Energy Resources for Converters

Posted by Esther Durkalski Energy has traditionally been in the top five cost categories for the forest products industry, according to the American Forest and Paper Association (AF&PA). Energy costs as a percent of operating costs have continued to increase dramatically. This past winter a million BTUs of natural gas ran as high $14.50. Four years ago that same amount cost $4. Many recently closed mills cited rising energy costs as a main or contributing factor in the decision to shut down. The U.S. needs a comprehensive national energy policy with the mechanisms to ensure everyone can access affordable energy from a balanced portfolio of sources. The U.S. Department of Energy (DOE) launched the Save Energy Now initiative to help industrial facilities reduce natural gas consumption. Energy supply disruptions caused by Hurricanes Katrina and Rita, and recent hikes in energy prices, are affecting everyone in the United States, including the nation’s industrial sector. Individual energy assessments could result in significant energy and cost savings for the selected plants. DOE energy experts will help plants determine the most effective ways to optimize energy use, particularly in steam and process heating systems. Through its free energy assessments, DOE is helping major manufacturing facilities to identify energy-saving opportunities, primarily by focusing on steam and process heating systems. The DOE's Energy Saving Teams have completed visits to 29 large federal facilities and 44 energy-intensive manufacturing facilities as part of the national "Easy Ways to Save Energy" campaign launched in October 2005. The first 21 industrial Energy Saving Assessments have identified a total of $64 million per year in potential energy cost savings. If implemented, these energy-saving measures could reduce natural gas consumption by more than 8 trillion Btu per year. Save Energy Now is part of the national campaign called Easy Ways to Save Energy unveiled by Secretary of Energy Samuel W. Bodman to highlight possible approaches for Americans. The Save Energy Now initiative will provide U.S. industry with technical assistance and information to save energy and money and increase productivity right now. Early last month, the DOE compiled a list of 200 industrial plants selected to receive an innovative, no-cost energy saving assessment. Of the recipients, 16 plants are owned by AF&PA member companies, including MeadWestvaco and Weyerhaeuser. All assessments will be completed this year. The DOE says if recommendations are implemented, it could reduce total plant natural gas consumption by more than 6 percent and save $10 million per year in energy costs for those plants alone. The purpose of the assessments is to identify immediate opportunities to save energy and money, primarily by focusing on steam and process heating systems. These processes consume nearly 80 percent of the energy used by U.S. industry. Weyerhaeuser is one of the companies that has benefited from assessments provided by energy experts using DOE software tools and technical information. These assessments continue to yield major bottom-line benefits for these companies as energy prices rise. For the small- to medium-sized manufacturers, the DOE has Industrial Assessment Centers (IAC) that provide a comprehensive industrial analysis at no cost. Engineering faculty and students conduct industrial assessments to identify opportunities to improve productivity, reduce waste and save energy. Recommendations from the IAC audits have saved manufacturers an average $55,000 annually. The Department of Energy’s website features a plethora of information about ways to reduce natural gas and electricity use, including tip sheets, case studies, webcasts by energy efficiency experts, and how-to information for conducting your own plant assessment. Visit www.eere.energy.gov for more information.