Projects
Clorox Chilled Water Optimization Project
Chilled Water System Optimization for Reduced Energy Consumption
Global Facility Solutions (GFS) partnered with The Clorox Company to optimize the chilled water system at their 350,000 sq ft Maryland manufacturing plant in Aberdeen, MD, leveraging the BGE Smart Energy Savers Custom Program to achieve significant energy savings and utility incentives.
Project Objectives
- Perform operational analysis of two 337-ton Trane centrifugal chillers operating 24/7 for 5+ days per week
- Reduce baseline and annual energy consumption for chillers producing 30°F chilled water for process equipment
- Leverage utility incentives and achieve significant energy savings
- Optimize process chilled water system for 24/7 operation at 4,160 volts
Scope of Work
- Conduct comprehensive review of energy consumption baseline for two process-related chillers
- Develop and implement energy-saving measures across 5 major system components
- Provide full MEP design and permit-level drawings for installation
- Perform energy modeling for savings verification
- Coordinate with BGE incentive team to secure maximum rebate
Solutions
Comprehensive chilled water system optimization, including:
- Installation of a 190-ton part-load chiller to improve process chilled water system efficiency
- Introduction of Variable Frequency Drives (VFDs) on 4 chilled water pumps and 3 cooling tower fans
- Replacement of two aging 100 HP water pumps with high-efficiency models
- Upgrade of ATC controls to manage new equipment and optimize system performance
- Full MEP design and permit-level drawings for installation of all new equipment
- Energy modeling for savings verification, projecting 15% overall system efficiency improvement
The Clorox Chilled Water Optimization Project, designed and implemented by GFS, delivered substantial energy savings and secured a significant utility incentive, demonstrating the effectiveness of strategic system upgrades in industrial settings. This project showcases GFS’s expertise in leveraging utility programs and implementing tailored solutions for energy-intensive manufacturing processes, resulting in a projected annual utility cost savings of over $80,000.
The audit provided ownership and property staff with valuable insights to inform targeted decision-making toward investment planning and achieving energy reduction goals.
Results By the Numbers
- $231,806 incentive awarded through the BGE Smart Energy Savers Custom Program ($0.28/kWh saved)
- Anticipated annual energy savings of approximately 827,900 kWh/year
- 10% to 20% reduction in baseline energy consumption
- Energy savings between 25 kW to 35 kW and 160,000 kWh to 220,000 kWh annually
- 190 Ton supplemental water-cooled chiller added to increase system efficiency
- Project payback period of less than 3 years
