Milling Journal - Q1 2009 - (Page 37)

utility costs can be accomplished without additional capital expense, step two requires an energy audit and, quite often, considerable capital outlay, though various state programs, along with rebates from utility companies, help. In order to achieve the greatest possible savings, energy auditors use the 80-20 rule to look at four main areas in the plant that use the most power— lighting, compressed air, motors, and boilers. Lighting Many mills are still using metal halide and high-pressure sodium fixtures that take forever to come on and cost twice as energy in any mill. More than half of a plants’ electric usage is attributable to them directly. Many of the motors in use in mills today are old and inefficient. Often, operators will add to the problem by rewinding an old motor to save money, but this practice generally results in a motor that is more costly to operate, once it’s returned to service. Steam Boilers When these workhorses of the industry originally were purchased, the thought was they would last forever, and while that is mostly true, they become less efficient over the years. Proper maintenance is crucial. Still, a lot of heat goes up the stack, and without a heat recovery system, that heat is lost. For every 40 degrees the stack temperature can be reduced, a mill can save 1% of its fuel cost, and since some stack temperatures are 200 degrees too hot, this is a good area to look for energy savings. For example, the installation of an economizer in the stack can return enough heat to pre-heat the water going into the boiler to save 10% of the fuel cost. For each 40 degrees the stack temperature can be reduced, a mill can save 1% of the fuel cost, and since some stack temperatures are 200 degrees too hot, this is a good area to look for energy savings. Mike Menzel Vice President, J-I-T Services, Inc. much to operate as high-intensity fluorescent lamps that use half the power, last longer, and put out just as much light. Some mills waste money by leaving the lights on when there is no one in the area. This costs nothing to correct. A behavioral change that encourages employees to turn out the lights in areas where they are not needed is a potential cost saver. Air Compressors It’s always a challenge to stay on top of leaks, but it pays when the leaks are minimized. Audits have revealed as much as 30% of the air generated by compressors is lost to leaks. There will always be some leakage, but a good rule of thumb is a constant 10% air leakage. To overcome the problem, some operators increase the air pressure, which only makes matters worse. Quick connections are likely to leak when hoses are left in, so operators should check those first. A compressor that runs more, costs more. Operators often can achieve a 20% reduction in leakage just by being more aware. Motors Motors are the biggest consumers of Response No. 371 MILLING JOURNAL First Quarter 2009 37 http://www.millelevatorsupply.com http://www.ebmmill.com http://www.rbhinc.com

Table of Contents Feed for the Digital Edition of Milling Journal - Q1 2009

Milling Journal - Q1 2009 Contents IAOM Moves Headquarters Grand Rapids Eats/Entertainment Resident Training Modules 2009 IAOM Conference and Expo Melinda Farris Interview NAMA’s 2009 Division Meetings The Industrial Fumigant Company Pest Management/Subramanyam Increasing Flour Mill Efficiency Addressing Dust Dangers Kice Pneumatic Survey Miller Profiles Buhler News Product Reviews Ug99 Prevention Arcadia Biotech Wheat Milling World News Security Guide 4th Quarter 2008 Flour Production IAOM Reference Guide Hammermills Aspirators Brushes Magnets OSHA Form 300A Mixers Packaging Research Facility Funding Safety Equipment Purifiers Bay State Names Levangie President Screeners Separators Level Indicators Sifter Accessories Great Lakes Regional Conference Ad Index

Milling Journal - Q1 2009

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