Industrial Assessment Center (SFSU) ENERGY CONSERVATION & WASTE MANAGEMENT ASSISTANCE FOR INDUSTRY A U.S. DEPARTMENT OF ENERGY SPONSORED PROGRAM ENGERGY REPORT PRESENTATION Presentation Date: June 13 th 2006

IAC-SFSU The IAC program is funded by the U.S. Dept. of Energy (Founded 27 years ago) and managed by Rutgers University New Jersey. San Francisco State University has been part of this project since 1992 The IAC at San Francisco State University is one of the 26 centers established in universities across the country.

What Does IAC Do National goals: to reduce energy consumption, minimize waste generation, and increase productivity efficiency Provide cost free engineering assessments Specifically targets small to medium sized manufacturers within 150 miles of San Francisco in Northern California The analyses include payback period calculations

IAC Faculty-Student Teams Faculties are experienced in energy and industrial waste related subjects. Dr. Ahmed Ganji – IAC(SFSU) Director – Head of the Mechanical Engineering Department Dr Shy-Shenq Liou – IAC(SFSU) Assistant Director – Director of School Of Engineering A group of students both graduate and undergraduate in electrical and mechanical Engineering working with this program. Graduate Student Engineers: Amit Kanungo, Kar Ying Thomas Chan, Ivan Zhao, Crystal Vines, Vishwanadh Undergraduate Student Engineers: Aren Hofland, Sasha Spoor, Yin Yin Wu, Harpreet Singh, Austin Chin

Audited Facilities 1 st Audit Location: South San Francisco, CA 2 nd Audit Location: San Jose, CA 3 rd Audit Location: Redwood City, CA

NO. 306 ASSESSMENT Location: South San Francisco, CA PRINCIPAL PRODUCTS: Asphalt S. I. C. CODE: 2951 N.A.I.C.S CODE: ASSESSEMENT DATE: 03/10/05 REPORT DATE: 05/31/05

Summary of Recommendations ECO No. Description Total Cost Savings ($/yr) Resource Conserved Impl. Cost ($) Simple Payback Period (years) 1. Change the E19S Rate Schedule to A10S 25,577Electricity100Immediate 2. Repair Air Leaks 847Electricity0Immediate 3. Tune the Thermal Oil Heater 8,056Natural Gas1, Insulate Bare Oil Heater Lines 1,779Natural Gas Replace Incandescent Lighting with Compact Fluorescent and Install On/Off Switches for Lighting in Tunnel Area 1,805Electricity Use a Blower Instead of Compressed Air 5,040Electricity4, Replace Quartz Lamps with Metal Halide Lamps 1,055Electricity1, Install Premium Efficiency Motors 856Electricity1, Overall Savings/ Simple Payback Period45,01510,0490.2

ECO No. 1: Change the E19S Rate Schedule to A10S Cost Savings$25,577 /yr processing charge $100 Simple Payback Immediate E19S ~ 1,000 kW maximum demand A10S -- less than 500 kW maximum demand

ECO No. 2: Repair Air Leaks Inspect and tighten loose fittings and valves of the compressed air lines on a monthly basis to reduce the compressed air leaks. Electricity Cost Savings $847 Maintenance Cost Included in Cost Saving Simple PaybackImmediate

ECO No. 3: Tune the Thermal Oil Heater Adjust the combustion system air-fuel ratio on the facility’s 2.25 MMBtu/hr thermal oil heater in order to realize higher heater efficiencies and natural gas energy savings. With 15% excess air, the oil heater efficiency is expects to be about 82 %. Natural Gas Savings $8,056 Implementation Cost $1,000 Simple Payback 0.1 year

ECO No. 4: Insulate Bare Oil Heater Lines Insulate the hot surfaces of the thermal oil heater lines. Natural Gas Cost Savings $1,779 Implementation Cost$244 Simple Payback0.1 yr

ECO No. 5: Replace Incandescent Lighting with Compact Fluorescent Replace 75-watt, 90-watt, 100-watt, 135-watt and 150-watt incandescent lighting with 20- watt, 24-watt, 26-watt, 42-watt and 42-watt compact fluorescent lighting to reduce energy consumption. Additionally, install a switch on top of the tunnel ladder to turn off the lights. Electricity Cost Savings $1,805 Implementation Cost$821 Simple Payback0.5 yr

ECO No. 6: Use a Blower Instead of Compressed Air Replace the compressed air that is used for removing debris from the underside of the conveyor from the raw material train with a medium pressure air blower. A blower could provide lower pressure air through larger nozzles to produce same amount of air flow rate. Electricity Cost Savings $5,040 Implementation Cost$4,802 Simple Payback1 yr

ECO No. 7: Replace Quartz Lamps with Metal Halide Lamps Replace the six existing 500 watts Quartz fixtures and lamps with 250 watts high efficiency metal halide fixtures and lamps to reduce the energy consumption. Additionally, install a bi-level controller for the MH lamp in the tunnel area to reduce lighting energy usage. Electricity Cost Savings $1,055 Implementation Cost$1,633 Simple Payback1.6 yr

ECO No. 8: Install Premium Efficiency Motors Install Premium efficiency electric motors to replace the existing standard motors currently used at this facility. Depending on the horsepower rating of a given premium efficiency motor, operating efficiencies may be from 1% to 10% higher than the operating efficiencies of the existing motors. Second Year Total Electricity Cost Savings $ 856 Two Year Incremental Cost Premium $ 1,423 (with PG&E Rebate) Incremental Payback Period 1.7yr

Summary – South San Francisco Plant Baseline Energy Usage Energy Usage After Implementation Reduction (%) Electric Energy (kWh) 933,120858,52174,5998% Natural Gas (MMBtu) 71,13269,6911,4412% Total Utility Costs ($/yr) $ 661,344616,32945,0156.8%

NO. 315 ASSESSMENT Location: San Jose, CA PRINCIPAL PRODUCTS: Asphalt, Concrete S. I. C. CODE: 2951, 3273 N.A.I.C.S CODE: , ASSESSEMENT DATE: 07/07/05 REPORT DATE: 09/23/05

Summary of Recommendations ECO No. Description Total Cost Savings ($/yr) Resource Conserved Impl. Cost ($) Simple Payback Period (years) 1.Repair Air Leaks2,293Electricity0Immediate 2.Insulate Bare Thermal Oil Heater Lines2,801Natural Gas Replace Incandescent Lighting with Compact Fluorescent and Install On/Off Switches for Lighting in Tunnel Area 4,328Electricity1, Insulate Bare Dryers16,750Natural Gas8, Install Daylight Sensors to Save Energy in Certain Area 724Electricity Reduce Compressed Air Pressure2,560Electricity2, Replace Standard V-Belts with Cog- Type Belts 1,805Electricity1, Change the E19S Rate Schedule to E19P19,997Electricity25, Install Lighting Occupancy Sensors in Offices and Twist Timer in Maintenance Rooms 1,185Electricity2, Install Premium Efficiency Motors7,138Electricity16, Replace Air Vibrator with Electric Vibrator 388Electricity1, Overall Savings/ Simple Payback Period59,96958,9411.0

ECO No. 5: Install Daylight Sensors to Save Energy in Certain Area Install daylight sensors (photocell) in various areas to reduce lighting energy usage. To turn off lights automatically during the daytime when enough natural light is available. Electricity Cost Savings $724 Implementation Cost$468 Simple Payback0.6 yr

ECO No. 6: Reduce Compressed Air Pressure Reduce energy consumption by lowering the air compressor’s operating pressure from 124 psig to 110 psig in the asphalt plant and install extra compressed air storage. Electricity Cost Savings $2,560 Implementation Cost$2,311 Simple Payback0.9 yr

ECO No. 7: Replace Standard V-Belts with Cog-Type Belts It is suggested that cogged V-belts be installed on all equipment that is currently using standard type V- belts. According to the U.S. Department of Energy’s Industrial Technologies Division study, cog-type belts run cooler, last longer and have an efficiency that is 2% greater than equivalently rated V-belts. Electricity Cost Savings $1, 805 Implementation Cost$1,076 Simple Payback1.0 yr

ECO No. 8: Change the E19S Rate Schedule to E19P The Schedule E19P service offers lower energy and demand costs. However, this will require the purchase and maintenance of the transformer (step down transformer) at a substantial cost. Furthermore, the electric utility company will no longer be responsible in the event of transformer failure. The E19S delivers power at the secondary voltage and the E19P delivers the power at the primary voltage. These voltages are 480 volts and 12,000 volts, respectively. Power supplied at the higher voltage is available at a lower cost. The higher voltage is reduced with a transformer before the facility uses it. Electricity Cost Savings $19,997 (10.7% of current total annual electric cost) Implementation Cost $25,300 Simple Payback 1.3 year

ECO No. 9: Install Lighting Occupancy Sensors in Offices and Twist Timer in Maintenance Rooms The savings are realized by installing occupancy sensors. Lights will turn off automatically when these areas have been unoccupied for an extended period of time. Electricity Cost Savings $1,185 Implementation Cost$2,421 Simple Payback2 yr

ECO No. 11: Replace Air Vibrator with Electric Vibrator The air vibrator uses compressed air and then expels it to the atmosphere. Similar to an air leak, this is essentially wasted air that is fairly expensive to produce. This wasted compressed air represents lost compressor horsepower, which translates into increased energy usage for the plant operation. Electricity Cost Savings $388 Implementation Cost$1,032 Simple Payback2.7 yr

Summary – San Jose Plant Baseline Energy Usage Energy Usage After Implementation Reduction (%) Electric Energy (kWh) 1,516,2401,383,894132,3468.7% Natural Gas (MMBtu) 46,74744,1782,5695.5% Total Utility Costs ($/yr) $ 637,711$577,742$59,9699.4%

NO. 322 ASSESSMENT Location: Redwood City, CA PRINCIPAL PRODUCTS: Asphalt, Emulsion S. I. C. CODE: 2951 N.A.I.C.S CODE: ASSESSEMENT DATES: 10/20/05 REPORT DATE: 01/26/06

Summary of Recommendations ECO No. Description Total Cost Savings ($/yr) Resource Conserved Impl. Cost ($) Simple Payback Period (years) 1.Repair Steam Leaks7,560Natural Gas0Immediate 2.Insulate the Dryers19,058Natural Gas11, Change the E19S Rate Schedule to E19P31,440N/A29, Install Premium Efficiency Motors2,290Electricity2, Insulate Cylinders and Bare Condensate Return Lines 1,643Natural Gas1, Install Variable Frequency Drives on the Dust Collectors’ Fan Motors in the Continuous Mix Line 19,762Electricity24, Install Daylight Sensors to Save Energy in Certain Area 237Electricity Replace MH-400 With MH-360 High Efficiency HID Lamps 509Electricity1, Install Variable Frequency Drive on the Burner’s Blower in the Continuous Mix Production Line 4,680Electricity15, Replace Standard V-Belts with Cog-Type Belts 527Electricity1, Overall Savings/ Simple Payback Period87,70688,9621.0

ECO No. 1: Repair Steam Leaks Inspect and repair fittings and valves of the steam piping on a bimonthly basis to reduce the steam leaks. By fixing the steam leaks, natural gas energy and costs would be conserved. Natural Gas Cost Savings $7,560 Implementation Cost Included in Cost Saving Simple Payback Immediate

ECO No. 6: Install VFD on the Dust Collector’s Fan Motor in the Continuous Mix Production Line Install a variable frequency drive (VFD) on the 200 dust collector fan motor in the Continuous Mix production line to eliminate the manual flow adjusting valve to allow 100% flow. A VFD will reduce the power consumption of the dust collector fan motor based on the temperature of the aggregate. Electricity Cost Savings $19,762 Implementation Cost $24,854 Simple Payback 1.3 yr

ECO No. 8: Replace MH-400 With MH-360 High efficiency HID Lamps High efficiency lower wattage Metal halide lamps have the same luminosity as the higher wattage lamps, but require less input power. Both MH- 400 and MH-360 lighting maintain the same luminescence. Electricity Cost Savings $509 Implementation Cost $1,320 Simple Payback 2.6 yr

Install a variable frequency drive (VFD) on the 75-hp burner blower used in the Continuous Mix line for the rotary asphalt dryer and eliminate the intake dampers. A VFD will reduce the power consumption of the burner blower motor when the required flow is less than the maximum. Electricity Cost Savings $4,680 Implementation Cost $15,259 Simple Payback 3.3 yr ECO No. 9: Install VFD on the Burner’s Blower in the Continuous Mix Production Line

Summary – Redwood City Plant Baseline Energy Usage Energy Usage After Implementation Reduction (%) Electric Energy (kWh) 1,586,6031,432,233154,3709.7% Natural Gas (MMBtu) 118,420114,0604,3603.7% Total Utility Costs ($/yr) $ 1,084,108996,40287,7068.1%

SFSU-IAC Contact Information Ahmad R. Ganji, Program Director –(415) IAC Office, SFSU-SCI 151 –(415) Yin Yin Wu, Audit Coordinator –(415)