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Industrial Newsbriefs

November 2011

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)

Cogeneration engine makes the most of whisky wastewater

"Scotch Distillery to Raise Concentration on Biogas-Fueled Cogeneration," published October 12, 2011, in Sustainable Plant, describes a cogeneration system built by GE for the Scotch whisky distillery William Grant & Sons. The system will run on biogas at 43% efficiency, and will produce 3 MW of additional electricity for plant operations. Whisky wastewater will provide the raw material for the biogas, and waste heat will be captured to produce steam for the distilling process.

CHP for municipal wastewater facilities

In October 2011, the EPA Combined Heat and Power Parntership released a new report, Opportunities for Combined Heat and Power at Wastewater Treatment Facilities: Market Analysis and Lessons from the Field. This report analyzes the opportunities for combined heat and power (CHP) applications in the municipal wastewater treatment sector, and documents the experiences of wastewater treatment facility operators who have employed CHP.

Presentations from the Combined Heat and Power Partnership National Meeting

Presentation materials from the Combined Heat and Power Partnership National Meeting, held October 5, 2011, are now available in PDF form on the EPA Combined Heat and Power Partnership website. CHP in an Industrial Setting was one of the primary topics of this half-day event, which drew over 100 attendees.

CHP Energy Star Awards announced

On October 5, 2011, the EPA Combined Heat and Power (CHP) partnership announced the CHP Energy Star award recipients for 2011. The awards recognize CHP installations which demonstrate outstanding pollution control and energy efficiency qualities. Recipients include three universities, the National Institutes of Health, and Dominion Transmission, a gas transmission company.

Energy Management

New Greenhouse Gas Protocol standards launched

The Greenhouse Gas Protocol, a joint effort of the World Resources Institute (WRI) and the World Business Council for Sustainable Development (WBCSD), has launched two new standards designed to help companies and industries measure, manage, and report greenhouse gas emissions along the entire supply chain. The Product Life Cycle Accounting and Reporting Standard is designed to measure the greenhouse gases associated with the full life cycle of products including raw materials, manufacturing, transportation, storage, use and disposal. The Corporate Value Chain (Scope 3) Standard is similar, but is intended to assess the emissions chain of companies rather than products. Both standards were launched on October 4, 2011.

Consultant offers tips for efficiency program success

In "Five Ways to Make Energy Savings Permanent," energy consultant Gary Faagau offers five ways for industrial facilities to improve their energy efficiency programs and "put him out of business." The five directives are: install an energy management system; make routine furnace adjustments; implement a monthly energy report; conduct mandatory annual trainings; and provide financial bonuses as a reward for success.

Automation software for plant equipment

"Take a Bite out of Lifecycle Costs," written by Dan Herbert, PE, and published October 18, 2011, in Sustainable Plant, describes how to monitor and reduce the lifecycle costs of industrial equipment by using automation software. Automation can reduce costs and energy intensity by reducing stress on equipment, enabling proactive maintenance, and regulating energy usage. Several specific examples are provided.

Benefits of water usage monitoring

"Wireless Monitoring of Water Usage," by staff, Mechanical Engineering, August 2011, is a case study showing the technology employed at an Irish pharmaceutical plant. By the end of the project, water usage could be monitored and managed, costs for installing cables had been avoided, and the opportunity for increased water supply as the plant grows had been secured.

Heat Recovery

Perspectives on the industrial heat value chain

In "The Heat Value Chain is Broken," October 4, 2011, Peter Garforth of Sustainable Plant discusses from a broad perspective the issue of waste heat capture from electrical plants and industrial facilities. Taking into consideration that 50% of the energy produced globally is lost as heat, the author emphasizes that more focus should be placed both nationally and internationally on capturing and using waste heat via cogeneration, heat sharing, and other processes.

Heat Treatment

Process control for heat treatment

"Advanced Process Controller Improves Refractory Production," by Steve Maus, Heat Treatment Market Manager, West Control Solutions, appeared in the August 2011 issue of Industrial Heating. This article describes the improvement in the finished refractory shapes that are used in various thermal processes in manufacturing. The improvement is due to a new process controller at the refractory manufacturing plant that ensures that the shapes, during firing, are subjected to even heating rates. A further advantage of the newly-installed control system at the plant is that it shows the monitoring staff well-defined curing cycles, and promptly notifies staff when problems arise.

Policy and Legislation

White House and DOE promote Advanced Manufacturing Partnership

On September 28, 2011, the White House and U.S. Department of Energy made a call for participation in the Advanced Manufacturing Partnership, a framework for the collaboration of business, industry, education, and policy leaders to work toward the development of innovative, energy-efficient manufacturing processes. To learn more, see the press release, or visit the program website.

Pumps and Fans

Tips for efficient pump operation

Opportunities for increasing the energy efficiency of fan systems are discussed in "Don’t Overwork Pumps and Fans: Part 2," written by V. Venkatesan and published October 18, 2011, in Sustainable Plant. The article outlines steps for optimizing the energy efficiency of fan systems, including the installation of speed controls, switching to inlet vane dampers, and switching off ventilation fans when requirements drop.

Pump failure: a consultant’s story

"A Pump War Story: Back to Basics," by Gary Wamsley, Engineering Consultant, appeared in the August 2011 issue of Mechanical Engineering. This article describes and discusses a training session provided for a plant's maintenance technicians – and the plant's new engineer – given by the author. It took place at a plant where water pumps were failing at an alarming rate; the cause was identified during the training.

Research

Fuel cell technology could improve coal efficiency by 90%

A new type of fuel cell system has the potential to greatly increase the efficiency of coal burning power plants, perhaps by as much as 90%. The technology works by collecting the emitted CO2 from power plant emissions, combining it with hydrogen, and using it to power a fuel cell which in turn produces additional electricity and emits only water. To learn more, read "Coal Plant + New Fuel Cell System = 90% Reduction in CO2 Emissions?" on the CleanTechnica blog, October 16, 2011.

UPCOMING EVENTS AND TRAININGS

Pacific Northwest

PGE Series: Chilled Water Systems
November 9, 2011
Wilsonville, Oregon

This free half-day seminar focuses on chilled water systems in large commercial buildings and industrial facilities, including high tech and data centers. Working together, operating staff and facility engineers will learn about opportunities to control energy costs and improve efficiency.

Pumping System Optimization
November 9, 2011
Idaho Falls, Idaho

The typical medium-sized plant spends over $1.4 Million a year on energy to run their pumping systems. Better system design and optimized pumping systems may result in savings that will average $350K per year on energy alone. In addition, 4,436 tons of CO2 emissions may be avoided by implementing the systems optimization concepts discussed during this course. For irrigation users, the class can show how to lower header pressures without throttle valves and explore ways to modify pumps by trimming the impeller. The course will show how the variable speed drive can save additional power by slowing down the pump speed, which will save energy and reduce cost in the process. This training is coordinated by NEEA Industrial Training project and sponsored by Idaho Power Company, Idaho Office of Energy Resources, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Adjustable Speed Drive Applications and Energy Efficiency
November 10, 2011
Hermiston, Oregon

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. This course is coordinated by the NEEA Industrial Training project and is sponsored by Umatilla Electric Cooperative, Energy Trust of Oregon, Pacific Power, Oregon Department of Energy, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Energy Data Analysis: Introduction to KPIs
November 10, 2011
Helena, Montana

Gain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with information that will help you effectively implement an energy management system at your company.

Compressed Air Challenge - Level 1
November 16, 2011
Yakima, WA

Are your compressed air energy costs under control? Even the smallest compressed air system is a relatively large source of energy consumption and cost. Make your company more profitable with the Compressed Air Challenge™, a series of seminars that applies proven techniques to achieve cost-effective solutions. Optimizing your compressed air systems can lead to higher productivity, energy savings, increased product quality and greater efficiency. This training is coordinated by NEEA Industrial Training project and sponsored by Avista Utilities, Pacific Power, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Energy Management: Introduction to Best Practices
November 30, 2011
Vancouver, Washington

Gain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with tools and resources that will help you effectively implement an energy management system at your company. This training includes practical exercises and in-class discussion.

PGE Series: Compressed Air Systems
December 1, 2011
Wilsonville, Oregon

This free half-day seminar provides an overview of how compressed air systems work and practical advice about making the most of your compressed air system investment. Compressed air systems can be one of the largest energy consumers in your facility. Learn how to start saving energy and money today.

Other Events, Trainings, and Webinars

PGE WEBINAR: Introduction to Compressed Air Systems
November 10, 2011, 12:00 PM PST

Compressed air systems can be one of the largest energy consumers in your facility. Learn how to start saving energy and money today. At this introduction webinar you will learn highlights from our four-hour seminar of how compressed air systems work and practical advice about making the most of your compressed air system investment. The four-hour seminar on this subject is scheduled December 1 in Wilsonville.

WEBINAR: Fundamentals of Compressed Air (Level 1); Four-Part Series
November 9, 2011 – December 7, 2011

This Web-based version of the popular Fundamentals of Compressed Air Systems training uses an interactive format that enables the instructor to diagram examples, give pop quizzes and answer students’ questions in real time. The curriculum will be organized into four 2-hour sessions: Introduction, Why Care About Air and Study Your Supply Side; Understand Your Demands & Are You On Base; Controls; and Maintain Systems Efficiency, Get with the Plan and Summary- Evaluation. Special registration rates for Compressed Air Challenge sponsors and groups of 10 or more are available.

Better Tools for Better Plants (Webinar)
November 15, 2011, 11:00 AM – 12:00 PM PST

As the Department of Energy transitions the Save Energy Now LEADER initiative to the Better Buildings, Better Plants program, it is developing and upgrading several on-line tools and resources to advance energy efficiency in the U.S. manufacturing sector. Representatives from DOE's Advanced Manufacturing Office will present an overview of the Better Plants program and describe how DOE's new tools and resources can help partner companies and others reduce energy in their industrial operations.

Advances in Lamps and Ballast (Webcast)
November 17, 2011, 11:00 AM – 12:00 PM PST

A recent industry survey of over 100 lighting manufacturers identified the newest advances in fluorescent and metal halide lamps and ballasts. Attend this Webinar so that you can take advantage of the latest advances in lighting: extended T8/T5 lamp life, cold weather lamps, NEMA Premium ballasts, reduced wattage and high-temperature high bay fluorescents, radio frequency lighting, LEDs, and more! In addition, we will also tell you the latest about daylighting, occupancy sensors, and timers.

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.

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.


Past issues available here