Click here for an Excel file listing the most commonly used measures

Ventilation

• Use underground controls to meet actual ventilation needs
• Replace oversized blowers with units of suitable capacity
• Use premium-efficiency motors
• Use variable-frequency drives (VFDs) to regulate variable-speed blowers
• Install baffles to improve air flow
• Use more efficient dust extractors
• Carry out preventive maintenance on ventilation systems

Milling (concentrators)

• Use sturdier plates
• Use acoustic signature to better regulate parameters and optimize milling time

Pumps

• Use variable-frequency drives (VFDs) to enhance pumping system flexibility
• Reduce load losses
• Use premium-efficiency motors
• Use more efficient or appropriately sized pumps

Other

• Use hybrid loaders to reduce the ventilation required to exhaust combustion gases
• Use automated scrapers to reduce compressed-air needs

Compression

• For details, see the following page. Please also check the ENERGY WISE programs for major customers to determine whether the suggested measures qualify.

Refining

• Use floating-rotor refiners
• Add dilution water directly
• Install antifriction controls
• Use disc rather than drum filters
• Replace high-consistency refiners with low-consistency models
• Use advanced controls in the thermomechanical pulp (TMP) refining process
• Use Low-E and Emax plates

Screening

• Replace separators with pressurized rotary-drum screens
• Optimize screen rotor speed
• Use more efficient new-generation screens

Cleaning

• Use cleaners with a low-pressure differential

Pumps

• Add variable-frequency drives (VFDs) to pump motors
• Reduce the use of pump impellers
• Use high-consistency pumps

Other

• Use mechanical conveyors instead of blowers to move chips
• Install timers and interlocks on pulpers
• Use more efficient (submersible) agitators
• Add oxygen sensors and use fine-bubble aeration for water purification

Compression

• For details, see the following page. Please also check the ENERGY WISE programs for major customers to determine whether the suggested measures qualify.

Aluminum electrolysis

• Optimize the anode-cathode space
• Use anodes made of less resistive materials
• Improve bath chemical control

Smelting

• Implement advanced furnace arc controls
• Install variable-frequency drives (VFDs) on combustion gas exhaust fans in arc furnaces
• Recover hot gases and add oxygen and natural gas for postcombustion to preheat metal and reduce furnace consumption
• Use direct-current arc furnaces

Metal forming

• Incorporate an induction holding furnace between the electric smelting furnace and continuous pouring
• Use lost-foam casting to form highly complex pieces in a single casting

Compression

• For details, see the following page. Please also check the ENERGY WISE programs for major customers to determine whether the suggested measures qualify.

Electrolysis

• Use more efficient anodes to improve the electrolysis process
• Use biocatalysts in new separation processes to reduce the amount of energy required for catalysis

Pumps

• Use more efficient membranes in the separation process to reduce the amount of energy required for pumping
• For details, see the following page. Please also check the ENERGY WISE programs for major customers to determine whether the suggested measures qualify.