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Energy Management The Infrastructure Approach. Dr. J. Patrick Kennedy, CEO and President. The Problem – Utility Side. The Problem – User Side. Cost of Energy Going up Not only actual, but built in (e.g. Recycle Pulp) Reliability Decreasing Unused Flexibility New Tariffs.
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Energy ManagementThe Infrastructure Approach Dr. J. Patrick Kennedy, CEO and President
The Problem – User Side • Cost of Energy Going up • Not only actual, but built in (e.g. Recycle Pulp) • Reliability Decreasing • Unused Flexibility • New Tariffs
Responses on the Horizon… • Dynamic changes occurring in the market • Deregulation • Cap and Trade Certificates • Market Based Pricing • Demand Response • Time of Day • LMP
Kodak Park • The Largest of Eastman Kodak’s Worldwide Manufacturing Sites • Located in Rochester, New York • Referred to as a “City Within a City” • 1300 Acres (5,200,000 sq m) • 150 Buildings • Nearly 30 Miles of Roads
Facts and Figures • >20,000,000 Square Feet (2,000,000 sq m) • 11,000 Employees • Operates Its Own Fire Department • Operates Its Own Railroad • Operates Its Own Water and Waste Water Treatment Plants • Operates Two Power Plants
Kodak Park Utilities • Kodak Park Utilities Power Plants • 2,000,000 Pound/Hour Steam Load • 125 MW Electric Load • 80,000 Ton Refrigeration Capacity • 30,000,000 Gallons/Day Process Water Load • 35,000 SCFM Compressed Air Load
600 Electric Distribution Meters 600 Additional Distribution Meters for: Steam, Chilled Water, Brine, Compressed Air, Process Water, Nitrogen, Natural Gas, etc. Significant Metering Used within the Power Houses to Manage the Generation Side Utility Metering
BAS Rosemount - Fix 32 Siemens - Apogee Emerson - Delta V SQL Based Historians DCS Fisher Provox Westinghouse WDPF Westinghouse Ovation Taylor Mod 300 Emerson - Delta V Interfaces
Goals • Reduce utility costs at Kodak Park through improved demand side management • Consolidation of the utilities data • Create Awareness via the Web • Grow a Culture of Energy Efficiency
Solution – Current status • Over 100,000 PI Points currently established • 23 ProcessBook / DataLink Users • 150 Concurrent Web Users • 180 + iView Pages • 27 Interfaces installed
Numerous water main breaks due to pressure control issues Increased visibility and easy access to this data has improved control and reduced the frequency of these “costly” water main breaks dramatically.
Expanded use of our Energy Information System has been an effective tool to help enable us to consolidate two High Purity Water Systems and a de-mineralized water system down to just one High Purity Water System.
Mini Projects • Demand Side • Better correlation of MFG energy usage to production volumes • Identified opportunities in manufacturing to implement an energy conservation mode between product runs • Extended carbon recovery cycles
Mini Projects II • More effective utilization of labs with fume hoods • More effective “Time of Day” scheduling for lighting and HVAC • Temperature / HVAC fan set points • System is considered an essential tool during our energy savings workshops (Kaizens) • Heightened awareness of many end users
Mini Projects • Generation side findings • Plant loading optimization • Boiler fan optimization • Exhaust head improvements • Better management of self generation vs. purchased power • Improved deaerator utilization
Harvest Time • The Energy Information System (EIS) has been an essential tool to help us reach our goal of: “One Powerhouse for Kodak Park” Collectively these efforts have yielded savings into the millions of dollars.
Case Study – Codelco • Five Operating Divisions (Chuquicamata, Radomiro Tomic, El Salvador, Andina, El Teniente), • Each full mining/metallurgical complex (mining, concentrators, smelting, refining, leaching, solvent extraction, electrowinning, utilities, and maintenance)
Projects • Water Management • Environmental Regulation • Asset Management • Troubleshooting • Operating Effectiveness • Energy Management • Inlet Vanes • Utilities (Power, Steam, Air) • Trading/Power Purchase
Lessons Learned • No BIG BANG – 1000 little bangs • Continuous Improvement Process • Combined Capital and Intelligence Operation • Infrastructure Approach – Remove Infrastructure from Projects • Lowers the Cost of Curiosity