2010 – Environmental Stewardship Initiative Members Meeting A look at the Bridgestone Wilson Plant……… 3/23/2010
Bridgestone Americas
AGENDA • About Bridgestone •Wilson Facility •Energy Activities •Plant Recycling Activities •Freedom Wildlife Habitat/Community Activities •Questions? Bridgestone Americas
We are a Global Player…………. Bridgestone Group makes tires on 6 of the 7 continents. We are not in Antarctica. 4 Tire plants 6 Tire plants
China
Europe Japan Middle East and Africa 3 Tire plants
9 Tire plants
Asia and Pacific
15 Tire plants
Americas
9 Tire plants
Bridgestone Americas
MISSION: Serve Society with Superior Quality We inherit the words and the spirit of our mission from our founder. His emphasis on “superior quality” means striving for excellence in technology, in products and service, and in all our activities. The quest for excellence is a quest for every individual at every Bridgestone company. So we encourage each other in the spirit of mutual respect and help one another make the most of our potential.
Shojiro Ishibashi (1889-1976)
Our commitment to quality is a worldwide commitment. We share the values of the community, including the universal desire for a sound environment. And we work conscientiously to improve the quality of life for people everywhere. Bridgestone Americas
OUR FACILITY
Bridgestone Americas
Bridgestone Americas
Wilson Overview 35 years of operation Region’s largest power user at 25 MW load 35 years without any layoff 2,179 full-time and contract teammates 648 retired teammates (500 within a 2 hour drive) 2,130,000 square feet under the roof Bridgestone Americas
Energy Activities
Bridgestone Americas
Energy - What are we doing to get better? Ted Rudolph W/O # Prepared by: Area: Energy Completion Dat Date prepared: Jan. 30, 2009Date corrected: Date corrected: Date corrected:
MANAGER APPROVAL BUDGET APPV.
ACTUAL $
$500 $0
CAPITAL EXPENSE
EST $ TO COMP.
$397 Budgeted Weight (MLB): $0
$103 $0
Implementation item
No.
No.
Initials:
324936
Activity Detail
Date: Person in charge
2009 ENERGY REDUCTION -MMBTU
1 MMBTU NEEDED TO MEET DIRECTORS CHALLENGE (MMBTU)
Actual
1
Lighting Optimization and Replacement
Ricky Vanhoute
E
2
Banbuary Air Leaks
John Musgrave
E
50,766
PLANNED IIP ENERGY REDUCTION TARGET - SHOULD BE 150% OF MMBTU ABOVE Target PLANNED IIP GENTANI REDUCTION (MBTU / LB) - ITEM ABOVE DIVIDED BY BUDGETED WEIGHT: PLANNED SAVINGS ($ / MLB) SAVINGS DIVIDED BY BUDGETED WEIGHT:
Planned
Type of Project (E=Electricity, MMBTU F=Fuel)
3
Tubing Air Leaks
Fred Moore
E
2.482804202
4
Stock Cutting / Calandering Air Leaks
Drew Howell
E
5
Tire Room / Dopers Air Leaks
Charlie Kirby
E
6
Curing Air Leaks
Mark Collier
E
% Yearly MMBTU Reduction Progress Rate
90.00% 80.00%
Final / Warehouse Air Leaks
8
Add Air Compressor
Carroll Mullen
E
Roach / Rudolph
E
70.00% 60.00% 50.00%
9
40.00% 30.00%
10
20.00% 10.00%
Mar
May
Jul
Sep
Planned Actual
Mar 915 915
April 886 886
May 915 915
June 886 886
July 886 886
Aug 915 915
Sep 886 886
Oct 915
Nov 886
Dec 886
Planned
24
23
26
25
26
23
21
30
28
28
27
24
307
-195 3
-239 3
-170 3
-206 1
-106 2
-110 2
12 2
151 1
79 1
1
1
0
-783 22
148 61 262 25 335 72
138 56 -12 23 155 66
135 63 262 25 409 74
47 60 109 24 314 72
51 64 200 26 385 180
71 59 275 24 391 71
59 54 440 22 418 67
11 65 322 26 361 74
10 61 86 23 26 72
59
58
53
22
22
18
76
76
60
669 713 1943 279 2794 960
-61 31
-1933 28
420 31
260 31
374 31
445 27
759 25
145 27
-88 25
25
25
13
320 317
Planned Actual Planned Actual Planned
389 0 0 0 0 0
183 0 0 0 0 0
312 500 500 0 0 0
290 500 500 0 0 0
220 500 500 0 0 0
263 500 500 0 0 0
280 500 500 650 0 7
174 500 500 1263 0 13
-155 500 500 1263 0 13
500
500
500
1263
1263
1263
13
13
13
1956 5000 3500 6966 0 72
Actual
0
0
0
0
0
0
0
0
0
Planned
7435
7487
8161
6871
7380
6723
7283
8816
8195
8454
7659
7497
91959
Mo.
Replace Blow Off at QCT and 6X10 Lines Replacement of diaphram pumps with centrifugal electric pumps or electric driven Tubing Total (all pages) *Note: For more than 10 projects, use additional IIP sheet.
Nov
500000
0
Actual
5858
1731
4846
6890
5363
5291
5639
5253
3043
0
0
0
43914
0
0
Actual Planned Actual Planned Actual Planned Actual Planned
7
Implementation status
Ken Stewart
E
Ken Stewart
E
Actual
Mo.
Lighting Optimization and Replacement Completed Christmas 2008. Will reap benefits Jan - Dec 2009
423000
0
Implementation status OCT, blow off and spong roll added installed in testing/tune up stage
Non Potable water being intergrated into Service / Process water
B and D Line back on. WILSON still only running one Boiler
Note Ran Sat Jan 3, 4-12
100% of urinals changed out to WaterFree Urinals
Aug
Feb
Non Potable water Process water 100%
10715 8029
Jul
Jan
Note Ran Sat Jan 3, 4-12
Capital Expense Requireme Requiremen t ($) nt ($)
Feb 826 826
Planned 0.156235025
Total MMBtu Savings
Jan 915 915
Actual
91,959
100.00%
0.00% Jan
2009
DEC. 31, 2009
A and C, B and D Lines back on. WILSON Running Both Boilers
100% on non potable water for Service and Process water #2 FSE Centrifugal Air Compressor on line
DA tank concerns
Sep
Mar
26 March Majority of heat turned off in plant, Also Ran Saturdays during Mar
Oct
Apr
Status and Comments
Also Ran Saturdays during Feb
Turned off one boiler shut down ABCD lines
May
Nov
Jun
Dec
Bridgestone Americas
Building Automation Savings HVAC Load Mgmt
Total Ave./Weekly Savings
$646.64
.
2010 Ave./Weekly Saving
$724,22 Bridgestone Americas
ENERGY SAVINGS ACTIVITIES
2009 ENERGY SURVEY
Summary of PSD Energy Survey at Wilson Plant Conducted May 12-14, 2009
WILSON
# of Items
2010 Wt MMBTU x106 savings
BTU/LB IMPACT
2009 Survey Savings Capital
CO2 eq. Ton/Yr
NOx Ton/Yr
SOx Ton/Yr
MGal. / Savings
$ / Savings
Electricity:
54
336
132,428
394 $ 984,138
$351,100
7,553
15.69
23.01
--
--
Fuel:
28
336
172,800
514 $ 2,723,988
$708,750
10,084
8.64
--
9,779
$85,857
Total:
82
336
305,229
908 $ 3,708,126 $1,059,850
17,637
24.33
23.01
9,779
$85,857
Note 1 - 2007 Wilson plant total MMBTU was 2,656,305 for electricity and fuel. This survey has identified 305,229 MMBTU reduction possibility. This is 11.5% of total MMBTU. Note 2 - The BSJ challenge for 2010 through 2014 is 2% per year improvement. Having identified 11.5% improvements gives the plant a good chance to meet the 2% MMBTU reduction target. Note 3 - From a Gentani standpoint, the weight in 2007 was 320,000 MLB vs. 336,000 MLB budgeted in 2010, so the weight should favorably impact the Gentani performance in 2010.
Bridgestone Americas
ENERGY SURVEY ACTION ITEMS
2009 ENERGY SURVEY WILSON PLANT
2009
Where
Utility Saving Item
Method
Mixing
Elec.
Ram up-down air savings: 26" diameter, 7' stroke, volume = ~250 ft^3. Need to weigh effects on cycle time.
Mixing
Elec
De-mister operation 2 @ 20 HP, 1 @ 30 HP, 2 @ 100 HP motors
Repiping, control valve 4 mixers * 3000 cycle/day per mixer * 250 ft3 * (300kwh/120000ft3) * 50%* .75 270 HP*total Shut down during NOT 350d
Mixing
Elec
Air leaks on dust collector - 1/4" at 30psi -> 40 cfm loss from energy manual
Calculation
KWH/Yr Savings
$/Y Savings
Capital
ROI
CO2 Ton/Yr
1312500
$0
$40,000
#DIV/0!
744
87075
$0
$0
#DIV/0!
49
(40 ft3/min) * (60 min/hr) 51600 * 8600 hr/yr * (300 kWh / 120000 ft3)
$0
$0
#DIV/0!
29
kw/HP * (8600 hr/yr) * 5% reduction Fix leak (in process)
2009 ENERGY SURVEY WILSON PLANT Decatherm Cost
2009 2009 Capital
$8.53 ROI
CO2 Ton/Yr
Where
Utility Saving Item
Method
Calculation
MMBTU $/Y /yr
Mixing
Fuel
60 psig steam reducing station, steam puffing about every 15 minutes, 6" pipe
re-adjust regulator to 60 psi
18.6
$159
$0
0.0
1.1
Mixing
Fuel
Oil Storage tanks, insulation missing, 2'x4'x6' tank = (2*2*4)+(2*2*6)+(2*4*6) = 88 ft2, plus additional tank ~12 ft2, total of 100 ft2 with no insulation. T=240F, from energy manual this is approximately a 300 btu/hr-ft2 difference in heat loss between
Insulate
165 lb/hr * (1 hr / 3600 sec) * (10 seconds) * (96 times per day, every 15 minutes) * (354 days/yr) * (1 DT / 10^6 btu)*(1/85% boiler eff)*1000 btu/lb 100 ft2 * 300 btu/hr-ft2 * 8600 hr/yr * (1DT / 10^6 btu) * (1/85% boiler eff)
303.5
$2,589
$500
0.2
17.6
Mixing
Fuel
Steam leaks (traps) fix leaks - oil storage tank: 6 leaks, 1/16" diameter, 20 psi -> extrapolate 10 lb/hr loss through leaks, from energy manual - hot room: 2 leaks, same conditions as oil tank steam
8 leaks *10 lb/hr loss * 1000 btu/lb * 8600 hr/yr * (1 DT / 10^6 btu) * (1/85% boiler eff)
809
$6,904
$0
0.0
47.0
Bridgestone Americas
Steam Trap Survey twice per year. 2007 STEAM SURVEY TEST RESULTS: Condition # of traps Blowing_________________32 Leaking_________________50 Plugged_________________33 Installation Problem_________7 Total # of Traps_________1161 #/Hr. Loss______________2803 Daily Steam Loss________$672.77 Monetary Loss Per Year___$245,561.88
DEC 2008 STEAM SURVEY TEST RESULTS: Condition # of traps Blowing_________________13 Leaking_________________28 Plugged_________________25 Installation Problem_________5 Total # of Traps_________1161 #/Hr. Loss______________1738 Daily Steam Loss________$417.11 Monetary Loss Per Year___$152,243.61
Condition of Trap Blowing Leaking Plugged Installation Problems Total # of Traps Inspected #/Hr. Loss Daily Steam Loss Monetary Loss Per Year
$ $
2007 32 50 33 7 1161 2803 672.77 $ 245,561.88 $
2008 13 28 25 5 1161 1738 417.11 152,243.61
38% Improvement Bridgestone Americas
What are we doing to get better? XLE Compressor vs. New Centrifugal Compressor (oil free air)
Bridgestone Americas
What are we doing to get better? • Upgrading from high pressure sodium (yellow light) to metal halide (white light). (1,100 fixtures) • Monthly Energy Conference Call with All Plants – Review Usage – Review Costs – Discuss major issues for the month.
• Mixing soap conversion from Pro-mold to Sasco • Pursuing Bio-mass boiler solution for steam. • Reclaim Water System
Bridgestone Americas
ENERGY - What can you do?
• Observe your equipment. Identify leaks. (Air, Steam, Condensate, Water) Communicate to Team Leaders or Maintenance • During times of NOT. Turn off unnecessary equipment. (55 Fans; 23 conveyors; 56 lights) • Close outside doors when possible. • Communicate ideas to reduce usage via the electronic cost savings suggestion Bridgestone system. Americas
Education - What does a steam leak cost?
Bridgestone Americas
How can I improve this Situation?
Apollo Oil Reclaim Operation and Maintenance General Operational Overview Unloading Mixer lube sludge is captured in covered 55 gallon drums. The drums are moved into the unload position and pumped from drums. The sludge is pumped through a duplex strainer into a holding reservoir to be used in the distribution loop.
Distribution The recovered lube oil is stored in a three reservoir, 400 gallon tank. The tank is divided into reservoirs to allow settling of heavier solids. One outlet on the third reservoir supplies oil to a 300 mesh duplex strainer. The oil is continuously cycled through the strainer and returned to the middle reservoir through a relief valve set at @30 PSI.
Bridgestone Americas
How can I improve this situation? DUST RING LUBE AND SEAL OIL RECYCLING • DUST RING LUBE OIL IS VERY EXPENSIVE! (~ $7.00/GALLON) •WE USE THIS OIL TO LUBRICATE RING WEAR POINT AND CREATE OIL SEAL
•SAVINGS OF APPROXIMATELY $200,000/YEAR TO THE PLANT!
Bridgestone Americas
Bridgestone Americas
Recycling Activities
Waste Management Partnership Waste & Scrap Product Recycle Rate Wilson Plant 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% % Recycled
•Decrease administrative costs through vendor consolidation •Maximize volume leveraging to obtain optimal pricing •Reduce wastes, enhance re-use, and increase recyclables •Reduce waste volumes to landfill •Comprehensive volume and cost tracking and reporting
2007
2008
2009 ytd
30%
53%
64%
•Improve risk management across site
Bridgestone Americas
2010 ESI Performance Goals •
Increase reclaim water usage to 50,000,000 gallons/year. (Key: C.O.W. improving/maintaining reclaim water quality)
•
Divert cured tire pin vents from landfill disposal. – 2008 – 283 tons to landfill – 2009 - YTD 46.3 tons to landfill – 2010 – 0 tons to the land fill
•
Divert scrap tire curing bladders from landfill disposal. – – –
2008 - 239 tons to landfill 2009 – YTD 47.7 tons to landfill 2010 – 0 tons to landfill
Bridgestone Americas
2010 ESI Goals continued •
Reduce hazardous waste generation – 2007 – 32,560 lbs/year – 2009 – YTD 978 lbs – 2010 – 19,500 lbs/year • Elimination of raw material solvents • Recycled cement overspray • Elimination of uncontaminated cement sponges
•
Reduce energy usage (65,000 MMBTU) – Energy Survey Task List – Air Compressor Utilization – Steam Trap Survey
•
Reduce VOC from Paints, Cements, Inks, and Solvents – –
Improved cement application Improve compounding so no cement is required
Bridgestone Americas
Community Activities
In January, we hosted 150 Wilson County middle school students during the Mock Envirothon.
Bridgestone Americas
Our annual Pastors’ Brunch is the second Tuesday in March. It helps our community leaders understand the work we do in the Wilson plant. Members of Scout Troop 806 were invited guests (we hope that more organizations will ‘adopt’ scouting as a way to help youth). Bridgestone Americas
NEPT Outreach Award This prestigious award was for Wilson teammates time, enthusiasm and energy promoting the NEPT (National Environmental Performance Track) efforts to organizations beyond our community. Jim Pridgen accepted this award at the annual meeting in Baltimore on May 22. Greer Tidwell also attended this ceremony. From left to right, Stephen Johnson, EPA Administrator, Greer Tidwell, Jim Pridgen, and Jimmy Palmer, Jr., Region 4 Administrator
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May brought MBU (merit badge university) and 250 scouts, leaders and parents to our habitat. Bridgestone Americas
Playing “hookie” from work, our management group spent a beautiful day in May working for Habitat for Humanity.
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In July, we applied to North Carolina Department of Environment and Natural Resources to be a part of their rising stewardship program. Bridgestone Americas
We are proud of our wildlife Bridgestone habitat and want Wilson to know Americas
We are proud of our collaboration with Wilson Community College and want everyone to know about it.
Bridgestone Americas
HONDA Corporate Citizenship Recognition
Immediately above – the award presented to the Wilson team from HONDA at their annual supplier meeting. Above right – the initial onsite visit and audit of Wilson’s application. Bottom right – presenting the plaque to the Wilson team in curing.
Bridgestone Americas
DEPARTMENT
ACTUAL
Mixing & Receiving (112, 701)
$12,841
Tubing (126)
$9,725
Stock Prep (122, 123, 124)
$19,188
Tire Rooms (172, 173, 174, 177, 184)
$51,554
Curing (161, 166, 551)
$24,085
Final (132, 133)
$22,559
Warehouse & Traffic (791, 720)
$8,828
QA (762, 765)
$5,418
Tech Service (761, 763, 764, 767, 766)
$10,238
Engineering (954, 983, 760)
$6,384
HR (910, 912)
$3,698
HSE (748, 749)
0
Financial, IT, Purchasing, Stores (931, 932, 933, 957, 714, 718)
$6,194
Plant Mgt, IE, Scheduling (900, 901, 906, 911, 953, 134)
$8,660
Cement House (158, 561)
$1,158
Corp. Gift
TOTAL
$34,200
$224,736.32
Our UNITED WAY campaign was a success
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Veteran’s Recognition Breakfast
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The first two weeks in November are the annual food drive. There is no local food bank – so we do it the old fashioned way – of actually collecting food and then distributing it to local 501C-3 agencies. In 2008, despite the economic conditions, we matched the 27,000 pounds collected the previous year. 6 different agencies shared the generosity of Wilson teammates. Each of the 27,000 pounds was personally handled by Wilson teammates. Bridgestone Americas
During December, the Wilson team adopted 100 people who needed a little help from the Salvation Army Christmas Angels. Our angels ranged from 3 months to 56 years old. They needed everything from microwave ovens to playpens and diapers. We helped meet their needs – and then had fun buying toys and unexpected gifts to help make their holidays merrier.
Bridgestone Americas
THANK-YOU QUESTIONS ? AND NOW FOR RECYCLED RYTHMS!! Bridgestone Americas