Plant-Wide Assessment Report for Shaw Industries, Plant #78; Aiken, SC Page: 3 of 144
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Table of Contents
1. EX E C U T IV E S U M M A R Y ............................................................................... 1
O v e rv ie w ................................................................................................... . . 1
Facility E nergy C onsum ption ...................................................................... 2
Assessment Recommendations Summary ................................................ 2
2. ENERGY MANAGEMENT ............................................................................. 6
In tro d u c tio n .............................................................................................. . . 6
Energy Management Performance ........................................................... 6
3. ENERGY RATES AND DATA ...................................................................... 10
O v e rv ie w ................................................................................................. . . 1 0
H istoric U tility C onsum ption ..................................................................... . 17
4. ENERGY PRICE SENSITIVITY.................................................................. 25
5. ENERGY SAVINGS OPPORTUNITY......................................................... 27
ESO1 - Extrusion: Replace DC Motors with AC VSD.............................. 29
ESO2 - Extrusion: Upgrade Belts to Cogged V-belts ............................. 35
ESO3 - Extrusion: Use Synthetic Oil in Gear Box ................................... 38
ESO4 - Extrusion: Replace Electric Bake-off with Natural Gas.............. 41
ESO5 - Extrusion: Upgrade Dowtherm Pipe Insulation .......................... 46
ESO6 - Steam: Repair/replace Traps / Add Drip Legs to Poly-tower Steam
S u p p ly H e a d e r............................................................................... . 4 9
ESO7 - Steam: Evaluate Savings of RO Water Treatment .................... 53
ESO8 - Steam: Verify Proper Operation of 02 Sensor........................... 56
ESO9 - Reduce Flash Losses from Condensate Tank............................. 60
ESO10 - Compressed Air: Repair Air Leaks ........................................... 64
ESO11 - Compressed Air: Evaluate Primary Air Storage....................... 68
ESO12 - Compressed Air: Lower Plant Pressure with the Use of Demand-
s id e S to ra g e ............................................................................... . . 7 3
ESO13 - Compressed Air: Install Compressor Controller....................... 76
ESO14 - Replace Heat Set Compressed Air Supply with Dedicated Low
Pressure Compressed Air Supply .................................................. 78
ESO15 - HVAC: ASD Spray Pumps....................................................... 81
ESO16 - HVAC: Enthalpy Controls on Airwashers................................. 84
ESO17 - HVAC: Cover Entrance for AGV.............................................. 89
ESO18 - Lighting: Retrofit in warehouse w/ Occupancy Sensor.............. 92
6. ESO's WITH UNFAVORABLE ECONOMICS.............................................. 94
Compressed Air: Reverse Aftercooler..................................................... 94
Combined Heat and Power and Distributed Generation .......................... 94
Install Backpressure Turbine to Reduce Steam Pressure at Heatset........... 95
Isolate Heat Set Area with Curtains ......................................................... 96
Use Nitrogen Evaporation for Useful Cooling............................................ 96
Recover Condensate from Heat Set ......................................................... 97
B e lt D riv e s ............................................................................................... . . 9 7
S h utoff S e co nd B o ile r .............................................................................. . 97
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Michael Brown PE, CEM; Soderlund, Matt; PE, Bill Meffert; Baldisserotto, Paolo & Jerry Zolkowski PE, CEM. Plant-Wide Assessment Report for Shaw Industries, Plant #78; Aiken, SC, report, April 10, 2006; United States. (https://digital.library.unt.edu/ark:/67531/metadc883683/m1/3/: accessed May 4, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.