Energy Assessments for Industrial Complexes

Introduction to the eBook discusses what is included in the eBook as well as importance of sustainable practices and business need for sustainability. Sustainability analysis tools are listed and discussed.

This chapter will help optimize the amount of lighting required in a specific room. Discussed methods and calculations will help managers to estimate if excessive lighting is currently being used and how much money may be saved by removing excessive lighting. In addition, this chapter will address a case of insufficient lighting.

Overall heat loss from the building is a sum of the losses of heat through windows, doors, walls, roof, floors, basements, ventilation systems and infiltration. This chapter specifically discusses heat loss through windows and sustainability techniques that help improve bottom line.

This chapter will discuss heat loss through doors, which is reasonably similar to heat loss through windows discussed in Chapter 3, and sustainability techniques that help improve bottom line.

Installation of garage door flaps and other draft prevention methods is generally an inexpensive and easy way to save money. More expensive decisions faced by business owners are insulation of the garage door and interlocking of the door with a heater/air conditioning unit. While former is nearly always good practice, two latter solutions require payback period calculations.

Selection of insulation depends on a large number of factors, such as availability of the space for insulation, climatic conditions, availability of funds and potential savings, etc. This chapter discusses different types of insulation available to customers.

Roofing selection depends significantly on purchase price, longevity of the roof, maintenance costs, and energy savings. There are number of roofs that may be considered in each case.

The decision to change appliances is typically made when an appliance is no longer functioning properly, but this chapter challenges that approach. Immediately replacing some appliances may be a sound financial and ecological decision. In addition, we discuss the selection of Energy Star® appliances.

Vending machines usually are not economical to replace, unless the current device’s maintenance costs and downtime are high. However, when a decision to replace a machine is made, Energy Star^® - rated machines should be considered. The location of the vending machine will also affect overall energy cost, but to a much smaller degree than sales profit.

A decision to replace computers and office equipment generally should not be based only on electricity demand. Typical decisions may be based on need of specific equipment, or elimination of such need (e.g., fax is no longer needed since company is now using direct fax-to-email system). Most of the savings in the office are associated with reduction or elimination of paper and ink use.

Proper selection of shower heads and proper management practices in shower rooms may result in significant water use savings with little investment.

Covering the pool and using the correct pool heater are the most costeffective and sustainable ways of managing the outdoor pool.

The two main methods of improving kitchen hood air flow are air flow adjustment (low investment, high return) and system replacement (high investment, high return). There are a number of other ways to improve the efficiency of the kitchen hoods.

Installing or reprogramming Variable Speed Drives (VSD) / Variable Frequency Drives (VFD) may be a very effective way to reduce energy consumption of motors. The selection and programming of the VSD are best for the professionals. When the device is properly programmed, quick payback periods are typically expected.

There are number of different sustainable ways to reduce the cost of boiler use with good paybacks. Methods of boiler cost reduction are presented in this chapter. The key concept of this chapter is that cost of boiler is significantly less than cost of operation of the boiler.

Engineers typically make plant machinery’s economic replacement decisions. Such decisions involve cost analysis, which allow determining when the current machine is to be replaced with a new one. A manager’s job may be to suggest when such analysis should be conducted, especially on older machines, and when production changes occur.

Compressors may offer opportunities for cost savings. Four major areas of such are system pressure reduction, installation of system controls, installation of variable speed drive (VSD), and leak repairs. Each of these areas requires attention of an engineer.

Belt conveyors are generally optimized by engineers. However, there are number of ways that may reduce cost of running belt conveyors, predominantly through maintenance practices.

Proper selection and good maintenance of a water heater may result in significant savings.

Furnaces, air conditioners and dehumidifiers are heavy users of energy. By properly insulating pipes, installing properly sized units, and considering various types of HVAC and dehumidifying devices, it is possible to save significant amounts of money while practicing sustainable business.

Some facilities may have heat recovery options available. These options may include parts washers, boilers, and any machines that produce significant recoverable heat. Often, such projects are expensive, but may still have reasonable payback periods.

Replacement of paper documents with computer files and reduction/elimination of paper-based correspondence are common sustainability methods that are usually costeffective.

Solid waste management cost reduction is generally achieved by removing recyclables from the solid waste stream. The savings are observed in reduced cost of solid waste hauling. The recyclable collection may turn profitable as well.

This chapter emphasizes the importance of applying the calculators for assessing the energy usage and pollution prevention for a hypothetical facility in Ohio. As a part of the study, we identified lighting fixtures and suggested alternatives for energy reduction and pollution prevention. We performed an energy assessment survey of the entire facility using the Energy Assessment Spreadsheet (EAS) tool developed at The University of Toledo to calculate reductions in energy use and costs associated with energy consumption of lighting fixtures. As a result, there is a reduction of electricity usage from 2,056,942 kilo Watt hour (kWh) to 1,477,059 kWh, or nearly 30% less energy expenses with an annual savings of over $55 thousand. Additionally, we performed a life cycle assessment using Economic Input Output Life Cycle Assessment (EIO-LCA) to determine the change in environmental impacts due to the use of energy efficient lighting. EIO-LCA revealed a reduction in Carbon Dioxide (CO2) gas emissions from 1,830 metric tons to 1,300 metric tons, which is approximately 30%. The pollution prevention (P2) calculator comprising of P2 Green House Gas (GHG) tool and the P2 Cost Calculator developed by the United States (U.S.) Environmental Protection Agency (EPA) was the third tool applied. The greenhouse gas reductions were calculated using the P2 GHG tool while cost savings related to energy savings were calculated using P2 cost calculator. There was a reduction of 492.823 metric tons of Carbon Dioxide equivalents (MTCO2e) GHGs for the electricity savings of nearly 580,000 kWh.

Energy assessment examples are presented and related to chapters in the eBook.