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197 Resources for

u.s. department of energy

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Alcoa/Alumax Reduces Energy Cost While Improving its Dust Collection Systems: In 1995, Alumax (subsequently acquired by Alcoa), an aluminum refiner, decided to improve the energy efficiency of its four-pot line dust collection systems at its smelter in Mount Holly, S.C. One consultant recommended installing variable frequency drive (VFD) controls on the four-fan system. Motor Challenge determined that the three-fan VIV...; Tags: U.S. Department of Energy; Case studies
Ohio Aluminum Industries: Compressed Air System Improvement Project Saves Energy and Improves Product Quality: Ohio Aluminum Industries is an aluminum component producer based in Cleveland, Ohio, and is part of Foundry Systems International (FSI) Group. In 2001, Ohio Aluminum Industries implemented the first phase of a compressed air system improvement project at its Cleveland, Ohio, plant. Working with Department of Energy Allied Partner, Air...; Tags: U.S. Department of Energy, industry; Case studies
Power Factor Study Reduces Energy Costs at Aluminum Extrusion Plant: In 1999, Alcoa North American Extrusions (NAE) conducted a power factor study at their facility in Spanish Fork, Utah. Low power factors waste money directly because of higher electricity bills, and indirectly by reducing the efficiency and capacity of the plant distribution system and the productivity of the equipment it...; Tags: U.S. Department of Energy; Case studies
Compressed Air System Upgrade Improves Production at an Automotive Glass Plant: In 2000, Visteon Corporation implemented a project that improved the compressed air system at its automotive glass plant in Nashville, Tennessee. The project involved replacing worn, unreliable compressors with smaller, more efficient units and reconfiguring the system to allow it to operate more effectively. Visteon is an automotive parts manufacturer...; Tags: U.S. Department of Energy, Visteon Corp., performance; Case studies
Compressed Air System Improvements at an Automotive Plant: The Ford Motor Company implemented a compressed air system improvement project at its Woodhaven Stamping plant in Woodhaven, Michigan. The Woodhaven stamping plant is a 2.7 million-square-foot facility with 2,400 employees that is part of Ford's Vehicle Operations Division. Compressed air used by the stamping presses and the plant's other...; Tags: U.S. Department of Energy, Ford Motor Co.; Case studies

Compressed Air System Improvements Increase Production at a Tin Mill: Weirton Steel's plant in Weirton, West Virginia is one of North America's most advanced integrated steel production facilities. Weirton Steel's management commissioned a compressed air systems assessment by Ingersoll Rand. The assessment's main conclusion was that most of the system's problems were being caused by excessive oil and moisture in...; Tags: U.S. Department of Energy; Case studies
Compressed Air System Optimization Saves Energy and Improves Production at a Textile Manufacturing Mill: Thomaston Mills, Inc. is a diversified manufacturer of textile products for the apparel, home furnishings, and industrial markets. A compressed air system improvement project was implemented at the Peerless Division of Thomaston Mills in Thomaston, Georgia. The compressed air system in the grey mill was surveyed in 1995 because the...; Tags: U.S. Department of Energy, home furnishing, manufacturing; Case studies
Compressed Air System Upgrade Generates Significant Energy Savings at a Steel Mill: U. S. Steel Group, a unit of USX Corporation, is headquartered in Pittsburgh, Pennsylvania. USX is a major worldwide producer of oil and natural gas, as well as the largest producer of steel products in the U.S. The Edgar Thomson plant engineers reviewed their compressed air system and realized that...; Tags: U.S. Department of Energy, natural gas; Case studies
Compressed Air System Upgrade Improves Production at a Steel Mill: U.S. Steel Group, a unit of USX Corporation, is headquartered in Pittsburgh, Pennsylvania. USX is a major worldwide producer of oil and natural gas, as well as the largest producer of steel products in the United States. The Edgar Thomson plant engineers reviewed their compressed air system and realized that...; Tags: U.S. Department of Energy, natural gas; Case studies
Compressed Air System Upgrade Results in Substantial Energy Savings: The BWX Technologies plant in Lynchburg, Virginia, is the main production site for its Naval Nuclear Fuel Division (NNFD). The Lynchburg plant engineers were aware that their compressors were venting large volumes of compressed air into the atmosphere. The plant engineers also knew that excessive moisture was present in the...; Tags: U.S. Department of Energy; Case studies
The Challenge: Improving Dust Collection Systems at an Aluminum Refinery: Alumax is the third largest producer of aluminum in the United States and has more than 100 plants in seven different countries. Alumax wanted to improve the energy efficiency of its four pot line dust collection systems. To identify the most energy-efficient system, the Showcase Team measured fan speed, air...; Tags: U.S. Department of Energy, power consumption; Case studies
Corporate Energy Conservation Program for Alcoa North American Extrusions: Alcoa is the world's leading producer of primary aluminum, fabricated aluminum, and alumina. Alcoa North American Extrusions (NAE) views energy conservation as a means of eliminating waste and increasing sustainability. Energy-efficient production processes not only reduce the amount of money required to purchase energy, but also yield benefits such as...; Tags: U.S. Department of Energy, Alcoa Inc., sustainability, benefit; Case studies
Alcoa North American Extrusions Implements Energy Use Assessments at Multiple Facilities: Compressed Air System Assessment at Elizabethton Extrusion Plant: In May 2001, Air Management of Powder Springs, Georgia, assessed the compressed air system at the Alcoa North American Extrusions (NAE) facility in Elizabethton, Tennessee. The result of the assessment was a proposal to optimize the compressed air system to meet current and future production requirements and reduce operating costs...; Tags: U.S. Department of Energy, Alcoa Inc., manufacturing; Case studies
Installation of Reverse Osmosis Unit Reduces Refinery Energy Consumption: The Flying J Petroleum Refinery, located in Salt Lake City, Utah, processes 25,000 barrels per day (BPD) of crude oil. The Flying J Petroleum Refinery replaced its hot lime softener, which removes hardness and alkalinity from boiler feed water, with a reverse osmosis unit. The benefits of this replacement project...; Tags: U.S. Department of Energy, benefit; Case studies
Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint: The Augusta Newsprint mill is part of a joint partnership between Abitibi Consolidated and the Woodbridge Company, Ltd. The boiler blowdown process involves the periodic or continuous removal of water from a boiler to remove accumulated dissolved solids and/or sludges. However, boiler blowdown wastes energy because the blown down liquid...; Tags: U.S. Department of Energy, partnership; Case studies
Consolidated Compressed Air System Reduces Power Consumption and Energy Costs: The Augusta Newsprint Mill in Augusta, Georgia, is part of a joint partnership between Abitibi-Consolidated and the Woodbridge Company, Ltd. In early 2001, the Augusta Newsprint Company undertook a project to consolidate two compressed air systems at its facility in Augusta, Georgia. Augusta Newsprint operated two distinct compressed air systems...; Tags: U.S. Department of Energy, Georgia, power consumption, partnership; Case studies
Four Equipment Upgrade Projects Reduce System Energy Losses at Augusta Newsprint: The Augusta Newsprint mill is part of a joint partnership between Abitibi Consolidated and the Woodbridge Company, Ltd. The Augusta Newsprint Company performed a plant-wide energy assessment that focused on many processes operating in their Augusta, Georgia mill. This study presents four projects that have several features in common. In...; Tags: U.S. Department of Energy, partnership; Case studies
Improving Several Fan-Driven Systems in an Oriented-Strand Board Manufacturing Facility: Louisiana Pacific Corporation is a producer of oriented-strand board (OSB) in Tomahawk, Wisconsin. It completed a fan system optimization project resulting in substantial energy and cost savings. Originally, some of the process equipment used in the Tomahawk plant was designed and installed in an OSB plant in Colorado. After the...; Tags: U.S. Department of Energy, Wisconsin, manufacturing, cost savings, board; Case studies
Procter & Gamble: Compressed Air System Upgrade Saves Energy and Improves Production at a Paper Mill: P&G is a major producer of consumer goods; it produces and sells a wide range of paper, laundry, cleaning, beauty care, health care, and food and beverage products to more than 5 billion consumers in more than 140 countries. In 2002, Procter & Gamble (P&G) improved the compressed air system...; Tags: Team management, Food & Beverage, U.S. Department of Energy, Procter & Gamble Co., paper product, beverage, team, food, health care; Case studies
Pump System Optimization Saves Energy and Improves Productivity at Daishowa America Paper Mill: Daishowa America is the U.S. subsidiary of Daishowa Paper Manufacturing Company, Ltd., of Japan. In 2000, Daishowa America implemented an improvement project on the effluent pumping system at its paper mill in Port Angeles, Washington. At the suggestion of NEEA, staff at the Port Angeles mill agreed to a review...; Tags: U.S. Department of Energy; Case studies