Innophos
Chicago Heights, Illinois
Intern: Rashad Nuruddin
University of Illinois at Urbana-Champaign
Innophos is a specialty phosphate manufacturing company. The Chicago
Heights plant specializes in the production of sodium and calcium
phosphates, with products being utilized in such industries as oral
care, pharmaceutical and baking.
The intern project focused on opportunities to improve energy
conservation, water conservation, heat loss, and other system improvements.
Results:
The intern worked on the following projects:
- Conducted a heat loss analysis and proposed a new heating design
for process filters that would reduce the plant's steam use. The
savings project has the potential to save $12,000 a year and create
a safer workplace environment.
- Assisted in calculating the water savings from converting AC systems
from water condensers to air condensers or supply fan systems. This
project has the potential to save $28,000 a year.
- Conducted a condensate line repair and insulation project in which
water was diverted from the sewer to the facility boiler. The estimated
annual savings in heat and water use was $28,000 dollars. The facility
will apply for a utility rebate after completion of the project.
- Proposed a design for reusing water used in a vacuum pump, by piping
the water to an existing process tank. The project has the potential to
save $3,400 a year on sewer fees.
- Calculated heat loss analysis from the process area to an open bag
house area. Proposed that a doorway vestibule be installed. This
project has the potential to save $4,300 during the winter months.
- Designed systems for improvements in production, quality and equipment
maintenance including a tank ventilation system to reduce tank and pipe
corrosion in the process area.
- Traced out water lines to calculate system head for the purpose of
installing a new pump that would reduce energy costs.
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