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Bayer Polymers: Plant Identifies Numerous Projects Following Plant-Wide Energy-Efficiency Assessment

Description: The Bayer Corporation undertook a plant-wide energy efficiency assessment of its New Martinsville, West Virginia, plant in 2001. The objectives were to identify energy saving projects in the utilities area. The projects, when complete, will save the company the loss of an estimated 236,000 MMBtu ($1.16 million) annually in energy from burning and leaking fossil fuels. Certain other projects will save the company 6,300,000 kWh ($219,000) of electrical energy each year. All of the projects could … more
Date: August 1, 2003
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BestPractices Corporate Energy Management Case Study: Alcoa Teams with DOE to Reduce Energy Consumption

Description: This is the first in a series of DOE Industrial Technologies Program case studies on corporate energy management. The case study highlights Alcoa Aluminum's successful results and activities through its corporate energy management approach and collaboration with DOE. Case studies in this series will be used to encourage other energy-intensive industrial plants to adopt a corporate strategy, and to promote the concept of replicating results with a company or industry.
Date: May 2004
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Chevron: Refinery Identifies $4.4 Million in Annual Savings by Using Process Simulation Models to Perform Energy-Efficiency Assessment

Description: In an energy-efficiency study at its refinery near Salt Lake City, Utah, Chevron focused on light hydrocarbons processing. The company found it could recover hydrocarbons from its fuel gas system and sell them. By using process simulation models of special distillation columns and associated reboilers and condensers, Chevron could predict the performance of potential equipment configuration changes and process modifications. More than 25,000 MMBtu in natural gas could be saved annually if a deb… more
Date: May 2004
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Kennecott Utah Copper Corporation: Facility Utilizes Energy Assessments to Identify $930,000 in Potential Annual Savings

Description: Kennecott Utah Copper Corporation (KUCC) used targeted energy assessments in the smelter and refinery at its Bingham Canyon Mine, near Salt Lake City, Utah. The assessment focused mainly on the energy-intensive processes of copper smelting and refining. By implementing the projects identified, KUCC could realize annual cost savings of $930,000 and annual energy savings of 452,000 MMBtu. The projects would also reduce maintenance, repair costs, waste, and environmental emissions. One project wou… more
Date: July 2004
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Neville Chemical Company: Management Pursues Five Projects Following Plant-Wide Energy-Efficiency Assessment

Description: Neville Chemical conducted a plant-wide energy efficiency assessment of its Anaheim, California, plant in the spring of 2002. The assessment justified five projects that would significantly reduce electricity and fuel costs. Four of the five projects, when complete will save 436,200 kilowatt-hours, or$31,840 of electrical energy each year. The remaining project will save 7,473 million British thermal units or$43,600 in fossil fuel each year. One year later, the same assessment team applied its … more
Date: July 1, 2003
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PCS Nitrogen: Combustion Fan System Optimization Improves Performance and Saves Energy at a Chemical Plant

Description: This U.S. Department of Energy Industrial Technologies Program case study describes how, in 2003, PCS Nitrogen, Inc., improved the efficiency of the combustion fan on a boiler at the company's chemical fertilizer plant in Augusta, Georgia. The project saved $420,000 and 76,400 million British thermal units (MBtu) per year. In addition, maintenance needs declined, because there is now less stress on the fan motor and bearings and less boiler feed water usage. This project was so successful that … more
Date: January 2005
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Raytheon: Compressed Air System Upgrade Saves Energy and Improves Performance

Description: In 2003, Raytheon Company upgraded the efficiency of the compressed air system at its Integrated Air Defense Center in Andover, Massachusetts, to save energy and reduce costs. Worn compressors and dryers were replaced, a more sophisticated control strategy was installed, and an aggressive leak detection and repair effort was carried out. The total cost of these improvements was $342,000; however, National Grid, a utility service provider, contributed a $174,000 incentive payment. Total annual e… more
Date: April 2005
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Techni-Cast: Foundry Saves Energy with Compressed Air System Retrofit

Description: In 2002, Techni-Cast improved its compressed air system at its foundry in Southgate, California. The project allowed the foundry to reduce its compressor capacity by 50%, which greatly reduced the foundry's energy and maintenance costs. The annual energy and maintenance savings from the project implementation are 242,000 kWh and $24,200, and the projects cost was $38,000. Because the plant received a $10,000 incentive payment from the California Public Utilities Commission, the total project co… more
Date: March 2001
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