Energy Management for the Metals Industry

Energy management training and solutions are not one size fits all. While some general methods apply, the metals industry has its own unique processes and environments for which a more tailored approach is necessary. Aimed at managers, engineers, and supervisors working in the metals industry, Energy Management for the Metals Industry offers specifics that can help readers in the metals field achieve energy savings for their companies. The book explains general energy management methods and offers approaches germane to the metals industry. It discusses the benefits and reasons for implementing an energy management program and the requirements necessary to begin one. The book covers defining and measuring performance, setting baselines, and benchmarking a plant and its processes. It also discusses analyzing data, identifying projects, improving processes, setting goals, and creating an action plan, while controlling and evaluating progress. Real-world examples highlight concepts and illustrate potential pitfalls.

Chapter One: Introduction Summary Purpose Why Energy Management? The Energy Management Program Steps to Energy Management Chapter Two: Commit to the Program Energy Manager Energy Team Energy Policy Chapter Three: Define and Measure Performance Data Collection Equipment List & Energy Profile Power and Energy Electricity Primary Fuels - Natural Gas, Oils, & Coal Gas Meters Secondary Fuels & Gases Process Performance Indicators KPI’s – Key Performance Indicators Setting Overall Goals Benchmarks Chapter Four: Analyze Data and Identify Projects Data Analysis Energy Intensity Project List Types of Projects Process Heating Waste Heat Recovery Furnace Testing Technical System Analysis Chapter Five: Do the Improvements Creating the Action Plan Project Methodology Chapter Six: Control and Evaluate Progress Track Progress Communication Recognize Achievements Certification Conclusion Appendices Appendix I – General Energy Resources Appendix II - Materials Specific Resources Appendix III - 250+ Ways to Reduce Industrial Utility Costs Appendix IV – Materials Specific Energy Saving Ideas Bibliography

Cynthia Belt has developed and managed energy programs at Aleris International, Superior Industries, and Kaiser Aluminum. Within just a few years at each company, these energy programs improved energy intensity by 15% saving the companies millions of dollars. She has published over 15 papers in the area of energy management in the metals industry and has co-edited several proceedings in energy and recycling. Cindy is Past-Chair of the Energy Committee within The Minerals, Metals, and Materials Society (TMS). She is involved in energy groups within TMS, American Foundry Society, and American Society of Mechanical Engineers. Cindy earned her Bachelor of Science, Mechanical Engineering degree from Ohio Northern University and is a Six Sigma Black Belt.