Cost-Saving Energy Efficiency Measures for Industrial Facilities (1/9)
American industrial companies spend $100 billion a year powering manufacturing facilities. Businesses can realize significant cost savings by taking simple steps to improve energy efficiency. These tips, from the federal Energy STAR program, can help companies boost the bottom line while reducing energy consumption.
1. Lighting (2/9)
Lighting is a significant electrical energy consumer, but that also means targeting its efficiency can result in big savings. Maximizing natural light; shutting lights in unoccupied areas; and using lighting controls, compact fluorescent lamps, and T-8 fluorescent tubes all make a difference.
Case Study: In Rahway, New Jersey, Merck used automatic shut-off lights and saved 380 megawatt-hours of electricity in a year.
2. HVAC (3/9)
HVAC systems keep workplaces comfortable and maintain air quality. Simple steps can improve efficiency. Businesses can choose energy-efficient HVAC equipment, commission or recommission existing HVAC systems, install energy monitoring and controls, repair leaky air ducts, consider heat recovery systems, and switch to light-reflective or green roofs.
Case Study: In Apple Valley, California, a commercial building used a mobile aerosol-sealant injection system (MASIS) to reduce duct leakage, resulting in a 34 percent efficiency increase of the building's HVAC system.
3. Motors (4/9)
Motors are used across industrial facility systems, such as refrigeration, HVAC, compressed air, and other processes. Focus on systems the motors operate for best results. Develop a motor management plan, choose motors strategically, maintain existing motors, select properly sized motors, correct power factor, and minimize voltage imbalances.
Next: Compressed Air
Case Study: In Columbus, Indiana, Cummins Engine Company chose energy-efficient HVAC motors and saved $128,000 in one year.
4. Compressed Air (5/9)
Compressed air is one of the least efficient parts of industrial plants - and one of the most expensive. Many efficiency methods are relatively inexpensive. Maintain compressed air systems, monitor compressed air use, target pipe and equipment leaks, shut off unnecessary compressed air, use sources besides compressed air, and use air at the lowest possible pressure.
Case Study: In Monroe, Michigan, Visteon established a leak management program that resulted in a $560,000 annual cost savings.
5. Pumps (6/9)
Pumps are used throughout industrial applications. Up to 20 percent of the energy pumps consume can be saved by adjusting equipment and pump control systems. To do so, implement a pump system maintenance program, monitor the system, reduce pump demand, install high-efficiency pumps, choose properly sized pumps, and replace drive belts.
Next: Hot Water and Steam Systems
Case Study: In La Crosse, Wisconsin, the Stroh Brewery Company reduced the diameter of its pump impeller - and its energy costs by $19,000 in one year.
6. Hot Water and Steam Systems (7/9)
Hot water and steam systems present several opportunities to make industrial operations more efficient. Businesses should identify needed steam uses and reduce steam generation pressure and volume when possible. They can also improve distribution system insulation, monitor and improve steam traps, recover flash steam, and repair leaks.
Next: Furnaces for Process Heating
Case Study: In Bedford Park, Illinois, Nalco Chemical Company reduced steam pressure from 125 psig to 100 psig and saved $142,000 in one year.
7. Furnaces for Process Heating (8/9)
Fired heaters account for nearly a quarter of the fuel manufacturers consume. To reduce this load, control the air-to-fuel ratio, improve heat transfer and containment, and recover flue gas heat.