1. Effective Strategies for Industrial Energy Efficiency: Opportunity Identification and Implementation

2. Effective Strategies for Industrial Energy Efficiency
Energy Efficiency through Industry and Process Specific Technical Assistance
MnTAP Intern Program: Achieving Results Today while Preparing for Tomorrow
Researching New Industrial Energy Efficiency Strategies and Opportunities

3. Minnesota Technical Assistance Program
Created in 1984
Located at the University of Minnesota
Provide pollution prevention, waste management, water conservation and energy efficiency assistance
Confidential and Non-regulatory

4. MnTAP Mission
Strengthening Minnesota businesses by improving efficiency, while saving money through energy, water and waste reduction.
Businesses remain competitive
Improve employee and public health
Protect the environment

5. Industrial Process Assistance
Pollution prevention
More efficient use of raw materials
Water conservation strategies
Energy efficiency opportunities
Cost savings for businesses!!

6. Energy Efficiency Assistance
Process energy focus
Compressed air system audits
Steam system/boiler efficiency
Process heat management
Motor, fan, and pump efficiency
Resources
Certified Energy Managers on staff
Case Studies
Process energy efficiency – Certified Energy Managers on staff.
Many examples from site assessments, special projects and Intern projects.
See MnTAP website on E2

7. Project: Industrial E2 Program
U.S. Department of Energy through the MN Department of Commerce
Outputs
Outcomes
200 people trained
100 businesses impacted
34 sites assessed
6 intern projects
3 teams launched
130,000 MMBtu reduced
250,000 lb chemical reduced
22 million gal water reduced
$1 Million yearly savings

8. Trident Seafood: Implemented Results
Motley, Minnesota
Participated in steam assessment training and an audit
Implemented four recommendations
Used most efficient boilers
Recovered heat with condensing economizer
Replaced inefficient equipment
Repaired boiler control system
Estimated Annual Savings
258,000 therms
$154,000

9. Project: Wastewater Treatment E2
U.S. EPA Region 5
Outputs
Outcomes
10 site assessments
1 intern project
4 assessment presentations
5 technology demonstrations
benchmarking
1.22 million kWh
$86,000
Project Recommendations
5.56 million kWh
$444,000
project
Current project is : benchmarking, assessments, and CHP component (3 interns) – 2 in 2017
Long term time horizon – large investments…
Bring in partners collaborative efforts now

10. MnTAP Intern Program – Achieving Results while Preparing for Tomorrow
Focus on solutions for P2/E2 projects
Students hired by MnTAP
Extra engineer for the summer
Reports direct implementation
Energy projects partner with utilities
Company cost-share suggested
Solutions online summary of 2013 projects
Summaries of 2015 projects

11. Impact Energy: Lloyd’s Barbeque Company
Mendota Heights, Minnesota
Manufactures:
Cooked meat products
Improve hot water management
Install wash tank temperature regulator
Optimize hot water pump pressure
Results:
50,000 therms
25,000 kWh
1.3 million gal water
$54,000

12. Impact Energy: Caterpillar Paving Products
Manufactures:
Road paving machinery
Improve compressed air efficiency
Optimize compressed air use
Install VSD
Upgrade control sequencing
Find and repair leaks
Repair >100 leaks
Isolate equipment not in use
Results:
300,000 kWh
$28,000
Brooklyn Park, Minnesota

13. MnTAP Intern Program Results
2016 Recommendations
3.1 million kWhs
143,000 therms
5 year Implemented Results*
11.5 Million kWh’s
1 Million therms
$2.4 Million savings
Students – experience in energy efficiency assistance
2016 MnTAP Interns
*Verified by direct follow up with companies

14. MnTAP Intern Program Success
“The outcome of the project has resulted in a minimum of 20% reduction in electrical demand of the aeration system and has created the momentum for even more reductions to occur.”
~Tracy Hodel, Assist. Public Utilities Director, City of St. Cloud WWTF
“Our intern was a great candidate for a future employee. He dove head on into his process improvements with an awesome hands on approach!”
~ Lee Gulbrandson, Manufacturing Engineering Manager, Lou-Rich
“Working to improve energy efficiency provided the perfect opportunity to expand my technical knowledge and analytical skills. This experience taught me how to work and communicate effectively with the variety of stakeholders involved in a large-scale manufacturing operation.” ~WB
“Xcel Energy values the MnTAP Intern Program and the projects that are identified each year. The program helps us to provide extra resources to our customers who value the high quality projects they get in return.”
~Molly Hiipakka, Xcel Energy Customer Solutions
The MnTAP Intern Program is considered a success by companies, utilities and students
Cost effective identification of efficiency opportunities
Provides interface with utility efficiency programs
Measures and verifies energy efficiency implementation
Provides students with industrial experience and strategies to carry energy efficiency focus into their careers

15. Energy Efficiency Research
Explore new industrial efficiency approaches
Industrial sector specific opportunities
Benchmarking
Develop tools and resources
Energy use calculators
Case Studies
Process energy efficiency – Certified Energy Managers on staff.
Many examples from site assessments, special projects and Intern projects.
See MnTAP website on E2

16. Motivating Manufacturing Energy Efficiency
CARD Grant
Integrated energy assessments and lean manufacturing in MnTAP intern projects to provide efficiency recommendations and implementation assistance
Motivating Manufacturing Energy Efficiency: E2 Assessments & GreenLeanSM Training with Directed Implementation
MN Dept of Commerce Division of Energy Resources CARD Reports

17. Motivating Manufacturing Energy Efficiency
Direct energy reductions
Variable frequency drives
Optimize process set point
Motor inventories
Maintenance schedules for high energy equipment
Upgrade lighting
Optimize compressed air
traditional

18. Motivating Manufacturing Energy Efficiency
Increasing Throughput
Optimize work flow
Streamline process set up/change over
Eliminate off-specification product
Achieve more production per unit energy
Lean manufacturing tools / assessments to augment savings

19. Project Outcomes Suggestions Recommendation Value Implemented
Reduction
Savings
Traditional Energy Efficiency 7
648,000 kWh
$59,000 6
257,400 kWh
$23,000
Lean Identified Process 11
586,800 kWh
2,200 therms
294 hr
75,000 lb
$491,000 4
438,400 kWh
11,000 therms
38,000 lb
$247,000
Lean Activities
29,000 kWh
2,600 therms
1,850 hrs
53,000 lb
$176,000 3
24,200 kWh
800 hrs
$55,000
Total 25
$726,000 13
$325,000

20. Impact Energy: Uponor Corporation
Apple Valley, Minnesota
Manufactures:
Extruded cross-linked PE pipe
Increase output with lower energy
Optimize curing process
Insulate extruder barrel
Results:
448,000 kWh
$44,000
One of 7 intern projects was:

21. Power Tool Energy Efficiency Research
CARD Grant
Define energy conservation potential for conversion of pneumatic to electric tools
Resource development
Pneumatic tool guide
Conversion cost calculator
Supported by a grant from the Minnesota Department of Commerce, Division of Energy Resources through the Conservation Applied Research and
Development (CARD) program.

22. Power Tool Energy Efficiency Research
Preliminary findings
$5,000,000 per year powering tools with compressed air
85% savings opportunity with electric alternatives
Electric driven tools have reasonable payback period
6 months (corded)
11 months (cordless / rechargeable)
Our preliminary results suggest

23. Call MnTAP For: Customized Technical Assistance Resource Conservation
Site Visits
Interns
Training and Resources
Resource Conservation
Air Emissions
Water Conservation
Energy Efficiency

24. Thank you – Questions?
Strengthening Minnesota businesses by improving efficiency, while saving money through energy, water and waste reduction.
Laura Babcock
Paul Pagel