Industrial Energy Savings    

Sustainability Projects

Industrial plants are major consumers of water. Water is used in many processes. Sustainability projects focus on reducing the consumption of water and the energy-costs associated with cooling water so it may be effectively used.

Water Conservation

Growing operational costs and lower than average occupancy rates spurred Apple Farm Inn and Suites, San Luis Obispo, Ca., to explore economic and facility efficiency benefits obtained through the installation of an ozone laundry system. At the Apple Farm Inn laundry facility, an evaluation was conducted in late 2006 to early 2007, comparing the costs of laundering by traditional methods versus ozone laundering.

Steam

Properly functioning steam traps open to release condensate and automatically close when steam is present.  Failed traps waste fuel, reduce efficiency, increase production costs and compromise the overall integrity of the steam and condensate systems.  Traps should be tested on a regular basis -- or the neglect may be quite costly.    

Lighting

Outdoor area lighting can be defined as streets, roadways, parking lots and pedestrian walkways. These applications have been subjected by conventional lighting technologies such as high-intensity discharge (HID) lamps and fixtures. HID lighting has been utilized for many years in outdoor area lighting applications and have well-documented performance attributes. Today’s advancements in Light Emitting Diode (LED) technology have resulted in a new alternative for outdoor area lighting, which has several advantages over existing conventional lighting.

HVAC Systems

Reducing energy costs and pollution emissions involves many areas within an industrial facility.  My studies have found seven (7) key (or common) areas where low cost practical projects can be implemented.  Combined, these projects provide savings exceeding 10% of the annual energy spend with an average payback of less than one year.

Cooling Systems

Industrial plants are major consumers of water. Water is used in many processes. Sustainability projects focus on reducing the consumption of water and the energy-costs associated with cooling water so it may be effectively used.

Boilers

This article will focus on a compressed air system assessment done at a printing facility in Canada. The energy costs at the time, in Manitoba, were $0.025 per kWh and the installation was of just 65 horsepower of air compressors.

Bill Mgmt/Demand Control

It’s no secret that cost-cutting is now a main focus for many business owners. When times get tough, the first reaction is figure out where it’s possible to spend less in order to maintain the bottom line. Over the last year, there have been countless examples of companies that eliminated programs, slashed entire departments, and sliced into salaries to protect profits.
This major mill complex upgraded their compressed air system and thereby eliminated $500,000 in annual rental compressor costs, reduced annual cooling-water costs by $500,000, and reduced electrical energy costs by $135,000 per year.
This article reviews two major processes in paper mills: compressed air quality and air compressor cooling.  The central air compressor room was expanded and relocated at the largest privately owned paper mill in Canada.  The compressor space was required by a plant expansion, which would occupy the original compressor space for increased production.
A paper mill in Wisconsin reduced its’ yearly water consumption by 547.5 million gallons and reduced its’ yearly air compressor maintenance costs by $470,000.  
This paper presents a discussion on the topic of Electric Demand Management as it relates to electric tariff rates, new power generation, and incentives to curtail peak usage.
Compressed Air Best Practices interviewed Mr. John Malinowski, Senior Product Manager-AC Motors, Baldor Electric Company.
This month’s article reviews the 7th of the key elements for Low Cost – High Value energy savings.  Each of the previous articles reviewed types of projects which are applicable at many facilities.  The projects ranged from simple procedural actions such as turning off equipment when it is not making a product to more complex, like adding a water to air heat exchanger and extracting heat from the coolant loops to provide warmed make-up air.
Compressed Air Best Practices interviewed Richard Feustel, the Corporate Energy Manager of Briggs & Stratton.
It is widely recognized that compressed air systems account for ten percent of all electricity and roughly sixteen percent of U.S. industrial motor system energy use. Seventy percent of all manufacturing facilities in the United States use compressed air to drive a variety of process equipment.
Compressed Air Best Practices spoke with Peter Kyriacopoulos. Mr. Kyriacopoulos is the General Manager/VP USA Region East for Atlas Copco Compressors.
Compressed Air Best Practices interviewed Michael D. Manzella.  Mr. Manzella is a Senior Vice President, Environmental, Health, Safety and Quality (EH&S), and also the Chief Sustainability Officer for RR Donnelley (RRD).