1973, the M.S.degrre in 1975 and the Ph.D. degree in 1978, all in Electrical Engineering, from Nagoya University, Nagoya, Japan. From 1978 to 1995 he was on the faculty of Nagoya University. From 1979 to 1981. he was a Research Fellow at Northwestern University. USA Since 1995, he is a Professor of Nagoya University at Center for Integrated Research in Science and Engineering 1962) was born in Sapporo, Yoichi Kaya (M Japan, on May 18, 1934. He received the B.S. degree in 1957, the M.S. degree in 1959 and the P h D degree in 1962, all in Electrical Engineering, from University of Tokyo. Tokyo, Japan. He is Professor Emeritus of University of Tokyo. Since 1995, he is n Professor of Keio University, Japan. Since 1996, he is Guest Professor of Nagoya University at Center for Integrated Research in Science and Engineering.