Energy Experts for the Chemical and Plastics Industry
Energy Engineering Serving the Chemical Industry
At Industrial Energy Engineering we take a fundamental chemical engineering approach to energy engineering. We look deep into the production process to uncover the fundamental energy needs of the process and the timing of that need. A mass balance methodology often leads to opportunities to better align energy delivery with process energy need. Pollution Capture and Control is similarly analyzed using mass balances and energy balances. Opportunities for heat recycle and reductions in non-production energy use are part of every energy assessment we perform.
Project 30851
Energy Recovery Unit Thermal Oxidizer Selection and Budgeting
A chemical maufacturer has waste solvent energy recovery units (ERUs) that do not meet the NOx emission standards.
Industrial Energy Engineering performed the role of Technical Assistant to the manufacturer for the selection, budgeting and purchase of new ERU units.
The client purchased and installed the new units at a cost of approximately 3.5 million dollars with guidamce from IEE and they are now operating as intended within the NOx standards.
Project 36658
Energy Assessments for Sustainability
A coatings and material science manufacturer wants an energy review of their manufacturing operations as part of a sustainability effort.
Industrial Energy Engineering performed Energy Assessments at five manufacturing facilities in northern Ohio. Each assessment identified between 3 and 10 projects to reduce energy with associated cost budgets, reduction quantities and recommendations.
The Projects were included in the corporate "To-do" list in order of priority. The client continues to implement these projects and utilize this list for future budgeting.
Project 37959
Thermal Oxidizer Safety and Operation Cost Analysis for Painting
A painting operation at a manufacturing plant had a pollution control system that was fundamentally flawed and had caught fire twice.
Industrial Energy Engineering analyzed the needs of the process against the design of the pollution control system. We found that the configuration of the pollution control system was not well matched to the physical chemistry of the paints being used. We recommended a different type of pollution control with more interactive controls to reduce the potential for fire and reduce the energy requirements of the system.
The client purchased a system with the recommended design and it is currently performing as intended, much more safely and with a significant reduction in operating cost.
Project 40142
Thermal Oxidizer Operation Cost Analysis for a Plastics Manufacturer
A Plastics manufacturing company has a thermal oxidizer with a high gas consumption.
Industrial Energy Engineering analyzed the energy consumption in detail on a microscale of 30 second intervals for a week. This showed that the oxidizer had not been properly tuned to the current production mix and also highlighted a flaw in the startup sequence. These problems had existed with this unit for over 20 years before IEE discovered them.
The client had a field crew from the manufacturer reprogram the unit. This corrective programming resulted in a significant reduction in operating expenses, and an improvement in unit safety.