Abstract

Chemical production uses ~25% of industrial energy in the United States, and effective energy management is essential to profitability. In many chemical plants, the most significant factor in minimizing energy costs is the use of cogeneration to provide both heat and power at a high overall efficiency. However, there are many other components of effective energy management.

Steam provides the integrating energy medium in most chemical plants. Two significant components in steam systems are steam turbines, for which maximizing efficiency is the primary goal, and steam traps, for which the goal is high reliability. The other major utility system is electrical, and its main consumers are typically pumps and compressors.

Many of the unit operations in chemical plants consume large amounts of energy. This is especially true of distillation, evaporation and drying, and care must be taken in the design and operation of the equipment to ensure the highest practical energy efficiency. However, there is generally a tradeoff between capital and energy costs, and this influences equipment choices.

Many chemical companies are actively pursuing energy efficiency programs to improve their facilities. The scope of these activities varies from company to company, but typically includes some or all of the following: follow best practices in operations and maintenance; invest in processes and infrastructure to reduce energy costs; implement systems to sustain progress.