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Industrial Newsbriefs

March 2012

Welcome to this edition of Industrial Newsbriefs, produced by the Washington State University Extension Energy Program, and sponsored by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE). Please forward this issue to those of your colleagues interested in industrial energy efficiency. View archive 

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Combined Heat and Power (CHP)

Pilot program for boiler CHP in Ohio

In a recent press release, the Public Utilities Commission of Ohio (PUCO) announced a partnership with the U.S. Department of Energy to launch a pilot program that will offer technical assistance to industrial boiler operators who invest in combined heat power in Ohio. This effort is a result of the upcoming U.S. EPA Clean Air Act standards (Boiler MACT), and "will enable owners and operators of industrial boilers in Ohio to evaluate and invest in those technologies that enable them to thrive economically while meeting environmental regulations." A workshop to discuss the pilot program is scheduled for March 9th in Ohio, and will also be webcast live on the PUCO website.

In February 2012, two articles on CHP appeared on the Sustainable Plant website:

"Engine Plant Cuts CO2 and Energy Costs with Cogeneration," published February 10, 2012, describes how a jet engine manufacturing facility was able to save energy and produce two thirds of its own power onsite by installing a CHP system and linking it to a heat-recovery steam generator.

"Improve Energy Security and Overcome Price Volatility with Cogeneration," published February 22, 2012, explains how cogeneration can buffer price volatility and increase power reliability while also saving energy. Common types of systems are briefly described, and an overview of system feasibility analysis is provided.

Compressed Air

The January/February 2012 edition of Compressed Air Best Practices is now available for download. This issue's topic is Bottling; included are several case studies of compressed air efficiency measures in industrial bottling plants, an article on PET bottle blowing efficiency, and an article showing how to determine if compressed air leaks are worth fixing.

Energy Management

BPA Energy Smart program exceeds expectations

The Bonneville Power Administration's Energy Smart Industrial (ESI) program provides guidance and assistance to industry partners for the implementation of energy efficiency and energy management measures. In 2011, the program was found to have exceeded expectations by producing 28 MW of documented energy savings, far surpassing the program's original target of 15 MW for the same year, and more than doubling the 12 MW energy savings achieved in 2010. To learn more, read "Industrial Energy Program Surpasses Expectations," published February 2, 2012, at EnvironmentalLeader.com.

Energy savings in the chemical industry

"Petrochemical Plant Proffers a Plethora of Energy-Saving Opportunities," written by Veerasamy Venkatesan, CEM, appeared February 2, 2012 on the Sustainable Plant website. This article describes specific examples of energy saving opportunities found in a petrochemical plant. An opportunity was identified to recover flash-steam by changing the configuration of the plant's condensate systems to optimize efficiency.

Grants and Funding

AMO State Incentives and Resource Database

The United States Department of Energy's Advanced Manufacturing Office (AMO) recently updated its State Incentives and Resource Database. The database allows users to search for grants, loans, rebates, trainings, and other opportunities by location, sponsor, program, industrial system, energy type, or keyword.

DOE funds for building and plant efficiency training programs

On February 16, the U.S. Department of Energy (DOE) and the National Institute for Standards in Technology (NIST) Manufacturing Extension Partnership Program announced funding to support training centers targeted at improving energy performance in commercial buildings and manufacturing plants. $1.3 million in funding will be provided to educational institutions and trade associations to create building efficiency training programs. For more information, see the press release.

Industrial Heating

Building a better furnace

"Continuous Melting Furnace," published in the February 2012 issue of Industrial Heating, describes a new kind of scrap metal furnace, currently patent pending, which the author states will achieve greater efficiency at lower cost than standard designs. The furnace operates continuously, greatly reducing down time and cleanup costs, and has a smaller footprint than currently available models. While this article is obviously intended to promote the new furnace and was written by its designer, it contains useful ideas and is enthusiastically written.

Motors

Plan for motor maintenance and repair

"Make Repair a Priority and Achieve Savings" was written by Motor Decisions Matter, and appeared in the January issue of Maintenance Technology. This short article encourages regular maintenance and repair of motors in accordance with ANSI standards, and provides examples of cost savings achieved by industry.

Policy and Legislation

WRI analysis of Midwest manufacturing energy

The World Resources Institute, with assistance from the Midwest Governor's Association, the University of Illinois, and the Great Plains Institute, released "Midwest Manufacturing Snapshot: Energy Use and Efficiency Policies" in February 2012. This working paper provides an overview of industrial energy expenditures in the Midwestern states, and analyzes each state's policies to reduce energy costs and emissions in manufacturing. The paper is intended to promote sound decision-making by policymakers.

Automation and control companies form coalition to promote industrial efficiency

An alliance of industrial automation and controls suppliers recently announced the formation of the Industrial Energy Efficiency Coalition (IEEC). The coalition's stated mission is to "leverage its expertise and track record in controls and automation for the industrial productivity to improve energy efficiency in industrial systems and processes and in business ecosystems." The partnership was announced at the ARC World Industry Forum in February 2012.

Resources

NWFPA launches collaboration space

The NW Food Processors Association (NWFPA) has launched a new web-based collaboration space at www.FoodInnovationMarketPlace.com. Designed with and by the community of suppliers and food processors, the site will help the industry's companies Connect, Collaborate and Learn. Join this site to start a dialog about energy efficiency, find a supplier, or contact rmarshall@nwfpa.org for more information.

New and updated steam resources from AMO

In January and February, 2012, The U.S. Department of Energy's Advanced Manufacturing Office (AMO) released an updated set of guidance documents related to steam system performance and efficiency. Improving Steam System Performance: A Sourcebook for Industry, 2nd Edition, is a 56-page document which provides an overview of steam systems, explains how to identify opportunities for improvement in steam system operation and efficiency, and offers a list of contacts, resources, and tools. In addition, 27 new tip sheets covering all aspects of steam systems management and techniques are now available on the AMO Steam web page.

Thermal Technologies

The following articles appeared in the January 2012 issue of Industrial Heating:

"Active Screen Plasma Nitriding – An Efficient, New Plasma Nitriding Technology" was jointly authored by Pierre Collignon, PD2i Europe; Jean Georges, Plasma Metal, Luxembourg; and Christian Kunz, PD2i North America. The article begins with a brief history of nitriding technologies and moves to a lengthy discussion of ASPN (active screen plasma nitriding). The advantages of ASPN are discussed; they include lower energy consumption.

"New Configuration May Make It Harder to Say 'No' to Thermal Regeneration" was co-authored by Sean Barraclough and Bryan J. Kraus; both of Olson Industries. The author provides some background to the changes in technologies employed to heat industrial furnaces. These technologies include the Stirling Engine, the Bessemer process, the Siemens-Martin process, an improved Bessemer process, and a "compact" thermal regenerative system. Finally, a new and improved system of thermal generation that offers lower initial costs as well as fuel savings is well-described.

UPCOMING EVENTS AND TRAININGS

Pacific Northwest

Adjustable Speed Drive Applications and Energy Efficiency
Two locations:
Everett, Washington: March 28, 2012
Spokane, Washington: March 29, 2012
This course addresses the choices available and relevant issues regarding the use of adjustable speed drives (ASD) with electric motors, and demonstrates the energy cost savings and other benefits made possible by this technology. In this course we explore how adjustable speed drives work and ways to assess the savings. Variable frequency drives (VFD) are the most common speed control method and is the major focus of the course content which will cover the benefits of pulse width modulation technology and well as discovering and mitigating harmful electromagnetic interference that can cause motor failure. Additional information on evaluating and specifying VFDs is provided.

Compressed Air Challenge - Level 2
March 28-29, 2012, Pocatello, Idaho
Optimizing your compressed air systems can lead to higher productivity, energy savings, increased product quality and greater efficiency. This advanced training teaches you to develop a system profile and address point-of-use issues, including determining actual air quality requirements and investigating and reducing highest point-of-use pressure requirements. This course is sponsored by Idaho Power Company, Rocky Mountain Power, Idaho Office of energy Resources, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Energy Efficiency of Chilled Water Systems and Cooling Towers
April 10-11, 2012, Nampa, Idaho
Chilled water systems, which provide cooling for industrial and commercial facilities, often account for a major portion of the energy consumed in these facilities. Attendees will learn how technology improvements can reduce energy costs by more than half. Topics include chiller machinery, refrigerant options, the impact of using variable speed for compressors, system pumps, and cooling towers. In addition, a case study will be presented that shows how an energy-efficient chiller was selected.

Pumping System Optimization
April 17, 2012, Missoula, Montana
The course will show how the variable speed drive can save power by slowing down the pump speed, which will save energy and reduce cost in the process. With the system running more efficiently, maintenance and operating costs will go down and the mean time between repairs will improve.

Introduction to Energy Data Analysis and KPIs
May 1, 2012, Longview, Washington
Learn how to find the existing opportunities for saving money and energy. Understand how to use the information already available at your company to identify the impact of energy on your business. You will leave this training with tools and resources that will help you effectively use energy productivity data to make improvements that will decrease your operating costs and increase productivity. This training includes practical exercises and in-class discussion.

Webinars and Online Courses

IEE&CHP Webinar #3: Elevating IEE Regulatory Issues for Commissioners
March 6, 2012, 9:00 AM PST
This Webinar will examine regulatory issues that impact utility incentive programs, such as flexibility and consistency in offerings, free-ridership, and risk mitigation techniques. Utility, commission, and industrial customer viewpoints will be shared.

US EPA Greenhouse Gas Reporting Program Webinar II: Navigating the Process and Understanding the Impacts
March 7, 2012, 9:00 – 10:30 AM PST
Please join Ohio University for a complimentary webinar to explore how the GHG Reporting Program is affecting Ohio companies. This webinar is the second in a series of informational sessions being developed by Ohio University and will expand upon the information presented previously. The ins and outs of the GHG reporting program will be discussed by a panel of experts. Part I is also available for viewing (see link above).

Slurry Pump Design & Testing (Slurry Webinar Series part 2)
March 13, 2012, 10:00 – 11:00 AM PST
Fee: $79
Session 2 is appropriate for engineers who are evaluating, designing and testing Slurry Pumps. In this session, Mr. Addie will discuss slurry pump types and their application, pump hydraulic design, mechanical design features, assembly, nozzle loads, and testing. After this session, you will be able to consider the various technical options and needs of a slurry pump and evaluate their worth in a design. Advance registration is required.

Superior Energy Performance and ISO 50001: How Superior Energy Performance will Help Your Plant Implement ISO 50001
Webcast, March 13, 2012, 11:00 AM – 3:00 PM PST
This webcast will focus on how Superior Energy Performance will assist U.S. Industry in implementing ISO 50001, the International Standards Organization's (ISO) international energy management standard. This standard provides industry with a framework for energy management, assists industry with the reduction of industrial energy intensity, and provides strategies for monitoring and verifying this progress. The presenters will also highlight the U.S. Department of Energy's plans to assist industry with standards implementation.

Energy Management Opportunities for Industrial Customers

Upcoming Dates:
March 14, 2012, 8:00-9:00 AM PST
April 24, 2012, 10:00-11:00 AM PST
With energy costs on the rise, improving energy efficiency is on everyone's mind. This webinar on industrial energy efficiency will cover the basics, including kW versus kWh, power factor, and more. We will also discuss end-use technologies such as motors, boiler or furnace heating systems, compressed air, industrial heat pumps, induction heating, and HVAC. You will learn to identify top energy-efficiency opportunities and potential savings for each; valuable information that will help you stay within your energy budget.

Slurry Pump Wear and Application (Slurry Webinar Series part 3)
March 27, 2012, 10:00 – 11:00 AM PST
Fee: $79
Session 3 is appropriate for engineers designing and applying slurry pumps. This session will focus on slurry pump wear, service classes, selection, application, materials of construction, operation and maintenance. Upon completion of this session, you will be able to estimate expected wear for a given duty and evaluate wear, capital cost, and hydraulic performance design tradeoffs. Advance registration is required.

Energy Efficiency Financial Analysis (Webinar)
April 5, 2012, 1:00-2:00 PM PST
As you purchase new, energy-efficient equipment in support of your 2012 energy plan, you will need to conduct a payback analysis to justify the investment. This webinar will discuss key financial concepts that lay the foundation for investment analysis, including: simple payback, time value of money, net present value, internal rate of return, and life-cycle cost analysis. We will also review real-world examples. Boost your confidence when discussing the justification for energy-efficiency investments with senior management by attending this webinar.

Adjustable Speed Drives
Two Dates:
June 8, 2012, 1:00-2:00 PM PST
October 4, 2012, 10:00-11:00 AM PST
In the right applications, adjustable speed drives (ASDs) offer great energy-saving potential from high power factor to improved speed control, soft-start capabilities, and more. This webinar will discuss how they work, the savings potential, best applications, sizing, and how to solve variable frequency drive (VFD) power-quality issues.

Steam End User Training – E-Learning
Self-paced online workshop
This course covers the operation of typical steam systems and discusses methods of system efficiency improvement. A brief demonstration of the BestPractices Steam System Tool Suite software is highlighted to help identify and quantify savings from selected potential improvement examples. The training is designed for plant personnel, such as energy managers, steam system supervisors, engineers, and equipment operators, who have steam system responsibilities in industrial and institutional plants.

Steam Systems E-Learning
Self-paced online workshop
This training course will provide an overview of the BestPractices Steam Tool Suite. The training course will begin with a navigational tutorial to guide you on how to move through the three modules. Each training module will demonstrate the capability of one tool and its interactions with the other tools. Interactive quizzes will be used to test your basic understanding of the tools after you complete the course.

Other Regions

Manufacturing Demonstration Facilities Workshop
March 12, 2012, Chicago, Illinois
The U.S. Department of Energy's (DOE) Advanced Manufacturing Office (AMO) will be hosting a workshop to discuss with stakeholders some of the key foundational aspects for a new group of Manufacturing Demonstration Facilities (MDF) currently in their planning stages. This workshop will provide critical information on the AMO program vision, the MDF program objectives, and opportunities associated with the development of proposals to respond to an anticipated Funding Opportunity Announcement for "Manufacturing Demonstration Facilities." The workshop will include overview presentations by government personnel, an information session to respond to questions from participants, and a networking session to facilitate interaction among the session participants.

Energy Challenges: 2012 Public and Land-Grant University Conference
April 29-May 1, 2012
Columbus, Ohio
The 2012 Conference on Energy Challenges will examine the role of public and land-grant universities in leading the technology, understanding and public education of advanced energy options. Join us for this vital discussion on how we can face our energy challenges and lead our nation into the energy future through discoveries in advanced energy expansion and innovations.

UW-Madison Engineering Professional Development Ammonia Refrigeration Courses
Various dates throughout 2012
Madison, Wisconsin or on-site
The University of Wisconsin – Madison Engineering Professional Development (EPD) is offering courses which provide comprehensive coverage of all aspects of ammonia refrigeration systems. Courses focus on specific topics, including ammonia system safety, energy efficiency, process hazard analysis, compliance auditing, mechanical integrity, piping, and design. EPD can deliver courses on-site and tailor programs to meet individual needs.

MORE TRAININGS IN INDUSTRIAL ENERGY EFFICIENCY

For a listing of other upcoming industrial energy efficiency trainings, visit the following websites:

Energy Events Calendar

Northwest Regional Training Calendar

U.S. Department of Energy Industrial Best Practices Training Calendar

Input Requested: Is there something else you would like to see in Industrial Newsbriefs?

If you have thoughts or ideas for what you would like to see in this publication, please email suggestions to Talia Mathews at MathewsT@energy.wsu.edu . We strive to keep this publication as useful and relevant as possible to you, our readers.


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