This facility is a masonry plant located in the central United States dedicated to the production of various types of concrete block. The complex encompassed 300,000 square feet of production area and minimal administrative office space. The plant has a peak electrical demand of approximately 2,500 kW and consumes in excess of 11 million kWh annually. At the request of the plant’s management, a survey was conducted to determine the potential opportunities for reducing energy expenditures. Along with the survey activities, participants were provided instruction in various energy management techniques.

Areas of Investigation:

The specific areas of focus for the survey included the electric utility rates, AC induction motors, compressed air systems, HVAC systems, and the interior/exterior lighting systems.

Survey Results/Savings Potential:

The survey identified cost effective opportunities from enhanced maintenance and improved operating efficiency of the AC motors, the compressed air system, and the lighting systems. Specific recommendations were provided for potential savings of $29,000 per year, with less than a one year average simple payback. This equated to an 11.4% reduction in annual electrical expenses.

Environmental Impact:

The recommended measures have the potential of reducing the amount of CO₂ discharged into the atmosphere by 1.1 million pounds annually. In addition, these measures can reduce the emission levels of SO₂ by 9,030 lbs. and NOx by 3,515 lbs. each year.

A summary of the recommendations and their estimated annual savings is presented in the following table.

Table – Recommended Measures Case Study No. 2