Columbia Concrete
Simple changes send this manufacturer's energy savings through the roof
Learn how the use of basic energy-saving measures can add up to big savings.
The situation
In 2001, natural gas prices spiked across North America, hitting their highest levels ever.
John Charlesworth, president of Columbia Concrete Products Ltd., a leading manufacturer of roof tile, was growing increasingly concerned about his gas bills. Gas costs were driving up his production costs. He contacted Terasen Gas for assistance.
The plan
In July, Elmer Beager and Adrian Partridge from Terasen Gas conducted an energy assessment at the site in Surrey.
They concentrated on the main gas users – the two boilers that supply steam to the kilns and the radiant heaters that are used for space heating in the workshops.
Their findings showed that real savings could be achieved by:
- insulating the bare steam pipe, vessels and valves
- resetting the parameters controlling conditions in the kilns
- improving time and temperature control on the radiant heaters
Elmer and Adrian also studied gas usage versus roof tile production volumes as well as day-by-day usage. This revealed that there was significant variation in gas usage per unit produced, meaning there was opportunity to obtain savings here, too. It also showed that there was substantial gas usage when the plant was closed, indicating that gas-fired equipment was being left on. As soon as John received the assessment results, he took action.
Actions
Columbia Concrete followed all the recommendations:
- the pipes and vessels were insulated, which allowed the ramp-up time for the boilers to be cut back
- the kiln parameters were reviewed and reset
- radiant heater controls, with override timers, were installed and usage was monitored in detail to ensure that nothing was left on needlessly
Results
Since taking these steps to save, gas usage per production unit has been reduced by 45 per cent, a major cost saving for Columbia Concrete.
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