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Heads Up CIPEC Newsletter

March 1, 2012 Vol. XVI, No. 5

New Brunswick to host first CanmetENERGY English-language process integration workshop

Building on the success of workshops held in Québec over the past two years, CanmetENERGY is expanding its offer to train energy specialists in heat recovery and process integration (PI). The first English-language PI three-day workshop will be held March 27 to 29 in New Brunswick, with workshops to follow in Ontario and Alberta in the fall of 2012.

$25,000 cost-shared assistance for process integration studies

The ecoENERGY Efficiency for Industry program is offering cost-shared assistance to industrial companies to perform ISO 50001 (energy management systems) implementation pilots and energy-related assessments.

NRCan will provide up to 50 percent of study costs to a maximum of

$25,000 for process integration (PI) studies
$25,000 for computational fluid dynamics (CFD) studies
$25,000 for ISO 50001 implementation pilots

For more information, visit oee.nrcan.gc.ca/industrial/financial-assistance/8280.

To date, eight PI workshops have been delivered to more than 100 engineers in Quebec through a partnership with the Bureau de l’efficacité et de l’innovation énergétiques, and more are scheduled for 2012. “The workshops are designed to transfer knowledge and tools to plant engineers and engineering firms in the area of process integration,” says Eric Soucy, Director, Industry Group, CanmetENERGY, Varennes Research Centre.

The upcoming, free-of-charge, workshop will allow a maximum of 15 participants to gain a deeper understanding of the concepts underlying PI and its importance in improving facility energy efficiency. Soucy notes that for the 2012 PI workshops, several new case studies have been added.

Participants will learn about pinch analysis and setting energy targets and will evaluate energy-efficient technologies for heat recovery potential in heat exchanger networks, steam production, refrigeration and compressed air systems. Practical examples will allow them to work with CanmetENERGY’s PI software Integration. Each participant will leave with a PI toolkit that includes the Integration PI software, a course manual and other practical documents.

Soucy notes that in the series of events to promote PI, Natural Resources Canada’s (NRCan’s) Office of Energy Efficiency is organizing another webinar for March, and a presentation will be delivered at the annual congress of the Association québécoise pour la maîtrise de l’énergie at the end of May. “We want to make companies aware of the huge potential savings that come with PI,” concludes Soucy.

Visit CanmetENERGY’s Calendar of Events for more information. Dates and other details will be posted as soon as possible. If you wish to be kept informed, send your contact information to integration@nrcan-rncan.gc.ca.

To learn more about CanmetENERGY’s activities on industrial processes, visit Industrial Systems Optimization.

EMIS at Marwood reaps significant savings

“We have already seen savings,” notes Tom Gilmore, Project Engineer at Marwood, Ltd. in New Brunswick, as he discusses the energy management information system (EMIS) that was implemented at the company’s Tracyville production facility.

Marwood, a CIPEC Leader in the Wood Products Sector, manufactures various wood products, such as lattice and fencing. The facility comprises eight separate production plants over 100 acres. About 260 employees work in eight-hour shifts, seven days a week, for 50 weeks per year. The company spends about $1.2 million in annual energy costs.

About five years ago, when Gilmore started looking at reducing energy costs, Efficiency NB started offering its Large Industrial Program. Gilmore took advantage of the EMIS training it offered, to learn about the type of system and information he needed to make a well-prepared case to senior management. Efficiency NB also provided planning and funding assistance that allowed the project to proceed.

The $75,000 EMIS project was completed in December 2010, with electricity meters installed in the treatment, pellet, specialties, remanufacturing, lattice and fence plants. “We are now collecting data that we will use to establish trends and ultimately identify opportunities,” says Gilmore.

Over the next months, Marwood will engage energy management consultants to train staff in EMIS, results reporting and target setting. Gilmore expects the system to be fully operational in the next six to eight months and is confident that it will meet their anticipated payback period of less than two years.

“With EMIS, we have already identified some waste loads at peak electrical-use time. Just having the knowledge of what energy is being used and where it’s being wasted gives people the ability to do things differently,” notes Gilmore.

In parallel to the EMIS implementation, Marwood conducted an energy audit in 2009, funded by Efficiency NB. The audit identified many energy savings opportunities, several of which have been implemented, including an air compressor upgrade and the installation of a heat recovery system.

Marwood’s lattice production used 13 percent of its annual $185,000 electricity bill on compressed air; the energy audit identified potential savings of about $15,300 by retrofitting a 150-horsepower (hp) air compressor with a new 50-hp unit, which cost $32,000. Receiver capacity was also increased, while air leaks were reduced and compressor controls were upgraded. Now a 25-hp unit can operate alone during low load periods and with the 50-hp unit in peak periods.

The audit also identified savings of about $50,000 annually in electrical consumption by installing a heat recovery system in the remanufacturing plant, which had an annual energy bill of $132,000. Now the two fans that remove sawdust from the manufacturing process direct the air through an air filter, where dust and fine particulate matter are separated. The filtered warm air is brought back into the building, reducing energy costs for heating and providing a more comfortable work climate.

Gilmore is looking to implement similar projects for Marwood’s facilities in Nova Scotia, in an effort to decrease production costs and improve efficiency. He points to the EMIS implementation as a great way to achieve this, noting that the EMIS process at the Tracyville plant has increased awareness among managers and coordinators.

Partnership between utility and industry groups to yield energy savings

Partnerships between BC Hydro and the BC Food Processors Association (BCFPA) and Canadian Manufacturers & Exporters – British Columbia Division (CME British Columbia) have resulted in about 140 companies participating in BC Hydro’s Power Smart Partner Program over the past two years. “The program includes an on-site assessment by a third-party energy manager that uncovers energy saving opportunities,” says Sasha Herman, Sector Manager, Power Smart, BC Hydro.

Herman explains that a few years ago, BC Hydro was looking to reach large industrial customers, those with an annual hydro bill of more than $50,000 but without the benefit of a utility Key Account Manager or internal Energy Managers to assist them with energy efficiency opportunities. The program that emerged has energy experts from Willis Energy Services Ltd. performing an energy audit and delivering a report detailing findings and recommendations as well as creating a customized energy management plan – funded up to 100 percent by BC Hydro.

As Herman notes, partnering with the BCFPA and the CME British Columbia is ideal because both of these organizations have a strong member base and considerable credibility within their industry. “This and the fact that tremendous opportunities exist for energy savings in the manufacturing and food processing sectors makes the program a perfect fit,” she adds.

Dave Eto, BCFPA’s President and Board Chair, says. “It is vitally important for B.C.’s food processors to run their operations as effectively as possible to be competitive locally and abroad. This includes saving costs wherever we can and being responsible environmental stewards of the resources we have. The BCFPA therefore fully embraces our partnership with BC Hydro. It not only helps the individual company but also helps grow the industry as a whole.” The BCFPA was honoured to be recognized for this work by receiving the 2010 BBC Hydro Power Smart Conservation Partner Award.

Peter Jeffrey, Vice-President, CME British Columbia, also appreciates the benefits of the program and the value in partnering with BC Hydro. “We have the ability to access companies at the executive level, and we speak manufacturing speak,” says Jeffrey, who believes that the partnership is a successful approach. “CME is always looking at ways for our membership and the manufacturing sector in general to become more competitive. The partnership with BC Hydro offers a win-win situation for everyone involved. Companies that might otherwise not have energy audit expertise benefit from a free energy assessment. BC Hydro gains electrical savings, while the CME can offer even more to its members and potentially attract new ones.”

CME’s role, as Jeffrey explains, is to “sell” the program and ultimately obtain senior level commitment to participation. CME will also be conducting a follow-up survey to determine the implementation rate and to identify the roadblocks to implementation. “It is our job to understand why implementation is not going ahead and to look for solutions,” he says. In a partnership based on the BC Hydro model, CME is also partnering with FortisBC on a pilot project that targets natural gas users with the goal of reducing consumption through energy audits followed by project implementation.

Herman notes that within the manufacturing sector, there has been broad representation of sectors, including wood products, metallurgy, agri-food and printing businesses. Already implemented projects include lighting, refrigeration, compressed air and pumping retrofits.

Nico Human, BCFPA CEO, also sees the partnership as a way to add value to membership. The BCFPA promotes the program, encourages members to subscribe, supports them during the process and conducts follow-up implementation surveys. “We can build and maintain relationships easily, both at the strategic and operational levels,” says Human. The BCFPA promotes the program at meetings of its committees and peer groups, through its newsletter and mass e-mailings and on BCFPA’s and BC Hydro’s Web sites. The organization also recognizes participating members at FoodProWest, its annual food-processing conference/showcase and celebrates success through its annual Sustainability Award.

To date, a range of food-processing companies have subscribed to the program, including Sunrise Soya Foods, Gordon Food Service, Happy Planet Foods and Johnston Packers Ltd. They have proceeded with such projects as lighting, refrigeration and compressed air upgrades.

“We have set up both the BCFPA and CME to effectively manage applicants moving through the energy manager process and beyond,” says Herman, adding that the numbers are encouraging. Of the 140 enrolled in the program, 110 have participated in the energy audit and 30 have committed to implementing recommended projects. “With the support of the BCFPA and CME, we will be able to move participants seamlessly from audits to implementation,” he adds. Indeed, the focus of the program’s third year is converting audits into energy efficiency projects.

For more information on BC Hydro’s Power Smart Partner Program, visit www.bchydro.com/powersmart/commercial/power_smart_partners.html.

For more information on BCFPA’s program, visit www.bcfpa.ca/services/bc-hydro-power-smart-program.

For more information on CME British Columbia’s program, visit bc.cme-mec.ca/.

The Lowe-Martin Group recognized for leadership in sustainability

“Receiving this award is incredible as it recognizes how far we, and our industry, have come in the past 20 years,” says Patrick Coyne, Director, Sales & Marketing, at The Lowe-Martin Group, a full-service printing company in the Greater Toronto Area (GTA) and a CIPEC Leader in the General Manufacturing Sector. Coyne is referring to his company’s receipt of the 2011 Partners in Project Green Leadership in Sustainability – Manufacturing Award.

Every year, Partners in Project Green gives out Sustainability Awards to recognize the innovative and inspiring efforts of businesses in the GTA. Leaders in sustainability are evaluated according to such criteria as adoption of environmental technologies and best practices, integration of sustainability into operational practice and influence within their industry. Winners are selected by a jury of their peers, which includes award recipients from previous years.

The Lowe-Martin Group’s Kestrel Road location – a carbon neutral facility – was an obvious choice for the award. Coyne explains that the company-wide Carbon Management Program was instrumental in achieving carbon neutrality as it prompted measurement of the facility’s carbon footprint. Coyne explains that “measurement allowed us to understand where action was required.” The Lowe-Martin Group then undertook initiatives to significantly reduce its carbon footprint, including lighting retrofits, increasing waste diversion to recycling and opting for Bullfrog Power Inc. To reach carbon neutrality, the company purchased offsets from CarbonZero.

“We have green teams in all of our facilities, and I chair an environmental steering committee,” says Coyne as he discusses the path for continuous improvement for the company in sustainability. “We will continue to measure our environmental footprint, to identify opportunities and to commit to carbon neutrality.” He notes that the company is planning to further reduce the waste going to landfills and is also eyeing alternative energy sources.

People Power Challenge to encourage employee action in sustainability

“The big idea behind the People Power Challenge is to champion and share successes of participating companies,” says Chris Rickett, Senior Project Manager, Partners in Project Green. He is referring to the recently launched challenge that aims to engage employees in energy, waste and water management and to encourage them to identify conservation opportunities.

The year-long, cross-sector People Power Challenge is open to any organization in the GTA. Sub-challenge 1, which ran between November 1, 2011, and February 29, 2012, concentrated on gathering employee momentum around waste management. The second sub-challenge, from March 1 to June 30, 2012, deals with energy efficiency. Engagement around water conservation is the goal of the final sub-challenge, which will take place between July 1 and October 18, 2012.

“The challenge facilitates employee engagement with tools and resources available to participating companies,” says Rickett. Support offered by Partners in Project Green includes webinars, template posters, e-mail blasts and an online reporting system. The latter is a scorecard that tracks employee events, ideas for conservation and action taken: the more entries, the more points.

To date, Partners in Project Green has recruited more than 25 companies, including Husky Injection Molding Systems Ltd., a CIPEC Leader in the Transportation Equipment Manufacturing Sector; Maple Leaf Foods, a CIPEC Leader in the Food and Beverage Sector; Mosaic Experiential Marketing; TD Bank Group; Bosch Canada; Ontario Natural Food Co-op; and Toronto Hydro-Electric System.

Companies will be evaluated at the end of each sub-challenge and on the challenge as a whole, based on their scorecard. “We are interested in how employees and the company act on the suggestions submitted – the implementation rate,” adds Rickett. Winners of sub-challenges will receive $1,000, while the grand prize winner will receive $2,500 toward implementing employee ideas. In addition, participating companies will be recognized in local media for innovative ideas; winners will be promoted at eco-business breakfasts and to members of local boards of trade.

Dollars to $ense Energy Management workshops

Dollars to $ense Energy Management workshopsSchedule for March, April, May and June, 2012

EEF: Energy Efficiency Financing
EM: Energy Monitoring
EMP: Energy Management Planning
SPOT: Spot the Energy Savings Opportunities
EMIS: Energy Management Information Systems
RCx: Recommissioning

(F) = French

Vancouver, B.C.
EEF – March 13
RCx: – May 2

Calgary, Alta.
RCx – April 12
RCx – May 16

Edmonton, Alta.
SPOT – April 4
EM – April 5

Winnipeg, Man.
SPOT – April 17
EM – April 18

Toronto, Ont.
RCx – May 17

London, Ont.
EMP – May 2
EEF – May 3

Ottawa, Ont.
EEF – April 26

Montréal, Que.
EMIS – May 10 (F)
EMP – May 15 (F)
EEF – May 16

Québec, Que.
SPOT – April 24 (F)
EM – April 25 (F)

Moncton, N.B.
SPOT – May 30
EM – May 31
SPOT – June 6 (F)
EM – June 7 (F)

Halifax, N.S.
RCx: – May 8
EMP – May 9

Register online at oeeforms.nrcan.gc.ca/index-eng.cfm?event=dollars-sense-registration.

Workshop schedule – Winter to spring 2012

Upcoming events

CD-adapco engineering workshop on Computational Fluid Dynamics – March 13 in Montreal

The event will highlight how those using or wanting to use computational fluid dynamics (CFD) can expand their capabilities to cut their time-to-results from weeks to days, or from days to hours, while reducing their license expenditure.

Attendees will be presented with several industrial examples which demonstrate both the business and functional advantages of turning engineering simulation loose on your everyday or niche applications.

For more information, visit www.cd-adapco.com/events/workshops/70140000000NF9w

To register for this free workshop, visit www.cd-adapco.com/registrations/registerme.html?r=25678c5b

For a complete list of industrial program events, visit oee.nrcan.gc.ca/industrial/opportunities/calendar/417.

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 subscribe page to change your contact information, to unsubscribe or to subscribe to Heads Up Energy Efficiency, our sister publication for commercial, institutional and federal government buildings. If you are experiencing difficulty accessing the subscription page, see our help section, call 613-996-6891 or send an e-mail to info.ind@nrcan-rncan.gc.ca.