Sample Presentation

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Industrial Assessment Center (SFSU) ENERGY
CONSERVATION WASTE MANAGEMENT ASSISTANCE FOR
INDUSTRY A U.S. DEPARTMENT OF ENERGY SPONSORED
PROGRAM  ENGERGY REPORT PRESENTATION Presentatio
n Date June 13th 2006

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IAC-SFSU

• The IAC program is funded by the U.S. Dept. of
  Energy (Founded 27 years ago) and managed by
  Rutgers University New Jersey.
• San Francisco State University has been part of
  this project since 1992
• The IAC at San Francisco State University is one
  of the 26 centers established in universities
  across the country.

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What Does IAC Do

• National goals to reduce energy consumption,
  minimize waste generation, and increase
  productivity efficiency
• Provide cost free engineering assessments
• Specifically targets small to medium sized
  manufacturers within 150 miles of San Francisco
  in Northern California
• The analyses include payback period calculations

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IAC Faculty-Student Teams

• Faculties are experienced in energy and
  industrial waste related subjects.
• Dr. Ahmed Ganji IAC(SFSU) Director
• Head of the Mechanical Engineering
  Department
• Dr Shy-Shenq Liou IAC(SFSU) Assistant Director
• Director of School Of Engineering
• A group of students both graduate and
  undergraduate in electrical and mechanical
  Engineering working with this program.
• Graduate Student Engineers Amit Kanungo, Kar
  Ying Thomas Chan, Ivan Zhao, Crystal Vines,
  Vishwanadh
• Undergraduate Student Engineers Aren Hofland,
  Sasha Spoor, Yin Yin Wu, Harpreet Singh, Austin
  Chin

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Audited Facilities

• 1st Audit Location South San Francisco, CA
• 2nd Audit Location San Jose, CA
• 3rd Audit Location Redwood City, CA
•  
•  

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  NO. 306 ASSESSMENT   Location South San
Francisco, CA   PRINCIPAL PRODUCTS Asphalt   S.
I. C. CODE 2951 N.A.I.C.S CODE
324121 ASSESSEMENT DATE 03/10/05   REPORT DATE
05/31/05  

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Summary of Recommendations
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ECO No. 1 Change the E19S Rate Schedule to A10S
E19S -- 500 1,000 kW maximum demand A10S --
less than 500 kW maximum demand

• Cost Savings 25,577 /yr
• processing charge 100
• Simple Payback Immediate

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ECO No. 2 Repair Air Leaks

• Inspect and tighten loose fittings and valves of
  the compressed air lines on a monthly basis to
  reduce the compressed air leaks.
• Electricity Cost Savings 847
• Maintenance Cost Included in Cost Saving
• Simple Payback Immediate

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ECO No. 3 Tune the Thermal Oil Heater

• Adjust the combustion system air-fuel ratio on
  the facilitys 2.25 MMBtu/hr thermal oil heater
  in order to realize higher heater efficiencies
  and natural gas energy savings.
• With 15 excess air, the oil heater efficiency is
  expects to be about 82 .

• Natural Gas Savings 8,056
• Implementation Cost 1,000
• Simple Payback 0.1 year

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ECO No. 4 Insulate Bare Oil Heater Lines

• Insulate the hot surfaces of the thermal oil
  heater lines.

• Natural Gas Cost Savings 1,779
• Implementation Cost 244
• Simple Payback 0.1 yr

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ECO No. 5 Replace Incandescent Lighting with
Compact Fluorescent

• Replace 75-watt, 90-watt, 100-watt, 135-watt and
  150-watt incandescent lighting with 20-watt,
  24-watt, 26-watt, 42-watt and 42-watt compact
  fluorescent lighting to reduce energy
  consumption. Additionally, install a switch on
  top of the tunnel ladder to turn off the lights.
• Electricity Cost Savings 1,805
• Implementation Cost 821
• Simple Payback 0.5 yr

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ECO No. 6 Use a Blower Instead of Compressed Air

• Replace the compressed air that is used for
  removing debris from the underside of the
  conveyor from the raw material train with a
  medium pressure air blower.
• A blower could provide lower pressure air through
  larger nozzles to produce same amount of air
  flow rate.
• Electricity Cost Savings 5,040
• Implementation Cost 4,802
• Simple Payback 1 yr

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ECO No. 7 Replace Quartz Lamps with Metal Halide
Lamps

• Replace the six existing 500 watts Quartz
  fixtures and lamps with 250 watts high efficiency
  metal halide fixtures and lamps to reduce the
  energy consumption.
• Additionally, install a bi-level controller for
  the MH lamp in the tunnel area to reduce lighting
  energy usage.
• Electricity Cost Savings 1,055
• Implementation Cost 1,633
• Simple Payback 1.6 yr

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ECO No. 8 Install Premium Efficiency Motors

• Install Premium efficiency electric motors to
  replace the existing standard motors currently
  used at this facility.
• Depending on the horsepower rating of a given
  premium efficiency motor, operating efficiencies
  may be from 1 to 10 higher than the operating
  efficiencies of the existing motors.
• Second Year Total Electricity Cost Savings
  856
• Two Year Incremental Cost Premium 1,423
• (with PGE Rebate)
• Incremental Payback Period 1.7yr

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Summary South San Francisco Plant
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  NO. 315 ASSESSMENT Location San Jose, CA
  PRINCIPAL PRODUCTS Asphalt, Concrete   S. I.
C. CODE 2951, 3273 N.A.I.C.S CODE 324121,
32732 ASSESSEMENT DATE 07/07/05   REPORT DATE
09/23/05  

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Summary of Recommendations
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ECO No. 5 Install Daylight Sensors to Save
Energy in Certain Area

• Install daylight sensors (photocell) in various
  areas to reduce lighting energy usage.
• To turn off lights automatically during the
  daytime when enough natural light is available.
• Electricity Cost Savings 724
• Implementation Cost 468
• Simple Payback 0.6 yr

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ECO No. 6 Reduce Compressed Air Pressure

• Reduce energy consumption by lowering the air
  compressors operating pressure from 124 psig to
  110 psig in the asphalt plant and install extra
  compressed air storage.
• Electricity Cost Savings 2,560
• Implementation Cost 2,311
• Simple Payback 0.9 yr

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ECO No. 7 Replace Standard V-Belts with Cog-Type
Belts

• It is suggested that cogged V-belts be installed
  on all equipment that is currently using standard
  type V-belts.
• According to the U.S. Department of Energys
  Industrial Technologies Division study, cog-type
  belts run cooler, last longer and have an
  efficiency that is 2 greater than equivalently
  rated V-belts.
• Electricity Cost Savings 1, 805
• Implementation Cost 1,076
• Simple Payback 1.0 yr

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ECO No. 8 Change the E19S Rate Schedule to E19P

• The Schedule E19P service offers lower energy and
  demand costs. However, this will require the
  purchase and maintenance of the transformer (step
  down transformer) at a substantial cost.
  Furthermore, the electric utility company will no
  longer be responsible in the event of transformer
  failure.
• The E19S delivers power at the secondary voltage
  and the E19P delivers the power at the primary
  voltage. These voltages are 480 volts and 12,000
  volts, respectively. Power supplied at the
  higher voltage is available at a lower cost. The
  higher voltage is reduced with a transformer
  before the facility uses it.
• Electricity Cost Savings 19,997
• 
  (10.7 of current total annual
  electric cost)
• Implementation Cost 25,300
• Simple Payback 1.3 year

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ECO No. 9 Install Lighting Occupancy Sensors in
Offices and Twist Timer in Maintenance Rooms

• The savings are realized by installing occupancy
  sensors. Lights will turn off automatically when
  these areas have been unoccupied for an extended
  period of time.
• Electricity Cost Savings 1,185
• Implementation Cost 2,421
• Simple Payback 2 yr

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ECO No. 11 Replace Air Vibrator with Electric
Vibrator

• The air vibrator uses compressed air and then
  expels it to the atmosphere. Similar to an air
  leak, this is essentially wasted air that is
  fairly expensive to produce. This wasted
  compressed air represents lost compressor
  horsepower, which translates into increased
  energy usage for the plant operation.
• Electricity Cost Savings 388
• Implementation Cost 1,032
• Simple Payback 2.7 yr

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Summary San Jose Plant
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  NO. 322 ASSESSMENT Location Redwood City,
CA   PRINCIPAL PRODUCTS Asphalt, Emulsion   S.
I. C. CODE 2951 N.A.I.C.S CODE
324121 ASSESSEMENT DATES 10/20/05   REPORT
DATE 01/26/06  

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Summary of Recommendations
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ECO No. 1 Repair Steam Leaks

• Inspect and repair fittings and valves of the
  steam piping on a bimonthly basis to reduce the
  steam leaks. By fixing the steam leaks, natural
  gas energy and costs would be conserved.
• Natural Gas Cost Savings 7,560
• Implementation Cost Included in Cost Saving
• Simple Payback Immediate

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ECO No. 6 Install VFD on the Dust Collectors
Fan Motor in the Continuous Mix Production Line

• Install a variable frequency drive (VFD) on the
  200 dust collector fan motor in the Continuous
  Mix production line to eliminate the manual flow
  adjusting valve to allow 100 flow.
• A VFD will reduce the power consumption of the
  dust collector fan motor based on the temperature
  of the aggregate.

• Electricity Cost Savings 19,762
• Implementation Cost 24,854
• Simple Payback 1.3 yr

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ECO No. 8 Replace MH-400 With MH-360 High
efficiency HID Lamps

• High efficiency lower wattage Metal halide lamps
  have the same luminosity as the higher wattage
  lamps, but require less input power. Both MH-400
  and MH-360 lighting maintain the same
  luminescence.
• Electricity Cost Savings 509
• Implementation Cost 1,320
• Simple Payback 2.6 yr

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ECO No. 9 Install VFD on the Burners Blower in
the Continuous Mix Production Line

• Install a variable frequency drive (VFD) on the
  75-hp burner blower used in the Continuous Mix
  line for the rotary asphalt dryer and eliminate
  the intake dampers. A VFD will reduce the power
  consumption of the burner blower motor when the
  required flow is less than the maximum.

• Electricity Cost Savings 4,680
• Implementation Cost 15,259
• Simple Payback 3.3 yr

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Summary Redwood City Plant
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SFSU-IAC Contact Information

• Ahmad R. Ganji , Program Director
• [phone]
• aganji_at_sfsu.edu
• IAC Office, SFSU-SCI 151
• [phone]
• eadc_at_sfsu.edu
• Yin Yin Wu, Audit Coordinator
• [phone]
• wu_at_sfsu.edu