Heads Up CIPEC – Volume 19, Issue 7 and 8

Volume 19, Issue 7 and 8

Issue 7

CEC seeking applicants for new trilateral energy management pilot program

The Commission for Environmental Cooperation (CEC) is launching an innovative pilot program that will promote energy management systems to companies with facilities in Canada, Mexico and the United States to support the implementation of ISO 50001certification. The North American Energy Management Pilot Program is a partnership involving Natural Resources Canada (NRCan), Comisión Nacional para el Uso Eficiente de la Energía (CONUEE or the National Commission for the Efficient Use of Energy), and the U.S. Department of Energy (USDOE).

The trilateral pilot, to be launched in early 2016, will offer companies targeted energy management training and coaching to achieve ISO 50001 certification to demonstrate improved energy performance.

The initiative is designed to promote the implementation of more robust energy management practices focused on continual improvement and supports efforts to develop a harmonized North American approach to energy management systems. 

The CEC is currently seeking applications from companies that have plants in at least two of the three countries. Companies will be selected based on senior level commitment to energy management and energy performance improvement, their experience with ISO management systems, their commitment to pursuing ISO 50001 certification, and their interest in expanding implementation to other North American or global facilities.

Through a series of workshops delivered by energy management experts, successful applicants will learn how to apply and implement the ISO 50001 Energy Management Systems standard to identify energy cost-saving opportunities. They will also gain an understanding of how a corporate-level energy management system can be applied and how to share best practices across multiple facilities to improve energy performance to ultimately reduce energy costs and lower their GHG emissions.

Companies will contribute US$12,000 and human resources to the program, which will allow them to prepare several plants for certification. Once the training is completed, certification costs for ISO 50001 will be borne by the company.

Pilot partners will be recognized nationally and internationally at events such as the Clean Energy Ministerial (CEM) 7 and by the CEM Energy Management Working Group.

The deadline for application is January 8, 2016. You are encouraged to visit the CEC Energy Program webpage for details on the program and to submit your application online.

For more information, please contact Bob Fraser, Sr. Engineering & Technical Services Advisor, Natural Resources Canada, at 343-292-8799 or bob.fraser@canada.ca

Organic Rankine Cycle system is a perfect fit for Nechako

“We are excited about transforming our excess process heat into usable energy,” says Alan Fitzpatrick, CEO of the Nechako Group of Companies and President of Nechako Green Energy. Since 2013, Nechako’s sawmill has been harnessing the heat from its lumber drying process to produce electricity using an Organic Rankine Cycle (ORC) system.

Nechako’s sawmill and planer mill are co-located in Vanderhoof, British Columbia, with a wood pellet facility and Nechako Green Energy Ltd., the electricity generating company, in an integrated industrial complex.

ORC technology works by vaporizing an organic fluid at a lower temperature than required to evaporate water. Once the vapour passes through a turbine to generate electricity, the fluid is cooled, condensed and returned to the beginning of the loop. At the Nechako mill, excess heat from the burning of hog fuel heats oil for use in the ORC system to generate 25 percent of the mill’s electrical load.

“Installed in February 2013, the 2.2 megawatt capacity ORC turbo generator, which is outfitted with advanced controls and safety features, achieved our production targets in the first year of operation,” says Fitzpatrick. He notes the project hit its target despite an increase in overall power consumption due to the addition of a new sawmill processing line.

The project was supported by funding from NRCan’s Investments in Forest Industry Transformation (IFIT) program. “ORC technology is an efficient, clean and reliable way of producing electricity,” says Jean-François Levasseur, IFIT Program Lead. “This project opens a whole new realm of possibilities for the Canadian forest industry.”

For its innovation, the Nechako Group has received a number of awards including the 2012 Clean Energy BC Project award, the 2012 Forest Innovator Award, the 2013 BC Lieutenant Governor’s Safety Excellence Award and the BC Hydro Energy Efficiency Project of the Year award in 2014.

While generating power from wood waste is relatively common in pulp mills, using an ORC system in a saw mill is a first. The concept, however, is quickly gaining momentum, says Fitzpatrick, noting that other companies are replicating the technology in their facilities. Moreover, he has been asked to speak and give presentations at conferences about Nechako’s experience with ORC and its benefits. According to Levasseur, ORC technology has a high potential of being replicated throughout the forest products sector because of the need for small scale heat and power and the access to wood residues.

“ORC technology was the most efficient system and the best fit for our needs,” says Fitzpatrick, adding that even with the ORC system, there is still a lot of unused energy. “We are exploring the possibilities of how to best use that energy; I feel that we are just getting started on our path of energy efficiency and transformation.”

CME launches new initiative to provide energy best practices for the general manufacturing sector

Paul Clipsham, Director of Policy & Programs at the Canadian Manufacturers & Exporters, says that the new Energy Pathfinder Initiative aims to identify low or no cost energy saving opportunities that will help companies in the Ontario manufacturing sector to stay competitive. “The intent of the Initiative is to identify energy saving opportunities, develop best practices and optimize end-use operations in the sector,” adds Michael Kelly, Co-Chair of CIPEC General Manufacturing Task Force and Process Engineer and Energy Manager at KI Pembroke.

The initiative was conceived by Canadian Manufacturers & Exporters (CME) in Partnership with the Independent Electricity System Operator (IESO) – who also supplied financial support, and other stakeholders. Clipsham notes that the initiative is a modification of a successful model run by the Nova Scotia division of CME. The initiative, to be completed by spring 2016, is being carried out by ICF International, an environmental project consulting company.

“The initiative stems from the need for small- to medium-sized manufacturing enterprises to take advantage of energy efficiency opportunities without significant capital or human resources,” notes Kelly. These businesses require low-capital strategies that yield savings through the performance optimization of existing equipment, electricity peak reduction and load shifting, and the mitigation of waste energy drivers.

Clipsham explains that in order to assess the opportunity of process energy management, the project will explore, define and quantify a sample of opportunities ('deep dives') in actual facilities and develop best practices to improve, control or optimize energy intensive processes in five strategically selected industry segments at the rate of one facility per segment within the Ontario industrial and manufacturing sector.

The targeted segments are:

  1. Plastics moulding and extruding
  2. Baking and tortilla manufacturing
  3. Metal machining (transportation and other machinery)
  4. Metal fabricating
  5. Meat products manufacturing

“How industrial processes are integrated to compound energy inefficiencies is relatively uncharted territory,” says Clipsham, noting that once energy drivers are identified, as is intended with the ‘deep dives’, then positive changes can be made.

From the five initial sites, a best practice scorecard will be developed to be used to benchmark four additional sites per target sub-sector via an onsite process energy audit. The benchmarking will determine to what extent the best practices are already in place and/or the potential for implementing them. The scorecards will be used to identify levels of adoption and technical potential by end-use. A report will be generated that summarizes findings, including energy initiatives implemented and associated savings at the five ‘deep dive’ sites.

Kelly is thrilled about getting more tools that will help the manufacturing sector address challenges in pursuing energy savings, project planning and implementation. “Resource allocation is one of the biggest issues for our sector and I see this initiative as a gap analysis that will take resource-stretched businesses to the next level in energy efficiency,” he notes. Clipsham agrees, adding that “we hope to identify numerous best practices that are repeatable in different manufacturing settings and that represent significant wins in energy costs and management.

Greening cement and its life cycle

New technologies and practices are now available to enhance the cement industry’s energy performance even further. Precast concrete, carbon sequestration technologies and cement additives have been developed by Canadian industry and researchers that show strong energy performance, significantly reduced environmental footprints and increased energy savings.

Lafarge Canada Inc. recently finished construction of the company’s Innovation Hub on a current Lafarge industrial site in Edmonton, Alberta. The facility, made of highly efficiency, precast concrete, houses a world-class laboratory and is a showplace for sustainable materials, such as polished thermal floors with reflective white pigment and concrete walls that engage thermal mass. When combined with an intelligent building management system, the building’s precast ‘sandwich’ panels eliminate thermal bridges that deliver strong energy performance.

The Hub also features radiant in-floor heating, a rain and industrial water reclamation system and an interior design that reduces the amount of concrete to be crushed and reused at end of life. The building’s footprint was measured using Life Cycle Assessment (LCA) and has an Environmental Product Declaration created by the Athena Sustainable Materials Institute.  Lafarge sees LCA as a tool to find ways to reduce the environmental footprint of its products and buildings.

For the full story, visit: www.worldcement.com/the-americas/09092014/Lafarge-Canada-creates-Environmental-Building-Declaration-for-Hub-444/.

CarbonCure Technologies, operating out of Dartmouth, Nova Scotia, retrofits existing masonry and ready-mixed concrete plants to reduce the carbon footprint of their products. Waste carbon dioxide, stored onsite within pressurized vessels, is injected into the mixed concrete and is permanently converted into a very fine solid material blended with concrete. 

In the process, carbonate ions, produced when carbon dioxide is mixed with water, react with the calcium in the cement to form a nanomaterial version of calcium carbonate (limestone). This binds carbon dioxide permanently into the concrete. Similar to chemical admixture systems, CarbonCure’s technology is designed to work with all production equipment and materials.

A number of facilities are already using concrete made using the new carbon sequestration technology including Ontario’s Pan Am Games Markham Pool in Markham and the Tridel Hullmark Centre in Toronto. For more information on the technology, visit:  http://carboncure.com/.

Researchers at Lakehead University in Thunder Bay, Ontario, have developed a cement additive that makes concrete up to 40 percent stronger while reducing GHG emissions. The additive is a type of sugar called a polyol that is a by-product of the pulp and paper industry.

The additive acts as a glue that makes the bond between the different materials in concrete even stronger. It holds the mix together more effectively with less material. The material has a good consistency with an intermediate hardening time allowing construction workers to easily mould it.

The additive is currently being tested and further developed by the GreenCentre Canada – a green chemistry commercialization centre, in order to best market it and explore other applications. For the full story, visit: www.innovation.ca/en/ResearchInAction/OutcomeStory/Greencement.

New incentive promotes energy management systems to B.C. industry

A new incentive, cost-shared by the Government of British Columbia and Natural Resources Canada, will offer up to $80,000 to B.C. industrial companies to help them implement energy management systems that will lead to compliance with ISO 50001 Energy Management Systems standard. The program, part of the B.C. Ministry of Energy and Mines’ Innovative Clean Energy (ICE) fund, supports the government’s mandate to reduce GHG emissions and promote the use of clean energy. “The intent of the financial incentive is to optimize fuel utilization,” says Nat Gosman, Director, Energy Efficiency Policy at the Ministry.

Gosman explains that the implementation of an energy management system (EnMS) enables companies to adopt a systematic approach to achieve continual improvement of energy performance. Companies that have implemented energy management system projects have reduced energy costs and increased business competitiveness while minimizing their environmental footprint.

The new incentive will cover expenses such as professional fees and internal employee salaries for energy management system pre-audits and business case development. Energy management system projects, including energy use assessments, energy baseline development, and energy performance monitoring and reporting, are also eligible for up to 75 percent of total costs to a maximum of $80,000. Funding for such projects is based on the implementation or enhancement of an energy management system. Funding for instrumentation, software and metering equipment is limited to 25 percent of total costs up to $40,000.

Gosman notes that incentives may be stacked with other funding, such as those available from BC Hydro, but “companies have to show that value has been added and that there is an incremental benefit.” The program is open to all sectors with projects to be completed by March 31, 2016.

Companies with an existing EnMS can use the incentive to move towards ISO 50001 implementation. “The program is very comprehensive,” notes Gosman, adding that several energy managers from different industrial companies in B.C. agree and are already engaged in the project submission process.

Issue 8

KI’s rewarding partnership with Enbridge Gas Distribution

“KI’s partnership with Enbridge Gas Distribution (Enbridge) and our Energy Solutions Consultant has been a driving factor behind the success we’ve had in managing our energy and in reducing our natural gas consumption by 30 percent in 2013 and 60 percent over our 2007-2009 baseline period,” says Michael Kelly, Process Engineer and Energy Manager at the Pembroke-based metal office furniture manufacturing company.

Over the past 10 years, one of Enbridge’s Energy Solutions Consultants (ESC) has worked closely with the Ontario manufacturing firm. This collaborative relationship has allowed KI to achieve significant energy savings.

Kelly explains that the facility has four 20-year old process ovens that are no longer adapted to current needs. Even after the initial purge prior to ignition, the ovens still exhausted four times the oven volume. The installation of programmable variable frequency drives (VFDs) on one of the facility’s four ovens was an easy solution to significantly reduce excess exhaust levels with no impact on productivity. The retrofit allows air purging prior to ignition but then adjusts the exhaust flow to levels that respond to process and combustion air needs at any given time.

The project qualified for a $16,000 incentive from Enbridge and is saving the company around 125,000 cubic metres (m3) of natural gas annually. A second oven will be retrofitted by the end of 2015 with the remaining two to be upgraded over the next few years. Kelly adds that some electricity savings can be attributed to the project as well since the oven exhaust motor was also upgraded. “We are now better able to monitor run times and deliver more appropriate preventative maintenance; everything is just more reliable.”

In reviewing the facility’s process equipment, KI identified another opportunity with the assistance of Enbridge’s ESC. Kelly explains that the chemical cleaner in the washing process, which required hot water to be effective, was replaced with a more ecological product that required only room temperature water. Natural gas savings are estimated to reach about 22,000 m3 per year from this project, which qualified for a $5,000 incentive from Enbridge. In addition, the existing three-stage washer was replaced with a more efficient five-stage washer and an associated 20-year old pump was upgraded. A second pre-treatment washer and chemical cleaner program will be replaced by the end of 2015.

Damir Naden, Enbridge’s Industrial Energy Efficiency Manager, explains that the utility offers both prescriptive and custom energy efficiency programs, noting that the latter is particularly popular. “Our larger customers are very appreciative of the personal attention they receive with an ESC who knows their facility’s energy issues.”

He explains that “ESCs develop the in-depth knowledge of a facility’s operations and processes needed to offer specific technology upgrades and solutions,” adding that the customer wastes no time trying different solutions. “Working with an ESC is a unique offer that provides a great deal of service and expertise at no cost.”

Carolyn Mendlowitz, Enbridge’s Industrial Program Marketing Manager, notes that Enbridge offers something for everyone, regardless of size of enterprise, starting with their Industrial Energy Solutions portal. “For those who are new to energy efficiency, our portal provides valuable advice and solutions.” Naden adds that Enbridge incentives and expertise are available to all of its customers in an effort to help them control and/or reduce energy costs and gain a competitive advantage.

Source: www.enbridgegas.com/businesses/energy-management/industrial/industrial-case-studies.aspx.

3M Canada to pursue ISO 50001 certification across Canada

3M Canada Company has its sights set on ISO 50001 certification for all of its Canadian, if not North American, facilities. The company is well on its way to achieving this goal in Ontario with the recent ISO 50001/SEP platinum level certification of its Brockville tape plant, the 2014 certification of its London plant and the June 2015 certification of its two facilities in Perth. “ISO 50001 certification is the best tool for integrating energy management into the corporate culture,” says Andrew Hejnar, Energy Manager at 3M Canada.

 “3M’s approach to energy management is based on three pillars, namely measuring energy, implementing technology and employee education,” says Hejnar. It was this approach that led 3M Canada’s flagship facility, the Brockville tape plant, to achieve the ISO 50001/SEP platinum level this year.

In October 2014, all indoor and outdoor lighting was changed to LED fixtures at the Brockville plant with savings of 300 megawatts (MW) in electricity since installation. Hejnar notes that since 2008, when all lighting was changed to T-8 fluorescent and with the LED upgrade, the plant has been able to reduce energy consumption by 83 percent with overall savings of 1.2 gigawatts (GW).  Both plants in Perth have also switched to LED and other 3M plants will be retrofitted in the near future.

3M has also done considerable work on compressed air optimization by replacing, where possible, large or inefficient compressed air users, such as drum mixers, with electric models. “We also have a strong leak prevention program that uses ultrasound technology to detect even the smallest leaks. With both of these approaches, we were able to reduce compressed air consumption from 1,000 to 700 cubic feet per minute (cfm3).”

Air balance studies at the Brockville and Perth plants helped reduce the amount of exhaust and make-up air. “We hire consultants to maintain our large HVAC units, requiring them to maximize their energy performance. Moreover, existing equipment is commissioned regularly to ensure optimum efficiency.”

Heat recovery systems to capture heat from dryers, boilers and compressors were installed in 2012 in the Brockville plant and in 2013 in both Perth plants. The excess heat is used for space heating the shipping and receiving areas. More recently, in Brockville, a heat recovery unit was installed to recover heat from the condenser water from the plant’s water chilling system. The heat is used to pre-heat make-up air in the winter. Moreover, as the glycol loop loses its heat, it serves to pre-chill the water for the chilled water system.

The Brockville plant will be the first 3M site in North America to use a combined heat and power system. Expected to be operational by the end of December 2015, the 2 MW natural gas-powered engine will be able to generate about 80 percent of the facility’s energy requirements. The project, supported by the Ontario Independent Electricity System Operator (IESO) and Hydro One, is being replicated at the Perth plants with a 1.4 MW combined heat and power (CHP) unit to be operational in January 2016. The high-grade heat from the CHP system exhaust will be recovered for use in the dryers while the low-grade heat will contribute to space heating.

With its Brockville, London and Perth plants now all ISO 50001 certified, Hejnar hopes to develop an ‘enterprise level’ approach to implementing ISO 50001 that would facilitate multi-site certification. Common ISO 50001 elements, such as energy training, purchasing, design and energy policy would be integrated at the corporate level. “This will allow us to bring in our other sites in Canada and eventually globally, easily and quickly,” he notes.

Compressed air upgrades at Barrick’s Hemlo mines strike gold

Projects like our compressed air initiative reflect our comprehensive Energy Management Program, which is part of Barrick Hemlo’s ISO140001 certified Environmental Management System,” says Andrew Baumen, Hemlo’s general manager. “Our energy management program also helps support continuous improvement efforts through the reduction of greenhouse gases and energy consumption, which aligns with Barrick Hemlo’s environmental and cost reduction strategies.”

Barrick’s Hemlo property, consisting of the Williams and David Bell mines, is located 350 km east of Thunder Bay, ON. The recent compressed air upgrades that Baumen is referring to are reducing costs at the mine as well as its GHG emissions.

The mine’s four 1,000-hp centrifugal compressors (30 years old) were aging and no longer serving the needs of the operation. An engineering study carried out in 2011 funded by the Independent Electricity System Operator (IESO, then OPA) determined that a compressor upgrade could generate significant savings for the mine in energy use and maintenance costs.

Project implementation, subsequently funded by IESO, consisted of the replacement of two of the four compressors. One of these was upgraded to a more efficient 1,000-hp centrifugal compressor to supply baseload requirements while another was replaced with a 600-hp screw compressor equipped with variable capacity control to serve as a trimming compressor. The other compressors remain as back-up units. The new compressors were installed in November 2014 and are saving the company around $150,000 a year.

The compressed air project also included the optimization of the existing heat recovery system where the waste heat from compressors is a key component. In the winter, the heat recovery system pre-heats outside air (as cold as -40oC) to 5oC, while it cools the compressors in the summer. With the compressor upgrade, the heat recovery system also needed optimization, a project that is currently underway and funded by Natural Resources Canada.

Another component of the compressed air project is the implementation of an annual compressed air leak study of the 100+ kilometres of underground piping at the mine. “With the new compressors, we can reap even greater benefits with regular maintenance,” says Chih-Ting Lo, Principal, EELO Solutions, an energy consultant for Barrick Hemlo.

There are also plans to use the existing 600-hp trimming compressor as the baseload compressor on weekends when compressed air requirements are lower. Additional savings could be gained by reducing compressed air use during shift changes with brief equipment shutdowns that do not affect production or safety.

In addition to energy efficiency projects, Barrick is also increasing its employee education campaign by advertising company success stories and recognizing staff with continuous improvement awards. “Low or no-cost measures, such as raising employee awareness, can contribute to reducing our base load,” states Russell Blades, Barrick’s corporate Senior Manager, Energy and GHG.

“At Barrick, we believe responsible energy use benefits the environment and society through reduced GHG emissions. As energy represents a significant proportion of our direct mining costs, responsibly managing our energy use is also vital to ensuring our profitability,” adds Blades.

CEE industrial initiatives promote energy savings

Four industrial initiatives promoted by the Consortium for Energy Efficiency (CEE) have helped members become more energy efficient. The CEE 2014 Annual Report summarizes the goal of the initiatives and how members can engage their customers more effectively for significant energy savings. 

CEE is an American and Canadian consortium of gas and electric efficiency administrators that aims to accelerate the development and availability of energy-efficient products and services. The consortium also works to encourage market uptake and ensure lasting public benefit of energy efficiency measures.

One of CEE’s initiatives promotes the adoption of Strategic Energy Management (SEM) in industry. Launched in early 2014, the initiative is already supported by 16 members from across North America including BC Hydro, Hydro-Québec and Efficiency Nova Scotia Corporation. Participants have achieved significant energy savings through increased capital expenditure projects and can also access new operations and maintenance savings streams.

CEE’s Premium Motors Initiative and its Motor Systems Initiative aim to transform the market for motor system efficiency. CEE’s early work focused on savings from prescriptive motor programs; now the CEE is encouraging a shift in focus to motor systems that include variable frequency drives (VFDs).

The popularity of CEE’s Distribution Transformers Initiative has increased steadily. The initiative’s goal is to increase customer awareness of the benefits of high efficiency transformers and to promote the development of new technologies. Since 2012, over 100 new efficient distribution transformer products became available. During the same time period the number of CEE members participating in the initiative has doubled.

CEE’s fourth program, the Municipal Water/Wastewater Initiative, promotes the integration of energy efficiency into standard operating procedure in the water supply and wastewater services. CEE has been involved in developing new test procedures that can provide better information about new wastewater blower technology.

CEE continues to promote these key initiatives focusing on barriers to adoption. For example, the consortium strives to have its members use industrial programs more effectively in order to achieve even greater energy savings.

To read the report, visit www.cee1.org/content/cee-annual-reports.


New CIPEC Leaders

Food and Beverage Sector

Agropur, Division Natrel – Burnaby, British Columbia
– Victoria, British Columbia

Bayview Greenhouses Inc. – Simcoe, Ontario

Glenwood Valley Farms – Langley, British Columbia

Forest Products Sector

Pacific BioEnergy Prince George Limited Partnership – Prince George, British Columbia

General Manufacturing Sector

Canadian General Tower Limited – Cambridge, Ontario

Steel Sector

Tree Island Steel Ltd. – Richmond, British Columbia


Call for story ideas

Has your company implemented successful energy efficiency measures that you would like to share with Heads Up CIPEC readers? Please send your story ideas for consideration to the editor, Jocelyne Rouleau, by e-mail at jocelyne.rouleau@canada.ca.

If you require more information on an article or a program, contact Jocelyne Rouleau at the above e-mail address.

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