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Building the Energy Program One Piece at a Time

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  • 1. Building the Energy Program One Piece at a Time Sharon Nolen, P.E., CEM TN Environmental Conference – Meadowview March 13, 2013
  • 2. Agenda  Eastman Chemical Company Overview  Building 469: A Case Study  Energy Management Program •  Organization •  Guiding Principles •  Strategy  Building 469: Results
  • 3. Eastman Chemical Company Overview Building 469: A Case Study Energy Management Program Building 469: Results
  • 4. Who we are   A global specialty chemicals company headquartered in Kingsport, Tennessee   Approximately 13,500 employees and over 44 manufacturing sites around the globe   A company dedicated to environmental stewardship, social responsibility and economic growth   ENERGY STAR® Partner of the Year two years (2012/2013)   Combined 2011 sales revenue of approximately $9.3 billion
  • 5. 5 Our manufacturing locations
  • 6. Major end-markets Automotive Building & Construction Tobacco Packaging Consumer Goods
  • 7. Our Eastman culture matters 7 Sustainability is an attitude and not an activity to participate in from time to time. It’s not a fad or unwelcome burden... but the constant awareness of one’s environment and actions. It is an opportunity to use our creativity and innovation to be part of the solution, for our world today and for future generations. Godefroy Motte Senior Vice President, Chief Regional and Sustainability Officer Eastman Chemical Company
  • 8. Eastman Chemical Company Overview Building 469: A Case Study Energy Management Program Building 469: Results
  • 9. B469: A Case Study   14,960 square feet   37 People   53 Computers   8 Heat Pumps   Fixed Outside Air Flow   Above the Ceiling Return Plenum
  • 10. B469 qualifies for ENERGY STAR label
  • 11. Eastman Chemical Company Overview Building 469: A Case Study Energy Management Program Building 469: Results
  • 12. Regular Reports Energy Management Program Executive Steering Team Energy and Climate Change Policy Team Energy Management Team Worldwide Manufacturing Team VP&GM, Worldwide Manufacturing Support
  • 13. Guiding principles Ensure the accuracy of utility information •  Creates a basis for sound business decisions •  Required for accurate reporting and life cycle assessments Maximize operating efficiency •  Control processes to reduce energy usage •  Maintain equipment at design performance •  Operate intelligently to keep efficiency high Incorporate energy efficiency in capital investments •  Minimize lifetime equipment costs •  Consider the impact on carbon emissions
  • 14. ENERGY STAR® Guidelines for Energy Management  Effective to structure a new energy program or to identify gaps in an existing program  Utilizing the guidelines have led to: •  Increased management visibility and involvement •  Over $10 million in funding for energy projects in 2012 •  2012 energy savings of $8 million •  Comprehensive database with over 1,000 energy-saving ideas •  Better understanding of energy intensity drivers
  • 15. 2013 ENERGY STAR® Partner of the Year   The U.S. Environmental Protection Agency (EPA) has named Eastman a 2013 ENERGY STAR Partner of the Year for strategically managing and improving energy efficiency during 2012.   Through its partnership with the ENERGY STAR program, Eastman has   Improved its energy performance   Saved money   Helped to protect the environment for future generations   Eastman is the only chemical company to every achieve the distinction of ENERGY STAR Partner of the Year more than once.
  • 16.  Continuously improve energy efficiency and minimize overall energy impact while contributing to regulatory compliance  Five pieces are key to the strategy •  Energy Awareness •  Goals and Measures •  Knowledge Resources •  Site Wide Initiatives •  Energy Efficiency Projects Energy Management Strategy 16
  • 17. Energy Awareness   Employee Engagement •  ENERGY STAR® Pledge •  Annual Eastman Energy Fair •  Green Team   Communication and Training •  “Energy Wise” SharePoint site •  Intranet articles •  Posters in dining, break, and conference rooms •  On-line training •  Training for managers to become sustainability ambassadors
  • 18. Encourage participation in 2012 ENERGY STAR pledge  Eastman was ranked in the top five in the business sector for pledge campaign ending in 2012  Over 200 employees signed the pledge at the fair, including Eastman’s Executive VP and Chief Sustainability Officer
  • 19. Raise awareness of things employees can do at home/work to save energy   Eastman recently held 2nd annual energy fair   Over 750 employees and contractors attended   Energy Team members demonstrated the work required to power a CFL bulb vs. an incandescent   Local stores and utilities shared energy saving ideas
  • 20. Goals and Measures  Energy Intensity Measures •  Energy intensity measures are tracked at a site level •  Feedback on current performance •  Prediction of future performance  Monitor and Drive Performance •  Quarterly reports to the CEO •  Frequent review by energy engineers
  • 21. Knowledge Resources  Internal Sharing of Best Practices •  Corporate Energy Management Team •  Worldwide Utilities and Energy Forum •  Site energy teams  External Resources •  ENERGY STAR® Partner •  Better Buildings, Better Plants •  Consultants
  • 22. Corporate Energy Initiatives  Initiatives: •  Leaks •  Lighting •  Insulation •  Steam Traps •  Metering •  Motor Efficiency •  HVAC  Evaluation •  Identification of best practices •  Degree of implementation
  • 23. Steam Leak Initiative Survey   What percent of total steam production is lost in leaks?   Is there a person with assigned responsibility for overseeing the repairing of leaks?   Frequency of site wide surveys?   Number of leaks detected in the last 12 months (or last survey cycle if survey frequency is longer than 12 months)?   Of the number of leaks detected in the last 12 months (or last survey cycle if survey frequency is longer than 12 months), how many have been repaired?   Do you track leak repairs in a database/spreadsheet?
  • 24. Energy Efficiency Projects  Capital Energy Efficiency Projects •  Metering and efficient equipment included in designs •  Energy surveys for project identification •  Capital budget for economically viable projects  Manufacturing Processes Modification •  Adjustments in operating procedures •  Long-term research to identify process redesign opportunities •  Inventory management to attain energy-efficient production rates
  • 25. Example Projects   Running a line from a source of high pressure natural gas to eliminate a compressor used on low pressure natural gas   Installing O2 meters to allow tighter control of excess air in a combustion process   Replacement of old equipment with newer more efficient equipment (i.e. boilers, pumps)   Installing additional piping to allow condensate return   Fine tuning temperatures of heat exchangers using refrigeration and steam to meet but not exceed requirements   Installing variable frequency drives to eliminate control valves
  • 26. Eastman Chemical Company Overview Building 469: A Case Study Energy Management Program Building 469: Results
  • 27. How B469 Earned the ENERGY STAR Label  Lighting Changes •  More efficient lighting •  Fewer light fixtures  Monitor Thermostats •  Maintain temperature set points at 72F •  Ensure that all thermostats are in the same mode  Improved Insulation •  Identified poorly insulated areas using infrared thermography
  • 28. How B469 Earned the ENERGY STAR Label   Occupant Involvement •  Turn off lights at the end of the work day •  Put computers in sleep mode at the end of the work day •  Turn off TV in canteen when not occupied •  Call the energy team when temperatures are a problem   Occupant Comfort •  Improved thermostat locations •  Diffusers   Balanced flows   Relocated as needed   Changed diffuser type as needed •  Installed personal dampers as needed   Personal Heaters Used Less
  • 29. Continued Energy Use Intensity Reduction  Building Automation System •  Use occupancy schedule to control HVAC and lights •  CO2 controlled outside air •  Control and troubleshoot via network server  EnerLogic™ Window Film •  Minimizes solar heat gain in the summer •  Minimizes radiant heat loss in the winter  Lighting Changes •  Reduce the number of lights that remain on 24/7  Continued Focus on Occupant Comfort  Continued Occupant Involvement  Continued Communication about Energy Use with Occupants
  • 30. Summary  Energy management requires a focused effort to succeed  Gains can be achieved with education and awareness but diligence will be required to maintain  Financial investments can result in step changes and some have attractive paybacks  These strategies can be applied on a macro or micro level with good results
  • 31. 31 Questions?

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