1st Edition

Energy Management for the Metals Industry

By Cynthia K. Belt Copyright 2017
    218 Pages 62 B/W Illustrations
    by CRC Press

    218 Pages
    by CRC Press

    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

      1. Summary
      2. Purpose
      3. Why Energy Management?
      4. The Energy Management Program
      5. Steps to Energy Management

    Chapter Two: Commit to the Program

      1. Energy Manager
      2. Energy Team
      3. Energy Policy

    Chapter Three: Define and Measure Performance

      1. Data Collection
      2. Equipment List & Energy Profile
      3. Power and Energy
      4. Electricity
      5. Primary Fuels - Natural Gas, Oils, & Coal
      6. Gas Meters
      7. Secondary Fuels & Gases
      8. Process Performance Indicators
      9. KPI’s – Key Performance Indicators
      10. Setting Overall Goals
      11. Benchmarks

    Chapter Four: Analyze Data and Identify Projects

      1. Data Analysis
      2. Energy Intensity
      3. Project List
      4. Types of Projects
      5. Process Heating
      6. Waste Heat Recovery
      7. Furnace Testing
      8. Technical System Analysis
      9. Chapter Five: Do the Improvements

      10. Creating the Action Plan
      11. Project Methodology

    Chapter Six: Control and Evaluate Progress

      1. Track Progress
      2. Communication
      3. Recognize Achievements
      4. Certification
      5. Conclusion


      1. Appendix I – General Energy Resources
      2. Appendix II - Materials Specific Resources
      3. Appendix III - 250+ Ways to Reduce Industrial Utility Costs
      4. Appendix IV – Materials Specific Energy Saving Ideas
      5. 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.

    "… contains practical, to-the-point and cost effective ways to improve energy efficiency in the metal industry. Practical, to-the-point and full of resourceful reference, good for engineers and plant managers to keep in their toolbox. This book is good for a practical reference book for a busy chemical/process engineer in the metal industry."
    — Krishda Tan, Calcination Process Engineer, Queensland, Australia

    "This is an excellent book that gives detailed information and guidance on conducting and managing energy management projects. The author has given many practical dos and do-nots for a successful energy management project. The material is very well organized and presented for use in an industrial plant. Although the title suggests that this book is for metals industry, most of the material given in the book is applicable to all industrial plants."
    — Arvind C. Thekdi, E3M Inc., North Potomac, Maryland, USA

    "Any metalcasting facility that is interested in using energy more efficiently and improving profits will benefit from this book. A huge number of real-world examples are presented. The author very effectively demonstrates her extensive experience and understanding of the unique requirements and potential solutions for the metalcasting industry."
    — Brian Reinke, American Foundry Society, Lemont, Illinois, USA

    "Cindy Belt has produced a book that has a very practical perspective. It is clearly oriented towards manufacturing personnel who can benefit from her methodology. She provides real world recommendations for identifying problems areas and potential solutions."
    — Edward Williams, Arconic, Pittsburgh, Pennsylvania, USA

    "…a practical guide to energy management in the metals industry. It goes from the big picture to the details and techniques on how to implement an energy program in the industry. It serves as a coaching tool for engineers and people in the industry who are involved in implementing energy management programs. Several real industry case studies are used in the book and examples illustrated with data. Overall a great book to have in your shelf if you are deciding on or starting the implementation of an energy management program in your industry."
    — Rodrigo Corbari, Vallourec Star, Youngstown, Ohio, USA