MEC Conference Akron Sept 2016 (2) · · 2016-09-19• Charter Steel ISO 50001. ... –...
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Workshop M Best Practices in Energy Efficiency, Energy Savings and Achieving a Reduction in Energy Consumption … Priceless Insights into the Energy Reduction Practices at Some of Ohio’s Best Companies 3:15 p.m. to 4:30 p.m.
Transcript of MEC Conference Akron Sept 2016 (2) · · 2016-09-19• Charter Steel ISO 50001. ... –...
Workshop M
Best Practices in Energy Efficiency, Energy Savings and Achieving a Reduction in Energy Consumption … Priceless Insights into the
Energy Reduction Practices at Some of Ohio’s Best
Companies
3:15 p.m. to 4:30 p.m.
Biographical Information
Anthony (Tony) J. Sutor, Industrial Efficiency Lead Ohio Development Services Agency, Office of Energy
(614) 387-2733 Fax: (614) 466-1864 [email protected]
Tony has spent the past twelve years at the State of Ohio in the Development Services Agency working as the Energy Specialist for the Office of Energy. His most recent assignments included: Development of RFPs and NOFAs for the ARRA (stimulus) funding for Targeting Industry
Efficiency, Bio mass/bio waste & bio fuels/alternative fuels; Managing the Energy Efficiency Program for Manufacturers-a program that utilizes a
Software Diagnostic tool to establish a Business Process for energy related issues in manufacturing, commercial and institutional facilities;
Management of Distributed Generation/Fuel Cell commercialization programs for OEO, including a recent distributed energy solicitation which leveraged $16.0 MM of projects with $1.0 MM of grant funding;
Managing the technical review process for Ohio Power Siting Board applications for ODOD; Promoting Ohio’s Energy Loan Fund to Business clients; performing technical review of
loan applications; Managing the technical review process of Ohio House Bill 264 (Ohio Public School Energy
Efficiency Program-Performance Contracting) for Ohio School Facilities Commission. Prior to joining the Ohio Development Services Agency, Tony spent 22 years working for a large natural gas utility in numerous capacities including management of a technical consulting team, business contract negotiations, sales management and account management.
Lawrence D. Boyd, Jr., CPEnMS, SEP PV - Industrial Lawrence Boyd and Associates
2708 Coventry Road, Shaker Heights, OH 44120 (216) 323-1898 [email protected]
Mr. Boyd manages Ohio Center for Industrial Energy Efficiency under contract to the Ohio Energy Office. Previously, he was with Energy Industries of Ohio (EIO) for 15 years where he managed industrial programs and technical research efforts. At EIO he was instrumental in initiating and managing Ohio’s Industry of the Future and Save Energy Now Programs as well as establishing for the Ohio Center for Industrial Energy Efficiency. The project he managed to identify improved materials for use in Basic Oxygen and Electric Arc Furnaces was awarded the 2006 Ohio Governor’s Award for Excellence in Energy. Mr. Boyd’s industrial experience includes the development and production of heterogeneous catalysts, experience in glass manufacturing and in the production of industrial solvents from biomass. Mr. Boyd holds BS and Master of Chemical Engineering degrees from Cornell University and an MBA from Cleveland State University. He is a DOE Energy Expert in Process Heating, a Certified Practitioner in Energy Management Systems and one of only 21 Performance Verifiers for DOE’s Superior Energy Performance program.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Office of Energy
Best Practices in Energy Efficiency, Energy Savings and Achieving
Company/Plant-wide Reduction inEnergy Consumption
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Financing Your Energy Project
• Overview of Office of Community Assistance-Energy Section
• Overview of Energy Loan Fund• Overview of Loan Fund Application Process• Details of the Energy Efficiency for Manufacturers Program• Energy Industries of Ohio-ISO 50001/DOE SEP• Case Studies
• Kowalski M&V• Charter Steel ISO 50001
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Office of Energy
Mission Statement:
To grow the economy of the state by connecting companies and communities to financial and technical resources that increase energy efficiency and deploy advanced energy technologies.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Office of Energy
Energy Loan Fund
• Low-cost loans that support energy efficiency and renewable energy improvements
• Provides financing for projects that reduce energy usage and associated costs, lower fossil fuel emissions, and/or create or retain jobs.
• Available for small businesses, manufacturers, and public entities.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Loan Fund
• Expected to result in Energy, Economic, and Environmental impacts that include:
• A minimum of 15% energy use reduction from existing conditions.
• A return on investment that allows the loan to be paid back within a reasonable time period.
• Economic impact such as job creation or retention.• Improvement in environmental quality.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Office of Energy
Loan Loss Reserve (LLR)
• Funding through partner organizations-Port Authorities• Provides backing of loans to enhance Port Authority
funding availability• Loans that support energy efficiency and renewable
energy improvements• Provides financing for projects that reduce energy usage
and associated costs, lower fossil fuel emissions, and/or create or retain jobs.
• Available for small businesses, manufacturers, and public entities.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Office of Energy’sEnergy Efficiency Program
for Manufacturers
Tony Sutor
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
• Developed in 2002 to engage Ohio’s manufacturers
• Multi-phase (Four Phase Approach) energy efficiency program
• Helps Ohio manufacturers reduce costs by diagnosing, planning, and implementing cost-effective energy improvements at their facilities.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
Phase I • Identification of energy cost saving actions
• Company management team examines their energy use and business practices.
• A two-hour diagnostic session is scheduled and conducted at the facility with key managers.
• Five customized “Action Steps” are identified by the diagnostic.
• Costs covered entirely by the Office of Energy
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
Phase II• Development of an energy plan that combines changes in
business process methodologies with the identification of cost-effective technical measures
• Completion of a technical energy audit of the company’s facilities.
• Development of an energy management plan and a list of technical opportunities that increase energy efficiency at the facility.
• The Office of Energy funds 50 percent of the plan to a maximum of $15,000.
Energy Efficiency Program for Manufacturers
Phase II Alternative Path• Conduct an ASHRAE level II audit (or equivalent as deemed by the
Office of Energy) of their facility and apply directly to the Energy Loan Fund.
• Audit results certified by P.E.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
Phase III• Implementation of energy cost savings measures
identified in Phases I & II.• Many companies are eligible for financing through the
Office of Energy to implement these measures. • Energy Loan Fund/LLR
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
Phase IV• Measurement and verification of the energy cost saving
measures.• Companies will work with their program facilitators to
verify the estimated energy savings data. • Financial assistance from the Office of Energy may
be available for on-going measurement and verification in preparation for the final report.
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Participation
• Phase I – Over 270 Companies
• Phase II– Over 140 Companies
• Phase III– Over 118 Companies
• Phase IV– Ongoing
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Results
To date, the program has invested more than $25 million to:
Reduce energy
usage by more than
1 Bcf of gas and 79,000
MWh of electricity annually
Save over $13 million
in combined
energy costs
annually
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
NEW ACTIVITY-pre-phase I Smart Energy Assessment
• Identified over 7000 potential customers• Seeking participation of 1000-1200 customers• Phone assessment using limited information• Identifies key opportunities utilizing statistical data• Opens up the opportunity for a more detailed assessment
via the Four Phase EEPM• Currently underway and results to be developed in fall
2016
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
NEW ACTIVITY-pre-phase I Smart Energy Assessment
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
NEW ACTIVITY-pre-phase I Smart Energy Assessment
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
NEW ACTIVITY-pre-phase I Smart Energy Assessment
The State of Ohio is an Equal Opportunity Employer and Provider of ADA Services.
Energy Efficiency Program for Manufacturers
NEW ACTIVITY-pre-phase I Smart Energy Assessment
Program Update and
Case Study Verification
Lawrence C. Boyd Jr.,CP EnMS, SEP PV- Industrial
Lawrence Boyd and Associates
• OCIEE Activities
• Case Study Verification– Kowalski Heat Treating
Agenda
OCIEE
• Established 2009• State Electric and NG IOU• Best Practices Training
– ~ 1100 attendees • Technical Assistance
– Compressed Air, Process Heating, EnMS• Support ODSA EEPM
• 3 to 4 Sessions per Year– Air Compressors– Steam Systems– Chiller Systems– Motors and Drives– Pumping Systems– Process Heating
• Starting in January
Best Practices Training
• Background– Heat Treating Job Shop
• Specializing in Precision Heat Treating– Participation in EEPM– Phase I and II Completed in 2012/ 2013
• Focus on Process Heating Units – Applied for Phase III Low Cost Loan in 2014– Equipment Procured, Installed in 2015
Kowalski Heat TreatingProject Verification
Phase II HighlightsPHAST Program
Phase II HighlightsPHAST Program
Phase II HighlightsPHAST ECM 1 Replace Insulation
Savings, kWh/yr Savings, $/yr % SavingsFurnace 17 63,128 6,628 12Furnace 15 87,932 9,233 25Furnace 07 80,704 8,474 28
PHAST ECM 2 Preheat Load to 275FSavings, kWh/yr Savings, $/yr % Savings
Furnace 17 65,832 6,912 13Furnace 15 26,988 2,834 8Furnace 07 21,060 2,211 7
Salt 1 7,072 743 2
PHAST ECM 3 Reduce Fixture WeightSavings, kWh/yr Savings, $/yr % Savings
Furnace 17 51,220 5,378 10Furnace 15 29,328 3,079 8Furnace 07 Does not Apply
PHAST ECM 4 Schedule to Reduce Reheating EnergySavings, kWh/yr Savings, $/yr % Savings
Varies with furnace and cooling rates yet to be determined
PHAST ECM 5 Reduce Radiation Losses from Salt BathsSavings, kWh/yr Savings, $/yr % Savings
Salt 1 152,424 16005 34Salt 2 14,720 1546 50
• New Air Heated Furnaces
• Replace Salt Baths
• Construct Preheat System
Loan Program Projects
Superior Energy Performance SEnPI
SEnPI = BTUCRPT /
BTUCBASE
BTUCRPt; Base Determined by Linear Regression
All Energy Sources Converted to Primary BtusFactors: Fuels = 1; Grid Electric = 3 x kWh
Other Sources as Defined or CalculatedC = Constant ConditionsRpt = Reporting Period Base = Baseline Period
SEP M&V Protocol
– Georgia Tech Tool 3.14 (DOE SEnPI Tool 4.0)• Excel-based Programs
• Enter Input Source and Variable Data
– Automatically converts to Source BTUs• Select Calculation Method/Data Range
– Results: Model, Statistics, Validity Checks • Calculates SEnPI
• Calculates % Improvement (1 – SEnPI) x 100
Tool Description – Input Screen
Electric Model
Calculated Savings
Graphical Representation
Kowalski Results
Contacts
• Larry Boyd, CP EnMS, SEP PV Industrial– Lawrence Boyd and Associates– 216-323-1898 (Phone)– [email protected]
• Tony Sutor– Ohio Office of Energy– 614-387-2733– [email protected]
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THANK YOUQuestions?
