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Learn How Others Have Saved

Facilities Like Yours Can Save Big

Energy efficiency projects can deliver large returns to your business. Find out more about how these companies are benefiting from DOE-sponsored plant-wide energy assessments and projects that they implemented on their own:

Alcoa
Augusta Newsprint Company
ExxonMobil
Cooper Cameron
Ford Motor Company
Nalco Chemical Company
Progressive Powder Coating
Rohm and Haas
Vulcan Chemicals

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'The methods used by DOE to identify potential savings opportunities became a key part of our Energy Efficiency Program. Alcoa's Energy Efficiency Network has now identified over $50 million in potential savings.' -Richard Notte, VP, Alcoa Energy Services

ALCOA
Following a plant-wide energy-efficiency assessment, Alcoa's Lafayette aluminum extrusions plant saved more than $1,500,000 by reducing its use of natural gas (260 million cubic feet) and electricity (2,500 MWh). Since the assessment, Alcoa's corporate Energy Efficiency Network has identified opportunities to save at least an additional $50,000,000. To date, the company has completed energy efficiency projects to realize more than $10 million of those additional savings. See case study (PDF 235 KB) Download Acrobat Reader

Augusta Newsprint Company
Boiler blowdown avoids the negative impacts of dissolved solids and impurities on boiler efficiency; Exterior of the Augusta Newsprint factory but also wastes energy because the discharged liquid is about the same temperature as the steam. To recover this energy, Augusta Newsprint implemented a project to route the liquid through a heat exchanger that preheats the new water coming into the boiler. The $15,000 project is saving almost $33,000 annually in fuel costs at the mill in Augusta, Georgia. See case study (PDF 179 KB) Download Acrobat Reader

ExxonMobil
By upgrading the control system of a recovery unit in its Baton Rouge, Louisiana, site, ExxonMobil reduced its annual energy consumption by 11%. The project reduced annual steam consumption by approximately 50 million pounds, or 43 billion Btu. It also improved product yield, reduced maintenance, and lowered monitoring (staffing) requirements. The project cost several million dollars with a 4-year payback. See case study (PDF 286 KB) Download Acrobat Reader

Cooper Cameron
This custom manufacturer of oil field machinery cut its energy costs by 46% and is saving $785,000 annually after taking the recommendations made during a free Industrial Assessment Center (IAC) analysis. The biggest savings came from the installation of a 480-to-120 volt transformer and a 120-volt line to power the computers in the production area. This separate power line enables the plant to shut down the 480-volt line during nights and weekends, saving about $537,500 annually. Repair of leaks in the compressed air system and other energy and waste-related measures produced the remainder of the savings. See case study (PDF 191 KB) Download Acrobat Reader

Ford Motor Company
'With several more projects underway, we expect more than $1,000,000 in additional savings by the end of 2003.' -Bill Ziemba, Supervisor for Energy LeadershipPower Train Operation, Ford Motor Company Ford's Cleveland Casting Plant has saved about $475,000 per year with just three of the projects recommended by its assessment completed and nine in progress. In all, the assessment identified 16 energy- and cost-saving projects in the plant's combustion, compressed air, water, steam, motor drive, and lighting systems. When implemented, the projects should save $3.28 million per year for the plant. Two other long-term projects promise an additional $9.5 million in cost savings. See case study (PDF 266 KB) Download Acrobat Reader

Nalco Chemical Company
Nalco's Clearing Plant in Bedford Park, Illinois, found a way to save 56,900 million Btu, worth about $142,000 annually. Changes in some of the plant's processes led personnel to evaluate the feasibility of incrementally reducing steam header pressure from 125 psig to 100 psig. See case study (PDF 199 KB) Download Acrobat Reader

Progressive Powder Coating
Progressive Armature entering new infra-red oven at Progressive Powder. Powder Coating, a metal finishing plant in Ohio, has increased production by 50%, reduced natural gas consumption by 25%, and reduced annual energy costs by approximately $54,000. After the need to cure thicker metal pieces forced the plant to slow the conveyor line speed in its manufacturing process, the company installed an infrared (IR) oven in between the powder coating booth and convection oven. The IR oven allowed the plant to increase its conveyor line speed and increase production by 50%. This successful project cost $136,000, with a simple payback of 2.5 years. See case study (PDF 404 KB) Download Acrobat Reader

'At our largest facility in Houston, multiple energy projects with various levels of DOE support have produced over $18,500,000 in cost savings per year and 4.25 trillion Btu/year combined fuel and power savings.' -Ray Baker, Energy Manager, Rohm & Haas Energy

Rohm and Haas
Since instituting a formal Energy Management Program in 1997, Rohm and Haas Texas has reduced its energy intensity by more than 23%, saving at least $18.5 million annually. The team approach to energy project selection and implementation has also reduced annual NOx emissions by 440 tons and greenhouse gas emissions by 67,000 tons. Senior management is actively involved in the Energy Management Program, which supports the company's sustainable development initiative. See case study (PDF 765 KB) Download Acrobat Reader

Vulcan Chemicals
As part of its Operational Excellence Program, Vulcan Chemicals implemented a process optimization project involving two chloromethane production units. The four-month project, which required no capital investment, reduced process steam demand by 22,000 million Btu for annual savings of $42,000. See case study (PDF 216 KB) Download Acrobat Reader

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