PolyOne Corporation
Henry, IL
Intern: Joshua Berger
Northern Illinois University, DeKalb
PolyOne is a leading global compounding and North American distribution
company with operations in thermoplastic compounds, specialty polymer
formulations, color and additive systems and thermoplastic resin distribution.
The Henry facility manufactures specialty polyvinylchloride resins for high
end specialty resins. The facility shares a site with Emerald Performance Materials.
The intern was tasked with identifying opportunities to reduce energy use at
the facility.
Results:
The intern made the following recommendations:
- Replace the two inlet air motors on the coal-fired boiler with premium
efficiency motors and install 3 Variable Frequency Drives on the inlet
motors and the one outlet air fan motor. This project has the potential
to save over $150,000 a year, with a payback period of 10 months and an
ROI of 115%. It would also reduce CO2 emissions by 2900 metric tons a year.
- Replace the T12 lamps with T8s and electronic ballasts and remove lamps
and ballasts from fixtures in over-lit areas. The project has the potential
to save over $2,000 a year with a ROI of 63%.
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