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Compressed Air System Improvement Project Saves Foundry Energy and Increases Production

Description: 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.
Date: May 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Additional Steam Traps Increase Production of a Drum Oven at a Petroleum Jelly Plant

Description: 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.
Date: March 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Rohm and Haas: Company Uses Knoxville Plant Assessment Results to Develop Best Practices Guidelines and Benchmark for Its Other Sites (Revised)

Description: 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 M… more
Date: July 1, 2003
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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W. R. Grace: Plant Uses Six Sigma Methodology and Traditional Heat Balance Analysis to Identify Energy Conservation Opportunities at Curtis Bay Works (Revised)

Description: 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 pr… more
Date: December 1, 2003
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Georgia-Pacific: Crossett Mill Identifies Heat Recovery Projects and Operational Improvements that May Save $9.6 Million Annually

Description: 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 natur… more
Date: November 1, 2003
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Citation Corporation: Compressed Air System Optimization Project Saves Energy and Improves Production at Forging Plant

Description: 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 payba… more
Date: May 1, 2003
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Ohio Aluminum Industries: Compressed Air System Improvement Project Saves Energy and Improves Product Quality

Description: 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.
Date: November 1, 2003
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Paramount Petroleum: Plant-Wide Energy-Efficiency Assessment Identifies Three Projects

Description: 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.
Date: July 1, 2003
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Weirton Steel: Mill Identifies $1.4 Million in Annual Savings Following Plant-Wide Energy-Efficiency Assessment

Description: 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 in… more
Date: January 1, 2004
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Corning Inc.: Proposed Changes at Glass Plant Indicate $26 Million in Potential Savings

Description: 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.
Date: January 1, 2004
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Progressive Powder Coating: New Infrared Curing Oven at Metal Finishing Plant Increases Production by 50%

Description: 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 s… more
Date: May 1, 2003
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Control Scheme Modifications Increase Efficiency of Steam Generation System at ExxonMobil Gas Plant.

Description: 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.
Date: January 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint

Description: 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 liqui… more
Date: February 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Achieve Steam System Excellence

Description: 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.
Date: December 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Anchor Glass Container Corporation Plant-Wide Energy Assessment Saves Electricity and Expenditures:Office of Industrial Technologies (OIT) BestPractices Glass Assessment Case Study

Description: Plant-wide energy assessments at the Anchor Glass Warner Robins and Jacksonville plants revealed opportunities that could result in significant annual energy savings.
Date: March 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Upgraded Lighting System Leads to Energy and Cost Savings at Augusta Newsprint Company

Description: 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.
Date: March 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Utica Corporation Plant-Wide Energy Assessment Report Final Summary

Description: 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.
Date: March 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Appleton Papers Plant-Wide Energy Assessment Saves Energy and Reduces Waste: Office of Industrial Technologies (OIT) BestPractices Forest Products Assessment Case Study

Description: 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.
Date: March 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Compressed Air System Upgrade Results in Substantial Energy Savings. Office of Industrial Technologies (OIT) BestPractices Project Case Study

Description: 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.
Date: January 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Compressed Air System Retrofit Increases Productivity at a Petroleum Packaging Facility.

Description: 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.
Date: January 1, 2002
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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Georgia-Pacific Palatka Plant Uses Thermal Pinch Analysis and Evaluates Water Reduction in Plant-Wide Energy Assessment

Description: 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.
Date: December 1, 2002
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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American Water Heater Company: Compressed Air System Optimization Project Saves Energy and Improves Production at Water Heater Plant

Description: 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 no… more
Date: November 1, 2003
Creator: United States. Department of Energy. Office of Energy Efficiency and Renewable Energy. Office of Industrial Technologies.
Item Type: Refine your search to only Text
Partner: UNT Libraries Government Documents Department
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