Aggregates Manager Digital Magazine
Issue link: http://read.dmtmag.com/i/581365
Using Energy Wisely OPERATIONS E nergy effi ciency and sustainability have be- come common words for industries, including the aggregates industry. Energy is one of the largest expenses for aggregate producers, so it is naturally one of the areas of focus when trying to cut back on operating expenses. Con- serving energy is important, whether it's electricity used to run the plant or fuel to run the fl eet of equipment. "Being energy effi cient or sus- tainable has always been at the forefront of electrical project design and is an integral part of the way I contribute to the overall goals of our sustainability program," says Leroy Goree, senior electrical engineering manager at Lehigh Hanson. "On the supply side, one of my functions within the company is to work with our purchasing group to ensure the most reliable and lowest priced power is delivered to the gate when we retrofi t or build a plant. On the demand side, we look at how we can make the most effi cient use of that power within our facility." There are many ways to address the high cost of energy. One way is through the use of alternative energy. Some operations are embrac- ing solar power and wind energy at their operations to reduce the amount of energy they need from the grid. Operations also adjust their hours of operation around peak-use hours when electricity prices can be higher. High fuel costs can be addressed through the use of tech- nology. Most manufacturers outfi t their new equipment with tracking software to monitor idle time and fuel consumption. Plus, aftermarket software is available to retrofi t on older equipment. A good energy management program that encourages using energy wisely and following best practices is essential. The Environ- mental Protection Agency offers help to companies that want to set up an energy management program. It also offers a wide selection of ideas and tools to help producers attain energy effi ciency through its Energy Star Challenge for Industry, which can be accessed at www.energystar.gov/. Cemex has an energy management program in place that employs a corporate energy management team and site energy teams at each plant. "The program, based on Energy Star guidelines, is implemented across all divisions of the company," says Bhas- kar Dusi, corporate energy manager. "Cemex has received numerous local and national energy and environ- mental awards, and is a strong advocate for energy conservation and sustainable manufacturing practices." Another important part of success- fully maintaining energy effi ciency is getting everyone in the company onboard. "It's all about the people really," says William Jerald, chief en- ergy engineer for CalPortland. "Buy- in is the only way it works. When the managers and operators see that we can actually do things that make the plant better, then we have a win and start gaining momentum with the people." AGGREGATES MANAGER Energy effi ciency begins with a good energy manage- ment program. The Environmental Protection Agency offers information to help companies get a program started through its Energy Star Challenge for Industry program. Once a program is established, an energy audit, or Energy Treasure Hunt, should be conducted at each plant to identify areas where excess energy is consumed. The Energy Treasure Hunt Guide: Simple Steps to Finding Energy Savings, found on the Energy Star website at www.energystar.gov, provides guide- lines and tools for conducting an energy audit. Many things that can be done to improve energy effi - ciency, such as determining when to run an operation, making sure equipment isn't running when employees go home, and using energy-effi cient lighting. The use of adjustable speed drives in the plant allows opera- tors to vary the speed of a crusher, adjust the fl ow of water throughout the plant, or change the speed of a baghouse exhaust fan so that the plant uses only the energy that is needed. Air compressor leaks can be major issues, as well, but can be identifi ed and fi xed easily to provide a quick return. 1 Start an energy management program 4 Address energy consumption problems