2024 P3 Project Overviews

Project Overview

Intern: Luke Papa 
Major: Mechanical Engineering 
School: University of Nebraska-Lincoln 

Company Background 

Greater Omaha Packing (GOP) is a beef packing plant based off 3001 L Street in Omaha, Nebraska. Since its inception in 1920, GOP has been committed to providing high quality products and continued improvement. The facility processes on average 2,400 cattle each day and ships to over 70 other countries along with every US state. They are recognized as a global business leader in the beef industry and strive to improve in sustainability throughout the facility.  

Project Description 

The maintenance department at Greater Omaha Packing sought assistance in 2024 with their systems and processes to increase energy efficiency and implement pollution prevention methods. Installation of a heat exchanger for the wastewater and hydraulic systems was investigated along with a compressed air leak assessment throughout the plant.  

Pollution Prevention Benefits 

Pollution prevention benefits were assessed, and recommendations were made to reduce water, natural gas, and electricity usage within the facility. For each recommendation, annual cost savings and implementation costs were calculated, along with payback periods. The environmental impact, in terms of greenhouse gas reduction, was also evaluated. Additionally, potential soft savings for each recommendation were analyzed.  

Results 

The pollution prevention benefits and results for each project are summarized in Table 11.

Project Overview

P3 Intern: Ryan Tolliver 
Major: Mechanical Engineering 
Station: Geneva, Nebraska 
School: University of Nebraska-Lincoln 

Company Background 

Nebraska Nitrogen is an anhydrous ammonia fertilizer manufacturing facility in Geneva, Nebraska that employs 35 people. With a storage capacity of up to 20,000 tons, this facility produces around 100 tons of ammonia each day. This ammonia is sold to farmers to supply nitrogen to their soil, promoting the crop growth that is needed to sustain our modern world. 

Project Description 

The biggest failure point in the production stream is the Worthington Multi Stage Compressor. The heart of the process, this compressor increases the pressure of process streams to the levels that are required for ammonia production. It is over 50 years old and causes the plant to shut down around 5 – 10 times every year. Reducing the number of unintended shutdowns would save hundreds of thousands of dollars each. The main portion of this project involved the creation of a database to analytically identify failure points to reduce the number of shutdowns. 

Pollution Prevention Benefits 

Each time the plant shuts down because of the back end of the process (everything at or after the compressor), the front end (everything before the compressor) is kept running at 35% capacity. This is to prevent damage caused by large temperature changes experienced by the primary reformer during a full shutdown, given that it requires high temperatures to work. The process gas that is created by the front end during shut down is then sent directly to the flare. This releases a significant amount of greenhouse gases as well as other pollutants into the air, presenting a major pollution prevention opportunity. 

Results 

The main project undertaken, being incredibly ambitious, was unable to be finished during this summer; however, great progress was made towards that end. The pipe replacement project was successfully planned and resulted in significant cost savings, reduced greenhouse gas emissions, and the elimination of dangerous safety concerns. 

Project Overview 

P3: James John Wiltgen 
Major:  Chemical Engineering 
School: University of Nebraska-Lincoln 

Company Background 

In 1957, the McCain siblings, namely Wallace, Harrison, Robert, and Andrew, established McCain Foods, a company focusing on the production of appetizers. Currently, McCain Foods has a global presence, with sales in over 160 countries. At the McCain Grand Island site, more than 500 employees work diligently to produce a daily output of over 400,000 pounds of appetizers, predominantly onion rings. This facility caters to different clients, ranging from Burger King to Freddy’s, by manufacturing a diverse range of onion ring varieties.   

Project Description 

In the summer of 2024, McCain took on John Wiltgen from the University of Nebraska-Lincoln's Partners in Pollution Prevention Program (P3) as an intern to assist them in reducing costs. The primary focus was to minimize wastewater surcharges by optimizing the wastewater process while the secondary focus was to reduce utilities use.  

Pollution Prevention Benefits

The goal for the summer was to find the optimal coagulant and flocculant dosage, reduce wastewater bill surcharges, and optimize wastewater treatment. One of the recommendations requires a capital cost, but it has a payback period of only 3 days.   

Results

The pollution prevention (P2) benefits are summarized in Table 1. 

Project Overview 

Nebraska Industrial Assessment Center Intern: Anuoluwapo Adeyemo 
Major: Architectural Engineering  
School: University of Nebraska- Lincoln  

Summer Activities 

During the summer I was assigned to 4  facilities assessment. My roles in these visits were  analyst (2 assessments), safety coordinator and equipment coordinator for one of the visits. The background of these facilities ranged from industrial products to food products down to health care. Three of the facilities were based in Nebraska while one was based in Minnesota. The industrial facility specialized in manufacturing of precision-forged and machined engine valves and gears. The food product facility specialized in the manufacturing of containers for canned foods like spam. Lastly, the health care facilities are hospitals whose specialty is in health care.  

Recommendations Description  

For these assessments, I worked on preparation of several Ars such as install HVLS fans, new destination for MUD,upgrade exit signs, upgrade facility lighting, brine reclamation system, deduct meter on irrigation, replace steam boilers with water heater. While for one of the health care assessment I worked on putting data to the good practices that the was already observing some of these good Practices included facility having a private well for irrigation and all facilities lighting already been converted to LEDs. 

Pollution Prevention Benefits 

Implementing Action Recommendations (ARs) can enhance the energy efficiency of assessed facilities, leading to reductions in overall energy use. This, in turn, helps decrease emissions, including greenhouse gases, and contributes to pollution prevention.  

Results 

The specific benefits of the ARs in terms of pollution prevention are outlined in Table 1. 

Project Overview   

NIAC Intern: Kael Frank  
Major: Environmental Engineering   
School: University of Nebraska at Lincoln   

Summer Tasks 

During the summer, I participated in 3 NIAC assessments. The first assessment was a forklift cab assembler where I was tasked with forklift charging optimization. The second assessment was at a metal can and lid manufacturer in which I found a use for HVLS fans. As well as another forklift charging optimization recommendation. The last assessment was at an animal feed manufacturer where I did a thorough calculation of heat losses in the facility.  

Recommendations Description  

The first recommendation regards forklift charging optimization at a forklift cab assembly facility. It was recommended that the charging strategy be changed to off-peak hours to reduce electric demand. Secondly, HVLS fans were recommended at a metal can manufacturer, for better cooling/heating in the facility and to allow removal of personal fans. The third recommendation followed the same off-peak forklift charging strategy as the first recommendation, but at a different facility. Finally, an insulation recommendation was written for various heat generation devices at a black manufacturer. 

Project Overview

Nebraska Industrial Assessment Center Intern: Allen Minta
Major: MS Environmental Engineering
School: University of Nebraska-Lincoln (UNL)

Summer Activities

This summer, I joined a diverse team of analysts on a total of 4 assessments with different roles on each: I was the lead on one, an analyst on all, and also doubled as a safety & equipment coordinator for 2 site visits.

Company Background

I assisted 4 facilities: Evonik Industries, American Wood Fibers, Cargill and Kraft Heinz. Evonik is one of the world’s leading specialty chemical companies. Situated in Blair, NE, this facility produces food and animal feed, and has also made many forays into the biotechnology and chemical industry. Evonik conducts research and development for its customers to improve their products. American Wood Fibers is an industry leader in the manufacture of wood products such as premium wood pellets and wood shavings. The facility is located in Clarks, NE but unfortunately has since been sold. Cargill provides food, ingredients, and industrial products to a diverse clientele. Cargill’s businesses also delivers solutions to bioindustrial customers. Kraft Heinz is a global food and beverage company with products ranging from cheese, meats, beverages, ketchup etc. Their brands include Kraft, Jell-O etc. Their plant is located in Mason City, IA.

Pollution Prevention Benefits

Some tangible and intangible benefits to the facilities include a significant reduction in their GHG emissions, improved worker satisfaction, as well as process optimization.

Results

The table below summarizes the pollution prevention impact my recommendations will have if all are implemented.

Project Overview 

P3/NIAC Intern: German Murcia-Martinez 
Major: Mechanical Engineering 
School: University of Nebraska-Lincoln 

Company Background

Throughout the summer, I participated in both ITAC and a P3 assessment. During my time with the ITAC, I participated in four different assessments, one of which I was the lead student. When I was not working with the ITAC, I was researching and compiling a report for Cargill Protein. Cargill Protein is a meat processer specializing in ground beef products. The plant has 411 employees. With all their products, Cargill Protein strives to deliver the highest quality to its customers. 

Project Description

Throughout the summer of 2024, German Murcia-Martinez, an intern from the P3 program of UNL, worked on several pollution prevention projects for several companies. Some of the goals of the summer projects were to increase sustainability by reducing water use, natural gas use, and energy consumption on-site. 

Pollution Prevention Benefits

Several pollution prevention suggestions were made that could reduce the electricity use, water usage, and natural gas usage in the plant, primarily on the production side. Some of these recommendations have little investment in the reduction of these measures. Some of the recommendations may have a high upfront cost. 

Results

The estimated savings and pollution prevention benefits can be found in Table 1 below. 

Project Overview 

This summer, I had the privilege of participating in the Pollution Prevention course and taking part in several hands-on assessments with the Nebraska Industrial Training and Assessment Center (NITAC). The course provided me with a solid foundation in energy efficiency and industrial process improvements, complemented by insights from industry experts. 

Throughout the summer, I contributed to four key assessments, where I had the chance to apply my knowledge and make a tangible impact: 

American Wood Fibers

At American Wood Fibers, I focused on making the compressed air system more efficient. This involved finding and fixing air leaks, servicing the air dryer, and recommending the switch from standard V-belts to cogged V-belts. The goal of these recommendations was to improve system performance, save energy, and extend the life of the equipment. 

Silgan Containers

At Silgan Containers, I worked on implementing a compressed air management plan to optimize air usage. In addition, I identified opportunities to reduce compressed air leaks and recover waste heat from the catalytic oxidizer. These recommendations will help the facility to improve overall energy efficiency and reduce operational costs. 

Rise Building Products

For Rise Building Products, I helped with applying for a tax exemption to reduce their operational costs. This involved understanding the financial benefits of tax exemptions and how they can help the company save money while being more sustainable. 

CHI Health Schuyler

At CHI Health Schuyler, I worked on improving the facility’s energy efficiency by upgrading the lighting, and exit signs, and installing occupancy sensors. These upgrades not only save energy but also make the facility safer and more efficient. 

Special Project

This summer, I worked on creating two short instructional videos. The first video explains how switching from standard V-belts to cogged V-belts in machinery can save energy and reduce costs. The second video focuses on utility bill analysis, showing how reviewing bills can help facilities find hidden savings. Both videos aim to make energy efficiency improvements simple and practical for industrial settings. 

Project Overview

NIAC Intern: Jordon Sanford
Major: Civil Engineering
School: University of Nebraska at Lincoln

Summer Activities

During the Summer, I participated in 5 NIAC assessments with a leading role on the fourth. The first assessment was at a
brewery. The second assessment was at a wood processing plant, during which I was the equipment coordinator. My third
assessment was at a vehicle assembly facility. For my leading assessment, we visited a siding manufacture, for which I wrote the report. My fifth and final assessment was at a food manufacturer.

Recommendations Description

On my first assessment, I wrote an AR on the most efficient way the facility could convert their electricity source to solar power, for which I recommended the facility purchase shares in their city’s solar farm. For the second assessment, I wrote a recommendation for the facility to implement a CHP (combined heating and power) system to their incinerator, significantly reducing their energy bills. On third assessment, I suggested that the facility replace their non- LED lights to LEDs to save on energy usage. On my lead assessment, I wrote two AR’s. One was over reducing the set point of the facilities air compressors, and the other was on implementing a compressed air management plan. For my fifth and final assessment, I wrote an AR about installing economizers on the facilities boilers.

The Recommendations are listed below in Table 1; they are organized chronologically.

Project Overview  

NIAC/P3 Intern: Aleea Stanford  

Major: Mechanical Engineering 

School: University of Nebraska-Lincoln 

Company Background

During the summer I participated in both ITAC and P3 assessments. Through the NITAC, I went on two assessments, one of which I was the lead student. In addition to NIAC assessments, I also worked at Universal Pure to provide recommendations to increase energy efficiency and reduce waste. At Universal Pure I focused on analyzing the current state of their dock door seals and how to increase energy efficiency. Universal Pure is a multifaceted company providing cold storage, high pressure processing, air tempering, and many other services to a variety of customers.   

Project Description

During the summer of 2024, Aleea Stanford, an NITAC intern from UNL, worked at Universal Pure in Lincoln, Nebraska to further assess their potential Pollution Prevention (P2) opportunities. This included examining dock doors seals, forklift battery charging practices, LED installation and identifying projects for future interns. 

Pollution Prevention Benefits

Several pollution prevention recommendations were made to reduce their overall energy consumption. Some of these recommendations had lower energy savings, but had other benefits that would provide positive impacts to the company such as safety.  

Results

The estimated savings and pollution prevention benefits can be found in Table 1 below.  

Project Overview  

NIAC Intern: Austin Young  

Major: Mechanical Engineering  

School: University of Nebraska at Lincoln  

Summer Activities 

During the Summer, I participated in 4 NITAC assessments with a leading role on the third. The first assessment was an engine valve and gear manufacturer where I was tasked with lighting solutions along with another member. The second assessment was at a wood processing plant in rural NE in which I collected data on compressed air leaks using an acoustic imager. For my leading assessment, we visited a food cans manufacturer in Minnesota for which I did a utility analysis and put together the final report. My fourth and final assessment was at a healthcare facility in rural Nebraska. My special project was an educational introduction to the concept of electrical demand reduction.  

Recommendations Description  

On my first assessment, I wrote two ARs, which are energy assessment recommendations. The first was a recommendation to program VFD’s (Variable Frequency Drives) on the motors running a specific process that involved idling times for which the motos could save energy by running at less power. The other AR involved changing old exit signs to newer LED models. For the second assessment, I wrote a recommendation for the facility to lower its air compressor setpoint by 10 psi, reducing energy consumption. On my lead assessment, I suggested that the facility apply for a tax exemption for utility cost used directly in production, and to install cool-air intake near the compressor system. On the last assessment, I wrote an AR on replacing single-paned windows with more energy-efficient alternatives.  

Project Overview

Nebraska Industrial Assessment Center Intern: Jenn Zuspan
Major: Mechanical Engineering
School: University of Nebraska-Lincoln

Summer Activities

During this summer, I participated in the assessment visit of 4 facilities as an analyst student. In addition, in some of the assessments I served as the equipment and safety coordinator in the assessment team. I served as the Lead Student for one of the assessment visits.

Recommendations Description

During these visits, I worked on the preparation of 4 ARs which are: replacing regular v-belts with cogged v-belts, removing an electrical meter no longer in use, and repair compressed air leaks for two assessments.

Pollution Prevention Benefits

All four recommendations can result in improvements in energy efficiency of the assessed facilities which will eventually have positive influences on pollution prevention by reducing the overall energy consumption and the produced emissions from the processes, like GHG emissions. The amount of pollution prevention benefits of the ARs are shown in Table 1.

Results

The table below summarizes the pollution prevention benefits: