The Weirton Steel Corporation performed a plant-wide energy assessment of its steel mill plant in Weirton, West Virginia. Based on the assessment results, the company found strong economic justification for six projects that would reduce the use of fossil fuel, electrical energy, and water. All of the projects would save fossil fuel either for heating steam or firing the furnace. This savings totals 108,300 million British thermal units (MMBtu) annually or $1.27 million. Other yearly savings include 119 million gallons of water ($87,110) and 84,000 kilowatt-hours (kWh) or $3,357 of electrical energy. All of the projects could be applied to other steel mills and possibly other industries using steam processes and furnaces.

In 2000, the Corning glass plant in Greenville, Ohio, consumed almost 114 million kWh of electricity and nearly 308,000 MMBtu of natural gas in its glassmaking processes for a total cost of approximately $6.4 million. A plant-wide assessment indicated that improvement projects could save nearly $26 million and reduce natural gas use by 122,900 MMBtu per year, reduce electrical use by 72,300,000 kWh per year, and reduce CO2 emissions by 180 million pounds per year.

This case study highlights control scheme modifications made to the steam system at ExxonMobil's Mary Ann Gas Plant in Mobile, Alabama, which improved steam flow efficiency and reduced energy costs.

This case study highlights a compressed air system upgrade at BWX Technologies manufacturing plant in Lynchburg, Virginia, which replaced antiquated compressors and dryers and implemented an improved control strategy, resulting in improved energy efficiency and savings in energy and maintenance costs.

This case study highlights a compressed air improvement project implemented at the Mobil lubricating-blending plant in Vernon, California. The project reduced the plant's energy production and maintenance costs, and increased reliability due to increased efficiency of the compressed air system.

This case study highlights International Truck and Engine Corporation's optimization project on the compressed air system that serves its foundry, Indianapolis Casting Corporation. Due to the project's implementation, the system's efficiency was greatly improved, allowing the foundry to operate with less compressor capacity, which resulted in reduced energy consumption, significant maintenance savings, and more reliable production.

Akzo Nobel's Surface Chemistry plant in Morris, Illinois, implemented an energy efficiency plan, which included a plant-wide energy efficiency assessment. The assessment revealed opportunities to save an estimated$1.2 million per year in operating and energy costs, reduce environmental impacts, and improve production capacity.

This case study highlights the upgraded compressed air system at a Michelin tire manufacturing plant in Spartanburg, South Carolina. The controls upgrade project enabled multiple compressor operation without blow-off, and significantly reduced energy costs.