In most heat generation equipment, significant sources of heat loss are the convection and radiation of energy from the system to the environment. This heat loss depends on the outside temperature of the heating equipment and can cause a significant reduction in process heating efficiency. Insulating materials such as brick and refractory materials used on equipment and pipes are essential to minimize the heat loss. Significant improvements in process heating efficiency can be achieved using new refractory fiber materials with low thermal conductivity and heat storage. Typical applications include furnace covers, installing fiber liner between the standard refractory lining and the shell wall, or installing ceramic fiber liner over the present refractory liner. Replacing standard refractory linings with vacuum-formed refractory fiber insulation can also improve the efficiency (EERE, 2008 p.19-20).
As the old insulation deteriorates with time, it is important to perform regular surveys of insulation efficiency and take corrective action.
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Commercial
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Ammonia
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| Parent Process: Steam Reforming | |
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| Energy Savings Potential |
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| CO2 Emission Reduction Potential |
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An assessment for an Australian ammonia plant estimated that the payback time for improving insulation on reformer furnace will have a payback time of less than one year (Australian Government, 2009). |
As an outcome of US Deparment of Energy's Industrial Technologies Program, this sourcebook describes basic process heating applications and equipment, and outlines opportunities for energy and performance improvements. It also discusses the merits of using a systems approach in identifying and implementing these improvement opportunities.
This case study, prepared by the Australian Government's Department of Resources, Energy and Tourism, looks at the assessment approach adopted by a major chemical manufacturer participating In The Energy Efficiency Opportunities (EEO) Program.
