Short-Term Opportunities (implement today for immediate results)
Mid-Term Opportunities (get results in 1 week to 6 months)
Longer-Term Opportunities (get results in 6 months or more)
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Short-Term Opportunities (implement today for immediate results)
Minimize air leakage into the furnace by sealing openings -
Reduces excess use of fuel used to heat ambient air entering the furnace
Estimated energy savings range: 2-5%
Cost: Low
Available Resources:
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Photo courtesy of Seco/Warwick Corporation
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- Alcoa Lafayette Operations Energy Efficiency Assessment (PDF 235 KB)
- AMCAST Industrial Corporation Energy Assessment (PDF 295 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
- Metlab Plant-Wide Assessment (PDF 640 KB)
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Maintain proper, slightly positive furnace pressure -
Prevents air leakage through openings such as partially open furnace doors, gaps around tubes or rollers, et cetera
Estimated energy savings range: 2-5%
Cost: Moderate
Available Resources:
- Alcoa Lafayette Operations Energy Efficiency Assessment (PDF 235 KB)
- AMCAST Industrial Corporation Energy Assessment (PDF 295 KB)
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Mid-Term Opportunities (get results in 1 week to 6 months)
Reduce weight of or eliminate material handling fixtures -
Includes fixtures, baskets, conveyors used to transport or support the material being heated in a furnace
Estimated energy savings range: 2-10%
Cost: Moderate
Available Resources:
- Metlab Plant-Wide Assessment (PDF 640 KB)
- Utica Corporation Plant-Wide Energy Assessment Report Final Summary (PDF 225 KB)
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Longer-Term Opportunities (get results in 6 months or more)
Modify the furnace system or use a separate heating system to recover furnace exhaust gas heat -
Preheating of load or charge material reduces fuel consumption
Estimated energy savings range: 5-15%
Cost: High
Available Resources:
- Anchor Glass Container Corporation Plant-Wide Energy Assessment (PDF 200 KB)
- Appleton Papers Plant-Wide Energy Assessment (PDF 220 KB)
- Metlab Plant-Wide Assessment (PDF 640 KB)
- Utica Corporation Plant-Wide Energy Assessment Report Final Summary (PDF 225 KB)
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Recover part of the furnace exhaust heat for use in lower- temperature processes -
Reduces fuel consumption by using exhaust gases from a higher temperature furnace to supply heat to lower temperature processes
Estimated energy savings range: 5-25%
Cost: High
Available Resources:
- Alcoa Lafayette Operations Energy Efficiency Assessment (PDF 235 KB)
- AMCAST Industrial Corporation Energy Assessment (PDF 295 KB)
- Anchor Glass Container Corporation Plant-Wide Energy Assessment (PDF 200 KB)
- Appleton Papers Plant-Wide Energy Assessment (PDF 220 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
- Metlab Plant-Wide Assessment (PDF 640 KB)
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