1. Energy Reduction
Increased efficiency of
steam generating
system at FHDY

2. Options explored
2008
1. BURNER – MANAGEMENT and FLAME SAFE GUARD
SYSTEM (RM 7895) 2008
– Install pressure controllers to manage steam
– Install VFD drives for burner blower
– Efficiency gains 10 to 12 %
2. Reduced steam pressure form 225 to 160 psi
– Could still be implemented
– Estimated savings $ 20K annual
– Production

3. Options explored
3. Replace two exiting boilers (450 HP) with
one 350 HP unit
– ROI: 4 years
4. Decided to conduct an accurate assessment
and establish windows of opportunity
– In service efficiency study 2010

4. Base line
 Energy Assessment completed on line 1
– Results
 Average HP 32.3
 Peak HP 98.8
 Gas cot saving 45.9 %
 Electricity and water savings 10 %
– CO2 savings: 422 ton/year

5.  Explored central boiler room
Drum pad 1
LAB
Bldg 2Bldg 4
S
c
a
l
e
BLDG 5
Warehouse
Office
Office
Bldg 1
Line # 1
Line 1
tanker
pad
PSA
Line
1
Tank
Farm
Bldg4
Tanker
Pad
Hazardous
waste drum
pad
BLDG 6
Line 3 Line 2
BLDG 6
Tank Farm
BLDG 8
Tank Farm
BLDG 7
Cooling Tower
I
s
o
T
a
n
k
e
r
s
t
o
r
a
g
e
N
MCC 2MCC 3
Hot oil unit
Manufacturers Rd
Parking
Parking
Emergency Shutdown
7" 7"
New
boiler
room
Phase I

6. Efficiency study Bldg 6
Measurement Value
In-Service Efficiency 71.6%
Expected Gas Saving Rate 12.7%
Average HP 76.55
Load in % of Boiler Capacity 25.6%
Max HP 201
Min HP 65
CO2 Saving in tons per year 201.1

7. Measurement Bldg 1 Bldg 6 Average
In-Service Efficiency 43.8% 71.6% 57.7%
Expected Gas Saving Rate 46.7% 12.7% 29.7%
Average HP 31.3 76.55 53.9%
Load in % of Boiler Capacity 20.9% 25.6% 23.2%
Max HP 96.35 201 66%
Min HP 10 65 37.5

8. Solution
 Install Two 200 HP EXG
 Locate in existing boiler room
 Install piping to connect buildings

9. Drum pad 1
LAB
Bldg 2Bldg 4
S
c
a
l
e
BLDG 5
Warehouse
Office
Office
Bldg 1
Line # 1
Line 1
tanker
pad
PSA
Line
1
Tank
Farm
Bldg4
Tanker
Pad
Hazardous
waste drum
pad
BLDG 6
Line 3 Line 2
BLDG 6
Tank Farm
BLDG 8
Tank Farm
BLDG 7
Cooling Tower
I
s
o
T
a
n
k
e
r
s
t
o
r
a
g
e
N
MCC 2MCC 3
Hot oil unit
Manufacturers Rd
Parking
Parking
7" 7"
New Steam
piping

10. Performance
Boiler nat gass usage (therms)
-
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
Jan
Feb
M
ar
Apr
M
ay
Jun
Jul
Aug
Sep
O
ct
N
ov
D
ec
2011
2012
2013
New boilers installed 4/5/2012

11. Opportunities
 Approximately $450,000.00 Savings / 2 Years
 95% Reduction in Maintenance Costs / 2 Years
 Perfect Continuance of Recent Green Efforts
 Approximately 1,400 tons C02 Savings / 2 Years
 Plant Now Operates Under EPA 10MMbtu Mandate
 100% Backup for Entire Current Plant Load
 Plant Easily Scaled for Future Expansion
 Consolidated Steam Plant – Maintenance / Costs
 Corporate Leader With a Corporate Showcase