A History of Project Success
Innovative Energy Engineering Projects
At Industrial Energy Engineering we specialize in providing innovative energy engineering project solutions to help our clients enhance their profitability and compliance. We offer a wide range of services, including Energy Assessments, Equipment Upgrade Design, Ventilation Analysis, Cost Estimation, Contracting Plan Development and Regulatory Technical Assistance, all tailored to analyze and technically support our clients. With our cutting-edge analysis technology and expertise, we can help you bring your ideas and solutions to life by developing the technical answers that generate equipment system designs and prices to form the capital budgets that allow you to make informed decisions to solve system problems and improve the profitability of your firm. Contact us today to learn more about how we can help you take your project to the next level.
Industrial Energy Engineering Projects
Process Troubleshooting
Equipment Selection and Cost Estimation
Process Troubleshooting
Our Energy Analysis process begins with a thorough assessment of the energy needs of the production process, followed by process troubleshooting. Tuning the energy systems to allow them to best serve production provides immediate cost savings.
Energy Analysis
Equipment Selection and Cost Estimation
Process Troubleshooting
Our team of energy engineers is made up of industry experts with years of experience. We bring a high degree of science to our energy analysis, ensuring that the physical-chemistry of the process is enhanced by the correct application of the right amount of energy at each step of production.
Equipment Selection and Cost Estimation
Equipment Selection and Cost Estimation
Equipment Selection and Cost Estimation
At Industrial Energy Engineering, our mission is to provide high quality designs that incorporate the latest technology. We select equipment by using a rigorous cost and performance criteria so that the highest level of economic payback is achieved.
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.
Project 40309
Thermal Oxidizer Troubleshooting
A chemical manufacturer has high operating costs, numerous shutdowns and safety incidents from the operation of their thermal oxidizer.
Industrial Energy Engineering analyzed the thermal oxidizer operating conditions, shutdown trip reports and design criteria. We discovered that since the product mix has changed dramatically over the past 20 years the current organic load to the oxidizer is less than 5% of the design load. This causes the unit to operated in an unstable range resulting in frequent shutdowns as well as low oxygen conditions that cause flames in the stack. A plan was developed which included new setpoints for some of the oxidizer controls.
The client hired a field crew from the manufacturer to reprogram the unit. This corrective programming resulted in a significant reduction in downtime and an improvement in unit safety.
Project 29941
Electric Arc Furnace Efficiency
A Steel Mill has a continuous improvement program to improve the cost/performance of the Electric Arc Furnace Melt Shop
Industrial Energy Engineering analyzed the current melt Energy Input and benchmarked this against the best-in-industry practices. This operation was below industry standard with greater energy use. The problem was traced to imbalances in the arc leading to energy consumption imbalances per phase. IEE recommended more frequent phase triangulation alignment maintenance to solve this problem.
Cost savings of about $15,000 per month were achieved.
Project 29037
Rotary Kiln Energy Analysis and Upgrade
An Activated Carbon Manufacturer has lower-than-desired production rates.
Industrial Energy Engineering developed a mass-energy balance of the Baker and Activator unit operations. A Heat Recycle was recommended and designed. Cost Estimates were developed and submitted to corporate.
The recommended modifications were implemented. This reduced the steam demand while improving the product Quality and increasing the production rate.
Project 21894
Troubleshooting a Carbon Baking Kiln Thermal Oxidizer
An Activated Carbon Manufacturer has a Thermal Oxidizer that experiences excessive scaling and buildup
Industrial Energy Engineering evaluated the kiln operating conditions vs the design criteria and found that the flow conditions and temperature fluctuations were outside the design conditions. IEE wrote a performance specification for a new thermal oxidizer.
The new thermal oxidizer was purchased and installation with significant performance and cost benefits.
Project 27590
Heat Recovery for a Chemicals Operation
A Chemicals Manufacturer has a high temperature stack gas that could be used to generate steam
Industrial Energy Engineering analyzed the energy release from the process, wrote a performance specification for equipment, solicited budgetary quotations from suppliers and contractors and delivered a full project budget.
The Project Cost of 4.5 million dollars has a payback of less than 4 years and is in the capital budget for next year.
Project 21894
Coal Mine Gas Combustion for Renewable Energy Credits
A Coal Mine ventilates methane gas to maintain a healthy atmosphere for mine workers
Industrial Energy Engineering showed that the mine gas could be combusted and the renewable energy credits for this activity can be sold for profit.
A test facility is currently operating at an the mine. Plans are in the works for nine systems costing over one million dollars each that are expected to pay back in less than eighteen months
Project 29092
Energy Assessment for Metals Component Manufacturer
A metals component manufacturer has Energy Bills that are much higher than expected
Industrial Energy Engineering conducted an Energy Assessment and determined that a key ventilation system component had malfunctioned on one of the main units. IEE recommended repair or replacement of the ventilation unit with the option of upgraded controls to further reduce energy consumption.
The Manufacturer repaired the key unit and is considering the option of controls upgrade.
Project 28989
Campus Heating Expansion
A University campus is expanding and questioned whether Central Steam or natural gas (or both) should be utilized for the new buildings.
Industrial Energy Engineering analyzed the heat requirements, the existing Central Steam Plan output, the configuration and the economics for the current and proposed campus heating system as well as the particular needs of each new building. IEE recommended that one building should be heated by the campus heating system. The second and third buildings should be heated with their own dedicated boiler systems.
The expansion project was constructed as recommended by Industrial Energy Engineering.
Project 29985
Steel Mill Ladle Control Efficiency
A Steel Mill has a continuous improvement program to improve the cost/performance of the Electric Arc Furnace Melt Shop
Industrial Energy Engineering analyzed the production timing and found gaps between the various control systems. IEE recommends better alignment between the ladle preheat and the melt control systems. This involves software upgrades and improved time-temperature data collection. The improvements are estimated to save $40,000 per year in natural gas with a $50,000 one time investment.
Cost savings of about $15,000 per month were achieved with programming changes. The client is still considering whether to purchase an integrated control system.
Project 20396
Energy Assessment of Institutional Boilers
A Hospital has large centralized boilers and a campus with multiple wings built at different times with different design philosophies
Industrial Energy Engineering constructed an energy balance of both the new and old boiler systems that revealed an error in the input data from the new boiler meters. These meters had never been correctly calibrated when they were installed.
The client had the meters recalibrated and the "ghost steam flow" problem was eliminated. This bolstered the hospitals confidence in their new systems and operational practices.
Project 30700
Campus Energy Assessment
An University Campus has a Boiler-Steam system that is subject to the Boiler MACT regulations
Offgas from a chemical mixing operation requires treatment for air emissions
Industrial Energy Engineering conducted an Energy Assessment as required by the Boiler MACT regulations with a focus on reducing costs. IEE found that the key to reducing fuel consumption is in the timing of when to use steam for water heat, and when to use dedicated building hot water boilers. IEE developed a preliminary action plan to be tested in the next winter months and basic guidelines to select the low-cost building heat for various ambient conditions.
The client campus implemented the program and found that the low cost heating solution was different for each building area depending on the distance from the central steam plant. The farthest away buildings were set to rely on their own boilers more often to minimize cost.
Project 40106
Containment and Control Design
Offgas from a chemical mixing operation requires treatment for air emissions
Industrial Energy Engineering evaluted potential containment and control systems and selected a hood and curtain option coupled with a thermal oxidizer as the minimum cost solution. Sketches of the layout and ducting were developed as well as equipment selection and a full cost estimate for a capital expense request.
The client is using this capital expense estimate in negotiations with the regulators to result in a lower cost solution that meets lesser compliance goals.
Project 40151
Ventilation Analysis for a Metals Fabricator
Dark Fog clouds on the factory ceiling. Poor ventilation. Unhealthy worker exposure conditions
Industrial Energy Engineering analyzed the ventilation and ductwork system and developed a model of the flows. The balance showed the root cause of the numerous ventilation problems. A plan was developed for a series of upgrades and a prioritized implementation plan.
The client is currently implementing the low cost and compliance driven upgrades, while capital expense discussions are proceeding for the larger solutions.
Project 27684
Pipe Mill Recuperation Efficiency
A Steel Pipe Mill has a Reheat Furnace with a recuperator that is not performing as efficiently as designed.
Industrial Energy Engineering analyzed the recuperation system and discovered that the location of a temperature probe was causing the control system to misread the temperature of the combustion air. This caused the control system to add dilution air when it was not required, lowering the recuperator outlet temperature.
The client opted to reprogram the temperature setpoint rather than move the temperature probe. An estimated $50,000 per year savings was achieved.
Project 21594
Energy Assessment of Glass Plant
A Glass Manufacturer has kilns with high heating energy costs that are reducing the company's profit margin.
Industrial Energy Engineering compared the existing kilns with more modern designs and showed that an integrated kiln recuperation design could be retrofitted to their kilns, allowing preheat air to reduce gas consumption.
The next kiln rebuilds ( in about two years) will include the recommended new recuperator.
Project 25477
Process Oven Efficiency
A catalyst manufacturer has ovens with a 1000 degree F stack gas temperature.
Industrial Energy Engineering constructed a mass-energy balance of the ovens and dryers. The balance was used to calculate the benefit of a heat recovery system. IEE developed a project budget using contractor and equipment quotations. The cost-benefit payback was under 2.5 years.
The client is studying the proposal and will consider the upgrades for the next year.