Energy Consumption Requirements for Air Pollution Control Equipment at An Iron Foundry

Abstract

Energy consumption requirements for air pollution control equipment were studied for varying removal efficiency levels at the Tyler Pipe Industries iron foundry in Tyler, Texas, based on plant fuel consumption data, and on field test measurements of cupola carbon monoxide and particulate control equipment. Natural gas consumption for CO removal increased from 0 in 1970 to 25.4% of the plant total in 1976. Operating costs to achieve 85% CO control increased from 0 in 1970 to $1.61/ton metal in 1976. Increasing cupola incinerator temperature from 800° to 1600° F increased CO removal efficiency from 60 to 97%, but also increased natural gas consumption by 150%. Electricity consumption requirements for 95% to 97% particulate control at the foundry increased from 0.1 % of plant total in 1970 to 18.7% in 1976. Electricity consumption for particulate controls increased plant operating costs from 0.004 in 1970 to 1.693 $/ton metal in 1976 as horsepower increased from 20 to 6,272. Cost-benefit methodology is needed to evaluate trade-offs between air pollution control, energy consumption requirements and operating costs of proposed regulations. Total air pollution control system must be considered in enforcing regulations instead of the source to be controlled alone for overall impacts. Need exists for process modifications to enhance energy recovery and development of energy-effective air pollution control equipment.