pollution prevention intern january: intercession, intern applications due • february: select...
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2017 Pollution Prevention(P2) Intern ProgramKansas State UniversityPollution Prevention Institute
Roadmap
• Contact info• Background• Purpose• Company focus• Intern focus• Impacts (through 2016)• Host Companies list• 2017 projections• P2 projects• Recap• Important Dates
Contact InformationApplications due December 8
http://www.sbeap.org/intern-program
Background
• Twelfth year of program (2006 pilot year)• EPA pollution prevention grant• Partnership with KDHE, Engineering Extension, other state/county
offices
Sustainability
Economy
EnvironmentSociety
Purpose
Reduced Emissions & Waste
Engineering &Environmental
Science
University Students
Business & Industry
Company Focus:
Company Focus: Tyson Fresh Meats, Inc.
• Corporate-wide goals:• Reduce 2020 water consumption by 12% from 2015 baseline• Reduce 2020 energy consumption by 3% from 2015 baseline
• Plant-specific goal:• Be landfill-free by 2030
• Other considerations:• Processes that appear to create product loss• Aging facility• Time constraints
Why interns?
1.Time to tackle projects2.Fresh pair of eyes/someone to ask “why?”3.Gives a place to start
Intern Focus:Carolyn Countess“I gained knowledge about an actual working environment as opposed to a school setting.”
“The professional advice and experience given by my supervisor changed my perspective about fulltime engineering jobs.”
Best part of internship:“I was actually getting
work done”
Real-World Impacts
• Water conserved• Waste diverted• Energy saved• Dollars saved• Emissions reduced
Environmental Impacts for Recommended ProjectsWater
(106 gallons)Solid Waste
(tons)Energy(MWh)
Operating/disposal(cost x106)
Greenhouse Gases (MTCO2e)
2006 — 1,025 1,533 $0.40 1,089
2007 25.4 5,506 7,066 $1.50 5,079
2008 187.1 1,707 26,019 $3.50 18,921
2009 9.9 6,720 8,705 $0.90 6,207
2010 22.2 585 6,158 $1.20 7,080
2011 6 318 5,723 $0.60 3,996
2012 11.8 126 6,548 $0.70 2,608
2013 7.8 519 4,322 $1.80 4,260
2014 — — 487 $0.05 346
2015 10.2 — 2,859 $0.40 2,843
2016 321.6 226 8,330 $1.00 11,000
Total 602 16732 77750 $12.05 63,429
Types of Projects (as of 2015)
• 249 projects• Energy – 139 (65%)• Water – 50 (20%)• Waste – 44 (18%)• Natural Gas – 10 (4%)• Chemical Replacement – 1 (0.4%)• Diesel – 1 (0.4%)
• Energy-related Projects – 199 (80%)
Host Companies*companies participating multiple years
Advantage Metal Recycling
Associated Purchasing ServicesAssociated Wholesale Grocers
Bombardier Learjet
Biosecurity Research InstituteCapstan Ag, Inc.
CertainTeed
Coleman Company, Inc.*Columbian Chemical Company
Compass Minerals*
CST Storage*Deffenbaugh Industries
Dillons Food Stores*
Florence ManufacturingFrito-Lay*
Frontier El Dorado Refining Co.
Gates Corporation*Grandview Products
GTM Sportswear
Haldex Brake*Hallmark Cards
Henke Manufacturing
Johnson Controls Inc.Johnson Co. Community College
Johnson Co. Dep. Health/Env.
Kansas Army National GuardKansas State University
Kickapoo Tribe
Madonna Rehab. HospitalMercy Regional Health Center*
The Monarch Cement Company
Philips LightingPrairie Band Potawatomi Nation
Robbie Fantastic Flexibles
Schwan's Global Supply*Smithfield Foods
SPX Cooling Technologies Inc.
Tyson Fresh Meats, Inc.Unilever Foodsolutions
VA Eastern KS Healthcare System
Via Christi*Webco Manufacturing, Inc.
Wolf Creek*
and others
2017 Internship: Preliminary Data
3300 MWh electricity30,000 MMBTU natural gas1480 tons solid waste53.5 million gallons water
$734,2605938 MTCO2e
Intern Focus:Carolyn CountessIndustrial/Manufacturing Systems Engineering,Kansas State University
What have you learned?“Doing things to improve environmental impact actually saves a company money, sometimes.”
Worst part of internship:“Waiting for vendors”
Compressed Air Leak Audit
• UE Systems• Ultrasonic Leak Detector
• Ultraprobe 9000• Spread sheet
• Found 18 leaks• 64,916 kWh/yr.• 82.9 MTCO2e Diverted• Est. annual cost of air leaks: $9,444
• Recommend bi-annual leak audits
Heater vs. Heat Exchanger• Need a new Washer System• Currently Using a Tank Heater• Recommendation
• Plate-and-Frame Heat Exchanger
• Estimated Savings• 12,091 MMBTU/yr.• $52,000/yr.• 643.34 MTCO2e
• 2 yr. Payback Period
Image provided by: http://www.alfalaval.us/microsites/gphe/types/semi-welded/
E-Room Energy
• Cooled Air Escapes through Two Parts Doors• Air Conditioner Constantly Runs
• Recommendations• Install a Door
• 223,488 kWh/yr.• $20,114/yr.
• Install an Air Curtain
43%57%
Paint Line UsageTimeRunning
Time NotRunning
E-Room Energy: Air Curtain• How it works
• Emits a Stream of Air Creating a Seal
• Possible Savings• 77,628 kWh/yr.• $6,986/yr.
• Temporary Solution• Automatic Door System Would be Better• Can be Relocated
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Curing Oven Technology
•Increase Line Speed from 8fpm to 12fpm•Use Natural Gas
Curing Oven Technology
Curing Oven Technology
•Recommend Infrared/Convection Combination• Estimated Savings
• 6,912 MMBTU/yr.• $30,137/yr.• 367.77 MTCO2e
•Secondary Recommendation• Update Insulation
Top Coat Oven Surface Temp
Offset Paint Addition• Offset Paint Area
• Used when Parts are too Large for the Normal Line
• Issue• Explosive Tendency Due to Lack of
Oxygen
• Solution• Add Exhaust System
Reduction Estimates by Project
• Total Estimated MTCO2e Reduction: 1,388.54
Program Elements
• Pollution prevention training at K-State(Industrial Sustainability, Jan. 8–11 & May 22–25)
• Placement x 10 weeks• Support
• Technical assistance• Site visit• Listserve
• Equipment
• Intern retreat• Final reports and presentations
Costs to company
• $17/hour, plus fringe • $7,480 (assuming 40 hrs./wk.*11weeks)• Charged only for hours worked (verified by company)
•Sept. 15: 2017 Intern Presentations to EPAHosted at K-State, ZOOM at www.sbeap.org
•Nov. 3: Food Processor Round Table
•Nov. 10: Informational webinar
•Dec. 8: Industry application deadline
A Look at 2018
• January: Intercession, intern applications due• February: select interns, pair w/host companies
Applications due December 8, 2017• March: confirm interns, preliminary site visits• Late May – Early Aug.: interns with host companies• Late June: intern retreat (1 day of progress report outs)• Late July: draft report• Early August: final report• Mid-September: EPA presentations at K-State
Questions or recommendations?
Applications due December 8http://www.sbeap.org/intern-program