Industries of the Future - West Virginia

About IOF-WV

Benefits/Impacts/Energy Savings

Summary of IOF-WV Implementation Activities

  • U.S. DOE sponsored Industrial Materials for the Future Project entitled "Multifunctional Metallic and Refractory Materials for Molten Metal Handling"
    • The MSA 2020 material developed by Metaullics, a West Virginia company, and West Virginia University for roll coating in the steel industry is now in industrial trials. The industrial trials for MSA 2020 are on-going at the Nucor plant in Armorel, AR, and the Nucor plant in Huger, SC. Industrial trials began at the Nucor plant in Crawfordsville, IN and at California Steel in Fontana CA. The processing patent has been filed with Metaullics, Stoody, ORNL, WVU and Specialty Welding as inventors.
    • The Galvanizing Energy Profiler Decision Support System (GEPDSS) was developed at West Virginia University and is now available for companies to use. The model uses inputs such as energy costs, equipment energy consumption, materials lifetime, and production and rejection information. It then yields information on energy consumption and production, and potential energy savings, product losses, and productivity rates as a result of implementation of new materials. The International Lead Zinc Research Organization is sponsoring further development of the GEPDSS software and broader use of the software at galvanizing lines around the world.
    • Two new refractory materials for molten aluminum containment have been developed and successfully tested – Bonite and TCON - the development of two new materials for improved corrosion and wear resistance which also offer better thermal management in molten aluminum contact applications. One material is a castable refractory based on calcium aluminate (bonite) developed with industrial partner Missouri Refractory Company. The other material is an alumina/silicon carbide composite material (TCON) developed with industrial partner Fireline, Inc. These materials have been validated through the exposure of material samples for over 2,000 hours in an industrial setting at Energy Industries of Ohio (EIO).
    • New Alloys and dross-cleaning procedures were developed for Galvalume process - Stellite 6B and Tribaloy T-401. Compared with Stellite 21, the new scraper alloys show 4.5X better wearing resistance. The new and improved scraping procedure is 1.5X more effective in dross removal than current procedure. Wheeling Nisshin is planning to adopt Tribaloy T-401 as new scraper overlay.
    • New Thermal Conductivity Technique Developed at ORNL Was Further Validated: The IR Thermal Diffusivity Method developed through this project was validated using current and previous measurements made on a high purity alumina (99.6% pure Coors Alumina) material that had been previously evaluated using Calorimetry (ASTM C202), Hot Wire (ASTM C1113), and Laser Flash (ASTM E1461) methods. Good agreement was found to exist between previous laser flash measurements and current IR giving validation to the new IR technique and confidence in the differences previously seen between measurements made using the new IR technique and those reported in data sheets for commercially available refractory materials.
  • U.S. DOE Industrial Technologies Program sponsored project entitled "Life Improvement of Pot Hardware in Continuous Hot Dipping Processes"
    • Designed the first small lab-scale hot zinc wear test machine and characterized the wear characteristics of dozens of the most promising bearing materials for the designers of zinc pot bearings.
    • A new zinc pot roller bearing design allowed an order of magnitude increase in bearing life (10 fold) by simply changing its design and suspension. This idea was patented by Dr. John Loth for WVU as: US Patent No: 7,040,482, "Bearing Life Extender for Conveyor Type or Zinc Pot Rollers". Issued May 9 2006
  • U.S. DOE Industrial Technologies Program sponsored project entitled "Intelligent Potroom Operation"
    • The goals of the project were to develop systems for data mining to better understand the aluminum reduction process, to develop an instrumentation and data logging package for monitoring the behavior of four smelting pots and to identify opportunities for advanced process controls to improve the energy efficiency of the aluminum reduction process. While the project did not lead to a commercial product, Century did gain significant knowledge about their equipment and process to effect changes in the way the pots were operated and maintained.
  • U.S. DOE Industrial Technologies Program sponsored project entitled "Energy Efficient Process for Making Tackifier Dispersions used to Make Pressure Sensitive Adhesives"
    • The project resulted in a better understanding of some of the parameters that affect variation in Dyna-Tech’s current processes which has helped them make a more consistent product. In addition, work carried out by Dr. Sam Jody at Argonne National Laboratory has identified a process to pulverize resins to a very small particle size. Dyna-Tech is analyzing the results to determine if that process has potential to be commercialized.
    • This project led to a funded project from Kraft Foods Global entitled, "Food Emulsions" which runs from July 1, 2007 to June 30, 2008. The total value of the project is $73,655.
    • Dr. Sam Jody led development of market size and market penetration estimates, and used the DOE-developed CPAT software package to calculate projected energy savings expected to result from the "Tackifier Dispersions for Pressure-Sensitive Adhesives" project. Total estimated energy savings are 8.4 trillion Btu/year by 2030 based on displacement of solvent-based adhesives with aqueous dispersions.
  • Development of ENERGEX Software
    • Dr. B. Gopalakrishnan developed the ENERGEX software and successfully converted it from DOS Based System to Windows Based System Using Visual Basic Dot Net.
  • U.S. DOE sponsored project entitled "Roof Mapping using Roof Bolter Drilling Parameters"
    • A mine roof geology mapping system was developed (MRGIS) which monitors the roof bolter drilling parameter as it drills the roof bolt holes and determines the types of roof strata and any fractures. The system has undergone underground production testing and JH Fletcher is selling the system.
  • U.S. DOE sponsored project entitled "In Mine Validation of Method Determining Characteristics of Coal Seam using Electromagnetic Transmission"
    • The RIMTM Radio-Imaging Method uses wireless synchronization between a transmitter and remote imaging receiver to produce images of coal seams. RIM™ sends an electromagnetic wave through the subject area, detects differences in conductivity between coal and surrounding materials, and produces images of the geological strata.
    • This project on imaging ahead of mining with seismic technology was selected for a 2004 top R&D 100 award.
  • U.S. DOE sponsored project entitled "Demonstration of Crosswell Imaging Technology and Advanced Drillstring Radar Navigation for Horizontal Directional Drilling"
    • The innovative drill-string radar (DSR) technology identifies coal-rock boundaries to guide horizontal drilling in coal seams. In contrast to conventional gamma sensors, this radio-wave-based sensor withstands drilling vibrations and can be used for real-time control. DSR thereby reduces the energy, risk, cost, and time required for horizontal drilling. Used in more than five mines.
    • The Drill String Radar (DSR) was selected for a 2005 top R&D 100 award and the data transmission system received the 2006 R&D 100 award.
  • Wood Polymer Composites Research Program
    • Development of advanced technologies and processes for manufacturing high-strength, degradation resistant wood-polymer composite (WPC) materials. Markets for WPCs are projected to grow 20% to 25% annually over the next five years, thus offering good economic development potential for West Virginia.
  • U.S. DOE National Energy Technology Laboratory sponsored project entitled "Development of a Multi-Purpose Dynamic IGCC Model for an Energy-Intensive Industry Cluster"
    • An economic and technical assessment of the feasibility of using modern IGCC technology to supply steam, heat, electricity, and chemical feedstocks to clusters of energy-intensive industries, for example, PPG, Bayer, Columbian Chemicals, CLL Carbon and other companies in the Marshall County area was conducted.
  • U.S. DOE sponsored "Low-Cost Reliable Energy & Chemical Feedstocks for Energy-Intensive Industry Clusters: Feasibility Study of a Coal-Fired Co-Generation Facility in Marshall County, WV"
    • A series of five energy generation case studies were developed, ranging from conventional subcritical combustion units to advanced integrated gasification combined cycle (IGCC) technology. The economic feasibility of locating a new power plant to supply electricity, steam, and chemical feedstocks for the cluster of energy intensive industries in the Marshall County of West Virginia was assessed. Modest discounted rates of return for the IGCC, combustion/gasification hybrid, and conventional power plant configurations were found for plant lives of 20 years. The sensitivity of the results was seen to be relatively high for changes in the cost/price of electricity and natural gas and moderate for changes in the price/cost of coal. The results of the current study indicate that additional, more accurate, investigation into the feasibility of a new power plant in the Marshall County area of West Virginia is warranted.
  • U.S. DOE sponsored "Plant-wide Assessment at the Bayer facility in New Martinsville, WV"
    • The IOF-WV assessment team conducted a plant-wide energy assessment at the Bayer facility in New Martinsville, WV from March 2001 to June 2003. The table below details the recommendations that were implemented at the facility.

    Recommendation

    Energy Savings
    ( MMBtu/yr)

    Cost Savings
    ($/yr)

    Implementation
    Cost ($)

    Payback
    (months)

    Insulate pipes and surfaces

    14,326

    $69,480

    $5,780

    1

    Steam leaks reduction

    5,513

    $35,070

    $1,330

    1

    Install Variable Speed Drives
    on the Cooling Tower Pumps in the plant

    15,844

    $153,082

    $264,000

    21

    Repair compressed gas leaks

    66,056

    $ 329,976

    $10,000

    1

    Burner replacement savings

    74,836

    $362,955

    $390,000

    13

    Total

    176,575

    $950,563

    $671,110

    -

  • U.S. DOE sponsored "Plant-wide Assessment at Pechiney (now Alcan) in Ravenswood, WV"
    • The IOF-WV assessment team conducted a plant-wide energy assessment at the Pechiney (now Alcan) facility in Ravenswood, WV from March 2002 to November 2003. The team identified $2.5 million in annual energy savings with average payback of less than 8 months
    • The assessment identified numerous areas for energy savings to occur. Several of the team’s suggestions have been completely or partially implemented, including the following:
      • Turning off comfort heating furnaces in summer months and in places where they are ineffective ($1,014,000/year)
      • Burner tuning and maintenance ($692,000/year)
      • Repair of compressed air leaks ($112,000/year)
      • Turn off idle equipment ($16,000/year)
      • Improve annealing furnace operating practice and modify nitrogen plant control strategies to prevent waste of nitrogen. ($75,000/year)
  • U.S. DOE sponsored "Plant-wide Assessment at PPG Industries in Natrium, WV"
    • The IOF-WV assessment team is conducted a plant-wide energy assessment at PPG Industries in Natrium, WV.
    • The IOF-WV assessment team has estimated that 47,890,356 kWh/yr in electricity, 6,113 MMBtu/yr in Natural Gas, 270,332 Mlb/yr in steam and 28,188 tons/yr in coal would be saved by implementing the team’s recommendations. The total energy cost savings would amount to approximately $4,074,332/yr. The total estimated implementation cost is $4,552,277, which gives an average simple payback of 14 months.
    • The team identified $2.2 million in savings and has worked with them to on an implementation plan resulting in $1.7 million in implementation and there are on-going discussions with PPG to implement the remaining recommendations.
  • Energy Assessment at M&G Polymers
    • IOF-WV team made recommendations for process modifications within the polyethylene terephthalate process to reduce energy consumption. M&G implemented a project to preheat reactor feeds that will save 30 billion Btu’s of natural gas annually. Other opportunities included adjusting excess air settings on their hot oil furnaces to compensate for process nitrogen added to the combustion gases.
  • West Virginia Development Office Energy Efficiency Program sponsored "IOF-WV Energy Assessment Program"
    • The West Virginia Development Office Energy Efficiency Program sponsors energy/productivity assessments at energy-intensive West Virginia companies that are not eligible for IAC assessments.
    • The IOF-WV assessment team conducted a WVDO energy assessment at Steel of WV in Huntington, WV in May 2003. The table below details the energy savings that were implemented at the facility.

    Recommendation

    Energy Savings
    ( MMBtu/yr)

    Cost Savings
    ($/yr)

    Implementation
    Cost ($)

    Payback
    (months)

    Shut off natural gas flame
    in the ladle pre-heat area

    57,120

    $359,285

    $10,280

    1

    Preheat Combustion Air
    in Ceramic Recuperator

    43,168

    $271,527

    $42,410

    2

    Implement a motor management system

    16,939

    $128,510

    $500

    1

    Insulate the furnaces and tundish dryer

    11,039

    $69,435

    $1,796

    1

    Replace drive belts on large motors
    with energy efficient cog belts

    3,265

    $22,178

    $2,475

    2

    Switch off the three hand torches
    when not in use

    2,460

    $15,475

    $7,780

    6

    Close doors on furnace openings
    to reduce heat loss

    1338

    $8,416

    $1,100

    2

    Use synthetic lubricants in compressors

    1044

    $7,018

    $475

    1

    Repair compressed air leaks

    713

    $4,791

    $250

    1

    Replace the existing T12 lighting ballasts
    and bulbs with T8 bulbs with electronic ballasts

    134

    $1,606

    $5,179

    39

    Total

    137,220

    $888,241

    $72,245

    -

    • The IOF-WV assessment team conducted a WVDO energy assessment at Wheeling Nisshin in Follansbee, WV on March 22, 2005. The table below details the energy savings that were implemented at the facility.

    Recommendation

    Energy Savings
    ( MMBtu/yr)

    Cost Savings
    ($/yr)

    Implementation
    Cost ($)

    Payback
    (months)

    Insulate the Bare Pipes and Surfaces of the CGL

    16,362

    $115,516

    $10,894

    2

    Use Vortex Nozzles (Air Amplifiers)

    2,947

    $29,021

    $2,200

    1

    Replace Drive Belts with Energy Efficient Cog Belts

    1,543

    $15,187

    $1,444

    2

    Replace the 400W High Pressure Sodium Bulbs with 310W High Pressure Sodium Bulbs in the plant

    1,246

    $12,243

    -

    Immediate

    Repair Compressed Air Leaks

    953

    $9,355

    $1,025

    2

    Implement a Motor Management System

    1,329

    $9,241

    $2,080

    3

    Insulate the Bare Pipes and Surfaces on the Boiler

    690

    $4,871

    $1,469

    4

    Install Occupancy Sensors in Designated Areas

    128

    $1,234

    $1,500

    15

    Total

    25,198

    $196,668

    $20,612

    -

  • West Virginia Development Office Energy Efficiency Program sponsored "Wood Industry Assistance Program"
    • The West Virginia Development Office Energy Efficiency Program sponsors energy/productivity assessments for West Virginia wood products companies that are not eligible for IAC assessments.
    • The total recommended annual energy savings are 12.3 million Kwh for electricity and 104,989 MMBTU for Natural Gas, Wood, and Oil for 2003 to 2005.
  • West Virginia Development Office Energy Efficiency Program sponsored "Engineering Student Energy Intern Program (Projects with Industry)"
    • The West Virginia Development Office Energy Efficiency Program sponsors faculty-led student design projects at West Virginia companies.
    • A project conducted at Cytec Company has resulted in a research grant with the Forestry Service on using wood biomass as an alternate energy source.
    • Century Aluminum is implementing a robotic handling system that was developed through the Projects with Industry Program. The aluminum pots have copper anode bars that are brazed onto steel blocks. Century Aluminum was doing this by hand which was slow and costly. The student team designed a robotic system that would handle these parts in a conveyor system and then automatically put them in a jig for a robot welder.
    • GE Silicone is implementing energy recommendations for their lab hood developed through the Projects with Industry program. The laboratory building at GE Silicone plant in St. Marys, WV has 35 lab hoods exhausting thousands of cfm constantly. The student team demonstrated that a great energy savings could be had by properly adjusting the lab hood sashes by the technicians in the lab. This could be immediately accomplished through training the technicians. In addition, the student team designed a permanent control system that would automatically adjust the lab airflow with the potential to save over $200,000 per year.
  • West Virginia Development Office sponsored "Glass Industry Assistance Program"
    • The West Virginia Division of Energy sponsors faculty-led student design projects at West Virginia companies. An IOF-WV student team conducted a Glass Industry Assistance Program assessment at Wissmach Glass. Wissmach is implementing the team’s recommendations by installing automated doors on their glass melting furnaces, installing new burners and recuperators on several furnaces, and installing new, modern controls on all of the furnaces.
    • We estimate the savings due to these measures at >$30,000 /year
    • Marble King has installed a recuperator on their glass furnace and is also installing a door on the "dog house". The savings from these recommendations are estimated to be $35,000 per year.
  • Industry sponsored project entitled "Implementation of Energy Recycling in West Virginia"
    • IOF-WV is partnering with Recycled Energy Development LLC to develop energy recycling projects with West Virginia companies. The team will develop strategies, technical roadmaps, consortia and partnerships to promote industrial energy efficiency in West Virginia and the region. Recycled Energy plans to invest $45 million to $55 million for a hot exhaust recycling system at West Virginia Alloys
  • Industry sponsored project entitled "Beneficial Reuse of Spent Foundry Sand"
    • Industry-led project on development and implementation of the new WV DEP guidelines on beneficial reuse of spent foundry sand in other applications such as construction and asphalt. The guidelines became effective June 1, 2000. To date one company has saved more than $950,000.
  • U.S. DOE BestPractices and other energy efficiency workshops
    • IOF-WV has hosted numerous energy efficiency workshops where attendees learn about energy efficiency and BestPractices and take those tools back to their plants to save energy and make their process more efficient...
      • October 4, 2007 "Process Heat Workshop" at the Robert C. Byrd Institute in Huntington, WV
      • May 10, 2007 "Industrial Energy Efficiency Measures" at the WVU National Research Center for Coal & Energy, Morgantown, WV
      • November 8, 2006 "Waste Heat Recovery Workshop" at the Marriott Hotel and Conference Center, Charleston, WV
      • November 7, 2006 "Reducing Natural Gas Costs in Industry" at the Marriott Hotel and Conference Center, Charleston, WV
      • March 9, 2006 "Industrial Efficiency Initiative: Save Energy, Maximize Profits", National Satellite Teleconference, at the WVU National Research Center for Coal & Energy, Morgantown, WV
      • April 11, 2006 "Natural Gas Efficiency Workshop" presented by the WVU Industrial Assessment Center at the WVU NRCCE in Morgantown, WV. The workshop will present natural gas savings in process heating, furnaces, ovens, boilers and steam systems, NG savings by insulation using 3E Plus, PHAST BP tool, and Steam System Suite BP tool.
      • May 17, 2006 "Process Heat Workshop" presented by the U.S. DOE BestPractices at the WVU Parkersburg Caperton Center for Applied Technology, Parkersburg, WV. The Process Heat Workshop includes basic instruction in the physics and chemistry of combustion and heat transfer, as well as tutoring in methods for analysis of energy efficiency of various processes and equipment. Technological improvements in combustion and heat transfer equipment will be discussed, and participants will be trained in the use of the DOE PHAST computer program for analysis of process heating systems.
      • November 9, 2006, "How to Cut Costs and Increase Productivity through Efficient Use of Energy, Waste Minimization and Best Practices" presented by the Industrial Assessment Center Workshop at the 2006 IOF-WV Symposium in Charleston, WV. This workshop will feature energy efficiency opportunities available through the WVU IAC and the DOE
      • November 2006 "Benefits of Lean Manufacturing" presented by the WVU Manufacturing Extension Partnership at the 2006 IOF-WV Symposium, Charleston, WV.
      • November 10, 2005 "Steam Training Workshop" presented by the U.S. DOE at the Dow Tech Center in Charleston, WV
      • November 8, 2005, "How to Cut Costs and Increase Productivity through Efficient Use of Energy, Waste Minimization and Best Practices" presented by the Industrial Assessment Center at the 2005 IOF-WV Symposium in Charleston, WV
      • April 5, 2005, "Fundamentals of Compressed Air Systems" presented by the U.S. DOE at the PPF Industries facility in New Martinsville, WV
      • October 27, 2004, "Industrial Energy Assessment Workshop – Get more product per BTU" presented by the WVU Industrial Assessment Center at the 2004 IOF-WV Symposium in Morgantown, WV
  • Implementation promotion activities
    • The WVU Industrial Assessment Center provides information on implementation of energy saving recommendations by interacting with the company personnel on the day of the assessment and subsequent periodic phone calls and visits where they discuss with them the various implementation benefits and strategies.