Case Studies by Industry

These case studies describe demonstrated energy improvement projects, process improvement projects, and/or assessments at the plant level. Many examine the bottom-line benefits that successful applications of energy-efficient practices and technologies can yield. These projects and the accompanying savings can be replicated at similar plants owned by the same company and by other industrial plants.

Aluminum

Alcoa/Alumax Reduces Energy Costs While Improving its Dust Collection Systems
(PDF 263 KB)
Alcoa North American Extrusions Implements Energy Use Assessments at Multiple Facilities (PDF 246 KB)
Commonwealth Aluminum: Manufacturer Conducts Plant-Wide Energy Assessments at Two Aluminum Sheet Production Operations (PDF 810 KB)
Corporate Energy Conservation Program for Alcoa North American Extrusions (PDF 197 KB)
Improving Dust Collection System at an Aluminum Refinery (PDF 128 KB) (Alumax)
Ohio Aluminum Industries: Compressed Air System Improvement Project Saves Energy and Improves Product Quality (PDF 990 KB)
Power Factor Study Reduces Energy Costs at Aluminum Extrusion Plant (PDF 180 KB) (Alcoa)

Chemicals

Compressed Air System Optimization Saves Energy and Improves Production at Synthetic Textile Plant (PDF 278 KB) (Solutia, Inc.)
Control Scheme Modifications Increase Efficiency of Steam Generation System at ExxonMobil Gas Plant (PDF 187 KB)
Dow Chemical Company: Assessment Leads to Steam System Energy Savings in a Petrochemical Plant (PDF 550 KB)
FMC Chemicals: Burner Management System Upgrade Improves Performance and Saves Energy at a Chemical Plant (PDF 403 KB)
Improved Steam Trap Maintenance Increases System Performance and Decreases Operating Costs (PDF 235 KB) (Velsicol Chemical Corporation)
Modernizing Controls Reduces Steam Consumption at ExxonMobil Chemical Plant (PDF 286 KB)
New Steam Turbine Saves Chemical Manufacturer $2.3 Million Annually (PDF 402 KB) (Texas Petrochemicals Corporation)
Optimizing Electric Motor Systems at a Corporate Campus Facility (PDF 192 KB) (3M)
PCS Nitrogen: Combustion Fan System Optimization Improves Performance and Saves Energy at a Chemical Plant (PDF 728 KB) (PCS Nitrogen, Inc.)
Reducing Steam Header Pressure Provides Attractive Operating Cost Savings (PDF 199 KB) (Nalco Chemical Company)
Reducing Steam Pressure Saves $42,000 Annually at Vulcan Chemicals (PDF 216 KB)

Forest Products

Advanced Quality Control System for the Thermomechanical Pulping Process Improves Quality and Reduces Energy Costs for Augusta Newsprint (PDF 309 KB)
Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint (PDF 178 KB)
Consolidated Compressed Air System Reduces Power Consumption and Energy Costs (PDF 197 KB) (Augusta Newsprint)
Four Equipment Upgrade Projects Reduce System Energy Losses at Augusta Newsprint (PDF 258 KB)
Georgia Pacific's Insulation Upgrade Leads to Reduced Fuel Costs and Increased Process Efficiency (PDF 64 KB)
Improving Several Fan-Driven systems in an Oriented Strand Board Manufacturing Facility (PDF 199 KB) (Louisiana Pacific Corporation)
Procter & Gamble: Compressed Air System Upgrade Saves Energy and Improves Production at a Paper Mill (PDF 907 KB)
Pump System Optimization Saves Energy and Improves Productivity at Daishowa America Paper Mill (PDF 208 KB)
Upgraded Lighting System Leads to Energy and Cost Savings at Augusta Newsprint Company (PDF 189 KB)
Weyerhauser: Compressed Air System Improvement Saves Energy and Improves Production at a Sawmill (PDF 385 KB)

Glass

Compressed Air System Upgrade Improves Production at an Automotive Glass Plant (PDF 327 KB) (Visteon Corporation)
Millwater Pumping System Optimization Improves Efficiency and Saves Energy at an Automotive Glass Plant (PDF 254 KB) (Visteon Corporation)

Metal Casting

Compressed Air System Improvement Project Saves Foundry Energy and Increases Production (PDF 188 KB) (International Truck and Engine Corporation)
Compressed Air System Retrofitting Project Improves Productivity at a Foundry (PDF 185 KB) (Cast Masters)
Improving Ventilation System Performance at a Metal Plating Facility (Lockheed Martin Armament Systems)
Techni-Cast: Foundry Saves Energy with Compressed Air System Retrofit (PDF 1.1 MB)

Mining

Fan System Optimization Improves Production and Saves Energy at Ash Grove Cement Plant (PDF 249 KB)
Kennecott Utah Copper Retrofits Smelting Applications from Air-Fuel to Oxy-Fuel Burners (PDF 204 KB)
Modernization of Electrolysis System at MagCorp Reduces Costs and Waste (PDF 174 KB)
Optimizing Pump Systems at Coal Slurry Preparation Plant (PDF 137 KB) (Peabody Holding Company)

Petroleum

Additional Steam Traps Increase Production of a Drum Oven at a Petroleum Jelly Plant (PDF 167 KB) (ExxonMobil)
Compressed Air System Retrofit Increases Productivity at a Petroleum Packaging Facility (PDF 179 KB) (Mobil)
Improving the Performance of Oil Well Pumping Units (OXY USA)
Installation of Reverse Osmosis Unit Reduces Refinery Energy Consumption (PDF 222 KB) (Flying J Petroleum Refinery)

Steel

Citation Corporation: Compressed Air System Optimization Project Saves Energy and Improves Production at Forging Plant (PDF 374 KB)
Compressed Air System Improvements Increase Production at a Tin Mill (PDF 256 KB) (Weirton Steel)
Compressed Air System Overhaul Improves Production at a Powdered Metal Manufacturing Plant (PDF 308 KB) (GKN Sinter Metals)
Compressed Air System Optimization Project Improves Production at a Metal Forging Plant (PDF 330 KB) (Modern Forge of Tennessee)
Compressed Air System Upgrade Generates Significant Energy Savings at a Steel Mill (PDF 331 KB) (U.S. Steel Group)
Compressed Air System Upgrade Improves Production at a Steel Mill (PDF 72 KB) (U.S. Steel Group)
Energy Team Pursues a Wide Range of Products to Improve Operations at a Steel Plant (PDF 178 KB) (U.S. Steel Group, December 2000)
Energy Team Pursues a Wide Range of Projects to Improve Operations at a Steel Plant (PDF 117 KB) (U.S. Steel Group, April 2000)
Implementing a Compressed Air System Leak Management Program at an Automotive Plant (PDF 316 KB) (Visteon Corporation)
Improving Steam Turbine Performance at a Steel Mill (PDF 122 KB) (Bethlehem Steel Corporation)
Modernization of Controls Improves Productivity and Reduces Energy Costs at a Large Steel Plant (PDF 262 KB) (Weirton Steel)
Ongoing Control System Modernization Project at a Steel Plant Improves Operations (PDF 282 KB) (Weirton Steel Corporation)
Rebuilding Steam Turbine Generator Reduces Costs at a Steel Mill (PDF 190 KB) (Bethlehem Steel Corporation)
Reducing BOF Hood Scrubber Energy Costs at a Steel Mill () (Bethlehem Steel Corporation)
Using Coke Oven Gas in a Blast Furnace Saves over $6 Million Annually at a Steel Mill (PDF 251 KB) (U.S. Steel Group)

Other Industries

American Water Heater Company: Compressed Air System Optimization Project Saves Energy and Improves Production at Water Heater Plant (PDF 815 KB)
City Of Milford Pump Optimization Project Yields $96,000 Net Present Value (PDF 491 KB) (City of Milford, CT)
Compressed Air Project Improves Efficiency and Production at Harland Publishing Facility (PDF 172 KB)
Compressed Air System Improvements at an Automotive Plant (PDF 256 KB) (Ford Motor Company)
Compressed Air System Modifications Improve Efficiency at a Plastics Blow Molding Plant (PDF 196 KB) (Southeastern Container)
Compressed Air System Enhancement Increases Efficiency and Provides Energy Savings at a Circuit Board Manufacturer (PDF 187 KB) (Sanmina Corporation)
Compressed Air System Optimization Saves Energy and Improves Production at a Textile Manufacturing Mill (PDF 217 KB) (Thomaston Mills, June 2001)
Compressed Air System Optimization Saves Energy and Improves Production at a Textile Manufacturing Mill (PDF 771 KB) (Thomaston Mills, December 2000)
Compressed Air System Project Improves Production at a Candy-Making Facility (PDF 184 KB) (H.B. Reese)
Compressed Air System Redesign Results in Increased Production at a Fuel System Plant (PDF 200 KB) (Caterpillar Fuel Systems)
Compressed Air System Renovation Project Improves Production at a Food Processing Facility (PDF 443 KB) (Mead-Johnson Nutritionals)
Compressed Air System Upgrade Results in Substantial Energy Savings (PDF 209 KB) (BWX Technologies)
Improving the Efficiency of Tube Drawing Bench (PDF 168 KB) (Greenville Tube Company)
Improving the Efficiency of a Brewery's Cooling System (Stock Brewery Company)
Improving Ventilation System Energy Efficiency in a Textile Plant (Nisshinbo California, Inc.)
Improving the Performance of a Waste-to-Energy Facility (City of Long Beach, CA)
Improving Sewage Pump System Performance (Town of Trumbell, CT)
J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant (PDF 638 KB)
Lehigh Southwest Cement Company: Compressed Air System Improvement Saves Energy at Cement Plant (PDF 340 KB)
McBroom Electric Teams with Cummins Engine Company to Save an Estimated $200,000 Yearly in Energy Costs (PDF 480 KB)
Motor Assembly Plant Saves $85,000 with Compressed Air System Improvements (PDF 262 KB) (Bodine Electric)
New Combustion Control System and Steam Traps Save $250,000 Annually (PDF 258 KB) (BWX Technologies)
New Water Booster Pump System Reduces Energy Consumption by 80% and Increases Reliability (PDF 208 KB) (General Motors)
Performance Improvements at Wastewater Treatment Plants (PDF 1.47 MB) (City of Fairfield, OH)
Plant Utility Improvements Increase Profits and Productivity at a Clothing Manufacturing Complex (PDF 314 KB) (MJ Soffe)
Progressive Powder Coating: New Infrared Curing Oven at Metal Finishing Plant Increases Production by 50% (PDF 406 KB)
Raytheon: Compressed Air System Upgrade Saves Energy and Improves Performance (PDF 638 KB)
Saving Energy at a Sewage Lift Station through Pump System Modifications (City of Milford, CT)
Town of Trumbull Pump Optimization Project Yields $60,000 Net Present Value
(PDF 103 KB) (Town of Trumbell, CT)
Upgrade of Compressed Air Control System Reduces Energy Costs at Michelin Tire Plant (PDF 202 KB)