INVISTA Enercase

enercase
Waste Heat Recovery
Dave Dove
Chief Operating Engineer, Operations
INVISTA, Kingston, Ontario
Union Gas - Working with you
Union Gas Account Manager, Ron Bruyns and technical staff have
been involved in energy planning with INVISTA for a number of
years. Their participation in boiler performance testing, steam
plant audits and accurate tracking of historical gas consumption
helped determine the project’s economic feasibility. Union Gas
also provided a $40,000 energy efficiency incentive based on
installed equipment.
Call the energy experts at Union Gas
Union Gas is committed to providing industrial energy users
with information on energy efficiency, technologies, services
and incentives. If you’d like to learn how heat recovery can work
in your industry, contact your Account Manager or
visit enersmart.com/largebusiness
Many industrial
and commercial sites
lose precious BTUs
– and dollars – through
exhaust waste streams.
INVISTA has installed
a system that captures
waste heat before it
exits the facility.
The system converts
process heat to
seasonal building
heat – and waste
energy into significant
budget savings.
EnerSmart. For the profit in energy efficiency.™
TM
CONSERVE • SAVE • PROFIT
Energy efficiency projects pay you year after year!
TM
CONSERVE • SAVE • PROFIT
Waste Heat Recovery
Printed on recycled paper using environmentally-friendly inks. ™ E
nerSmart is a trade-mark of Union Gas Limited.
© Union Gas Limited 2009 04/2009 UG20090051
‘‘
‘‘
Capturing heat from our processess makes
us more competitive in the long-term.
Recovery
Recovery
enercase
EnerSmart Programs
Can an air
bag fibre maker
really show a
hospital or
a university
how to lower
energy costs?
enercase
Solution
INVISTA’s solution uses waste process heat for
seasonal building heat throughout the manufacturing
and support areas.
Summary
Waste Heat Recovery
•A forced circulation heat recovery glycol loop with
distribution piping condenses steam at various process
areas and transfers the recovered heat to air
handling units.
INVISTA recovers waste heat and energy dollars
Summary
At INVISTA’s Kingston plant, a new glycol heat recovery loop, installed in 2003, enables waste process heat to be recovered
and redirected for building heat. The results decrease natural gas consumption, reduce emissions and lower heating costs.
An innovative performance contract with energy services company Cogenex made the project possible without up-front
capital from INVISTA. The agreement ensures ongoing monitoring and maintenance of equipment to guarantee savings
performance. Any industrial plant with processes generating hot waste streams and substantial seasonal building heat loads
can apply this heat recovery system.
•Heat exchangers were installed in process units
parallel to existing raw water heat exchangers
and existing scrubbers in the various nylon
polymerization areas.
•A high-pressure steam flash tank and an additional
shell and tube heat exchanger recover heat from
steam condensate.
Are you wasting process
heat that could lower
your energy costs?
•A dedicated control system feeds glycol to the heat
exchangers when steam is available.
•Air handling units were retrofitted with glycol coils.
Existing steam coils or direct-fired natural gas
heaters provide back-up for high heating loads.
Background
Challenge
Environmental Benefits
Wins & Highlights
INVISTA is one of the world’s largest producers of
As part of the nylon manufacturing process, heat
is wasted when steam, generated by the process,
is condensed with cooling water or vented to the
atmosphere. Industrial waste heat recovery usually
captures waste heat from a high temperature
manufacturing process and applies it to other
manufacturing processes operating at lower
temperatures. Since the Kingston site’s nylon
polymerization processes all operate within the same
temperature range, the challenge was to identify a
viable alternative use for the recovered heat.
•2004 Energy Efficiency Award from Natural
Resources Canada
•Heat recovery loop converts waste process
heat to building heat
*
Other businesses that use
waste heat for space heating
include district heating
systems and high-temperature
processing plants.
Business Benefits
•No up-front capital required
•Natural gas savings = 3.1 million m3 per year
•Annual energy cost savings = $800,000
•Annual savings of $800,000
•Performance contract with Cogenex saves
INVISTA capital and guarantees results
•$80,000/year goes to INVISTA’s bottom line
•$40,000 incentive from Union Gas
•Full savings retained upon expiry/buy-out of contract
•Installation completed with no unscheduled shutdowns
‘‘
‘‘
high-performance fibres. Its’ Kingston site supplies advanced
nylon fibres used in the manufacture of automobile airbags
and carpets. The company has completed an expansion at
the Kingston site to meet the growing demand for side curtain
airbags. This project is one of several innovative, energy
saving initiatives put in place under a Master Energy Service
Agreement with Alliant Energy Integrated Services - Cogenex.
Working with INVISTA staff, Cogenex identifies candidate
projects. If a project is economically viable, Cogenex completes
the design and installation and is then paid from the measured
energy savings that result.
Our waste heat is now handling 50%
of our building heat requirements.
Steve Hughes
Utilities Optimizer
INVISTA, Kingston, Ontario
enercase
Solution
INVISTA’s solution uses waste process heat for
seasonal building heat throughout the manufacturing
and support areas.
Summary
Waste Heat Recovery
•A forced circulation heat recovery glycol loop with
distribution piping condenses steam at various process
areas and transfers the recovered heat to air
handling units.
INVISTA recovers waste heat and energy dollars
Summary
At INVISTA’s Kingston plant, a new glycol heat recovery loop, installed in 2003, enables waste process heat to be recovered
and redirected for building heat. The results decrease natural gas consumption, reduce emissions and lower heating costs.
An innovative performance contract with energy services company Cogenex made the project possible without up-front
capital from INVISTA. The agreement ensures ongoing monitoring and maintenance of equipment to guarantee savings
performance. Any industrial plant with processes generating hot waste streams and substantial seasonal building heat loads
can apply this heat recovery system.
•Heat exchangers were installed in process units
parallel to existing raw water heat exchangers
and existing scrubbers in the various nylon
polymerization areas.
•A high-pressure steam flash tank and an additional
shell and tube heat exchanger recover heat from
steam condensate.
Are you wasting process
heat that could lower
your energy costs?
•A dedicated control system feeds glycol to the heat
exchangers when steam is available.
•Air handling units were retrofitted with glycol coils.
Existing steam coils or direct-fired natural gas
heaters provide back-up for high heating loads.
Background
Challenge
Environmental Benefits
Wins & Highlights
INVISTA is one of the world’s largest producers of
As part of the nylon manufacturing process, heat
is wasted when steam, generated by the process,
is condensed with cooling water or vented to the
atmosphere. Industrial waste heat recovery usually
captures waste heat from a high temperature
manufacturing process and applies it to other
manufacturing processes operating at lower
temperatures. Since the Kingston site’s nylon
polymerization processes all operate within the same
temperature range, the challenge was to identify a
viable alternative use for the recovered heat.
•2004 Energy Efficiency Award from Natural
Resources Canada
•Heat recovery loop converts waste process
heat to building heat
*
Other businesses that use
waste heat for space heating
include district heating
systems and high-temperature
processing plants.
Business Benefits
•No up-front capital required
•Natural gas savings = 3.1 million m3 per year
•Annual energy cost savings = $800,000
•Annual savings of $800,000
•Performance contract with Cogenex saves
INVISTA capital and guarantees results
•$80,000/year goes to INVISTA’s bottom line
•$40,000 incentive from Union Gas
•Full savings retained upon expiry/buy-out of contract
•Installation completed with no unscheduled shutdowns
‘‘
‘‘
high-performance fibres. Its’ Kingston site supplies advanced
nylon fibres used in the manufacture of automobile airbags
and carpets. The company has completed an expansion at
the Kingston site to meet the growing demand for side curtain
airbags. This project is one of several innovative, energy
saving initiatives put in place under a Master Energy Service
Agreement with Alliant Energy Integrated Services - Cogenex.
Working with INVISTA staff, Cogenex identifies candidate
projects. If a project is economically viable, Cogenex completes
the design and installation and is then paid from the measured
energy savings that result.
Our waste heat is now handling 50%
of our building heat requirements.
Steve Hughes
Utilities Optimizer
INVISTA, Kingston, Ontario
enercase
Waste Heat Recovery
Dave Dove
Chief Operating Engineer, Operations
INVISTA, Kingston, Ontario
Union Gas - Working with you
Union Gas Account Manager, Ron Bruyns and technical staff have
been involved in energy planning with INVISTA for a number of
years. Their participation in boiler performance testing, steam
plant audits and accurate tracking of historical gas consumption
helped determine the project’s economic feasibility. Union Gas
also provided a $40,000 energy efficiency incentive based on
installed equipment.
Call the energy experts at Union Gas
Union Gas is committed to providing industrial energy users
with information on energy efficiency, technologies, services
and incentives. If you’d like to learn how heat recovery can work
in your industry, contact your Account Manager or
visit enersmart.com/largebusiness
Many industrial
and commercial sites
lose precious BTUs
– and dollars – through
exhaust waste streams.
INVISTA has installed
a system that captures
waste heat before it
exits the facility.
The system converts
process heat to
seasonal building
heat – and waste
energy into significant
budget savings.
EnerSmart. For the profit in energy efficiency.™
TM
CONSERVE • SAVE • PROFIT
Energy efficiency projects pay you year after year!
TM
CONSERVE • SAVE • PROFIT
Waste Heat Recovery
Printed on recycled paper using environmentally-friendly inks. ™ E
nerSmart is a trade-mark of Union Gas Limited.
© Union Gas Limited 2009 04/2009 UG20090051
‘‘
‘‘
Capturing heat from our processess makes
us more competitive in the long-term.
Recovery
Recovery
enercase
EnerSmart Programs
Can an air
bag fibre maker
really show a
hospital or
a university
how to lower
energy costs?