Heads Up CIPEC Newsletter - March 2014

Heads Up CIPEC Newsletter

March 2014 Vol. XVIII, No. 3

Energy Summit 2014 news

Do you want your company to save money, be more profitable and competitive?

Energy Summit 2014, to be held May 14 and 15 in Niagara Falls, will be hosted by Natural Resources Canada (NRCan) and the Canadian Industry Program for Energy Conservation (CIPEC) in partnership with Excellence in Manufacturing Consortium (EMC). The Summit, with the theme of Efficiency Meets Profitability, will continue CIPEC’s tradition of delivering Canada’s premier industrial energy conference since 2003.

Take part in the best energy conference of 2014, the Energy Summit 2014 – Where Efficiency Meets Profitability. Join over 400 industry decision-makers from across Canada. It is a must attend event. This year’s theme of linking efficiency with profitability will featureworkshops on energy management systems, the ISO 50001 Energy Management Systems standard, water management and innovative and alternative energy solutions.

Energy Summit 2014 keynote speakers to share experience about innovation, ISO 50001 and hidden savings

State-of-the-art innovations to improve productivity, efficiency optimization and the discovery of remarkable hidden savings with energy efficiency are just some of the topics that the keynote speakers will discuss at the 2014 Energy Summit co-hosted by the Excellence in Manufacturing Consortium (EMC) and Canadian Industry Program for Energy Conservation (CIPEC).

Simon Olivier, Vice President, Growth, Market Strategy and Business Development at GE Canada, Andrew Cooper, Energy Specialist at New Gold Inc. and Paul Rak, owner and Certified Energy Manager at Veriform Inc. will be engaging participants with wide-reaching presentations about their experience in turning energy efficiency into significant profits.

Simon Olivier

Simon Olivier, Vice President, Growth, Market Strategy and Business Development at GE Canada

“The Summit is a key industry event and is very well aligned with GE Canada’s business and investment strategies,” says Olivier. He sees the conference as a showcase for connecting energy efficiency, productivity and profitability. Moreover, Olivier notes that another important aspect of the Summit is networking and fostering relationships; “It’s all about collaboration and open source innovation.”

Innovation underpins Olivier’s work at GE Canada, where he has held many senior positions, and is currently responsible for developing the company’s market positioning as well as business development. Olivier, who holds an engineering degree and an MBA, recently served on the Board of Directors of the Canadian Wind Energy Association, and is a member of the McGill Global Strategy and Leadership Expert Panel. For his wide-reaching involvement and contribution to business development and innovation, he received the “Young Business Leader of Quebec” award in 2009.

Olivier is planning to share GE’s experience of successful initiatives such as the Ecomagination program, the company’s current interest in industrial Internet – the convergence of machine and intelligent data capture and analysis to improve efficiency in operations – and the concept of “The Power of One,” which refers to the significant savings that can be achieved with only one percent increase in efficiency.

Cooper has similar views about efficiency. “I am passionate about minimizing waste and maximizing efficiency,” he says. This philosophy has led him to initiate energy efficiency and sustainability projects, such as setting up an energy management information system (EMIS) and an ISO 50001 compliant Energy Management Systems standard (EnMS) at New Gold’s New Afton mine in Kamloops, British Columbia. “I see great value in ISO 50001 as the vehicle to make energy management sustainable in an organization.”

Andrew Cooper

Andrew Cooper, Energy Specialist at New Gold Inc.

Cooper, who has a degree in electrical engineering, started his career in South African gold mines, subsequently worked in the steel and petrochemical sectors, and, once in Canada, turned his attention again to the mining industry. After a period as an electrical engineer and engineering manager at the Sifto Salt Mine in Goderich, Ontario, Cooper became a Certified Energy Manager, and eventually moved into the position at New Gold that he holds today.

At the Summit, Cooper plans to share his company’s experience with energy management and provide participants with the “heartbreak and humour of ISO 50001 implementation and certification.” He is also looking forward to “hearing real-life stories and sharing what works and what does not.”

Rak, who has seen the evolution of energy management from the ground up, says that “Since industry now has a good understanding of energy issues, we can now focus on implementation. The concept of saving energy to create wealth makes sense intellectually but concrete examples, beyond changing lighting fixtures, are needed.” At the Summit he hopes to share one of those concrete examples with the audience – the potential for even greater savings in maintenance costs from energy efficiency projects.

Rak owns Veriform Inc., a manufacturing company, and its offspring Verigreen, an energy management firm; the combination of the two entities underlines his passion for green manufacturing. Rak has a wealth of energy management experience having led nearly 300 energy projects and spoken at over 50 sustainability events sharing his story on how profits can be multiplied by applying sustainability to everyday business operations. He has won several awards including the 2009 Cambridge Chamber Excellence Award in Sustainability.

Paul Rak

Paul Rak, owner and Certified Energy Manager at Veriform Inc.

Rak summarizes what his colleagues also believe to be a profitable outcome of the Summit; “we will discuss and learn about the many facets of energy efficiency and sustainability, including new developments, innovations and best practices.”

For more information on the Summit and the keynote speakers, visit www.energy2014.ca

OPA proud supporter of Energy Summit 2014

“The OPA is proud to be a partner in the upcoming Energy Summit,” says Andrew Pride, Vice-President, Conservation, Ontario Power Authority (OPA). “The event promises to be an unmatched opportunity for attendees to engage in discussions and workshops about industrial energy efficiency strategies.”
 
“The Energy Summit provides the OPA with a terrific opportunity to demonstrate the value in the programs that we offer,” says Pride. Pride is referring to OPA’s funding of embedded energy managers and the industrial accelerator program. Both programs focus on energy efficiency and conservation in industrial facilities. 

Pride notes that Energy Summit 2014 is an important event that gets energy efficiency information into people’s hands. “Here attendees can learn about the latest technologies and insights that will further their energy conservation goals.” He adds that an event such as the Summit is also about participants meeting and sharing their experiences in energy management.

“In order to achieve our goals of energy conservation, we need the involvement of many partners, such as CIPEC,” Pride adds. The OPA and NRCan see many opportunities for industry in energy management and both organizations aim to help industry realize those opportunities. 

Pride says that, at the Summit, the OPA will highlight the importance of human capital in energy management and how the Embedded Energy Manager program supports this asset. Also on the agenda is the role of energy conservation in the industrial sector and how it creates value for Ontario’s electricity system.

Calling all exhibitors

Looking to generate new business and build relationships? Need help positioning your company with industry leaders and energy efficiency experts?

CIPEC and EMC can help move your business goals forward.

Take part in the best energy conference of 2014, the Energy Summit 2014 – Where Efficiency Meets Profitability. Join over 400 industry decision-makers from across Canada. It is a must attend event. This year’s theme of linking efficiency with profitability will featureworkshops on energy management systems, the ISO 50001 Energy Management Systems standard, water management and innovative and alternative energy solutions.

By participating in this conference you will have the opportunity to

  • Promote and showcase your company
  • Find out the latest from world-class energy experts and discuss opportunities in energy and water management, waste heat recovery, innovative practice and technology and much more.

For more information please contact gabrielle.allard@nrcan-rncan.gc.ca or smcneilsmith@emccanada.org. To find out more about the conference please visit www.emccanada.org/group_spaces/energy_summit.

Chrysler Canada ISO 50001 certification part of doing business

“Our core lessons learned during the implementation of the ISO 50001 were on the organizational side,” says Josh Orentlicher, Environment Specialist at Chrysler Canada Inc.’s Brampton Plant. “Technology is not enough to solve energy issues; it also takes high-level corporate support, senior management buy-in and targeted employee engagement.” The facility received its ISO 50001 Energy Management Systems standard certification on December 18, 2013.

Chrysler Canada Inc. has over 2800 employees at its assembly plant in Brampton, Ontario, a CIPEC Leader in the Transportation Equipment Manufacturing sector.

Orentlicher notes that the facility already had an active energy management program in place and had experience in implementing ISO standards as it was already ISO 14001 and ISO 9001 certified. Additionally, Chrysler, Fiat & Co. operates under the principles of World Class Manufacturing (WCM). WCM specifically mandates improved energy conservation and energy waste reduction.

In March 2013, Chrysler Canada’s Brampton Assembly Plant started the formal approach to certification in order to be an early adopter. Orentlicher notes that the company’s corporate management group played a key role in moving the certification forward, as did the energy team. After a thorough gap analysis, Phase I of implementation started with a document audit in October 2013. A month later during Phase II, a week-long audit was conducted with successful results and final certification.

Some of the projects that were part of the certification process included the installation of a programmable logic controller (PLC) for paint shop facility lighting and the implementation of a Siemens Demand Flow® system that improves the efficiency of the facility’s chilled water system.

Orentlicher says that ISO 50001 certification will drive further engagement; “it has become a part of how we do business.” In order to ensure this required level of engagement, the energy team meets weekly with skilled trade workers and engineers from each functional department to review current energy losses, energy efficiency projects currently underway and their progress.

While all employees have already had introductory energy awareness training, the company is developing computer-based energy management training for more in-depth instruction. Moreover, specific employees associated with high-energy-use equipment will receive specialized energy training.

Orentlicher notes that there are 33 projects on the future projects list, including a major lighting retrofit, process ventilation optimization and potential participation in an electricity demand response program. While the metering capability on electrical systems is very good, he says that monitoring systems need to be improved to enable better measurement and management of natural gas.

CIPEC webinar: Energy Savings in Compressed Air Systems

Date: April 16, 2014 – English session – French session T.B.D.
Time: 13:00 DST
Location: Online, delivered through your Web browser
Duration: 90 minutes
Cost: Free

Does your organization use compressed air systems and are you monitoring compressed air like you do for other utilities?

Saving the environment and saving money can be as easy as patching a hose. That means you’re on the front line for energy-saving opportunities. It’s the most expensive and sometimes the most inefficient utility in many plants. For example, for every 100 units of energy, fewer than 10 units are turned into useful compressed air. 

Now’s your chance to find out more!

The Canadian Industry Program for Energy Conservation (CIPEC), through Natural Resources Canada, is offering members of Canada’s industrial community a unique opportunity to learn more about compressed air systems by holding a one-hour webinar information session. 

Agenda:
  1. Introduction and Overview
  2. Compressed Air Inefficiencies and Opportunities
  3. Rollstamp Manufacturing Case Study
  4. MB Hydro Case Studies (Motor Coach Industries, Griffin Wheel, Boeing)
  5. Conclusion and Q&A
Speakers

Denis Lamoureux, CET
Industrial Engineering Officer, Natural Resources Canada

Tejal Desai
Maintenance, Rollstamp Manufacturing – Division of Magna International

Ron Marshall, CET, CEM
Industrial Systems Officer, Manitoba Hydro

To register or to receive more information, please contact Francis Charette at francis.charette@nrcan-rncan.gc.ca or 613-996-7744 

Priority will be given to CIPEC Leaders. For more information about becoming a CIPEC Leader, click here

Canadian cement industry continuously decreasing energy use and emissions

“The Canadian cement industry is on a steady path of continuous improvement,” notes Adam Auer, Director of Sustainability and Stakeholder Relations at the Cement Association of Canada (CAC) and the CIPEC Cement Sector Task Force Chair. He is commenting on the recently released annual Labor-Energy Input Survey by the U.S.-based Portland Cement Association, which reports on trends for both the U.S. and the Canadian cement industry.

In general, the survey shows that cement industry energy consumption in 2012 decreased from previous years. This is confirmed by the CAC’s 2012 Environmental Performance Report, which reports data from a Canada-specific analysis of energy use, among other environmental metrics. That report, which covers the 2000 to 2010 period, shows a downward trend in average cement CO2 intensity. Auer explains that this is largely due to the Canadian industry’s conversion to lower carbon Contempra™ cement, increased use of supplementary cementitious material and an increasing use of low carbon fuels in cement manufacturing. Similarly, air emissions (e.g., NOx, SOx, particulate matter) have been relatively stable or on a general decline since 2002.

Over the past 10 years, there has also been a general trend of improved energy efficiency due to a reduction in both thermal and electrical energy use. In fact, the sector has achieved an 11-percent increase in efficiency since 2007. Auer notes that the improvements largely come from gains in thermal efficiency. With climate change being a major driver for energy efficiency improvements, increasing thermal efficiency, which is the best way to reduce the industry’s CO2 emissions, is important to the industry – “We get the biggest bang for our buck here,” notes Auer.

Auer explains that, across Canada, the industry invested in major capital upgrades in the 1990s resulting in the newest and most efficient plants in North America. “We are now in another cycle of capital improvements that will focus on innovation and technology to achieve efficiencies.” The cement industry will continue to see incremental improvements, says Auer, but notes that the costs of these incremental achievements have gone up.

He notes that the fuel mix depends not only on fuel prices but also on the production capacity of each fuel (e.g., coal has more capacity than natural gas). So while coal and petroleum coke use remain the same, the trend is towards using low carbon fuels. Auer explains that the industry is looking at the use of biomass as well as certain non-recyclable by-products from other industries that would otherwise end up in landfills (e.g., construction and demolition waste, which contains high levels of waste biomass.) “The proportion of alternative fuel used depends on the jurisdiction and varies between 30 percent of fuel mix in Quebec to two percent in Ontario. In Europe, substitution rates are as high as 60 percent. The increased use of low carbon fuels is one of the biggest levers to reduce CO2 emissions in our industry,” explains Auer.

One of the big news stories for the Canadian cement industry is ISO 50001 certification, with large savings already achieved by early adopters such as St. Marys Cement Inc. (Canada). Other ways that the industry has achieved improvements has been to control the quality of the raw mix, optimize the fuel mix, manage kiln efficiencies, invest in heat recovery systems, and optimize compressed air use.

Auer summarizes saying that “our biggest priority is increasing our capacity for substituting virgin fossil fuels with low carbon fuels.” He adds that the industry is constantly looking for and finding efficiencies to keep energy use and emissions on a downward trend but notes that new disruptive technologies will be needed to drive deeper reductions.

Embedded energy managers deliver considerable savings for Atlantic Packaging

“Every company should take part in the embedded energy manager program,” say Adam Murree and Chris Russell, both energy managers at Atlantic Packaging’s Scarborough mills, under the OPA’s embedded energy manager program. Both attest to the benefits of having someone dedicated to energy issues in an organization in order to move energy conservation forward.
  
Atlantic Packaging, a CIPEC Leader in the General Manufacturing sector, has two facilities located in Scarborough, Ontario – the New Forest Paper Mill and the Scarborough Liner Mill. The company employs about 90 to 100 employees between the two facilities, which operate 24/7 year-round except for about two weeks for scheduled maintenance.

The Ontario Power Authority’s (OPA’s) saveONenergy embedded energy manager initiative funds 80 percent of energy manager salaries as well as an additional 80 percent of annual expenses.

Murree explains that Atlantic Packaging and New Forest are Toronto Hydro’s first and second largest customers. In 2013, the two facilities combined to use over 270 million kilowatt-hours (kWh) and about 53 million cubic metres in natural gas consumption. As a result, when OPA’s embedded energy manager initiative was announced, the company jumped at the opportunity to have a dedicated person to oversee and reduce energy consumption through energy management at each of these highly energy-intensive facilities.

“Since our hiring, we have doubled our targets, having saved 1200 kW of demand and over 9 million in kWh of electricity use,” say Murree and Russell. Murree explains that one of the first measures taken was the development of a Global Adjustment curtailment plan. The software that was developed in house allows the Energy Department to accurately forecast Ontario Demand during peak periods and significantly reduce the economic impact of the global adjustment charges on each facility.

Russell notes that his projects at New Forest completed in the last quarter of 2013 saved over 500 kW of demand load. One major project was the addition of freeness analyzers to the refiners of the mill’s paper machines at a cost of $240,000 with an expected savings in electrical power of 25 percent annually and a payback period of less than six months.

Other projects included the installation of variable frequency drives (VFDs) on couch pit agitators that were in constant operation. Now, one unit can be turned down or off and the motors will alternate their operations. Electricity savings since the $38,000 project was completed in September 2013 are at almost $54,000 to date.

Murree says that at the Scarborough Liner Mill, procedures were modified to run the pulper only five minutes per hour leading to over 184 kW of non-incented demand savings with zero cost to implement. Retrofitting LED lighting upgrades have also achieved considerable energy use reduction.

Russell is currently investigating distributed generators to produce useable heat in the Scarborough Liner Mill. At the New Forest Paper Mill, the development and implementation of an energy management information system (EMIS) is ongoing while data mining is planned to identify new energy saving opportunities.

Murree and Russell will also be implementing an employee engagement program to raise energy efficiency awareness. Murree says that participation in OPA’s Demand Response DR3 program is being considered in addition to the use of sludge as a replacement fuel for natural gas. Additionally, both energy managers are working on water conservation and water effluent quality for the facilities.

Albert Payne, Toronto Hydro Account Manager, notes that there are now 12 embedded energy managers in the Toronto region, and the utility is still receiving more applications. “We have been getting excellent feedback and are going beyond our goal of a 300-KW demand response load reduction per facility with an energy manager.”

Payne notes that energy managers have monthly meetings with technical presentations and training. They receive program updates, go over reporting requirements and energy management planning and discuss how to engage employees in energy efficiency. Their goal is to promote an energy management culture within their organization.

Murree says that in addition to Toronto Hydro’s monthly meetings, the OPA has formed a working group for energy managers. “We share ideas here, find out what works and what doesn’t,” says Murree. Moreover, Toronto Hydro is gathering a repository of best-in-class projects that will be available to energy managers in the program.

Quebec program offers significant incentives to encourage use of residual forest biomass

The residual forest biomass program, launched at the end of November 2013, is designed to encourage the industrial, institutional and commercial sectors to consider the use of residual forest biomass. In doing so, the program aims to reduce GHG emissions and the use of fossil fuels. The Quebec government has allocated $47.2 million to support this program, with the goal of reducing GHG emissions by 70 000 tonnes CO2 equivalent (CO2eq) over the life of the program.

Nicolas Laflamme, Project Manager, Bioenergy at the Bureau de l’efficacité et l’innovation énergétique (BEIE) within Quebec’s Ministry of Natural Resources explains that the program is the fusion of two previously successful programs – the heavy oil conversion program and the forest biomass for heat program. Laflamme notes that the earlier heavy oil conversion program had a high implementation rate, particularly by the province’s large energy users such as the mining and smelting sectors. The previous forest biomass program was also popular, says Laflamme, noting that 10 projects were implemented.

Laflamme notes that it is important to differentiate between forest biomass and residual forest biomass, which the program targets. Residual forest biomass refers to that which is left over from sawmills, harvesting and other forestry operations or industries; the material that is normally not used.

One such project, and one that Laflamme hopes to see replicated in other industries, was carried out at Les Serres Lefort Inc. A few years ago, the company converted a heating system to residual forest biomass by installing two 6000 kilowatt (kW) boilers, a 1.3 million-litre hot water reservoir and thermal screens in greenhouses with high ceilings. The goal was to reduce the use of propane by 8 million litres and GHG emissions by nearly 13 000 tonnes annually. The total cost of the project was $7.7 million with the program contributing $5 million.

Laflamme expects a good mix of small to large organizations from a range of sectors to apply for funding for the new program. The incentive corresponds to the companies’ economic realities and their expectations for return on investment. Large and small energy users, more or less than 36 000 gigajoules per year, are encouraged to convert to biomass energy.

The program offers two funding streams, one for a feasibility analysis and the other for implementation. The analysis track offers funding for studies on potential biomass conversion as well as studies of the availability and supply of biomass. For such studies, the program will fund 50 percent of eligible costs or a maximum of $25,000 per site for small to medium energy users and a maximum of $50,000 per site for large energy users.

For implementation projects, whereby residual forest biomass is used to produce thermal energy for space or process heat and to replace fossil fuels wholly or in part, the program offers a maximum of $5 million for each application. For large energy users, the program provides the lowest of either 75 percent of eligible expenses, the amount necessary to realize a one-year payback period or $50 per tonne of reduction in CO2eq multiplied by the period of time of participation in the program (usually between 7–10 years). For commercial and institutional sectors, the program will provide the lower of 75 percent of expenses or $125 per tonne of reduction in CO2eq for a three-year payback period.

For more information, visit: http://www.efficaciteenergetique.mrnf.gouv.qc.ca/en/business-clientele/biomasse-forestiere-residuelle/# (in French only).

New CIPEC Leaders

Electricity Generation Sector
Enwave Energy Corporation – Toronto, Ontario
- Walton Street Steem Plant
- Pearl Street Plant
- Simcoe Street Cooling Plant

Food and Beverage Sector
Ferrero Canada Ltd. – Brantford, Ontario
Mondelez Canada Inc. – Hamilton, Ontario

Forest Products Sector
Tekwood, a division of Teknion Ltd. – Toronto, Ontario
- 575 Canartic Drive
- 607 Canartic Drive

Dollars to $ense Energy Management Workshops

Industrial Calendar of Events

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@nrcan-rncan.gc.ca.

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

You can also use the subscription page to update your contact information, or to unsubscribe or subscribe to the Heads Up: Building Energy Efficiency newsletter, our sister publication for commercial, institutional and federal government buildings. If you are experiencing difficulty accessing the subscription page, send an e-mail to info.ind@nrcan-rncan.gc.ca