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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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.