Reducing Energy and Emissions Saves Navistar Money
Terry Sexton, regional environmental coordinator, Navistar
As part of Navistar’s sustainability initiatives, and to prepare for a “carbon constrained” future, Navistar developed internal energy conservation and greenhouse gas reduction goals in 2008 for its manufacturing facilities. Using the 2008 monthly energy consumption intensities as a baseline, facilities are challenged to annually reduce electricity consumption intensity during production periods and non-production periods between 2009 and 2013. Meeting the stated goals will reduce energy consumption, reduce greenhouse gas emissions and generate potentially millions in savings by the end of the fifth year. Simply setting energy and greenhouse gas reduction goals also can be a challenge. Should you utilize absolute values or normalization factors? What tracking mechanisms should be used? The tracking and reporting mechanisms and the action plan chosen by Navistar to meet such goals are discussed in detail in this presentation. An essential part of the action plan involves the successful use of a $2 million “Energy Fund” for energy capital projects. A review of the journey to an approved, stand-alone energy fund also will be discussed.
Cutting Energy Costs with Airborne/Structure-borne Ultrasound
Mark Goodman, vice president of engineering, UE Systems Inc.
According to the U.S. Department of Energy, industry consumes one-third of the energy produced in the United States. Compressed air and steam are two of the most costly utilities; add to this the cost of inefficient motors and pumps, and the typical energy bills climb. Ultrasound technology is ideally suited to identify sources of energy waste and to improve asset availability through a comprehensive condition monitoring and energy conservation program. This presentation will review the basics of airborne/structure-borne ultrasound technology and how it is used to locate costly leaks in compressed air and steam systems. Strategies for conducting energy leak surveys along with methods of recording, analyzing and reporting results will also be discussed.
Maintenance, Reliability and Transforming Waste into Green Energy
Allan Trout, manager of maintenance, analysis and reporting, Wheelabrator Technologies
This session will demonstrate how Wheelabrator Technologies transforms waste materials such as municipal solid waste (MSW), tires, wood chips and culm into green energy. This is energy in the form of steam and electricity that can be used to power homes and businesses and help reduce America’s dependence on foreign oil and fossil fuels. The presentation will also explore the ways good maintenance and reliability practices enable the green operation of the Wheelabrator facilities. This will include a discussion of the predictive and preventive maintenance methods and procedures used to monitor equipment condition and the key performance indicators and reports used to evaluate compliance to established maintenance goals.
A Dynamic New Approach to Energy Management
Christopher Russell, principal, Energy Pathfinder Management Consulting
Virtually all facilities have potential energy savings, and energy engineers can prove it. After the technology is settled, the budget and spending debates begin. For many organizations, energy performance depends more on money issues than on technical feasibility. Energy managers should be prepared to demonstrate the money impacts of energy improvements if they want to win greater organizational support for their initiatives. A strong justification addresses more than “payback.” In addition to project cost, show how much it costs to reject a project. Show a break-even cost, which is the most that should be paid, given the facility’s investment criteria. Provide a cost-benefit criterion that compares the cost-to-save vs. the cost to buy energy on a per unit basis. This discussion provides a dynamic new approach to capital budgeting and project justification.
Optimized Boiler Package Evolves from the Super Boiler
Earle Pfefferkorn, president, Cleaver-Brooks Package Boiler
Cleaver-Brooks, in partnership with the U.S. Department of Energy and the Gas Technology Institute, developed the world’s first Super Boiler. Roughly 40%, or more than 80,000 firetube boilers in the marketplace today, are more than 25 years old. The vast majority of these units are operating well below today’s efficiency standards. The energy and emissions savings potential is significant when weighing the cost/price alternatives ranging from complete boiler replacement to retrofitable energy-saving options. This session will outline the history of the Super Boiler project, examine the efficiency/fuel and emission savings, and detail future developments of the project.
Saving Energy & Earning Revenues through Regional Demand Response Programs
Gregg Dixon, senior vice president, EnerNOC Incorporated
Industrial facilities universally struggle with escalating energy costs. Today’s energy crisis has led to rising peak demand, creating unprecedented challenges such as uncertain grid reliability and an increased risk of blackouts and brownouts. EnerNOC will demonstrate how commercial, industrial and institutional end-users can capitalize on regional demand response programs with no cost and no risk. Demand response, the voluntary reduction of electric demand in response to grid instability, provides financial incentives to participating facilities that agree to conserve energy. It acts as a cornerstone to total energy management, enabling facilities to optimize their energy consumption and make a sustainable impact on their energy bills. With demand response, facilities receive advance notice of potential blackouts and can proactively protect their equipment and machinery from sudden losses of power. Demand response is then put into action through simple and easy-to-perform load curtailment, backup generation, and/or a combination of the two.
Save Big Bucks, Big Energy with Reliability Excellence
Darrin Wikoff, principal consultant, Life Cycle Engineering
Reliability Excellence is the foundational step necessary to stabilize performance and remove variation. Practices aimed at improving reliability can pay big dividends in striving toward sustainability success. Regularly monitored and well-maintained equipment can save energy, increase uptime, drive profitability and advance core sustainability objectives. Armed with robust reliability systems, you can ensure sustainability of both manufacturing and the environment while saving big money that would have otherwise been lost on energy and waste. This presentation will show you how companies have successfully reduced energy and disposal costs through a focused effort on manufacturing process reliability.
Improving Energy Efficiency and Productivity in Steelmaking
Lawrence Boyd, director of core programs, Energy Industries of Ohio
Energy Industries of Ohio (EIO) conducted a project titled “Improving the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs and Side Vents” under a U.S. Department of Energy grant at Republic Engineered Products, North America’s leading supplier of special bar quality steel. This effort, which began in mid-2002 in that company’s Basis Oxygen Shop, resulted in a 98% reduction in maintenance needs, saved energy and improved productivity. The equipment installed in this project recently surpassed 10,000 melting cycles, whereas the old design would have been replaced four times by now. Estimates on the remaining life of this equipment suggest that it may be in service for as long as 21,000 heats. This presentation will review the results of this project and its benefits to steel makers.
How Toyota Facility Became a Zero-Landfill Site
Jef S. Friedman, safety and environmental leader, Toyota Motor USA
Toyota's Cincinnati Parts Distribution center is a 200,000-square-foot warehouse that receives and ships more than 12,000 line items daily. This facility warehouses service parts and accessories that are sent to 125 facing dealers in Michigan, Ohio, Kentucky, Tennessee and Southern Indiana. The facility has approximately 38 warehouse associates, 10 management/professional staff and 90 regional sales associates in an adjoining building. Prior to 2007, the facility had its 42-cubic-yard dumpster picked up about every three weeks and taken to the Mt. Rumpke landfill. The site investigated the alternatives to landfill and came up with incineration. Now, all waste is either recycled or incinerated; nothing is sent to the landfill. This session will share Toyota’s methodology and game plan toward physical waste reduction and resource optimization. By following this model, your plant can reduce its environmental impact and attain production and cost benefits.
Proven Strategies to Manage Energy Use in Buildings
Kurt W. Paulus, senior project manager, Trane
In this case study you’ll learn the energy management strategy that Ingersoll Rand employed in its Residential Systems facility in Tyler, Texas. The strategy is expected to net $1.1 million in recurring annual energy cost avoidance for the next eight years. The analysis process and how the energy management program was implemented, including policy decisions, behavior changes, process changes, replacement projects, and improved operations and maintenance practices will be discussed.
Energy Reduction as a Core Component of Cost Reduction
Jerry Osheka, director of environmental compliance, PPG Industries Inc.
In this session, you'll learn how PPG Industries secured management support and then designed the implementation process for their position on energy sustainability and climate change, followed by the creation of, and commitment to, energy reduction goals. Their strategy for energy reduction as a core component of cost reduction will be discussed in detail.
Optimize Asset Performance at the Least Energy Cost
Rod Ellsworth, vice president of global asset sustainability, INFOR
Did you know that you can integrate energy demand management with asset management at your plant or facility to help maintain and extend the life of your assets by reducing your overall energy consumption? An energy and carbon management strategy combined with enterprise asset management functionality will let you identify, optimize and automate proactive maintenance, comparing both the asset performance and its energy usage across your enterprise. Numerous companies such as a high-profile paper manufacturer and a Tier 1 automotive manufacturer have integrated energy into their maintenance strategies and have reduced energy consumption by a minimum of 6 percent, consequently reducing their carbon emissions. In this session, you’ll learn the strategy to improve the operational, financial and environmental performance of your assets while preserving capital and lowering energy costs.
SKF’s Inside/Out Approach to Energy and Sustainability Management
Mike Roberts, program manager for energy and sustainability management, SKF
SKF’s approach to energy and sustainability has five easily identifiable features, all essential in achieving its goals: commitment to a specific, quantifiable goal for CO2 reduction, identification and empowerment of facility energy “champions”, comprehensive assessment of energy and sustainability status, visible project and program execution, and monitoring and tracking results. In this session, you’ll learn how SKF executed this strategy in its plants, and hear a summary of the results of company assessments, the programs that have been initiated and the results achieved. Specific examples in the areas of employee awareness and compressed air system monitoring will be described.
