Heads Up CIPEC Newsletter - April 2014

Heads Up CIPEC Newsletter

April 2014 Vol. XVIII, No. 4

Don’t miss out on Energy Summit 2014

Energy Summit 2014: Where Efficiency Meets Profitability, Canada’s premier industrial energy event, is not to be missed with its incredible line-up of energy experts.

The Summit, taking place on May 14 and 15 at the Sheraton on the Falls Hotel in Niagara Falls, Ontario, will offer participants an unmatched opportunity to share best practices, network and learn about the latest innovations in industrial energy efficiency. The Summit will feature topics such as energy management, the ISO 50001 Energy Management Systems standard, emerging technologies as well as case studies and success stories. Participants will also have the opportunity to engage in solutions-based workshops, panel sessions and plant tours.

Plan to also attend the CIPEC Leadership Awards Ceremony and Dinner on May 14. The awards highlight projects that are aligned with the Government of Canada’s commitment to protecting jobs and increasing productivity and competitiveness while ensuring a more sustainable future for Canada’s industries by investing in responsible energy use.

To view the conference program and list of presenters visit the conference Website.

Register now and get ready to learn about transforming energy management challenges into lucrative business opportunities.

www.energy2014.ca.

Contact: Gabrielle Allard, Senior Industrial Energy Efficiency Engineer, Office of Energy Efficiency, Natural Resources Canada

Tel.: 613-947-3456 – gabrielle.allard@nrcan-rncan.gc.ca

New CIPEC Board member brings foundry perspective to the table

Bradley Robertson, Senior Continuous Improvement Leader at ESCO Limited and incoming CIPEC Executive Board member

“It’s a win-win situation for CIPEC members,” says Bradley Robertson, Senior Continuous Improvement Leader at ESCO Limited and incoming CIPEC Executive Board member. He is commenting on the successful partnership that is CIPEC, the industry networking that the group makes possible and the linkage to innovation that it facilitates.

“I am a strong believer in partnerships that bring people with common interests together,” says Robertson. For him, CIPEC also represents a forum for sharing ideas and best practices that can be adapted to different industries and companies. “CIPEC provides us with information that we can put to use.”

Robertson is approaching his 22nd year at ESCO, a designer and manufacturer of highly engineered wear parts and CIPEC Leader in the Foundry sector. During this time, he has been involved in technical, maintenance, production and energy aspects of the company, and has gained a profound knowledge of the foundry industry.

“Even though our sector is small, we are a significant energy user and are very keen to conserve and reduce our use of it.” For this reason, the sector became involved with CIPEC early on with such initiatives as sector-specific benchmarking and customized energy training. Robertson has also been an energy advisor to the Canadian Foundry Association since 2009.

“I think the NRCan-industry partnership has been extremely fruitful in that industry identifies needs and NRCan helps develop solutions or offers resources,” says Robertson. At CIPEC, “we tie the science and the research innovations back to real-life applications. CIPEC’s work is of great value to its membership,” says Robertson, pointing to the advancement of the ISO 50001 Energy Management Systems standard in Canada as one of many outstanding CIPEC initiatives. Robertson also sees CIPEC’s biennial energy conferences as essential sources of information and networking. “I am looking forward to the Energy Summit 2014 where I will gather new ideas to bring back to ESCO.”

With his fellow board members, Robertson plans to continue CIPEC’s good work such as energy benchmarking and energy efficiency training opportunities, and also wants to draw on new elements and developments in energy efficiency to keep the organization on the leading edge.

RETScreen Plus solves mystery of unexplained increasing gas consumption at Weston bakery

“The analysis was powerful and allowed us to discover and ultimately address the reason behind the unexplained rise in natural gas consumption that we were seeing,” says Darren Borden, Energy Management Engineer at Weston Foods (Canada) Inc. The analysis that Borden is referring to was performed by GreenQ Partners, an energy management company, using RETScreen Plus software developed by scientists at Natural Resources Canada.

RETScreen Plus is an advanced analysis tool that can analyze utility consumption and its key drivers, such as weather, to produce a quantitative relationship. The software uses regression analysis to determine the link between important factors and energy consumption or production. It can also be used to track the actual versus predicted performance of a project using a cumulative sum function tool (the cumulative sum of differences between actual and predicted values).

“We couldn’t explain a “hiccup” in sub-metering data from our bread oven in our Sudbury bakery,” says Borden. In the summer of 2013, Borden contracted GreenQ Partners, which had experience in using RETScreen Plus, to investigate the issue.

Data analysis showed that three years of pooled gas consumption data was nearly perfectly correlated with production levels, which indicated no major issues. However, when data was pooled and separated seasonally (summer and winter), and the tool was used to identify deviations from the 2010 baseline, a creeping growth (two to three percent) became evident in winter gas consumption every year of the three years analyzed.

Anatoli Naoumov, GreenQ’s managing director, explains that RETScreen Plus allowed him to quantify the seasonal loss of oven efficiency caused by miscalibration of the temperature sensor used every year during oven maintenance. The software also allowed for the separation and quantification of production and non-production natural gas consumption, which became a valuable tool for costing, budgeting and operation management. It also identified a maintenance defect – burners in a hard-to-reach area needed replacement.

The results of the analysis led to a change in operational procedures – third party calibrators are now required to show a certificate of recent sensor calibration (within one month). Accurate calibration means that gas consumption should return to 2010 levels saving the bakery about 15 000 cubic metres (m3) of natural gas per season. The maintenance issue, also being addressed, will result in annual savings of 20 000 m3 of gas at little or no cost to the company. Borden has already seen improved gas efficiency and stability in the data between seasons. A future project identified with the RETSCreen Plus tool is the pre-heating of combustion air, which represents a 40 000 m3 in potential gas savings.

Naoumov notes that successful use of RETScreen Plus requires a clear understanding of the data being analyzed, the nature of the analysis, and diligent result interpretation. “It is a very powerful tool and there are vast opportunities for analyses,” he says, noting that it would be particularly effective for repetitive industrial processes, such as refrigeration.

Borden is pleased with the outcome, indicating that RETScreen Plus is a key tool in identifying potential energy issues. He adds that “this kind of analysis can also make the case for preventative maintenance.” Borden concludes that he “would definitely use RETScreen Plus again as it can turn sub-metering data into a management model that describes device operation and efficiency, and highlights discrepancies.”

Tolko Industries uses Pinch Analysis to uncover energy savings

“We conducted a pinch analysis to identify short- and long-term energy use options for the mill, and recommend realistic payback period projects to improve thermal energy consumption,” says Tamsin Patience, Technical Manager at Tolko Industries’ The Pas, Manitoba Kraft Paper Division. The analysis delivered as promised with a number of project recommendations, many of which have already been implemented.

Pinch analysis, a process integration (PI) technique, is a comprehensive method of analysis, based on thermodynamic principles, that was developed for the design of highly energy-efficient processes. By considering all the energy flows in a given process, it can determine what the minimum energy consumption would be in the presence of optimal heat recovery. This information is very useful as it allows comparing a plant’s current energy use with its targeted minimum consumption, thereby identifying the true potential for energy savings. More specifically, pinch analysis can:

  • determine the optimal energy consumption level for a given process as well as the potential for improvement through better heat recovery;
  • identify heat recovery projects as a means to reduce energy consumption;
  • identify the potential for cogeneration and the possible uses for heat pumps; and
  • identify water use reduction projects resulting in energy savings,

Funding from NRCan’s ecoENERGY Efficiency for Industry Financial Assistance program and Manitoba Hydro helped to cover the cost of the pinch analysis.

Tolko’s The Pas operation, a CIPEC Leader in the Forest Products sector is a single line-paper machine with a production capacity of 476 tonnes (t) per day or 166 000 t per year. Patience explains that the paper-making, pulping and chemical recovery processes are very energy intensive. Additionally, steam generation for the facility’s turbine and other processes is a significant user of fuel. Given the high energy consumption and rising energy costs, the company decided to use pinch analysis to identify and implement operational, low or no-capital, projects to reduce energy costs.

Talking about the analysis, Patience notes that initially the company prepared a set of up-to-date process flow diagrams that included all fibre, steam, water, chemical lines and equipment. Subsequently, a mill-wide simulation model incorporating all of these processes was constructed and validated. Any discrepant data was examined in greater detail and poor equipment performance detected.

Ultimately, the pinch analysis identified practical heat recovery and process modification projects including future process modification and any water reuse opportunities. A cogeneration analysis was also done to identify new opportunities for improved performance. Some of the no- or low-cost projects identified included the reduction of steam venting through the condensate tank, completed in the fall of 2012.

Water usage was also analyzed, and the amount of fresh water make-up in the machine room was decreased. It was also recommended that mechanical seals on all process pumps be installed to avoid excess water use. Patience notes that this project was implemented in 2013 and early 2014. Furthermore, the shower water flow has been optimized in the washers and the screen room was closed with temporary piping installed in November 2013, with a view to continue with a permanent installation. Patience notes that this project will reduce fresh water consumption, improve pulp washing efficiency and reduce soda losses.

Patience indicates that energy savings to date from all of these projects have reduced energy consumption, notably decreasing the amount of fossil fuels consumed in the mill’s power boiler. She notes that several long term projects, such as blow heat recovery and switching to electric boilers identified through the analysis are being considered. The pinch analysis also supported the company’s strategy to operate its turbo-generator.

“The pinch analysis gave us a working simulation model of the entire mill, allowing us to see the effects of future process changes and upgrades,” says Patience; adding that “it provided us with information that enabled us to reduce energy costs. We would definitely recommend this analysis to any industry with applicable processes.”

NRCan’s ecoENERGY Efficiency for Industry program now offers increased financial assistance for an expanded list of energy management projects

Natural Resources Canada (NRCan), through the ecoENERGY Efficiency for Industry program, is offering financial assistance for projects that improve industrial energy performance. Energy efficiency contributes to NRCan’s mandate to enhance the responsible development and use of Canada’s natural resources, the competitiveness of Canada’s industrial sector, and its contribution to the economy, while improving the quality of life for all Canadians. Cost-shared assistance of up to 50 percent of eligible costs to a maximum of $40,000 is now available.

Energy management projects such as ISO 50001 Energy Management Systems standard implementation projects as well as energy analyses – process integration and computational fluid dynamics – are eligible for assistance.

ISO 50001 Standard studies aim to support organizations in taking a systematic approach to achieve continual energy performance improvement leading ultimately to energy cost savings and greenhouse gas emissions reductions. Funded ISO 50001 projects require a final report of energy performance improvements and details on the measures undertaken to meet the standard including energy baseline, energy performance targets, timeline for achievement of targets, monitoring and reporting procedures as well as projected results from the implementation.

Financial assistance is also available for process integration (PI) studies, which consist of a global energy analysis to determine the best use of heat in a facility. In PI studies, a site-wide approach, employing an energy and mass balance and specialized tools such as pinch analysis, is used to help improve the energy efficiency and competitiveness of industrial facilities.

Support for Computational Fluid Dynamics (CFD) studies is available as well. CFD studies analyze fluid flow and heat transfer in industrial processes thus identifying the most efficient system design and operation parameters. CFD uses numerical methods and algorithms to solve problems involving fluid flows to help optimize system efficiency, reduce unwanted emissions, perform parametric studies and assess design performance.

Other eligible energy management projects may include, but are not limited to, the following: development and dissemination of tools and information related to energy efficiency; development, organization and delivery of training; assessments, evaluations and benchmarking studies; and development of technical guides and reports, implementation roadmaps and best practices studies.

For more information on NRCan’s financial assistance, visit nrcan.gc.ca/energy/efficiency/industry/financial-assistance/5387.

AV Nackawic mill en route to dramatically reduce energy use and GHG emissions

“Our goal is to significantly reduce energy use and greenhouse gas (GHG) emissions,” states Rajeev Goel, Plant Manager at the AV Nackawic pulp mill, a CIPEC Leader in the Forest Products sector. Since 2010, the mill has made great strides in achieving this goal with numerous energy efficiency and waste reduction projects.

The mill, located in Nackawic, New Brunswick, is part of the Adiya Birla Group and manufactures dissolving grade pulp from various hardwood species, which is used in producing rayon fibre. The facility employs around 350 employees and operates 24/7 year-round.

In 2010, the facility received a $2.37 million grant, through NRCan’s Pulp and Paper Green Transformation Program (PPGTP), to enhance its clean energy production and improve its energy efficiency. With this investment, the mill reduced its water and energy consumption by recycling filtrate within the bleach plant process. In addition, by upgrading its rotary lime kiln, the mill reduced its energy consumption, purchased lime consumption, the amount of suspended particulate matter and quantity of sulfur produced.

NRCan funding was also used to reduce oil consumption and GHG emissions in the recovery boiler with a retrofit of the cyclone evaporator that reduces liquor solids content to 68 percent as well as the installation of a new, strong black liquor storage system.

Another project supported by the PPGTP grant was the power boiler upgrade to an over-fire air system (to reduce NOx emissions). Additionally, wood grinding equipment was installed for more efficient combustion. This upgrade increased the mill’s annual production of renewable energy by 12 040 gigajoules, displaced fossil fuels (used for steam generation), and lowered its GHG emissions by 6 250 tonnes per year.

Moreover, the mill is increasingly substituting biomass or natural gas for bunker C oil. Aditya Birla’s goal for the mill is to reduce or eliminate its bunker C oil use by 2017. To that end, one step has been to change one of the lime kiln’s burners to natural gas in January 2012.

In 2013, bunker C oil was also substituted with propane gas in another burner used for non-condensable gases (NCG) incineration from digestion and evaporating processes. This modification reduced oil use by one-third. After recently commissioning the mill’s power boiler and modifying it with a gas burner (as a pilot project), the mill is planning to switch the boiler over from bunker C oil to about 90 percent natural gas as of April 2014.

Goel notes that AV Nackawic has also implemented a hog fuel management system, using the Six Sigma approach that promises significant savings. In a 2013 pilot, oil use was reduced by about 7926 U.S. gallons from the year before, with both years having similar weather conditions. “The project did not require capital investment only employee involvement to achieve the savings,” notes Goel. Planned for the near future are upgrades to the heat-recovery system, among other energy efficiency projects.

AV Nackawic Management team feels that employee involvement is key to improving energy efficiency. Goel says, “We seek ideas from employees, get them involved at the conceptual stage and then share all operational and maintenance plans with them.” Weekly newsletters as well as frequent manager-employee “contact” meetings communicate energy efficiency news and keep everyone up-to-date.

Participation in People Power Challenge gets employees engaged in conservation

Now in its third year, the People Power Challenge (PPC) offers participants a free turnkey employee engagement program. Jennifer Taves, Project Manager, Communications & Engagement at Partners in Project Green, says that this edition of the PPC has even more amazing features that allow companies to “tap into their best resource – their staff – for ideas that can lead to significant savings.”

“We have also sweetened the prize purse for 2014 with companies able to win up to $5,000 in a six-month challenge,” notes Taves. Participants will compete from April 1 to September 30, 2014 for one of two $5,000 and one of two $2,500 prizes.

The PPC works on a points system; the companies with the most points win the challenge. Points can be earned by getting employee suggestions and pledges for sustainable solutions, by implementing sustainability projects (credit will be given for projects implemented from January 1 to September 30, 2014) and by communicating sustainability tips and tricks through apps.

In contrast to the previous PPC editions, the 2014 version allows companies to focus their employee engagement on areas that are of the most interest to them be it energy conservation, waste or water management, or any other environmental area. Also new this year is a built-in employee engagement tracking system and metrics whereby companies can measure the impact of the campaign on their employees. The PPC also motivates employees through built-in recognition and incentives, and allows companies to create a media buzz for themselves.

During the PPC, there will also be ongoing coaching seminars and a forum for sharing best practices among participants. As participants share case studies, they will receive additional points in the challenge. These stories will also be communicated on a wider scale. As with all the previous PPCs, participants receive communication tools and constant support to deliver their engagement strategy.

Taves notes that the PPC is well on its way to at least 15 competitors; “We just announced the Challenge and eight facilities – Canadian Tire Brampton, Canadian Tire (AJ Billes Distribution Centre), City of Mississauga, Rockwell Automation, Velcro Industries, Menkes Property Management, Kuehne and Nagel Inc. and the International Centre – have already signed on.”

Many organizations keep coming back to reap the many benefits of PPC participation. Velcro Canada Inc., last year’s Grand Champion in the small- to medium-sized category for example, was recognized for their efforts by the Velcro Corporation. This has had many positive impacts on the employees at the Toronto facility. The Ontario Natural Food Coop collected so many ideas from their employees during the 2012 PPC waste challenge that they were able to chart a road map to implanting their waste management plan.

For more information, visit www.partnersinprojectgreen.com/ppc2014 or contact Jennifer Taves at jtaves@trca.on.ca or 416-661-6600 ext. 5570.

Reminder – 36th Annual Industrial Energy Technology Conference, May 20 to 23, 2014, New Orleans

The Industrial Energy Technology Conference (IETC) is a one-of-a kind conference that focuses on a wide range of topics of importance to industrial energy managers, utility experts, government program managers, vendors and others. The latest technologies and expertise on smart manufacturing, corporate energy management, energy conservation opportunity analysis, and case studies of successful, real-world industrial efficiency projects are presented.

Attendees at the 36th annual IETC will hear about what companies are successfully implementing, gauge the impact of new trends, see where the industry is heading, and share their experiences in meeting the challenges we are all facing. Participants will be in the company of those who are facing the same challenges, and those who have some of the solutions.

The IETC is hosted by the Energy Systems Laboratory at the Texas A&M University System and the Louisiana Department of Natural Resources.

For information on the conference, contact Jim Eggebrecht, IETC Executive Director, at jim@esl.tamu.edu or visit the conference website at ietc.tamu.edu.

Celebrate SCC’s World Accreditation Day 2014 on June 9th

Is your organization looking to tap into export markets, or seeking to increase its energy efficiency, reduce costs and improve energy performance? Then register today for the Standards Council of Canada’s (SCC’s) World Accreditation Day 2014 breakfast event. The event will be held on Monday, June 9, from 8:30 to 11:30 a.m. at theOttawa Convention Centre.

The theme of this year’s global event is Accreditation: Delivering confidence in the provision of energy. Come discover the importance of accreditation and certification procedures, standards, regulations and testing – and how they help ensure the safety of your products and services and can help you gain a competitive global edge.

Event features:

  • networking breakfast
  • keynote speaker:
    • Patrick Hardy, Co-founder and Chief Operating Officer of ClimateCHECK, an innovative greenhouse gas management solutions organization
  • moderated panel discussion, including:
    • Jean-François Comeau, Director of Business Development, Enviro-Access inc., one of the three Canadian Environmental Technology Advancement Centres
    • Inderpal Jaswal, Registrar and Manager, Quality Assurance, QUASAR, the auditing, quality management and ISO certification arm of the Canadian Welding Bureau Group
  • information session on ISO 50001,the internationally recognized Energy Management Systems standard. SCC recently launched a new accreditation program for organizations looking to implement this standard to increase their energy efficiency, reduce costs and improve energy performance — and for certification bodies wanting to help their clients do so. Paul W. Birkeland, Founder and Principal, Global Strategic Energy, will lead this session.

View the agenda.

Register now – There is no charge to attend this event.

New CIPEC Leaders

General Manufacturing Sector

Amec Usinage inc. – Saint-Augustin-de-Desmaures, Quebec

Dollars to $ense Energy Management Workshops – Summer schedule

Recommissioning for Buildings
Date: June 21
Location: Vancouver, British Columbia
Offered in collaboration with Langara College

Energy Management Planning
Date: September 20
Location: Vancouver, British Columbia
Offered in collaboration with Langara College

To register, call the Langara College’s Continuing Studies Registration Office at 604-323-5322

Complete list of industrial 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