Bridgestone Americas

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Mar 23, 2010 - Note 3 - From a Gentani standpoint, the weight in 2007 was 320,000 MLB vs. 336,000 MLB .... Monthly Energy Conference Call with All Plants.

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

Bridgestone Americas

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.

Bridgestone Americas

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

Bridgestone Americas

Veteran’s Recognition Breakfast

Bridgestone Americas

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

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