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Achieve Steam System Excellence
This fact sheet describes OIT BestPractices Steam program's systems approach to help companies operate and maintain their industrial steam plants and thermal manufacturing processes more efficiently.
Additional Steam Traps Increase Production of a Drum Oven at a Petroleum Jelly Plant
Additional steam traps were installed on the drum oven at a petroleum jelly production facility at an ExxonMobil plant in Nigeria. The installation improved heat transfer and saved energy.
Advanced Quality Control System for the Thermomechanical Pulping Process Improves Quality and Reduces Energy Costs for Augusta Newsprint
In July 2001, the Augusta Newsprint Company partnered with Invensys' Pacific Simulation group to implement an advanced quality control (AQC) solution for the thermomechanical pulping (TMP) process at Augusta Newsprint's Augusta, Georgia, site. The goal of the project is to decrease energy and raw material costs while maintaining final pulp quality. The project involves coordinating AQC in 3 areas of the paper mill to reduce the amount of energy required for manufacturing. In addition, a time-of-day production (TODP) feature will use current power market pricing data to adjust production rates in the pulping operation to minimize the average cost of purchased energy. The AQC implementation is currently in progress.
Akzo Nobel Morris Plant Implements a Site-Wide Energy Efficiency Plan
Akzo Nobel's Surface Chemistry plant in Morris, Illinois, implemented an energy efficiency plan, which included a plant-wide energy efficiency assessment. The assessment revealed opportunities to save an estimated$1.2 million per year in operating and energy costs, reduce environmental impacts, and improve production capacity.
American Water Heater Company: Compressed Air System Optimization Project Saves Energy and Improves Production at Water Heater Plant
In 2001, American Water Heater Company implemented a system-level improvement project on the compressed air system that serves its manufacturing plant in Johnson City, Tennessee. The plant now operates with less compressor capacity, which has reduced its energy consumption and maintenance needs. The project's total cost was $228,000. The annual compressed air energy savings (2,345,000 kWh) and maintenance savings total $160,000, yielding a simple payback of 17 months. Furthermore, the system now supports the plant's production processes more effectively, which has improved product quality and increased production.
Anchor Glass Container Corporation Plant-Wide Energy Assessment Saves Electricity and Expenditures:Office of Industrial Technologies (OIT) BestPractices Glass Assessment Case Study
Plant-wide energy assessments at the Anchor Glass Warner Robins and Jacksonville plants revealed opportunities that could result in significant annual energy savings.
Appleton Papers Plant-Wide Energy Assessment Saves Energy and Reduces Waste: Office of Industrial Technologies (OIT) BestPractices Forest Products Assessment Case Study
Plant-wide energy survey at the Appleton Papers, Inc. West Carrollton paper mill resulted in 21 recommendations for projects to reduce energy consumption and waste production and improve process efficiency.
Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint
The boiler blowdown process involves the periodic or continuous removal of water from a boiler to remove accumulated dissolved solids and/or sludges. During the process, water is discharged from the boiler to avoid the negative impacts of dissolved solids or impurities on boiler efficiency and maintenance. However, boiler blowdown wastes energy because the blown down liquid is at about the same temperature as the steam produced. Much of this heat can be recovered by routing the blown down liquid through a heat exchanger that preheats the boiler's makeup water. A boiler blowdown heat recovery project at Augusta Newsprint Company's Augusta, GA mill will save almost $31,000 annually in fuel costs.
Compressed Air Project Improves Efficiency and Production at Harland Publishing Facility
Case study describing a project which configured a printing machine so that it consumes less compressed air and required lower pressure to operate effectively. Project replicated throughout the company, leading to energy cost savings of $200,000 per year, or 2.9 million kilowatt-hours.
Compressed Air System Improvement Project Saves Foundry Energy and Increases Production
This case study highlights International Truck and Engine Corporation's optimization project on the compressed air system that serves its foundry, Indianapolis Casting Corporation. Due to the project's implementation, the system's efficiency was greatly improved, allowing the foundry to operate with less compressor capacity, which resulted in reduced energy consumption, significant maintenance savings, and more reliable production.
Compressed Air System Project Improves Production at a Candy-Making Facility
The H.B. Reese Company successfully completed an upgrade of this compressed air system at its facility in Hershey, PA. The plant took two compressors offline while increasing throughput and quality.
Compressed Air System Retrofit Increases Productivity at a Petroleum Packaging Facility.
This case study highlights a compressed air improvement project implemented at the Mobil lubricating-blending plant in Vernon, California. The project reduced the plant's energy production and maintenance costs, and increased reliability due to increased efficiency of the compressed air system.
Compressed Air System Retrofitting Project Improves Productivity at a Foundry. Office of Industrial Technologies (OIT) Metal Casting BestPractices Project Case Study
This case study highlights International Truck and Engine Corporation's optimization project on the compressed air system that serves its foundry, Indianapolis Casting Corporation. Due to the project's implementation, the system's efficiency was greatly improved, allowing the foundry to operate with less compressor capacity, which resulted in reduced energy consumption, significant maintenance savings, and more reliable production.
Compressed Air System Upgrade Improves Production at an Automotive Glass Plant
In 2000, The Visteon automotive glass plant improved its compressed air system at its automotive glass plant in Nashville, Tennessee. This improvement allowed Visteon to save $711,000 annually, reduce annual energy consumption by 7.9 million kilowatt-hours, reduce maintenance, improve system performance, and avoid $800,000 in asbestos abatement costs.
Compressed Air System Upgrade Results in Substantial Energy Savings. Office of Industrial Technologies (OIT) BestPractices Project Case Study
This case study highlights a compressed air system upgrade at BWX Technologies manufacturing plant in Lynchburg, Virginia, which replaced antiquated compressors and dryers and implemented an improved control strategy, resulting in improved energy efficiency and savings in energy and maintenance costs.
Consolidated Compressed Air System Reduces Power Consumption and Energy Costs Office of Industrial Technologies (OIT) Forest Products BestPractices Technical Case Study
Augusta Newsprint Company consolidated two compressed air systems at its facility in Augusta, GA. The results are a more streamlined system, added storage capacity, backflow prevention, and the elimination of unused equipment.
Control Scheme Modifications Increase Efficiency of Steam Generation System at ExxonMobil Gas Plant.
This case study highlights control scheme modifications made to the steam system at ExxonMobil's Mary Ann Gas Plant in Mobile, Alabama, which improved steam flow efficiency and reduced energy costs.
Fan System Optimization Improves Production and Saves Energy at Ash Grove Cement Plant
This case study describes an optimization project implemented on a fan system at Ash Grove Cement Company, which led to annual energy and maintenance savings of $16,000 and 175,000 kilowatt-hours (kWh). In 1999, Ash Grove Cement Company implemented an optimization project on a fan system in its cement plant in Durkee, Oregon. Because of a severe vibration problem, the fan system would often fail and require frequent repairs to the ductwork and adjoining machinery. The plant replaced the belt drive with an Adjustable Speed Drive (ASD) to improve the control of the fan system and lower its energy consumption. This change eliminated the vibration problem and improved the system's airflow control and energy efficiency. The project led to annual energy and maintenance savings of $16,000 and 175,000 kilowatt-hours (kWh). In addition, the fan system's improved reliability allowed the plant to achieve its desired production level. Because of partial funding from the Northwest Energy Efficiency Alliance (NEEA), the total project cost was approximately $10,000, which gave the Durkee plant a simple payback of 7.5 months.
Four Equipment Upgrade Projects Reduce System Energy Losses at Augusta Newsprint
Augusta Newsprint Company performed a plant-wide energy assessment that implemented four projects involving pumping systems presented in this study, which are projected to reduce energy consumption by over 5,200 megawatt hours.
Metlab Plan-Wide Assessment. Office of Industrial Technologies (OIT) BestPractices Assessment Case Study
This OIT BestPractices case study describes the methods and results of a plant-wide energy assessment at Metlab's aircraft component manufacturing plant in Wyndmoor, PA. Recommendations derived from the assessment, if implemented, can save an estimated $528,400 annually, reduce natural gas use by 50,070 MMbtu per year, and reduce electrical use by 329,400 kWh per year.
Millwater Pumping System Optimization Improves Efficiency and Saves Energy at an Automotive Glass Plant
In 2001, the Visteon automotive glass plant in Nashville, Tennessee renovated its millwater pumping system. This improvement saved the plant $280,000 annually in energy and operating costs, reduced annual energy consumption by 3.2 million kilowatt-hours, reduced water consumption, improved system performance, and reduced use of water treatment chemicals.
Ohio Aluminum Industries: Compressed Air System Improvement Project Saves Energy and Improves Product Quality
In 2001, Ohio Aluminum Industries implemented the first phase of a compressed air system improvement project at its Cleveland, Ohio, plant. By completing this phase, the plant stabilized the system's pressure and improved its performance. Furthermore, it yielded annual energy savings of 716,000 kilowatt-hours and $73,200. The total cost for the project's first phase was $83,500, making the simple payback slightly more than 1 year.
Optimizing Electric Motor Systems at a Corporate Campus Facility
3M conducted an in-house motor system study in 29 buildings at the 3M Center. The company evaluated approximately 1,000 electric motors and upgraded systems, resulting in reduced electricity use and cost savings of $77,554 per year.
Pump System Optimization Saves Energy and Improves Productivity at a Daishowa America Paper Mill
Review of pumping system at paper mill led to installation of mechanical Adjustable Speed Drives on two pumps, which resulted in annual energy savings of $32,000 and 700,000 kilowatt hours.
Upgrade of Compressed Air Control System Reduces Energy Costs at Michelin Tire Plant. Office of Industrial Technologies (OIT) BestPractices Project Case Study
This case study highlights the upgraded compressed air system at a Michelin tire manufacturing plant in Spartanburg, South Carolina. The controls upgrade project enabled multiple compressor operation without blow-off, and significantly reduced energy costs.
Upgraded Lighting System Leads to Energy and Cost Savings at Augusta Newsprint Company
New metal halide light fixtures have replaced the 1960s-era mercury vapor light fixtures at Augusta Newsprint Company's facility in Augusta, Georgia. The results have included increased lighting levels, decreased maintenance costs, and reduced energy demand. Annual energy savings total nearly $65,000; with a total installed cost of $100,000, the project will pay for itself in 1.5 years.
Utica Corporation Plant-Wide Energy Assessment Report Final Summary
Utica Corporation conducted a plant-wide energy assessment of the manufacturing processes and utilities at its facility in Whiteboro, NY. As a result of the assessment, the company is now implementing six energy conservation projects that will result in significant cost savings and efficiency improvements.
W. R. Grace: Plant Uses Six Sigma Methodology and Traditional Heat Balance Analysis to Identify Energy Conservation Opportunities at Curtis Bay Works (Revised)
The plant-wide energy assessment at W. R. Grace's Curtis Bay Works helped identify four projects with combined potential savings of $840,000 per year. A separate, unique project that would partner W. R. Grace with the City of Baltimore to recover and use landfill gas (methane) to cogenerate steam and electricity was also identified during the assessment. If implemented, the project would recover gas from the landfill to replace 40% of the electricity and 65% of the fuel currently required to produce steam at Curtis Bay Works. Annual savings are estimated at $900,000 to $1.2 million.
Weirton Steel: Mill Identifies $1.4 Million in Annual Savings Following Plant-Wide Energy-Efficiency Assessment
The Weirton Steel Corporation performed a plant-wide energy assessment of its steel mill plant in Weirton, West Virginia. Based on the assessment results, the company found strong economic justification for six projects that would reduce the use of fossil fuel, electrical energy, and water. All of the projects would save fossil fuel either for heating steam or firing the furnace. This savings totals 108,300 million British thermal units (MMBtu) annually or $1.27 million. Other yearly savings include 119 million gallons of water ($87,110) and 84,000 kilowatt-hours (kWh) or $3,357 of electrical energy. All of the projects could be applied to other steel mills and possibly other industries using steam processes and furnaces.
Bayer Polymers: Plant Identifies Numerous Projects Following Plant-Wide Energy-Efficiency Assessment
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 be duplicated in other chemical manufacturing facilities and most of the projects could be duplicated in other industries utilizing steam, pumps, and/or compressed air.
Citation Corporation: Compressed Air System Optimization Project Saves Energy and Improves Production at Forging Plant
In the 1990s, a subsidiary of the Citation Corporation, Interstate Forging, implemented a compressed air system improvement project at its Milwaukee, Wisconsin, forging plant. This improvement enabled the plant to maintain an adequate and stable pressure level using fewer compressors, which led to improved product quality and lower production downtime. The project also yielded annual energy savings of 820,000 kWh and$45,000. With a total project cost of$67,000, the plant achieved a simple payback of just 1.5 years.
Corning Inc.: Proposed Changes at Glass Plant Indicate $26 Million in Potential Savings
In 2000, the Corning glass plant in Greenville, Ohio, consumed almost 114 million kWh of electricity and nearly 308,000 MMBtu of natural gas in its glassmaking processes for a total cost of approximately $6.4 million. A plant-wide assessment indicated that improvement projects could save nearly $26 million and reduce natural gas use by 122,900 MMBtu per year, reduce electrical use by 72,300,000 kWh per year, and reduce CO2 emissions by 180 million pounds per year.
Dow Chemical Company: By-Product Synergy Process Provides Opportunities to Improve Resource Utilization, Conserve Energy, and Save Money
Forty Dow Chemical Company plants in Texas and Louisiana could save $15 million per year and reduce emissions by reusing wastes as described in this Industrial Technologies Program case study.
FMC Chemicals: Burner Management System Upgrade Improves Performance and Saves Energy at a Chemical Plant
FMC Chemicals Corporation increased the efficiency of two large coal-fired boilers at its soda ash mine in Green River, Wyoming, by upgrading the burner management system. The project yields annual energy savings of 250,000 MMBtu.
Ford Cleveland: Inside-Out Analysis Identifies Energy and Cost Savings Opportunities at Metal Casting Plant; Industrial Technologies Program Metal Casting BestPractices Plant-Wide Assessment Case Study
The Ford Cleveland Casting Plant used results from its plant-wide energy efficiency assessment to identify 16 energy- and cost-saving projects. These projects addressed combustion, compressed air, water, steam, motor drive, and lighting systems. When implemented, the projects should save a total of$3.28 million per year. In addition, two long-term projects were identified that together would represent another$9.5 million in cost savings.
Georgia-Pacific: Crossett Mill Identifies Heat Recovery Projects and Operational Improvements that May Save $9.6 Million Annually
An assessment team conducted a mill-wide energy survey at Georgia-Pacific's Crossett, Arkansas mill to update a previous pinch analysis. Three heat recovery projects were identified that could reduce annual costs by $4.8 million and reduce natural gas use by 1,845,000 x 106 Btu. The overall payback period for the heat recovery projects would be less than 1 year. Furthermore, by implementing operational improvements, the mill could save $4.8 million more annually and 1,500,000 x 106 Btu in natural gas.
Georgia-Pacific Palatka Plant Uses Thermal Pinch Analysis and Evaluates Water Reduction in Plant-Wide Energy Assessment
This OIT BestPractices Case Study describes the methods and results used in a plant-wide assessment at a Georgia-Pacific paper mill in Palatka, FL. Assessment personnel recommended several projects, which, if implemented, have the potential to save the plant more than 729,000 MMBtu per year and$2.9 million per year. In addition, the plant could reduce water use by 2,100 gallons per minute.
J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant
This DOE Industrial Program case study describes how the J.R. Simplot Company saved energy and money by increasing the efficiency of the steam system in its potato processing plant in Caldwell, Idaho.
Lehigh Southwest Cement Company: Compressed Air System Improvement Saves Energy at a Lehigh Southwest Cement Plant
In 2001, Lehigh Southwest Cement Company improved the compressed air system at its cement plant in Tehachapi, California. Consequently, the system was able to operate more efficiently with less compressor capacity and at a lower system pressure. The project yielded total annual savings of 895,000 kWh and $199,000. The initial project cost was $417,000, but Southern California Edison provided a $90,000 incentive payment to reduce the cost to $327,000. Simple payback was about 20 months.
Neville Chemical Company: Management Pursues Five Projects Following Plant-Wide Energy-Efficiency Assessment
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 knowledge of Neville's processes in a plant-wide assessment at Neville's Pittsburgh plant, and identified 15 projects with more than$715,000 in projected annual savings.
Paramount Petroleum: Plant-Wide Energy-Efficiency Assessment Identifies Three Projects
The Paramount Petroleum plant-wide energy assessment identified a cost-effective electrical power and heat energy production facility and systems that could benefit from either fuel-burn adjustments or a new drive/control system. This could lead to independence from a local electric utility with much improved reliability, estimated annual energy savings of 1,200,000 kWh of electricity, and estimated annual savings of$4.1 million for energy reduction and other improvements.
Progressive Powder Coating: New Infrared Curing Oven at Metal Finishing Plant Increases Production by 50%
Progressive Powder Coating in Mentor, Ohio, is a metal finishing plant that uses a convection oven in its manufacturing process. In an effort to save energy and improve production, the company installed an infrared oven in between the powder coating booth and the convection oven on its production line. This installation allowed the plant to increase its conveyor line speed and increase production by 50 percent. In addition, the plant reduced its natural gas consumption, yielding annual energy savings of approximately$54,000. With a total project cost of$136,000, the simple payback is 2.5 years.
Rohm and Haas: Company Uses Knoxville Plant Assessment Results to Develop Best Practices Guidelines and Benchmark for Its Other Sites (Revised)
Rohm and Haas conducted a plant-wide energy assessment at its Knoxville, Tennessee, chemicals manufacturing facility. The assessment identified potential annual energy savings of nearly 47,000 MMBtu in steam and fuel and 11,000 MWh in electricity. Annual cost savings were estimated at almost$1.5 million. After the assessment was replicated in California and Kentucky plants, the companys additional estimated cost savings were$500,000 annually. Additional annual energy savings were about 23,000 MMBtu and 6,000 MWh. The assessments also indicated the plants would reduce nitrous oxide emissions.
Save Millions by Improving Operating Efficiency and Productivity
Summary of AMCAST Industrial Corporation's plant-wide assessment to identify energy and cost saving opportunities at the corporation's facility in Wapakoneta, Ohio.
Valero: Houston Refinery Uses Plant-Wide Assessment to Develop an Energy Optimization and Management System
This Industrial Technologies Program case study describes an energy assessment team's recommendations for saving $5 million in energy, water, and other costs at an oil refinery in Houston, Texas.