Energy Audits Icon

Detailed Recommendations and Options for Future Planning

An examination of energy-intensive processes is the first task that should be completed to ensure your process equipment is running at optimal conditions and in compliance with your operating permit as well as meeting your performance needs. Even well-maintained systems require reconditioning or upgrading to maximize operational performance. CleanCap’s skilled aftermarket service team will complete a full inspection to gather operational data such as temperatures, flows, and pressures to analyze any equipment trends that may be causing minor failures that can eventually lead to catastrophic shutdowns. Identifying ineffective energy use is important as it may result in improper product curing, reduced VOC abatement equipment destruction removal efficiency (DRE), and ultimately result in reduced profits and unscheduled downtime. CleanCap’s highly qualified and experienced aftermarket service team can perform an Energy Audit inspection that includes detailed recommendations and options for future planning, parts replacement, or repairs.

The CleanCap team encourages facility operators, managers and/or site maintenance teams to participate in each Energy Audit assessment. This allows the operations and maintenance teams to provide feedback to CleanCap with real-time data. This allows the CleanCap team to monitor the equipment’s historical run data and continual performance therefore allowing us to calculate real-time energy savings and emission reduction plans.

Process HeatingSteam SystemOther
Energy Assessments
Examine Energy-Intensive Processes
Measure Systems Performance
Identify Ineffective Energy Use
Recommend Ways to Improve Energy Efficiency and Reduce Greenhouse Gas (GHG) Emissions
Project Verification
Verify Projected Energy Savings
Tools
Load Balance
Score Card
Excess Air
Furnaces & Ovens
Heat Recovery
Like to Like
Thermal Oxidizer

Simple Fixes

During an Energy Audit, the CleanCap specialist performing the audit will identify “low-hanging fruit” opportunities for energy efficiency improvements that a plant can implement in the near term with little to no cost. These actions tend to be overlooked activities, such as powering down a motor when not in use, putting a door on the furnace, or replacing worn seals or insulation. These simple fixes have minimal implementation costs and immediate paybacks.

Process Changes

CleanCap Energy Audits focus on processes and equipment. The assessments are tailored to locate where a plant is having inefficiencies and where energy is being wasted. The recommended changes might include:

  • Controls Tune-up such as setting the process and / or equipment to go into a stand-by mode during shift changes and lunch breaks.
  • Upgrade Permanent Total Enclosures (PTEs) to minimize dilution air intake
  • Recirculate Dryers, Ovens, and Furnaces
  • Cascade operation to minimize flow to the Air Pollution Control equipment, such as a Regenerative Thermal Oxidizer (RTO)
  • Tune Burner Systems – Air / Fuel Ratio
  • Supplemental Fuel Injection (SFI)
  • Conversion to a Catalytic Oxidizer [i.e. RTO to Regenerative Catalytic Oxidizer (RCO)]
  • Pre-Filtration [i.e. Wet Electrostatic Precipitators (WESPs), Cartridge Filters, Cyclones, Baghouses]

Tools Used with the CleanCap Industrial Energy Audit Program

Load Balance: This tool quantifies how much natural gas is being consumed at a plant.  The tool measures gas consumption per year based on the plant’s billing records.  This is essential for every plant assessment since the actual amount of gas usage must be established to quantify potential gas savings.

Score Card:  This tool ranks energy efficiency opportunities and their feasibility in a plant.

Excess Air: This tool can be utilized to calculate energy savings for upgrading a burner or repairing leaks for induced draft systems.

Furnaces and Ovens: This tool models and quantifies gas energy savings associated with improved furnace or oven efficiency.

Heat Recovery: This tool measures potential energy savings resulting from waste heat recovery. The report covers combustion air preheat, flue gas to air, flue gas to water, and water to water opportunities.

Like to Like: This tool determines gas savings if a piece of equipment is replaced with a new, more energy-efficient technology.

Thermal Oxidizer: This report compares scenarios with different thermal oxidizers depending on the equipment’s application and performance requirements.  It also helps to calculate savings associated with various thermal oxidizer technologies.

Other Aftermarket Services

Preventative Maintenance Icon

Preventative Maintenance

Equipment Upgrades Icon

Equipment Upgrades
& Retrofits

Energy Audits Icon

Energy Audits

Spare Parts Icon

Spare Parts