Energy Usage Reduction Program

Transcription

1 Energy Usage Reduction Program Presented By: Samuel R. Day Earth Recycle Image Source:

2 Columbus Castings History First batch of steel melted from Parsons Avenue location in 1902 Largest steel foundry in one location in the United States Energy Policy: Columbus Castings is committed to a more focused approach toward managing our energy resources, and have an overall goal to reduce our energy use 10% annually.

3 Energy Usage Reduction Program Program created May 2012 to help reduce natural resource consumption Program Highlights: Cross-sectional energy team Energy usage data tracking Multi-variable energy usage calculation formula Energy reduction action items including theoretical savings calculations Usage savings analysis Focus on low/no cost energy savings

4 Energy Team Energy Champion Executive Sponsor Team members Manufacturing Engineer/Maintenance Coordinator Facilities/Electrical Engineer Melt Shop Supervisor General Plant Supervisor Employee engagement built from the shop floor up

5 Energy Usage Data Tracking Electric and Gas Metering Sub-meters installed for each department Additional sub-meters installed on high energy use equipment Daily usage tracking Multi-variable energy usage tracking System built off all variables involved in energy usage (equipment run times, hours of operation, products produced, sub-meter usages etc.) Baseline data collected as long as possible prior to efficiency upgrades

6 Completed Items - EAF Reduce pre-heat temperature for on-deck ladles Utilize slag heels in electric arc furnace Minimize overheating of molten steel Reduce unnecessary usage of fume collection systems

7 Completed Items Annealing Process organization Maximize parts per load Leak repairs Minimize wasted natural gas Burner tuning Maximize burner efficiency New insulation Minimize heat loss

8 Completed Items Leak Repair Leak detection and repair program Compressor Analysis Leak Repair Start Usage Hours Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 B-2845 B-3777 B-3776 B Total Compressor Usage Usage Hours Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13

9 Completed Items - Shutdowns Implementation of standardized department shutdown checklists Electric Usage Start of weekend shutdowns Natural Gas Usage Start of weekend shutdowns 1500 kwh MMBtu Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 0 Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 2011 weekends 2012 Weekends 2013 Weekends 2011 weekends 2012 Weekends 2013 Weekends

10 Completed Items Misc. Minimize unnecessary usage of dust collection systems Restore cooling tower efficiency and readjust temperature set points Minimize unnecessary usage of equipment Employee engagement

11 Future Energy Savings Replace 1000 watt sodium lights with high efficiency LED lights with motion detection 7,000,000 kwh/year savings estimate Replace old compressors with new high efficiency compressors 4,000,000 kwh/year savings estimate Use reciprocating compressor as trim compressor 300,000 kwh/year savings estimate Pressure set-point reduction 600,000 kwh/year savings estimate Continuation of leak tag/repair program

12 Project Limitations Return on Investment projects will not receive funding if the return on investment is not low enough to include in future budgeting Man power/time Having enough employees to complete timely efficiency repairs while keeping up with daily tasks Financing Large capital projects tend to get pushed to the side Use of financial institutions to purchase new equipment on a leasing plan with minimal buyout Employee s lack of willingness to change

13 Benefits of Energy Reduction Decreased run-time of equipment promotes longer equipment life Lower utility bills reduce bottom line costs Decreases impact on the environment through the generation, transmission, and consumption of natural resources Process improvements can have positive impacts on quality of product produced

14 Energy Savings KWH Usage Reduction 2,000, ,000,000-4,000,000-6,000,000-8,000,000 Electric Annual Usage (kwh) 68,000,000 1 Year Reduction 6,869, % Total Reduction 6,953,685 10,000 Dekatherm Usage Reductions 0-10,000-20,000-30,000-40,000-50,000 Natural Gas Annual Usage (DTH) 394,748 1 Year Reduction 36, % Total Reduction 44,083 SCF Usage Reduction 5,000, ,000,000-10,000,000-15,000,000-20,000,000-25,000,000 Oxygen Annual Usage (SCF) 108,637,638 1 Year Reduction 15,502, % Total Reduction 19,742,935

15 Reduction of Natural Resource Consumption for a Better World Questions Image Source: