Emerson Exchange 365
Blogs
    • 16 Nov 2016

    Optimizing Energy Usage in Multi-Fuel Boilers

    Steam is a critical part of many process manufacturing processes and the energy to produce it can be a significant source of operational costs. I recently caught up with process automation hall-of-fame member Greg McMillan and Emerson’s Scott Pettigrew at the Emerson Exchange conference here in Austin. Greg and Stan Weiner had recently interviewed Scott in a ControlGlobal.com article, Boilers as fast as can be...
    • 9 Sep 2016

    Reducing Demand Charges in Energy Bills

    The cost of electrical power has grown more complex over time. It used to be that your kilowatt-hours (kwh) consumed were tallied to arrive at the cost. As the metering has grown more sophisticated, variable rates have emerged based on peak energy usage, time of day, usage thresholds and more. I connected with Emerson’s Bill Thackston to learn about a meeting he recently attended on energy management information...
    • 30 Aug 2016

    Energy Management-Plan Do Check Act

    Plan. Do. Check. Act. From Wikipedia : PDCA (plan–do–check–act or plan–do–check–adjust) is an iterative four-step management method used in business for the control and continual improvement of processes and produc...
    • 12 Aug 2016

    Optimizing Sugar Mill Boiler Performance

    Steam boilers are used in sugar mills to generate electricity and for heat in various stages of production, such as crystallization process . This process converts the sugar syrup into sugar crystals. Optimizing the performance of the boilers improves energy efficiency and reliability for this required heat and electricity. I caught up with Emerson’s Scott Pettigrew when he was in town last week and he shared...
    • 13 Oct 2015

    Improving Boiler Operations with Better Measurements

    Emerson’s Bob Sabin , Tim Badger and Scott Pettigrew teamed up on the presentation, Fix Tough Measurement Problems to Improve Boiler Operation. Their abstract: While boilers are crucial to plant/mill business results, many times their performance is lacking. Poor combustion causes higher fuel costs and increased emissions. Lack of reliability and response hurts site production throughput and quality. A root cause...
    • 23 Jul 2015

    Reducing Plant Energy Consumption

    In an earlier post, Identifying Components then Optimizing Industrial Energy Consumption , we discussed how energy optimization initiatives were affected by what could be measured. Emerson’s Jonas Berge added a great comment to that post, which I will share here to bring it greater visibility. Running fans at excess speed, failed steam traps, fouling, inefficient combustion, pipe leaks, poor insulation on steam...
    • 21 Jul 2015

    Avoiding the Impact of Steam Trap Failures

    According to the U.S. Energy Information Administration , industrial manufacturers are larger energy consumers than the transportation, residential and commercial sectors. The industrial sector accounts for around 30 trillion BTUs of energy consumed annually. Energy-intensive processes are found in many industries including chemicals, refining, mining & metals, pulp & paper to name several. Optimizing steam...
    • 6 Jul 2015

    Real-time Measurements Improve Energy Efficiency

    The latest Innovations in Process Control publication by the Emerson team in Europe has an article on where additional measurements can help identify opportunities to reduce energy consumption and improve operations. For readers who have English as a...
    • 9 Jun 2015

    Optimizing Energy Consumption with Real-Time Feedback

    As energy prices slowly creep higher from earlier lows, the need for managing energy usage remains constant for most process manufacturers and producers. The U.S. Department of Energy’s Energy-Intensive Process Portfolio list processes in the refining, petrochemicals, chemicals, plastics metals, pulp & paper as large energy consumers. In an earlier post, Identifying Components then Optimizing Industrial Energy...
    • 16 Apr 2015

    Identifying Components then Optimizing Industrial Energy Consumption

    When optimizing operating costs at a production facility, the bias is toward that which can be measured. For example, the cost of chemicals additives for a process is something easily measured based upon the amount consumed. For components such as the energy to produce steam, the costs may not be so clear. Emerson’s Barbara Hamilton shared a couple of stories with me about how cost optimizations changed once...