energy and productivity workshop for competitiveness: energy intensity_john thornton_dec 2...
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Energy and Operations Efficiency Workshop for Idaho Food Processors
John ThorntonNorthwest Food Processors Association
Twin Falls, Idaho December 2, 2010
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Plant Productivity:Measuring Plant Energy Intensity
NWFPA Energy Projects1. Energy Intensity Baseline2. Access to Energy Data pilot3. Energy Mapping and Assessment
pilot
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Energy Intensity Baseline2009: First time to measure energy intensity
of an entire industrial sectorPrimary Objectives:
Determine best way to measure energy intensity
Set a baseline energy intensity value that best represents the NW food processing industry
Compare processing methods (frozen foods, dehydrated products, canned product, etc.)
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Baseline Participants70+ NW Food Processing Plants
Identity protected by confidentiality agreement
Prepared by: With support from:
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Energy Intensity DefinedWhat is it?
Energy Intensity is the quantity of energy required per unit of output.
EnergyConsumed
ProductionVolume
=
Using less energy to produce a product reduces energy intensity5
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Calculating Energy Intensity
Standard Units of Measure:
Energy Consumed = BTUs• 1 kWh = 3,412 BTUs• 1 Natural gas therm = 100,000 BTUs• 1 Gallon propane = 91,600 BTUs
Production Volume = Pounds• Plants determine conversion rate
BTUsPounds
(BTU = British Thermal Unit)
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Data Collection Example
x 3,412x 100,000x 91,600
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Why Measure Energy Intensity?“You can only manage what you measure”Data collection and reporting is critical for
any energy efficiency strategyCorporate or industry-wide
Sets a benchmark for comparison
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Energy Intensity Baseline
Measures 2006 2007 2008 2009
2010
Number of Plants 56 65 71 63 16
Aggregate Energy Intensity (BTU/Lb) 2,204 2,071 2,088 2,080 1,056
Median Energy Intensity (BTU/Lb) 2,267 2,132 2,266 2,362 1,906
Mean Energy Intensity (BTU/Lb) 5,630 5,071 4,941 4,995 6,910
Est. Error % Primary Method 2.8% 2.9% 7.9% 11.9% 44.6%
Est. Error % Secondary Method
Confidence = 95% 12.9% 11.7% 7.4% 2.7% 129.2%
Confidence = 90% 5.0% 5.0% 0.8% 3.8% 91.4%
Confidence = 85% 0.3% 0.4% 3.6% 5.6% 69.4%
November 30, 2010
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Histogram of 2009 Intensity Data
Mean: 4995 BTU/Lb
Median: 2362 BTU/Lb
Aggregate: 2080 BTU/Lb
Median = geometric center of all individual plant energy intensities
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Intensity by Processing MethodProcessing Method BTU’s/Pound
Dairy, Milk, Cream, Cheese 375
Grain & Oilseed 473
Frozen Foods 1,073
Baking 1,125
Prepared Refrigerated Foods 1,153
Seafood 1,182
Canning 1,913
Animal Slaughtering & Processing 2,570
Prepared Non Refrigerated Foods 3,257
Dehydrators 4,656
Source: NWFPA analysis of 1987 – 2007 energy efficiency audits conducted at 129 ID, OR, and WA food processing plants by the Industrial Assessment Centers at Oregon State University and University of Washington.
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Participate in Energy BaselineIt’s not too lateReceive annual updatesGet access to the complete studyContact John Thornton at NWFPA:
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Energy Mapping and AssessmentIdentify 10-year savings potential in a sample
of food processing plants, analyze and reconcile against energy reduction goal.
Determine common approach for food processing facilities.
Determine the major energy efficiency areas for Energy Roadmap focus.
Identify barriers to energy efficiency implementation and propose solutions.
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Access to Energy Data pilotWhat?
Determine most effective and cost-efficient methods to collect and present energy data
Deploy hardware and software for energy monitoring systems in food processing plants
Document energy/operations results from access to energy data
Develop industry-wide approach for energy management systems
What does it mean to me?Ability to easily access energy consumption data to aid
plant decision making and improve operations.Assistance to defray costs metering and sub-metering
costs not otherwise covered.15
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Access to Energy Data pilotSuccess story:Discovered night-time energy consumptionSimple solution:
Mechanical timerto turn off load atnight.
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Participate in NWFPA Energy ProgramsNWFPA is an Advocate for members’ interests
and a Resource for enhancing their competitive capabilities. NWFPA is your partner for improvement, also to work with other partners to improve the competitiveness of your business.
Engage NWFPA as your efficiency advocate & resource, contact John Thornton:
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