Commercial & Industrial Energy Efficiency

Industrial Papermill

CDH Energy has identified and evaluated energy efficiency measures in numerous commercial and industrial facilities. We have been very successful at addressing the needs of industrial clients, including characterizing and quantifying distribution of electrical and thermal loads, and finding energy saving alternatives that do not disrupt the quality or reliability of their operations. The unique requirements of industrial clients often require industry-specific approaches to reducing energy use.

Projects have included lighting retrofits, compressed air improvements, boiler heat recovery, HVAC systems, waste water treatment plant aeration systems, and a wide array of highly specialized industrial process improvements. Some projects have included extensive construction and process line upgrade projects at industrial facilities that are expanding production.

In commercial buildings we often work to improve the efficiency of HVAC and central plant equipment and processes. We often find that significant savings can be realized by considering control improvements that optimize the efficiency of the integrated system at part load conditions – as opposed to simple measures that only look at the rated efficiency of single components.

Example Projects

Injection Molding Facility: Compressed Air, Machine Upgrades, and Plant Expansion – Auburn, NY

CDH Energy evaluated a 200-HP variable speed air compressor upgrade for a manufacturer of injection molded and blow molded plastic components. CDH reviewed the baseline compressed air data and savings calculations provided, and verified the post installation conditions. Compressed air loading was found to be larger during the post installation case than estimated in the savings calculations, and an adjustment to the savings calculations were performed based on post installation M&V. The project was found to provide approximately 250,000 kWh/year in savings. CDH Energy examined the operation of the ammonia industrial refrigeration system, the largest single point use of energy in this refrigerated warehouse facility. SCADA trend data for the compressor operation and utility billing trends were used to quantify the annual refrigeration energy consumption. It was determined that the facility could benefit greatly from reducing the head pressure of the refrigeration system. As this was a simple control change, with minimal installed cost, the upgrade had an immediate payback for the facility.

CDH Energy then provided technical review and M&V assistance services to NYSERDA for incentive application(s) for upgrading several injection molding and blow molding machines. The project involved installing battery powered data loggers to perform baseline power measurements on both the existing machines, and the new machines. Power data were normalized based on the production volume and reject rate for each machine, and a difference in production normalized energy was established. Across four machine upgrades, Currier Plastics realized an energy savings of approximately 950,000 kWh/year.

After successfully completing incentive applications for the four individual machine upgrades, the facility engaged NYSERDA, with the assistance of CDH Energy, for technical assistance in evaluating an incentive application for a new construction plant expansion that doubled the size of the production floor. CDH Energy evaluated the upgrade for energy savings from interior and exterior lighting systems, expansion to the compressed air system, new process chilled water system, and individual production machine upgrades compared to the existing production capacity of the facility. The project is projected to save nearly 2 million kWh/year over operations performed at the existing plant on a production normalized basis.

Data Logger Panel     Injection Molding Machine     Air Compressor

Industrial Facility: Lighting and Compressed Air Upgrades – Geneva, NY

CDH Energy evaluated an ESCO provided lighting upgrade for the facility. The project involved upgrading metal halide and T-12 fixtures to T-5HO and T-8 fixtures in a portion of the facility. The project resulted in approximately 250,000 kWh/year of savings. The facility returned applied for incentives for the upgrade of the remaining high pressure sodium, metal halide and T-12 fixtures to T-5HO and T-8 fixture with occupancy and daylighting control. This second phase resulted in nearly 1 million kWh/year of savings. Pre-inspection both post-inspection, and M&V were performed.

CDH Energy then performed savings verification for a variable speed compressed air upgrade at the facility. An evaluation of sub-metered baseline data and flow power relations for the five existing compressors was used to develop the compressed air profile for the plant. Savings were evaluated using the established baseline profile and the flow power curve for the new variable speed compressor. Savings of approximately 300,000 kWh/year were established for the project.

Air Compressor

Waste Water Treatment Plant: Blower Upgrade – Cortland, NY

CDH Energy evaluated an upgrade for the waste water treatment plant (WWTP) aeration system. The existing system utilized four 150-HP centrifugal blowers that had reached the end of their lives. The centrifugal blowers had limited capability to reduce the delivered air volume, and often provided excess oxygen, resulting in wasted energy consumption. The blowers were replaced with new 100-HP turbo blowers, with up to 50% flow modulation. This upgrade results in a decrease in both the flow normalized power (W/SCFM), as well as a decrease in the energy per unit process treated (kWh/lb BOD). Annual savings from the plant upgrade total approximately 450,000 kWh/year, and have been verified via M&V.

P1290377          Dsc01048

Supermarket: Lighting Evaluations – New York State

For a NYSERDA incentive program, CDH Energy evaluated 88 lighting upgrade projects. To cost-effectively evaluate this large number of projects CDH Energy employed site sampling, after establishing consistency in the type and quantity of fixtures at groups of store locations. For the front of store projects, pre-inspection were waived on a portion of the projects. For back of store projects, pre-inspection was performed on all stores. Stores selected for inspection are based on the total volume of energy savings, with typically the top 50% inspected. CDH reviewed the M&V data supplied by the ESCO who deployed battery powered lighting & occupancy loggers. Across these projects the supermarket has realized nearly 20 million kWh/year in savings.

Hpim3761     Hpim3760     Hpim3759