Kodak Plant in New York Saves Energy and Money with a More Efficient and Economical Pumping System
July 1, 2005
A Kodak chemical plant in Rochester, New York, is saving more than 1 million kilowatt-hours, $52,000 in energy costs, and another $48,000 in demand charges—all as a result of a project to improve the energy efficiency of its two lake-water pumping stations.
This system-level project was recommended as part of an assessment conducted using the Department of Energy's (DOE) Pumping System Assessment Tool (PSAT). The assessment was carried out by Dr. Barry Erickson, who is affiliated with a DOE Allied Partner, Flowserve Corporation.
The Rochester plant is home to Kodak's corporate headquarters, its largest U.S. manufacturing operation, and a research and development facility. A few years ago, plant managers realized that many motor and process systems installed there in the 1950s were not operating efficiently and did not work properly with newer equipment. So, they commissioned an energy efficiency assessment that eventually helped them optimize the lake-water pumping system to reduce energy and operating costs.
The lake-water system includes two pumping stations containing a total of 12 pumps. Dr. Erickson found that many pumps had a low ratio of flow rate to input power. He also noted that some pumps would operate much more economically during off-peak, rather than peak, periods.
The assessment report described the most energy-efficient pump combinations and other measures that would save energy while meeting the plant's water requirements. As part of the project, pump impellers were trimmed, valves were replaced, and piping was reconfigured. All together, this project is saving about $100,000 per year at the Rochester plant.
Kodak has also been using DOE's MotorMaster+ software tool to evaluate motors at the plant. As a result, more than 600 motors have been retrofitted to be more efficient and to save more than 7 million kWh and $500,000 per year.