Detailed Energy Investigations
Kinergetics is different from other firms when it comes to identification of energy efficiency opportunities
We start with how the process uses energy since that is where the larger opportunities often exist. Portable metering equipment is often used to verify process parameters and to help ensure accurate energy cost savings estimates.
We consider support systems (compressed air, steam, refrigeration) as appropriate or when requested by our customers.
Energy Record Evaluation
Evaluation of past energy usage (electricity, natural gas, water use) is done to establish seasonal trends and look at current energy usage and spending.
On-Site Assessment
At this stage, we will visit the facility itself and perform an on-site assessment to identify potential projects.
Here, we can cast a wide net for energy reduction opportunities or focus on specific systems of interest.
Project Analysis and Reporting
Based on data gathered during the site assessment, we will determine estimated project savings and cost with engineering analysis.
Results are presented in a way that enables facility personnel to understand the basis for the opportunity and savings.
Projects identified have yielded savings ranging from
10-20X
the fees incurred for the work
A Quick Look Into More Specific Investigations
Combined Heat & Power (CHP)
We have provided feasibility analysis and design for combined heat and power (CHP) and on-site power generation for over 15 years, and are now providing complete CHP evaluation, design and installation.
Our expertise with numerous complex industrial process operations provides unique perspective with respect to integrating CHP into an existing facility; effective Integration is critical for trouble free and economically viable CHP operation.
To learn more about our CHP experience in ethanol plants, click here
Corn Syrup High Concentration
With over 10 years of ethanol specific experience and over 25 years of process industry experience, Kinergetics’ approach is to review each plant’s unit operations and conditions, and then to design the Syrup Concentrator™ so that its operating parameters are effectively integrated with the facility processes.
Combined with the unique Syrup Concentrator™ design, this approach results in thermal efficiencies well in excess of 90%, minimal pumping power and a low cost of operation.
Read more about Kinergetics’ Syrup Concentrator™ here
Process Cooling System Optimization
Kinergetics takes a systems based approach to identify energy cost avoidance opportunities on Freon and ammonia based chillers and their related heat exchangers and cooling towers.
Sub-metering is often used to identify baseline efficiencies, system loads, and the impacts of operating characteristics.
Kinergetics has evaluated systems ranging from 150 to 60,000 tons
Syrup Heating for Corn Oil Extraction
The Kinergetics’ syrup heating system uses specially engineered shell and tube exchangers to maximize heat transfer and handle the “shear thinning” nature of the syrup.
Combined with the unique exchangers, steam conditioning and other design attributes, the Kinergetics syrup heating system is a cost effective approach offering high heat transfer performance, limited potential for burn-on, and ease of cleaning.
Read more about Kinergetics’ expereince with syrup heating in Ethanol plants here
Pseudo-Pinch Evaluation & Design
What is Pseudo-Pinch Design?
Psuedo-Pinch Design is the combination of certain aspects of advanced evaluation ethadologies such as Pinch and Availability Analysis with practical design.
What are the benefits of doing a Pseudo Pinch Evaluation?
With this type of evaluation, it is easier to identify “hidden” energy efficiency opportunities. You are also able to assign practical minimum utility targets, and reasonable cost to energy flows within a facility.
What type of savings can be identified?
PseudoPinch Design was first applied during an energy investigation at an ethanol plant in 2016.
Application of PsuedoPinch Design lead to idetification of a fuel reduction of approximately 17 MMBTU/Hr in a portion of the facility
What industries can Pseudo Pinch be used in?
While initially applied to ethanol production, PseudoPinch can be applied in any facility, including those with CHP and waste heat to power opportunities.
The image above shows the relative value of low-pressure steam in a paper mill.
The Energy Ratio sets value based on enthalpy, and shows very little changes with temperature.
The Availability Ratio shows the more correct values as the Ratio drops with temperature.
Unfortunately, the steam is worthless when at 70 degrees Fahrenheit.
Above is a grid diagram of an existing heat recovery network developed during application of Pseudo-Pinch at an ethanol facility.
A total fuel use reduction of 32 MMBTU/Hr was identified.