KPPC: Partnering to Improve Our Environment, Health & Economics

1. KPPC: Partnering to Improve Our Environment, Health & Economics Eastern Kentucky Power Envision Energy Conference October 18, 2006 Cam Metcalf Executive Director www.kppc.org

2. The Big Squeeze is on! There is a new global business environment! Public Concerns Inefficient use of Resources Market Environmental Water Climate Resources Life Cycle Management Globalization E-Commerce Cost Containment Developing Countries Organization Social – “Interested Parties” Legal & Other Requirements Regulations Homeland Security Take Back Laws Self Reporting Responsibility & Roles Transparency Accountability Resource Scarcity Core Values Technology Diffusion Corporate Values Leader’s Values Societal Values Materials P2 Technologies Connectivity 2

3. Our “Universal Backyard” • NIMBY • NOTE • BANANA • CAVE • NOPE 3

4. What is KPPC? • KPPC is a non-profit organization established in 1994 through legislative mandate • Statewide technical assistance program • Based at the University of Louisville’s Speed School of Engineering • Funding from companies that generate solid & liquid hazardous waste • Hazardous Waste Assessment Fund (20%) 4

5. Kentucky Pollution Prevention Center Mission The Kentucky Pollution Prevention Center (KPPC) at the University of Louisville is Kentucky’s primary resource for technical information and assistance to improve environmental performance. The Center facilitates and promotes the proactive implementation of management systems and technologies to improve the competitiveness of businesses, industries and other organizations. 5

6. P2 = Source Reduction • P2 means “Source Reduction” & other practices that reduce or eliminate the creation of pollutants through: • Increased efficiency in the use of raw materials, energy, water or other resources; or • Protection of natural resources by conservation. Resource Management 6

7. Move Up theWaste Management Hierarchy Source Reduction/E2 Reuse/Recycling Energy Recovery Treatment Disposal Continual Improvement 7

8. P2 is SellingMultimedia Approaches • W ater • A ir • S olids • T ime • Energy Efficiency (E2) 8

9. Resource Accounting Non-product Resource Use $ Interim/Final Product Throughput In $ Non-product Resource Loss 9

10. KPPC Energy Assessments & Cost Savings Dollars Assessments 10

11. Low Temperature Conversion Coating Manufacture of Reclining Chair Parts • Previously used high temperature multi-step phosphated process • Successfully trialed single step non-phosphated experimental material at ambient temperatures • Reduced H2O usage from 93,000 g/yr to 13,000 g/yr or ~ 86% (NO DRAINS) • No sludge technology/minimize solid waste • Tank life extended from 7 wks. to 18 wks. • Substituted water-based paint (cures @ 225OF) for solvent-based paint (cures @ 325OF) • Saved $200,000 in energy (2005 prices) • Improved quality performance Processed parts to paint Cross hatch adhesion test 11

12. Energy Management Program MANAGEMENT TECHNICAL POLICY GOALS MONITOR & MEASURE TARGETS ENERGY PROFILE PROJECTS ENERGY ASSESSMENT MEASURE & VERIFY 12

13. “Low Hanging Fruit!”Utility Bill Analysis • Billing/Rate Structure • Six Facilities • Over $550,000 in Total Annual Savings • One Month Average Payback • Minimal O&M & Implementation Costs • Power Factor Improvements/Demand Reduction • Two Facilities • Over $20,000 in Total Annual Savings • 1.4 Year Average Payback • Minimal O&M • About $37,000 in Implementation Costs 13

14. Pump Case Study • Wastewater Pump House • (3) 200 hp pumps (Using DOE’s PSAT Tool) • 23-month payback to complete motor wiring for VFDs (or remove VFDs) • $10,000/yr. savings to switch to Demand-Based Rate 14

15. E2 Assessment Opportunities • Reduce Energy Use in Process & Facility • Boilers & Steam Systems, HVAC • Compressed Air Systems • Plug Load • Motors & Pumps • Lighting • Building Envelope 15

16. Overall Results

17. E2 = Less GHG Emissions • Electricity Reduced/Saved – 2,738,480 kWh • Save 375 Metric Tons of Coal • Reduce CO2by 1,698 Metric Tons • One of main GHG (Risen 30% Since Industrial Revolution) • Reduce Methane by 14,068 Metric Tons • More Potent GHG Than CO2 • Reduce Nitrous Oxide (NOx) by 24,334 Metric Tons • Combines with Sulfur Dioxide (SO2) & Sunlight to Make Smog 17

18. Technology Diffusion Initiative • Technical Assistance for Implementation • Opportunity & technology identification • Identify interested clients • Top management (core values & goals) • Financial (procurement & financing) • Legal considerations & contracts • Installation, startup & training 18

19. Daylight Harvesting Ballasts Photosensor Dip Switch Light Fixtures Skylights Skylights Row 1 Row 2 Row 3 19

20. Daylight Harvesting Ballasts 20

21. Daylight Harvesting Ballasts Results 21

22. Daylight Harvesting Ballasts Benefits: • Average of 50% energy savings • Demand reduction • Better quality light • Requires no wiring to central control panel • Can integrate with on/off control systems • Qualifies for state & federal energy incentives • Easy installation • Initial low cost premium (~$52 vrs. $34) 22

23. VendingMiser Testing Energy Savings 30% to 60% A typical refrigerated vending machine can use over 2.600 kWh/yr At $0.08/kWh = $210/yr

24. VendingMiser Testing Temperatures inside the machine ran between 41 and 43˚F without the Vending Miser. The red line indicates that power usage was significantly reduced when traffic was low, nights and weekends.

25. TDI – Boiler Controls • What are Boiler Controls? • Add-on controls to space heating boilers (Hot Water/ Steam) to reduce short-cycling & improve efficiency Boiler Controls work because boilers: • Are Sized for the coldest day • Short cycle • Are Inefficient • Do not have hot water resets & other controls 25

26. TDI – Boiler Controls Results 26

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28. Sustainable Performance Triple Bottom Line Society Economics Environment • Triple Bottom Line • Social well-being • Strategic plan for economic goals • Guiding Principles for Environmental Management System • Pollution Prevention & Energy Efficiency • Compliance with all regulations • Continual improvement • Conservation of natural & cultural resources 28

29. KY EXCEL is a voluntary program open to any individual, business or organization that wishes to improve & protect Kentucky’s environment in ways that extend beyond Kentucky’s environmental requirements. www.dca.ky.gov/KYEXCEL 29

30. Evolution of Environmental Management Planning Sustainability “Master” = EMS Excellence Proactive “Leader” = EMP Implementation “Partner” = EMP Development Acceptance & Compliance Mission Driven Tolerance Denial Reactive 30

31. KPPC Contact Info Cam Metcalf ………… cam.metcalf@louisville.edu Kentucky Pollution Prevention Center (KPPC) 420 Lutz Hall University of Louisville Louisville, Kentucky 40292 Phone: (502) 852-0965 Fax: (502) 852-0964 Web Site: www.kppc.org 31