Workshop AA Energy Savings Champions— Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Large National Corporations Wednesday, February 20, 2019 11:15 a.m. to 12:30 p.m.
Biographical Information Michelle Cross, CEM, Energy Advisor, CHP Program AEP Ohio 301 Cleveland Ave SW, Canton, OH 44702 330-438-7028 mcross@aep.com Michelle Cross is a Professional Engineer with 18 years of experience in manufacturing and the electric utility industry. She began her career as a Process Manager with Anheuser Busch. In 2008, she joined American Electric Power to manage environmental capital projects for generation facilities. In 2010, she joined the energy efficiency department for AEP Ohio and manages the Combined Heat and Power Program, Continuous Energy Improvement Program and the Data Center Program for business customers. Michelle has a Bachelor of Science degree in Chemical Engineering from The Ohio State University, is a licensed Professional Engineer in the state of Ohio, a Project Management Professional and a Certified Energy Manager. Richard W. Niese, Concept Designer and Team Lead Worthington Energy Innovations 1445 Worthington Woods Blvd., Suite B, Worthington, OH 43085 380-390-4600 Richard.Niese@wei.energy Rick Niese is a mechanical engineer for Worthington Energy Innovations with a background in energy, thermal systems and power generation. Rick develops concept designs for energy savings projects utilizing WEI’s technologies and specialized solutions and has implemented them for multiple industrial and manufacturing plants, food and beverage operations, and healthcare facilities. In his role as a Concept Designer and Team Lead he studies the details of a customer’s energy profile to separate energy needed from energy purchased. This analysis leads to identifying opportunities to reduce energy usage and improve process operations. Integrated into the startup team for projects he has designed, Rick is responsible for seeing projects through from initial identification to final commissioning which ensures that the original design intent of the project is realized by the customer. In addition, through WEI’s Monitor and Verification program, Rick continues to sustain and improve the operation for the years to follow. Rick is a graduate of The Ohio State University in Columbus, OH with a B.S. in Mechanical Engineering and has ten years’ experience in the energy industry.
Biographical Information Don Burton, Engineering Manager, Worthington Industries 614-438-3105 deburton@worthingtonindustries.com Don Burton began working in the steel industry soon after graduating from Youngstown State University in 1978 as an electrical engineer. He joined Worthington Industries in 1984 as a corporate engineer, serving multiple facilities in the mid-west. In 1989, he became engineering manager at the Worthington Steel Columbus facility on Dearborn Drive. Worthington Steel is a value-added steel processor marketing primarily to the automotive industry. As engineering manager, Don has managed many engineering disciplines all supporting a 300,000 square foot facility housing cold rolling, slitting and heat treat operations. He finds that today’s challenges are the same as they were 35 years ago. Maintain reliable equipment with an eye on integrating state of the art technology while reducing operating expenses to stay ahead of the competition. His responsibility for the Dearborn Campus substation and power distribution system includes management of system maintenance and upgrades as well costs savings opportunities. Energy management has always been a priority and has become a greater focus in the past 10 years. While many energy related projects have been completed, the current goal is to create a culture that will engage all employees to be energy reduction conscience. Andrew Stroh, CEM, Energy Manager Abercrombie & Fitch Co. 6301 Fitch Path, New Albany OH43054-9269 614-283-6074 Andrew_Stroh@anfcorp.com Andrew Stroh is the Energy Manager for Abercrombie and Fitch Co. and is a Certified Energy Manager (CEM) with the Association of Energy Engineers (AEE). He has specialized in commercial and industrial demand side energy management and reduction for 10 years. His background involves utility program implementation and energy portfolio management for end users in the public and private sectors. Andrew is responsible for utilities and energy procurement at Abercrombie & Fitch Co.
Worthington Industries & Worthington Energy Innovations Energy Savings Champions Best Practices & Case Studies in Energy Reduction & Energy Efficiency Wednesday, February 20, 2019 at 11:15 AM – 12:30 PM Rick Niese Don Burton Concept Designer & Team Lead Columbus Steel Engineering Manager Worthington Energy Innovations Worthington Industries
Agenda Introduction • Worthington Industries & Worthington Energy Innovations Columbus Steel Manufacturing Facility • Value‐add steel processing facility • Annealing, Cold Rolling and Slitting • History of Energy Partners Energy Conservation Measures Columbus, OH • HV Controls • Emulsion Heater Conversion • Pumping Optimization • Energy Dashboard Performance & Value • Utility Savings • Improved environmental control • Monitor & Verification This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Columbus Steel Manufacturing Facility Tandem Mill Single Stand Mill Annealing Slitter This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Columbus Steel Manufacturing Facility MAIN PLANT ANNEALING Rolling Mills & Slitters This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Energy Conservation Measures HV Controls – Positive Pressurization & Cool Air Heating TM • Utilize process rejection heat to heat the facility and minimize natural gas usage by HV units Emulsion Tank Heater Conversion • Convert electric heaters to natural gas to leverage low cost natural gas Emulsion Pumping Optimization • Detailed review of process piping and pumping revealed opportunity to significantly reduce pumping energy Energy Dashboard • Cloud‐based energy dashboard that integrates utility and production data This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Baseline HV Operation Baseline System • Process heat in annealing utilized for heating the main plant in the winter • Some local control for annealing fans. Sections of fans operating independently • No central control of Main Plant fans or HV units • The control program did not actively monitor the Main Plant • No SCADA computer or user friendly interface Annealing furnace being removed ANNEALING MAIN PLANT Infiltration Air Natural Gas HV Units This document contains confidential and proprietary information. Not to be copied or reproduced without consent
TM WEI TECHNOLOGY – PLANT PRESSURIZATION & COOL AIR HEATING Existing Operation Cool Air Heating TM This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Optimized HV Operation ANNEALING MAIN PLANT Exfiltration Air Natural Gas HV Units Optimized System • Cool Air introduced in the upper third of the annealing bay • Cool air falls and mixes with warm air from process equipment • Warm air pushed from annealing into the main plant • HV control system receives information from annealing process PLCs • Control system monitors building pressure on all four walls and between annealing and main plant • Central SCADA computer with setpoints, schedule, overrides, alarms, and data archive This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Baseline – Electric Emulsion Heater Electric heaters installed in side of tank ran nearly 24/7 Baseline System • (8) Electric heaters @ 19.5 kW each ran to keep tank warm – 156 kW total (532,272 btu/h) • Ideal temperature is 125 ° F to 130 ° F to prevent separation of oil and water but electric heaters struggled to meet this • Electric Rate of $0.061/kWh = $17.87/MMBTU This document contains confidential and proprietary information. Not to be copied or reproduced without consent
Optimized – Natural Gas Emulsion Heater Natural Gas Heater Tube installed inside tank above electric heaters Optimized System • Added 720,000 Btu/h fire‐tube natural gas heater (35% more heat capacity than the electric) • Challenging exhaust pipe routing to avoid overhead crane • Averaging 7 ° F warmer tank temperatures while also reducing utility cost Natural Gas Rate of $3.50/MMBTU ( 1/5 th the cost of electric) • • Data available via the Global Control system – Allows for trending and troubleshooting • Alarms and email notification if electric heaters are ever enabled This document contains confidential and proprietary information. Not to be copied or reproduced without consent
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