DOE Save Energy Now Assessments Lead to Savings of More Than $1.5 Million for Three U.S. Industrial Manufacturing Facilities
August 05, 2008
Through its Save Energy Now initiative, the U.S. Department of Energy (DOE) Industrial Technologies Program (ITP) has helped U.S. manufacturing plants identify potential savings of more than $807 million in energy costs and 77.1 trillion Btu of natural gas—the amount consumed by more than 1 million single-family homes. The goal of Save Energy Now is to drive a 25% reduction in U.S. industrial energy intensity by 2017.
Three new Save Energy Now case studies, highlighted below, reveal the specific energy savings recommendations identified by DOE, and how companies are taking steps to reduce their energy use and save money. These three companies are saving a combined total of $1.5 million per year, so far, after implementing some of these measures.
J.R. Simplot Fertilizer Plant Saves $335,000 and 75,000 MMBtu in Fuel
The J.R. Simplot Company is a major food and agribusiness corporation based in Boise, Idaho. The company's Don Plant in Pocatello, Idaho, produces more than 1 million tons of phosphate fertilizers, feed phosphates, and related industrial products annually. To reduce energy consumption, the facility implemented three of the recommendations identified during the Save Energy Now assessment, resulting in total annual cost savings of $335,000 and energy savings of more than 75,000 MMBtu.
"Thanks to the Save Energy Now assessment, the company is more efficient and no longer wasting steam," said Paul Malek, Area Manager for the J.R. Simplot Don Plant. "We have done steam trap maintenance that has improved our recovery of condensate throughout the plant and we have also changed some operations. We were running boilers every shift to keep them hot and just venting the steam. The assessment determined we didn't need to do that." Read the full case study (PDF 525 KB). Download Adobe Reader.
Kaiser Aluminum Save $360,000 and Improves Furnace Efficiency by 11.1%
Kaiser Aluminum, a leading producer of fabricated aluminum products for aerospace, general engineering, automotive, and custom industrial applications, operates 11 facilities in the United States. The company's aluminum extrusion plant in Sherman, Texas, participated in a Save Energy Now assessment of its process heating system. Employees implemented two of the energy-saving recommendations identified during the assessment and achieved annual cost savings of $360,000 and energy savings of 45,000 MMBtu, and improved furnace efficiency by 11.1%. In addition, Kaiser is using DOE's Process Heating Assessment and Survey Tool (PHAST) to analyze systems at five additional plants.
"The Save Energy Now assessment was a tremendous asset in helping us identify energy savings opportunities," said David Conrow, Vice President of the Kaiser Aluminum Production System. "The process provided insight into new areas we had not previously considered and validated merits of potential projects we previously identified. We found the experience quite helpful." Read the full case study (PDF 637 KB).
Shaw Industries Tackles Rising Fuel Costs by Saving 93,000 MMBtu in Natural Gas and No. 6 Fuel Oil.
Shaw Industries is a major manufacturer of floor products that produces approximately 1.1 million square yards of finished polyester carpeting per week at its plant #20 in Dalton, Georgia. The Save Energy Now assessment identified several steps the plant could take to improve its energy efficiency. By integrating the most cost-effective recommendations into their energy management program, Shaw saved $872,000 and 93,000 MMBtu in natural gas and No. 6 fuel oil.
“Our plant was very fortunate to be selected for the U.S. Department of Energy Save Energy Now study,” said Shaw Industries Plant Engineer Robert Davidson. “With rising fuel costs and ever advancing competition, the need to be as energy efficient as possible is paramount. This study helped to shine the light on both large and small opportunities to become more efficient. The results speak for themselves.” Read the full case study (PDF 532 KB).
Read more Save Energy Now case studies at www.eere.energy.gov/industry/saveenergynow/case_studies.html.
About Save Energy Now
Save Energy Now is a national effort of DOE's Industrial Technologies Program to drive a 25% reduction in industrial energy intensity by 2017. Save Energy Now energy assessments are performed by DOE Energy Experts who are trained in the use of DOE's energy analysis software tools and work with representatives from the company to analyze their most energy-intensive manufacturing process systems. See current results.
Apply for An Assessment Today
Save Energy Now energy assessments are offered at no cost. Learn more about the assessment process and complete an online application form at: www.eere.energy.gov/industry/saveenergynow/apply.html.