Bayer Polymers: Plant Identifies Numerous Projects Following Plant-Wide Energy-Efficiency Assessment Page: 4 of 4
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to control six 75-horsepower (hp) motors and six 200-hp motors would yield total
electrical energy savings of 4.64 million kWh annually (a rough but conservative
estimate) and a 10.2-million-pound annual reduction of CO2.
Project 4-Compressed air system optimizationA limited assessment of the
compressor system at the Bayer
plant identified one partially
loaded compressor that
frequently vents up to 500
standard cubic feet per minute
of compressed air. This venting
occurs when the inlet throttle
of the compressor attempts to
balance the system supply to
the actual plant demand. The
WVU team recommended
replacing this 800-hp centrifugal
compressor with a 400-hp
reciprocating compressor. The
new compressor would supply
the required compressed air flow,~II_~-
bu-a -r half t rt pe a- no
but at nearly half the rated power, and nocompressed air would be wasted. This modification is expected to yield total electrical
energy savings of 1.53 million kWh annually and also reduce electrical demand
charges. The reduction in electricity usage will also reduce annual emissions of CO2
by 3.34 million pounds.
Project 5-Four low-cost projects
The following low-cost projects each had a payback of 1 month or less:
1) Insulating steam system components including pipe saddles, flanges, boiler end
covers, and lines where needed
2) Repairing steam leaks in overhead lines
3) Adjusting the fuel/air ratio in Boiler 7 for a 1% efficiency improvement (based on
combustion efficiency tables)
4) Repairing compressed gas leaks (air, NG, and nitrogen).
Repairing the NG leaks alone will save about $321,000 per year. The second greatest
savings, $70,000 per year or 14,300 MMBtu/yr, will come from insulating the steam
system components. The four low-cost projects together are projected to prevent
95,000 MMBtu/yr of lost heat energy and reduce CO2 emissions by 11 million
pounds annually.BestPractices is part of the Industrial
Technologies Program, and it supports the
Industries of the Future strategy. This strategy
helps the country's most energy-intensive
industries improve their competitiveness.
BestPractices brings together emerging
technologies and energy-management best
practices to help companies begin improving
energy efficiency, environmental performance,
and productivity right now.
BestPractices emphasizes plant systems,
where significant efficiency improvements
and savings can be achieved. Industry gains
easy access to near-term and long-term
solutions for improving the performance of
motor, steam, compressed air, and process
heating systems. In addition, the Industrial
Assessment Centers provide comprehensive
industrial energy evaluations to small- and
medium-size manufacturers.
PROJECT PARTNERS
Colt Atlantic
Division of Colt Services
Burford, GA
FOR ADDITIONAL INFORMATION,
PLEASE CONTACT:
Industrial Technologies Clearinghouse
Phone: 800-862-2086
Fax: 360-586-8303
clearinghouse@ee.doe.gov
Visit our home page at
www.oit.doe.gov
Industrial Technologies Program
Energy Efficienc y
and Renewable Energy
U.S. Department of Energy
Washington, DC 20585-0121A STRONG ENERGY PORTFOLIO
FOR A STRONG AMERICA
Energy efficiency and clean, renewable ener-
gy will mean a stronger economy, a cleaner
environment, and greater energy independ-
ence for America. Working
with a wide array of state, community,
industry, and university partners, the U.S.
Department of Energy's Office of Energy
Efficiency and Renewable Energy invests in
a diverse portfolio of energy technologies.DOE/G0-102003-1677
August 2003
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Bayer Polymers: Plant Identifies Numerous Projects Following Plant-Wide Energy-Efficiency Assessment, text, August 1, 2003; Golden, Colorado. (https://digital.library.unt.edu/ark:/67531/metadc1405510/m1/4/: accessed April 19, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.