Heads Up CIPEC – Volume 20 No 2

Sponsorship and exhibitor opportunities at Energy Summit 2016 unequalled

Energy Summit Registration update

The Early Bird Registration fee has been extended to March 30, 2016. To register, visit www.emccanada.org/group_spaces/energy_summit.

“Sponsorship of Energy Summit 2016 offers the best opportunity for those in the energy industry to directly engage manufacturers, other sectors and related stakeholders,” says Scott McNeil-Smith, Director, Strategic Planning and Communications, Excellence in Manufacturing Consortium (EMC). He adds that “as previous Energy Summit sponsors will attest to the greatest benefits are the direct connection with key decision-makers in organizations.”

Energy Summit 2016, to be held May 17 and 18 in Niagara Falls, will be hosted by EMC, Natural Resources Canada (NRCan) and CIPEC. The Summit, with the theme, From Ideas to Action, continues CIPEC’s tradition of delivering Canada’s premier industrial energy conference since 2003.

The exposure that event sponsors will have is unique as is the opportunity to build collaborative relationships with sustainability and energy efficiency project experts. McNeil-Smith notes that all sponsors from the successful Energy Summit 2014 are returning and more are welcome to interact with the large audience that is expected at this year’s event.

Sponsors can participate in the event at different levels. As premier partners, they will receive exposure on all print, electronic and visual presentation materials at the Summit and will have the highest logo presence. Sponsors at this level will also receive ten full conference passes, premium exhibitor space, the opportunity to present and have input into a dedicated topic stream, and introduce speakers in that stream. Sponsors can also choose among the platinum, gold and silver contribution levels, each with significant perks.

Exhibitors can also benefit tremendously from the exposure that they will have at Energy Summit 2016. If you are looking to generate new business and build relationships, the Summit is the event for you. It is the perfect opportunity to position your company with industry leaders and energy efficiency experts.

By taking part in the best energy conference of 2016, you will join over 400 industry decision-makers from across Canada and will be able to promote and showcase your company. Moreover, you will have access to the latest from world-class energy experts to talk about opportunities in energy and water management, waste heat recovery, innovative practice and technology and much more. It is simply a must attend event.

Do not miss out on the opportunity to build long-term business relationships. Sign on at www.energy2016.ca and click on the ‘Partners and Exhibitors’ tab.

CIPEC’s webinar on Energy Management Systems – a must attend event on March 30

“The link between energy management and climate change is real,” says Michael Kelly, Process Engineer and Energy Manager at KI Canada Corporation, a CIPEC Leader, and winner of the 2014 Employee Awareness CIPEC Leadership award. This is one reason why the company decided to invest in an energy management system (EnMS) and establish an Energy Awareness Campaign (EAC).

For manufacturers, the implementation of an EnMS is key to becoming more energy-efficient, and, for some organizations, an EnMS can lead to ISO 50001 Energy Systems Management standard compliance. An increasing number of Canadian companies are using EnMS to better manage their energy costs and identify areas for energy efficiency improvements.

To help organizations to implement EnMS in their facilities, CIPEC is offering an hour-long webinar on March 30th that will feature KI Canada Corporation. The company, a manufacturer of office furniture located in Pembroke, Ontario, has been a leader in using EnMS to reduce its energy costs and to continually improve its operations. “For KI, the EnMS offers another cost avoidance strategy,” says Kelly.

Since the launch of its corporate energy policy in 2012, the company has implemented an EnMS and their Employee Awareness Campaign (EAC), leading to measures that have resulted in a reduction of more than 1.9 million cubic metres (m3) of natural gas and 4.9 gigawatt-hours (GWh) of electricity and an equivalent GHG emissions reduction of over 7,150 tonnes. This represents reductions of over 60 percent (normalized per Million$ sales).

During the upcoming webinar, Kelly will share his experience about implementing an EnMS at KI Canada Corporation. He will discuss the need for upper management engagement in energy efficiency, setting targets, using the Plan-Do-Check-Act continual improvement framework, and developing the business case for committing resources to energy improvements. Kelly will also touch on KI’s partnering with Enbridge, the Ottawa River Power Corporation and NRCan for incentives, employee training and various energy studies.

In addition, Kelly will highlight the importance of establishing an EAC on the road to a culture change that recognizes the cost of energy. Participants will also learn about the various projects that have led to the company’s energy savings, including retrofits of timers and motors, the addition of compressor controls, variable frequency drives on process ovens, destratification fans, and many other improvements that can be applied across industrial sectors.

Moreover, Kelly will emphasize how an EnMS can be an essential tool in moving towards ISO 50001 certification. “By implementing an EnMS, an organization is able to ready itself for compliance.”

For more information on the webinar, contact info.ind@nrcan-rncan.gc.ca.

Combined heat and power system delivering big savings at Campbell Company of Canada

“Our new CHP system is cutting our energy costs while providing a reliable power supply,” says Doug Dittburner, Chief Engineer and Manager of Power Services at the Campbell Company of Canada. The multi-million dollar installation of a combined heat and power (CHP) system took place at the company’s 51,097 square-metre plant in Toronto, Ontario. Construction began in February 2015 and was completed ahead of schedule, being operational in December 2015.

A detailed engineering study, completed by CEM Engineering, that was 100 percent funded by the Independent Electricity System Operator (IESO), shows estimated annual savings with the CHP system at 25.7 gigawatt-hours (GWh) and a demand savings of 3.8 megawatts (MW). “We are over-delivering on these estimates,” says Dittburner. With incentives from Toronto Hydro and the Independent Electricity System Operator (IESO) that covered 40 percent of the cost, the project payback period will be four years and the return on investment 25 percent.

Dittburner says that the company has been considering CHP for a number of years but implementation was possible only now because of available incentives combined with the low cost of natural gas. Moreover, given significant and expensive power outages in the last few years, and the company’s strong commitment to environmental responsibility, the time was right for the project.

The installation consists of a Cleaver Brooks heat recovery steam generator, which recovers the energy from the CHP combustion flue gas, as well as a Solar Centaur 50 gas turbine generator and a Vilter fuel gas booster compressor. The CHP unit can supply the facility with 4.6 MW of power and up to 90,000 pounds per hour (PPH) of steam at 170 Psi.

An NRCan-cost shared Process Integration study showed more opportunities during the installation of the CHP system. For example, by installing a new, second condensing economizer at the CHP outlet, additional heat from the CHP flue gas can be recovered. This could heat some of the facility’s process water to 85oC. Thus, “the potential steam savings could amount to $97,000 annually, making this project even more efficient,” says Dittburner.

“Our CHP system makes the most of our power and steam generation,” notes Dittburner, adding that, in the future, “We plan to produce over 90 percent of our plant’s steam and power requirements and do so efficiently.” Already, other companies in the food and beverage sector are visiting the installation and considering CHP systems for their own facilities.

HVAC reconfiguration translates into energy and maintenance savings for CAE

A reconfiguration of heating, ventilation, air conditioning (HVAC) units and new heat recovery and cooling systems will allow CAE to reap up to 31 percent in energy cost savings and reduce its greenhouse gas (GHG) emissions by 309 tonnes of CO2 equivalent per year. The $10.6 million project at CAE’s Ville St-Laurent, Quebec, facility was launched in 2013 and will be completed by mid-2016.

The 92,000 square-metre (m2) building has undergone 16 expansion phases in 50 years and is a mix of office, warehouse, computer/simulation, and manufacturing space. The facility operates on a 24/7 schedule and employs 3,500 people that design, manufacture and test flight simulators and flight training equipment.

David Héon, Manager, Facility Services/Health, Safety and Environment at CAE notes that existing HVAC equipment was between 20-30 years old and, although a one-to-one replacement of the old rooftop units with new units would have been less expensive, the long-term benefits of a complete system redesign were determined to be more significant.

The project also helps CAE meet the requirements of the Montreal Protocol to phase-out the use of the refrigerant R22 by 2020. A $3.1 million Hydro-Québec incentive and senior management buy-in were important change drivers.

Héon explains that CAE worked with Ecosystem to design and implement a new HVAC system configuration to best fit the company’s needs, adding that the close collaboration with the supplier was essential in this successful project in that the supplier guaranties the cost, incentives and annual cost savings . Ecosystem replaced 149 dispersed rooftop units (each with two to three associated compressors and electric or gas heating systems) with 38 new HVAC units that are served by three central plants, which each contain a heat-recovery chiller, a high efficiency centrifugal chiller and a condensing boiler.

Glycol-water distribution systems were added to allow heat from the interior zones and computer labs to be recovered and transferred to the perimeter zones and the outdoor air units. High efficiency hot water boilers were installed to supply heat during peak winter periods. Ventilation was optimized in the paint workshop and centralized controls were replaced and optimized.

The new central plants, which connect to the new rooftop units, consist of heat recovery chillers that run on R-134 and R-123 refrigerant, and efficiency centrifugal chillers. Moreover, three new mechanical rooms were built at the facility, allowing CAE to centralize the production of cooling and heating energy indoors and greatly reduce maintenance costs. Cooling efficiency during summer months was improved by 35 percent compared to the former smaller direct expansion compressors located in the rooftop units.

“A measurement and verification process allows CAE and Ecosystem to track the site’s avoided costs on a monthly basis. Savings are also calculated by taking into account seasonal variations in the weather,” says Héon. “We modeled savings as a function of heating and cooling degree days, which allowed us to estimate the avoided costs.”

Moreover a third-party consultant was engaged to evaluate monthly savings using this model and also as a function of the variations in utility rates. Since the beginning of the project, electric utility rates have increased by over 10 percent but this project has helped CAE mitigate this rate increase.

The new rooftop reconfiguration not only translates into significant annual energy savings but also means less management and maintenance as well as improved employee comfort.

Héon says that to date 75 percent of the projected savings have been realized, noting that “each month we notice an improvement.” He says that the project is now in its final stage of refinement with only a few more measures to be implemented by summer 2016.

Kitimat smelter modernization increases energy efficiency and cuts emissions

After a multi-billion dollar modernization project, Rio Tinto’s aluminum smelter in Kitimat, British Columbia, is now one of the most efficient and cost-effective smelters. The Kitimat Modernization Project (KMP) has increased the smelter’s production capacity by nearly 50 percent to 420,000 tonnes annually while reducing overall GHG emissions by half.

The Kitimat smelter, part of Rio Tinto’s B.C. operations, was established in 1954 to produce high-value primary aluminum and aluminum alloys for Pacific Rim customers. However, after 60 years of operation it is coming to the end of its life. Moreover, the environmental performance of the old smelter was no longer sustainable.

Commissioning of the KMP began in 2014. The smelter is expected to be fully operational in 2016 and will bring the plant into the first decile of the industry in terms of performance. A key part of the modernization project is the company’s state-of-the-art Aluminium Pechiney Prebake (AP-40) technology, the cleanest technology available in the industry for the aluminum reduction process. Kitimat’s refurbished smelter features a new potline. The AP-40 technology uses 13,150 kilowatt-hours (kWh) per tonne of ore, which is equivalent to a reduction of 33 percent in energy consumption per tonne of aluminum, compared to the previous Soderberg technology used.

The new smelter with its state-of-the-art technologies now offers high energy efficiency, automated control systems, and low GHG emissions in aluminium production. The Kitimat smelter produces aluminum with two tonnes CO2 equivalent per tonne of aluminum compared to the average 12 tonnes.

Battery energy storage project provides reliable and clean back-up power to Field, British Columbia

A state-of-the-art battery energy storage facility now ensures a reliable supply of clean electricity to the remote community of Field, British Columbia. The $5.98 million project, built by BC Hydro and funded by the Government of Canada Clean Energy Fund, will help meet Field’s electricity needs for up to seven hours in the event of a power outage.

The remote community of Field, in Yoho National Park, receives its power via a radial feeder from Golden. However, power supply can be unreliable as the 55-kilometre long distribution feeder is subject to severe environmental conditions because the line runs through mountain passes and forests where access can be difficult. As a result, BC Hydro evaluated options of battery storage and diesel generation.

BC Hydro chose to install a 1-megawatt battery energy storage system (BESS) as the cleaner power option. The BESS, installed by S & C Electric, consists of a sodium-sulphur (NaS) battery that can tolerate temperatures between -50oC and +40oC and in snow depths of up to 1.2 metres.

Since the system’s installation in July 2013, the battery has exceeded seven hours during power outages. Thanks to the BESS, the outages did not affect the community’s residents or businesses and supplied the town with a total of 53.5 hours of back-up power.

In addition, the battery can discharge at times of high demand to reduce peak load and stress on the system. BC Hydro also benefits operationally as the BESS allows extra time for field crews to safely respond to and resolve unplanned outages.

The project also includes community engagement and education, whereby BC Hydro is providing Field residents and businesses with information about energy conservation that will help extend the life of the battery back-up during outages.

The first-of-its kind in Canada, the Field project demonstrated the viability of integrating energy storage into the electricity grid, which could pave the way to an increasing number of opportunities to store electricity generated from intermittent and renewable sources of energy.

Dollars to $ense Energy Management workshops – winter schedule

Workshops offered in collaboration with Langara College
Location: Vancouver, British Columbia
To register, call the Langara College’s Continuing Studies Registration Office at 604-323-5322

Recommissioning for Buildings
Date: March 11

Energy Efficiency Financing
Date: March 18

Notice: Please allow eight to 10 weeks from the planning to the delivery of a customized Dollars to $ense workshop.

Canadian Institute for Energy Training (CIET) – spring and summer schedule

Certified Energy Manager (CEM)
Halifax – April 11-15
Winnipeg – April 18-22
Toronto – April 25-29
Quebec City – May 2-6 (offered in French)
Victoria – May 2-6
Vancouver – May 9-13
Toronto – June 6-10

Certified Measurement and Verification Professional (CMVP)
Toronto – April 5-7
Montréal – April 5-7 (offered in French)
Halifax – May 4-6
Vancouver – May 25-27

Certified Energy Auditor (CEA)
Toronto – May 31-June 3

Certified in the Use of RETScreen® (CUR)
Toronto – May 24-26

Motors, Variable Speed Drives & Energy Efficiency
Toronto – May 19
Montréal – May 26 (offered in French)

Energy Efficiency for Managers
Toronto – April 26
Montréal – June 8 (offered in French)

Certified Professional in Energy Performance Contracting (CPE)
Toronto – May 3-6

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@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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