www.o-i.com owens-illinois, inc. melbourne plant water reduction
TRANSCRIPT
www.o-i.com
Owens-Illinois, Inc.
Melbourne Plant Water Reduction
Presentation Title | Subsection Owens-Illinois, Inc.
Melbourne Plant Water Reduction
At the beginning of 2007, the Plant upgraded a number of Towns water cooled systems to recirculating closed-loop systems.
• This had a significant on water consumption To further reduce water consumption, a Lean Six Sigma Project (led
by Michael Brown) was commenced. A number of water reduction activities and projects were carried out
including:• Temperature controlled Variable speed drives on cooling tower
fans• Awareness education amoungst all Employees• New floor cleaning equipment• On-line water metering• Installation of low-water consumption cooling towers on air
compressors
Presentation Title | Subsection Owens-Illinois, Inc.
Apr-11May-10J un-09J ul-08J ul-07Aug-06Sep-05Oct-04Nov-03Dec-02Feb-02
800
700
600
500
400
300
200
100
0
Month & Year
Avg. Daily
- m
3 o
f w
ate
r
Melbourne Plant Average Daily Water Consumption
Closed lo
op coolin
g syste
ms
installe
d
LSS P
rojec
t Sta
rted
Melbourne Plant Water Reduction
Presentation Title | Subsection Owens-Illinois, Inc.
Melbourne Plant Water Reduction – New Cooling Towers
The new compressor cooling towers were a significant departure from “normal” cooling towers:
• Closed loop• Used an air-water heat exchanger• When temperatures low, air was the only cooling used• When temperatures were high, water-cooled evaporative pads
were used to pre-cool the air prior to the air-water heat exchanger
• Control of water and fan speed through PLC logic.
Presentation Title | Subsection Owens-Illinois, Inc.
Melbourne Plant Water Reduction – New Cooling Towers
Jun-11Feb-11Oct-10Jun-10Feb-10Oct-09Jun-09Feb-09Oct-08
100
80
60
40
20
0
Mth. & Year
Daily
Avera
ge -
m3 o
f w
ate
r
Compressor Cooling System - Average Daily Water Consumption
First to
wer commiss
ioned
One old tower s
witched off
(trial p
eriod)
Old tower started again
(insufficient cooling)
New towers commissioned
Old towers isolated
Presentation Title | Subsection Owens-Illinois, Inc.
Melbourne Plant Water Reduction – New Cooling Towers
Significant water savings have been achieved by using these towers• Water reduction from approx. 70m3 / day to 20m3 / day• Reduction of Legionella risk• Reduction of fan power from approx. 166kW to 110kW• Elimination of water treatment chemicals:
MB Compressor Cooling TowerChemical Treatment Cost per Month
$0
$500
$1,000
$1,500
$2,000
$2,500
$3,000
$3,500
$4,000
$4,500
Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10
Presentation Title | Subsection Owens-Illinois, Inc.
Melbourne Plant Water Reduction
O-I uses an internal Benchmark for water consumption Based on the water used per glass bottle-making machine per day Best Practice is 30m3 water / machine / day Melbourne Plant is now one of the lowest users of water in the O-I Group
Apr-11May-10J un-09J ul-08J ul-07Aug-06Sep-05Oct-04Nov-03Dec-02Feb-02
120
100
80
60
40
20
0
Month & Year
m3/m
ach
ine/day
Best Practice Target
Water consumption: m3/ machine/ day