Achieving "Superior Energy Performance"

This Webinar, sponsored by South Texas Section of the AIChE, Texas Industries of the Future and AIChE Center for Energy Initiatives, was presented at the 15th Texas Industrial Energy Management Forum. It presents what the Texas plants learned about implementing an energy management system and demonstrating energy performance improvements—the benefits, the barriers, and the lessons learned.

The Superior Energy Performance is a national site-based energy efficiency certification program that was launched in 2011. The program is organized around ISO 50001.

Superior Energy Performance was piloted from 2008 to 2010 in Texas by four plants: Cook Composites and Polymers, Houston plant; Freescale Semiconductor, Inc., Oak Hill plant; Owens Corning, Waxahachie plant; and Union Carbide (a subsidiary of Dow Chemical Company), Texas City plant. The plants provided substantial input into the design of the program, as did other end-users on the US Council for Energy-Efficient Manufacturing. The four plants saw verified energy performance improvements from 6.5% to over 15% over a two to three year period.

Moderator

Michael Gromacki

Vice President of Operations / Chief Sustainability Officer

Dixie Chemical Company, Inc.

Presentations

“The Future of Energy Management: ISO 50001 and Superior Energy Performance”

Paul Scheihing, U.S. Department of Energy, Industrial Technologies Program

Mr. Scheihing will present the status of Superior Energy Performance, a national energy-efficiency certification program that was piloted in Texas. He will also describe the forthcoming international standard for energy management, ISO 50001 and its relationship to the Superior Energy Performance certification program.

“Implementation of Superior Energy Performance at a Semiconductor Fab”

Mark Krawczyk, Freescale Semiconductors, Inc.

Freescale integrated energy management into their existing environmental, health and safety management system based on ISO 14001 and OHSAS 18001. The energy management system helped transform the emphasis from efficiency at the project level to focusing on improving key performance indicators (KPIs) developed to monitor the operation of major energy using plant systems. KPIs are used for continual improvement of energy efficiency in central utility plant and at point of use in manufacturing.

“Implementation of Superior Energy Performance at a Small Batch Chemical Plant”

Deb Magoon, Cook Composites and Polymers, Inc.

Ms. Magoon leads Cook Composites and Polymers Co (CCP) Integrated Management Systems which includes health, safety, environmental, quality and now energy. She will provide her perspective on integration of the energy management system into existing systems, creating an effective balance of plant involvement and corporate support. CCP leveraged its experience in the Texas pilot project at the Houston plant to develop a corporate program on energy management.

“Implementation of Superior Energy Performance at an Insulation Plant”

Michele Mazza, Owens Corning, Building Materials Group Energy Leader

This presentation shares first-hand experience of implementing a Management System for Energy and Superior Energy Performance by the Owens Corning Waxahachie, Texas plant. At the time that the plant volunteered for the Texas Pilot Program, the Owens Corning - Waxahachie plant was considered a large plant with a mature energy program - large, due to their actual size and energy consumption; and mature, due to the company/plant’s structure and process for energy, which was already imbedded within the organization. The presentation discusses the resources required during implementation, identifies external and internal challenges faced during implementation, outlines the benefits a large, mature company should realize from implementing such a program, as well as the challenges the Owens Corning – Waxahachie plant faces going forward.

Panel Discussion

Mark Krawczyk, Freescale Semiconductor

Deb Magoon, Cook Composites and Polymers

Michele Mazza, Owens Corning

Dave Hake, Dow Chemical