U.S. Department of Energy - Energy Efficiency and Renewable Energy
Advanced Manufacturing Office – Industrial Distributed Energy
J.R. Simplot Fertilizer Plant Saves $335,000 Following Save Energy Now Assessment
July 18, 2008
As part of their corporate culture, employees at J.R. Simplot's Don Plant in Pocatello, Idaho, are continuously looking for ways to improve and reduce energy use. In fact, during the U.S. Department of Energy (DOE) Save Energy Now energy assessment conducted at the plant, employees were anxious to implement several recommendations before the assessment was completed. This enthusiasm helped the Don plant achieve annual cost and energy savings of $335,000 and 75,000 MMBtu in natural gas with a simple payback of 6.5 months.
DOE Energy Expert Bill Moir of Steam Engineering, Inc.used DOE's Steam System Assessment Tool (SSAT) software to identify seven recommendations to reduce energy consumption at the Don plant. Of the seven, the Don plant:
- Reduced vented steam by optimizing boilers
- Improved condensate recovery by repairing the condensate line and pumping stations
- Repaired steam traps and fixed steam leaks.
Since the completion of the assessment, employees at the Don plant have developed more tracking tools, protocols, and efficiency measures based on the SSAT software and the Save Energy Now methodology, and additional recommendations are under consideration.
"Thanks to the Save Energy Now assessment, the company is more efficient and no longer wasting steam," said Paul Malek, Area Manager for the Don plant. "We have done steam trap maintenance that has improved our recovery of condensate throughout the plant and we have also changed some operations. We were running boilers every shift to keep them hot and just venting the steam. The assessment determined we didn't need to do that."
To learn more about J.R. Simplot's Don plant assessment, including energy savings recommendations that can be applied to your plant, read the full case study (PDF 535 KB). Download Adobe Reader. See additional Save Energy Now case studies.
Apply today for a Save Energy Now energy assessment to start saving energy in your plant. If you already participated in an assessment, be sure to implement the recommendations and complete an assessment report with your DOE Energy Expert.