No short cut to the energy efficient plant

In researching an article on “the energy efficient
plant” for the May/June issue of Manufacturing Business
Technology, I came across a few perhaps overlooked ways to
save energy at the plant level. For example, in speaking with
analyst firm ARC
Advisory Group, I learned that one overlooked area of savings
is the management of air compressors. Simple tactics like fixing
leaking hoses, and shutting down compressors whenever possible, can
save big bucks when multiplied across work centers and plants.

In speaking with users of plant automation technology from vendors
such as Honeywell
International  and Rockwell Automation’s Pavilion division, I found that
advanced process control (APC) can bring a process such as
combustion for a boiler or furnace to the next level of efficiency.
APC uses software to model and optimize the interplay of multiple
variables in a plant-floor process so that the process can achieve
the optimal balance of output, quality, and energy efficiency.
APC—one user told me—also tends to have a quick
payback. Return on an APC project can be had in a
year—compared to several years or even a decade for a major
piece of process equipment. The payback tends to be quick because
APC layers on top of existing pieces of equipment and control
systems to make small tweaks in a real-time process. These tweaks
might be small, but for energy-intensive pieces of equipment and
processing operations, even a small tweak can generate significant
savings.

Another promising energy saver I heard about from more than one
source: variable speed control. With variable speed control
technology, industrial equipment like motors and fans can be
controlled in a softer, steadier way, which saves energy.

But the tougher, overarching message from the research is that the
really big gains require years of comprehensive work and
organizational change. ARC Advisory Group finished up a
survey-based report on
Best Practices For Energy Management in January, and found that
“leaders” on energy management tend see energy
efficiency as a core competency. They have a high-level directors
or “czars” who oversees energy and manufacturing
sustainability initiatives, set aggressive reduction goals, and
systematically share best practices between plants. In
short—they rely on people and business practices to ensure
energy savings over time—not on any one technology.

Keep an eye out for the May/June issue for more details on how APC
helps save energy. And, I very much want to hear from others about
technology that can bring solid–and relatively rapid–energy
savings. At the same time, the reality is that the big energy
savings spring from a major organizational commitment.