Milling Journal - Q4 2008 - (Page 24) Consequently, the plant replaced many of its older motors and refitted several others with soft starters that reduce the peak load necessary to getting them up and running, thus saving a considerable amount of energy over time. Lighting The energy audit also had determined that a substantial amount of energy could be saved by substituting the mill’s outdated high-pressure sodium lighting units with high efficiency fluorescent tubes that use only 25% of the energy the sodium lamps required. “The new lighting scheme provides more light for a lot less money and earned us an additional rebate from KCP&L,” Moberg noted. The Rebate Program Michelle McConnell, a product analyst at KCP&L (816556-2901), says when large and small customers become more energy-efficient, it reduces the utility’s need to construct new power plants to meet the increasing energy demand. “We would rather help our customers pay for upgrades with rebates than build a new power plant,” McConnell explained. “Building power plants is very expensive, so if we can help our customers save energy and save some money, we both benefit.” McConnell explained that Custom Rebate Retrofit Construction Programs provide customers with financial incentives for installing qualifying electric-saving measures including HVAC systems, motors, variable-speed drives, lighting, building controls, and pumps. She adds that all upgrades—whether “We would rather help our customers pay for upgrades with rebates than build a new power plant. Building power plants is very expensive, so if we can help our customers save energy and save some money, we both benefit.” Michelle McConnell Energy Consultant, Kansas City Power & Light retrofits or new installations—must meet a standard cost/benefit ratio, have more than a two-year simple payback, and have preapproval before equipment is purchased or installed. The maximum amount of dollars for rebates differs from state to state. The most money available for any one project in Missouri, for example, is $52, 276 for new construction, and $41, 821 for retrofits. In Kansas, the numbers drop to $35,142 and $28,114, respectively. “For any of the various projects, we first conducted thirdparty energy audits to determine whether each project met the utility’s cost/benefit ratio requirements,” Moberg explained. “Using that information, we then applied for a rebate on the new motors. Once the plan was approved by KCP&L, we bought the new motors and installed them. After that, we looked at the lighting and applied for that rebate.” The rebate program worked so well that General Mills did not stop with the lighting and motors. Pneumatic System Savings “The next thing we examined more closely was our pneumatic system. We quickly discovered another opportunity for significant energy savings,” Moberg explained. “The tubing size was fine, but the motors and pumps were not only old, they we too big and very costly to operate. So we looked at the 67 units in the plant, with the idea of refitting the system to allow us to use smaller pumps and motors, thereby decreasing our energy consumption, saving us even more money,” he said. Companywide Initiative “All of our flour mills across the country want to reduce their carbon footprint and become good citizens in the communities where these facilities are located, “ Moberg explained. “Some of our facilities are exploring wind generators, while several others are considering solar panels on the roofs of their warehouses. “These things are still in the talking stage at this time, but our aim is to go green as soon as that is possible.” The Future The plant has made huge strides in going green, thus far, but even more energy savings are planned for the future. “One of the most costly processes we have is producing compressed air,” Moberg said. “It’s a difficult and expensive process to change, but we are looking into a multi-year plan to address that issue.” Phil Jacobs, senior writer 24 Fourth Quarter 2008 Response No. 241 MILLING JOURNAL http://www.bratney.com http://www.bratney.com
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