A leading multinational fertilizer manufacturer set ambitious energy reduction goals for two of its U.S. production sites — targeting a 1% reduction in the first year and 20% in the long term. To achieve these goals, the company needed a comprehensive understanding of site-wide energy performance, identification of inefficiencies, and a clear roadmap to prioritize cost-effective improvement opportunities.
KBC conducted a Strategic Energy Review (SER) at both sites, applying a structured approach to uncover and quantify energy-saving potential. Using advanced techniques such as benchmarking, gap analysis, Pinch Analysis, and steam system modeling, KBC identified performance gaps and built Investment Roadmaps outlining actionable projects and timelines to realize the savings.
At the first site, immediate savings of 2.2% in the first year exceeded the initial target, with total potential savings of up to 17.8% — advancing the site’s performance to the top quartile among peer facilities. The second site, though newer and more constrained, achieved no/low-cost savings of 1.2% and identified a total of 6% potential savings through targeted improvements in furnace efficiency, compressor optimization, and steam system management. Combined, these opportunities represent more than $9 million in annual energy savings potential.