My Story: 2011 arrival to the plant Annual energy 23 billion lbs. steam and 1.0 billion kWh electric produced in cogeneration plant plus 1.7 billion kWh.

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Presentation transcript:

My Story: 2011 arrival to the plant Annual energy 23 billion lbs. steam and 1.0 billion kWh electric produced in cogeneration plant plus 1.7 billion kWh electric purchased Avg 300 MW Avg 2.6 million lbs. steam/hr. >$210 million annual energy cost 275 million bushels of grain processed

“The barrier to Great is Good”

The Rules Accountability: R ≠ NR + AGS Juan Luciano Urgency: Patience is not a virtue Craig Huss Business Focus: Resource according to value Thomas Mort

Energy Savings Bottleneck IDEAS Accurate Engineering and Cost Approval Implementation Resource according to value. Not according to plant engineers calendar.

Structured + Focused Process Yields More Savings Future State Current state + $$$ $$ Time 5 Keys to Success 1.Energy/Project Manager 2.Project Tracking/Targets 3.System Expert support 4.Standardized Best Practices 5.Local Ownership % Improvement from Completed Energy Cost Reduction Projects

Utility Incentive Programs Example: Ameren’s ActOnEnergy program

What do you see in this photo?

Heat Recovery Project

7 million btu/hr of “free” energy

Waste Water Treatment Plant Project Modification of impeller size on more than 12 pumps Pumps provided cooling water to the plant Only a limited number of pumps could be sent out at a given time. Project cost: $198,495 Project savings per year: $473,307 Energy Savings per year: 12,455,436 kWh

Concept: Challenge Set points When it’s cold do we really need the same amount of cooling towers as we do in the summer? NO result: 4 towers are shut down.

21 X 4,000 hp Air Compressors 21 Air Compressors Leaks, Drains and Control improvements Project cost: $5.7 million less $1.2 million utility incentive Project savings per year: $1.53 million Energy Savings per year: 40,300,000 kWh

Imagine the team building when they receive 3 checks totaling $1,097,748

Change Management A successful energy reduction program is not all technical: Change Management is often the most difficult part. Current Status Equilibrium +/- Incursions: Recession Competition New Goals Regulations Growth Elements: Knowledge Skill Resources Desire Belief Improved Status Warning: even small obstacles can prevent great projects.

Thomas C. Mort, BS, CEM