Utilities Optimization
Energy savings and utility cost reductions are key to increasing profitability. In virtually every industry, utilities account for a high percentage of the monthly operating budget. If your plant is a heavy energy user or generates its own steam or electricity, you probably feel enormous pressure to find a solution for energy cost reduction. But even if you actively try to promote energy savings, it can feel like wasted effort — it simply takes a lot of power to run your business.
Fortunately, advances in technology make it possible for plants to experience energy efficiency savings in many ways. MAVERICK Technologies can help you identify utility optimization opportunities and act on them. We work with small, midsize and large plants in all industries, but particularly in the areas of oil and gas; chemical and petrochemical; pulp, paper and wood; and food and beverage. With years of experience in industrial energy efficiency, we have delivered significant energy cost reductions for our clients through improved boiler efficiency and other enhancements. You'll experience maximum savings because we apply our enterprise-wide knowledge of industrial automation industrial automation, business intelligence and enterprise services to every project.
MAVERICK's utilities optimization services will help you:
- Evaluate your energy usage and opportunities for utility cost reductions through a utilities optimization study.
- Pinpoint energy usage inefficiencies and identify solutions for reduced overall plant energy consumption and increased energy efficiency savings.
- Reduce energy demand and the costs of meeting that demand, cutting your overall operating budget.
- Optimize steam generation, electric power generation and cogeneration processes.
- Optimize plant refrigeration (chilled media) generation, distribution and utilization.
- Improve the use of waste heat recovery.
- Optimize plant instrument air and service air generation, distribution and utilization.
- Apply real-time calorimetry and heat rate monitoring in BTU / unit of production for improved industrial energy efficiency.
- Study the cost of generating power in-house versus purchasing it.
- Optimize the use of thermal heat sinks such as cooling towers, lakes and reservoirs.
- Minimize your carbon footprint through industrial energy reduction.
Partner with MAVERICK to optimize your utilities and perform at your best.
Utilities Optimization Study
Think of how much you currently spend on utilities. Then imagine reducing this amount by 5 percent. Or 10 percent. Or even 20 percent. Now think of all you could do with those energy efficiency savings. You could invest in automation improvements on the plant floor, system upgrades, further product development, additional resources, training or any number of other capital expenditures. MAVERICK's utilities optimization study makes it all possible. You'll improve your overall plant energy efficiency, reduce your operating costs and experience a fast payback. All of our optimization studies have identified returns that exceed the cost of the study.
Energy flow is both a challenge and an opportunity for improved cash flow management. Make it your opportunity for significant savings. A team experienced in your industry will apply our expertise in utilities optimization to your business in order to deliver measurable results. The cost of the study can be rolled into ROI payback calculations for the recommended improvements, which may range from minor changes to major systems modifications.
We'll begin with identification and mutual agreement on the scope of the study. The typical utility optimization study comprises six steps:
- Onsite evaluation — We'll review the way your systems are operated and maintained. The process involves direct observation and interviews with operating and maintenance staff to understand how the facility operates on a daily basis. Then we'll review the operating data to understand how much energy your facility uses weekly, monthly and annually.
- Inspection — Our team will inspect your systems and review available system documentation to determine adequacy of instrumentation, operating efficiency, controllability and reliability.
- Testing — We'll utilize available historical operating data and conduct testing as needed to determine unit efficiencies and the actual flow of purchased / generated thermal and electric energy throughout your facility.
- Calculation and cost analysis — We'll analyze the collected data and determine which modifications will help save you money, and how much.
- Documentation — You will receive a report containing a summary of our findings, a detailed cost-benefits analysis and all of MAVERICK's expert short- and long-term recommendations for specific improvements that will reduce your energy costs.
- Change Implementation — MAVERICK stands ready, willing and able to partner with you as your agent for change, implementing fixed-price projects that accomplish any or all of the recommendations in the utilities optimization report.
Don't miss your opportunity to significantly reduce your operating budget. Reducing energy usage is not only a more responsible way to operate your business, but it will improve your profitability and set you apart in the marketplace.
Utilities Optimization Case Studies
MAVERICK Technologies works with manufacturing and process facilities across all industries to reduce the cost of thermal and electric energy generation, distribution and consumption. Read some of our case studies below.
Utilities Optimization for a Prominent Plastics Manufacturer
After installing new boiler combustion controls, this manufacturer had trouble tuning them and maintaining boiler efficiency due to high exhaust temperatures. MAVERICK thoroughly tested the boilers and recommended adding flue gas recirculation and economizers and repairing the condensate return systems to improve unit efficiency. The team also suggested implementing a steam-powered hot water tank heater to eliminate cleaning labor, as well as vacuum centrifuge technology to increase production, product consistency and efficiency of the product drying step, reducing overall energy use. The projected payback period for the tank heater recommendation was under six months due to the labor savings alone.
Municipal Utility Unit Controls Implementation
MAVERICK provided concept design, systems engineering, integration and startup support to help GE retrofit DCS controls for municipal electric power generating units at the city of Alexandria, LA. This was the first application of a GE Mark VI DCS to conventional multiburner boiler systems. Separate coordinated combustion control systems (CCS) and burner management systems (BMS) were provided for each boiler / turbine generator. The new combustion control strategy improvements that MAVERICK provided as part of the CCS significantly improved operating efficiency and reliability for these generating units.
Utilities Optimization for a Large Midwestern Brewery
MAVERICK conducted a thorough survey of this brewery and recommended changes related to utility systems design, control strategy and daily operating methodologies in order to improve efficiency, reduce utility consumption and shorten the ROI for the plant’s new control system. The project aimed to achieve cogeneration of at least 50 percent of demand and to improve condensate recovery by 2 percent. Even though this plant already operated with extremely sophisticated systems, MAVERICK was able to identify opportunities to reduce demand by up to 5 percent and to save up to $91,000 per year.
Boiler Replacement for a Prominent Plastics Manufacturer
Through a utilities optimization study, MAVERICK identified numerous opportunities for improving condensate return, reducing boiler emissions, minimizing heat energy loss and improving steam utilization. Because these improvements would reduce the cost of steam and improve the reliability of steam generation, MAVERICK became the customer’s agent of change to procure and install a new steam boiler. For this project, MAVERICK provided a turn-key design to replace two worn boilers with a new more efficient unit. Services included writing the procurement specs, assisting with bid evaluations, demolition planning, installation supervision and new instrumentation design and procurement. MAVERICK also designed and installed the new boiler BMS system and was awarded a contract to replace the BMS systems on two other boilers.
Find additional utilities case studies in our project gallery. >
Utility Optimization Resources
Explore the links below for more information on industrial energy efficiency and utility cost reductions for your facility.
Energy Information Administration — Energy Savings
Find links for energy-savings tips.
Energy Tips — Steam
Benchmark the fuel cost of steam generation.
Flex Your Power — Industrial Energy Saving Tips
Flex Your Power is California's statewide energy efficiency marketing and outreach campaign.