Spreadsheet: 87714d1287583613-wks_chg-not-firing-val-list-cond-formatting-problem-plant-project-list-template-proposal-rev2
Sheet: FY2011

Tate & Lyle Projects List |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | [NAME] (do not delete!) |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | [NAME] (do not delete!)
Div | Plnt | Plant Depart | Project Description | AFE # | Status | Category | Sub-Cat | Investm (k$) | Saving (k$/y) | Project Manager | Assigned Year | Completion Date | Execution Time(mons) | Simple Paybk Time (yrs) | Comments |  | Cost Red Categories | 2009-03-31 00:00:00 | 2009-03-31 00:00:00 | 2010-03-31 00:00:00 | 2010-03-31 00:00:00 | 2011-03-31 00:00:00 | 2011-03-31 00:00:00 | 2011-03-31 00:00:00 | 2011-03-31 00:00:00 | 2012-03-31 00:00:00 | 2012-03-31 00:00:00 | 2013-03-31 00:00:00 | 2013-03-31 00:00:00 | 2014-03-31 00:00:00 | 2014-03-31 00:00:00 | 2015-03-31 00:00:00 | 2015-03-31 00:00:00
ALL | ALL | [NAME] | [NAME] | 10000 | ALL | ALL | ALL | 0 | 0 | [NAME] | 2000-01-01 00:00:00 | 2000-01-01 00:00:00 |  | 0 |  |  |  | Capital | Savings | Capital | Savings | Capital | Savings | Capital | Savings | Capital | Savings | Capital | Savings | Capital | Savings | Capital | Savings
ALL | ALL | [NAME] | [NAME] | 99999 | ALL | ALL | ALL | 0 | 0 | [NAME] | 2029-03-31 00:00:00 | 2029-03-31 00:00:00 |  | 0 |  |  |  | Completed | Completed | Completed | Completed | Completed | Completed | Planned | Planned | Planned | Planned | Planned | Planned | Planned | Planned | Planned | Planned
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | Ener/Wtr | 462 | 1934 | 188 | 499 | 21 | 47 | 2090 | 0 | 4615 | 0 | 460 | 0 | 0 | 0 | 0 | 0
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | Ingred | 0 | 110 | 134 | 553 | 0 | 0 | 0 | 0 | 2400 | 0 | 0 | 0 | 0 | 0 | 0 | 0
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | Yield/Val | 272.5 | 4850 | 27 | 1020 | 85 | 250 | 75 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | Fixed | 0 | 2101 | 1500 | 520 | 0 | 0 | 192 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | FY Total | 734.5 | 8995 | 1849 | 2592 | 106 | 297 | 2357 | 0 | 7015 | 0 | 460 | 0 | 0 | 0 | 0 | 0
 |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | Total |  |  |  |  | 12521.5 | 11884 |  |  |  |  |  |  |  |  | 12521.5 | 11884
SFI | [NAME] | Feed | Increase gluten meal moist from 7.5 to  9.5% |  | 1.Compl | CostRed | Ener/Wtr | 0 | 210 | Franklin | 2009-03-31 00:00:00 | complete |  | 0 | Increased gluten yield and reduced drying cost. |  |  | 0 | 210
SFI | [NAME] | Feed | Optimize boilout caustic use |  | 1.Compl | CostRed | Ingred | 0 | 10 | Olsen | 2009-03-31 00:00:00 | complete |  | 0 | Reduced caustic usage |  |  | 0 | 10
SFI | [NAME] | Feed | Get SSD Drier economizer in service |  | 1.Compl | CostRed | Ener/Wtr | 20 | 130 | Schlueter | 2009-03-31 00:00:00 | complete |  | 0.1538461538461539 | Increased energy recovery and reduce coal/gas usage |  |  | 20 | 130
SFI | [NAME] | General | Reduce Outside Contractor spend |  | 1.Compl | CostRed | Fixed | 0 | 1500 | Niebrugge | 2009-03-31 00:00:00 | complete |  | 0 | Reduced about 20 personnel. |  |  | 0 | 1500
SFI | [NAME] | General | Reduce overtime, currently 16% |  | 1.Compl | CostRed | Fixed | 0 | 370 | Niebrugge | 2009-03-31 00:00:00 | complete |  | 0 | Down to below 10%. |  |  | 0 | 370
SFI | [NAME] | Malto | [NAME] reprocess tank |  | 1.Compl | CostRed | Yield/Val | 31.5 | 160 | Robbins | 2009-03-31 00:00:00 | complete |  | 0.196875 | Reprocess OOS Splenda vs selling as distressed. |  |  | 31.5 | 160
SFI | [NAME] | Malto | Recover #2 Jet flash to [NAME] |  | 1.Compl | CostRed | Ener/Wtr | 36 | 18 | Osterholt | 2009-03-31 00:00:00 | 2009-02-09 00:00:00 |  | 2 | Unable to finish due to corrosion concerns. |  |  | 36 | 18
SFI | [NAME] | Malto | Malto evaporator, Add Single Effect |  | 1.Compl | CostRed | Ener/Wtr | 190 | 75 | Osterholt | 2009-03-31 00:00:00 | complete |  | 2.533333333333333 | Utilize flash steam on the single effect evap to reduce energy costs |  |  | 190 | 75
SFI | [NAME] | [NAME] | Process water for w/m machine flushes |  | 1.Compl | CostRed | Ener/Wtr | 0 | 25 | Franklin | 2009-03-31 00:00:00 | complete |  | 0 | Reduce water usage |  |  | 0 | 25
SFI | [NAME] | Spray | Optimize feed dry substance on [NAME] |  | 1.Compl | CostRed | Ener/Wtr | 0 | 75 | Goodall | 2009-03-31 00:00:00 | complete |  | 0 | ~15mmlbs/yr production increase up to next bottleneck |  |  | 0 | 75
SFI | [NAME] | Spray | Get washer Pods on line on Spray 2 |  | 1.Compl | CostRed | Ener/Wtr | 48 | 616 | Goodall | 2009-03-31 00:00:00 | complete |  | 0.07792207792207792 | Increase spray 2 production by 8mmlbs/yr and reduce water usage by 180,000 Gal/day |  |  | 48 | 616
SFI | [NAME] | Starch | Optimize propylene oxide specific consumption |  | 1.Compl | CostRed | Ingred | 0 | 100 | Erny | 2009-03-31 00:00:00 | complete |  | 0 | Lengthen reactions from 24 hours to 32 hours. |  |  | 0 | 100
SFI | [NAME] | Starch | Increase %1A quality |  | 1.Compl | CostRed | Yield/Val | 0 | 1000 | LaDage | 2009-03-31 00:00:00 | complete |  | 0 | Improved to over 99% 1-A first pass |  |  | 0 | 1000
SFI | [NAME] | Starch | Glycol & hot oil heating on Flash #1 |  | 1.Compl | CostRed | Ener/Wtr | 168 | 187 | Sauer | 2009-03-31 00:00:00 | complete |  | 0.8983957219251337 | Drying cost savings only as final moisture is controlled at South Plant |  |  | 168 | 187
SFI | [NAME] | Utilities | Lower 162 psig header to 158 psig |  | 1.Compl | CostRed | Ener/Wtr | 0 | 57 | [NAME] | 2009-03-31 00:00:00 | complete |  | 0 | Increased power generation at lower pressure |  |  | 0 | 57
SFI | [NAME] | Utilities | Lower 50 psig header to 42 psig |  | 1.Compl | CostRed | Ener/Wtr | 0 | 41 | [NAME] | 2009-03-31 00:00:00 | complete |  | 0 | Increased power generation at lower pressure |  |  | 0 | 41
SFI | [NAME] | Utilities | Optimize biogas usage |  | 1.Compl | CostRed | Ener/Wtr | 0 | 500 | [NAME] | 2009-03-31 00:00:00 | complete |  | 0 | Better utilization of biogas to reduce natural gas usage. |  |  | 0 | 500
SFI | [NAME] | Utilities | New solid waste contract |  | 1.Compl | CostRed | Fixed | 0 | 231 | Wiederhold | 2009-03-31 00:00:00 | complete |  | 0 | Reduced cost with new contract and recycling |  |  | 0 | 231
SFI | [NAME] | Feed | Increase HSW addition to feed (reduced wet feed sold) |  | 2.Active | CostRed | Yield/Val | 100 | 2520 | Schlueter | 2009-03-31 00:00:00 | partial |  | 0.03968253968253968 | Eliminate generation of wet feed and sale of HSW. 90% complete. |  |  | 100 | 2520
SFI | [NAME] | Feed | Increase germ yield |  | 2.Active | CostRed | Yield/Val | 100 | 815 | Swift | 2009-03-31 00:00:00 | partial |  | 0.1226993865030675 | Increase .15#/bu to 1.67#/Bu. Actual of 1.63 over last 2 months. |  |  | 100 | 815
SFI | [NAME] | [NAME] | Maximize gluten meal yield |  | 2.Active | CostRed | Yield/Val | 41 | 355 | Swift | 2009-03-31 00:00:00 | complete |  | 0.1154929577464789 | Increase by 0.1lb/bu to 2.35 lb/bu. 2.46 lb/bu in December. |  |  | 41 | 355
SFI | [NAME] | Chemicals | Bulk Rail HCl |  | 1.Compl | CostRed | Ingred | 47 | 63 |  | 2010-03-31 00:00:00 | 2009-09-09 00:00:00 |  | 0.746031746031746 | Reduce cost by going to rail vs bulk truck. |  |  |  |  | 47 | 63
SFI | [NAME] | Packaging | Minimize switch-over material amounts |  | 1.Compl | CostRed | Yield/Val | 0 | 400 | [NAME] | 2010-03-31 00:00:00 | 2009-11-09 00:00:00 |  | 0 | Matrix is being put together. Plan to implement in November. |  |  |  |  | 0 | 400
SFI | [NAME] | Packaging | Switch to food-ink; eliminate poly-lined bags (where possible) |  | 1.Compl | CostRed | Ingred | 67 | 370 | [NAME] | 2010-03-31 00:00:00 | 2009-04-09 00:00:00 |  | 0.1810810810810811 | Bag savings by going to non-lined bags. |  |  |  |  | 67 | 370
SFI | [NAME] | Starch | New cloth on Flash 3 Larox Filters (2nd Trial in progress) |  | 1.Compl | CostRed | Yield/Val | 0 | 255 |  | 2010-03-31 00:00:00 | 2010-01-01 00:00:00 |  | 0 |  |  |  |  |  | 0 | 255
SFI | [NAME] | Starch | Decrease modified starch cake moisture - plastic plates |  | 1.Compl | CostRed | Fixed | 1500 | 520 | Goodall | 2010-03-31 00:00:00 | 2009-08-09 00:00:00 |  | 2.884615384615385 | [NAME]/yr, Energy savings-$120k/yr |  |  |  |  | 1500 | 520
SFI | [NAME] | Steephouse | Steep 11 Screen Replacement |  | 1.Compl | CostRed | Yield/Val | 14 | 85 |  | 2010-03-31 00:00:00 | 2009-08-09 00:00:00 |  | 0.1647058823529412 | Improve yield by improving steeping. |  |  |  |  | 14 | 85
SFI | [NAME] | Utilities | Reduce plant air usage through metering and daily review |  | 1.Compl | CostRed | Ener/Wtr | 0 | 140 |  | 2010-03-31 00:00:00 | 2009-05-09 00:00:00 |  | 0 | Reduced electrical usage by taking a compressor off line. |  |  |  |  | 0 | 140
SFI | [NAME] | Utilities | Trasar use for boiler chemical control |  | 1.Compl | CostRed | Ingred | 20 | 120 |  | 2010-03-31 00:00:00 | 2009-09-09 00:00:00 |  | 0.1666666666666667 | Reduce boiler chemical usage. |  |  |  |  | 20 | 120
SFI | [NAME] | Utilities | Recover dextrin condensate |  | 1.Compl | CostRed | Ener/Wtr | 15 | 65 |  | 2010-03-31 00:00:00 | 2010-03-10 00:00:00 |  | 0.2307692307692308 | Condensate currently going to the sewer. Recover as good condensate to boiler. |  |  |  |  | 15 | 65
SFI | [NAME] | Utilities | Polymer Dilution Skid |  | 1.Compl | CostRed | Ener/Wtr | 50 | 121 |  | 2010-03-31 00:00:00 | 2010-03-10 00:00:00 |  | 0.4132231404958678 |  |  |  |  |  | 50 | 121
SFI | [NAME] | Utilities | Refinery Condensate Reclaim to Feedhouse hot water loop |  | 1.Compl | CostRed | Ener/Wtr | 36 | 80 |  | 2010-03-31 00:00:00 | 2009-05-09 00:00:00 |  | 0.45 | Saving water by replacing fresh water with vapor condensate. |  |  |  |  | 36 | 80
SFI | [NAME] | Utilities | Cathode system for well #1 |  | 1.Compl | CostRed | Ener/Wtr | 17 | 24 |  | 2010-03-31 00:00:00 | 2009-12-09 00:00:00 |  | 0.7083333333333334 | Avoided maintenance and replacement cost |  |  |  |  | 17 | 24
SFI | [NAME] | Wetmill | High efficiency centrifuge nozzles |  | 1.Compl | CostRed | Ener/Wtr | 70 | 69 |  | 2010-03-31 00:00:00 | 2009-12-09 00:00:00 |  | 1.014492753623188 | AFE is prepared but not approved yet. |  |  |  |  | 70 | 69
SFI | [NAME] | Feed | Increase HSW addition to feed (reduced wet feed sold) |  | 2.Active | CostRed | Yield/Val | 13 | 280 | Schlueter | 2010-03-31 00:00:00 | 2009-08-09 00:00:00 |  | 0.04642857142857143 | Eliminate generation of wet feed and sale of HSW. |  |  |  |  | 13 | 280
SFI | [NAME] | Feedhouse | Reprogram FH Hot Water loop for MAX flow (up to tower flow limit) |  | 1.Compl | CostRed | Ener/Wtr | 0 | 20 | Erny | 2011-03-31 00:00:00 | 2010-09-10 00:00:00 |  | 0 | Only req'd re-programming. Done. Saving's based on 600kbut/hr more HR. |  |  |  |  |  |  | 0 | 20
SFI | [NAME] | Quality | [NAME] data from SAP |  | 1.Compl | CostRed | Yield/Val | 85 | 250 | Purdue | 2011-03-31 00:00:00 | 2010-07-10 00:00:00 | 6 | 0.34 |  |  |  |  |  |  |  | 85 | 250
SFI | [NAME] | Refinery | Refinery Jet Flash Steam Recovery |  | 1.Compl | CostRed | Ener/Wtr | 21 | 27 | Osterholt | 2011-03-31 00:00:00 | 2010-06-10 00:00:00 |  | 0.7777777777777778 | Done and in operation. A few minor operational issues, but working OK w/ training. |  |  |  |  |  |  | 21 | 27
SFI | [NAME] | Feed | SSD/Feed dryer Improvements |  | 2.Active | CostRed | Ener/Wtr | 620 | TBD | Erny | 2011-03-31 00:00:00 | 2010-11-01 00:00:00 | 6 | TBD | Construction in progress; majority complete by Nov-1-2010 |  |  |  |  |  |  |  |  | 620
SFI | [NAME] | Modified | Use changover for starch products |  | 2.Active | CostRed | Yield/Val | 75 | TBD | Diehl | 2011-03-31 00:00:00 | 2010-10-10 00:00:00 |  | TBD | Construction in progress; expect startup complete by Jan-1-2011 |  |  |  |  |  |  |  |  | 75
SFI | [NAME] | Steephouse | Mixer for LSW tank |  | 2.Active | CostRed | Ener/Wtr | 10 | TBD | [NAME] | 2011-03-31 00:00:00 |  |  | TBD | Savings in Outside Services for cleanouts. Expensing on maintenance (mixer, pump) |  |  |  |  |  |  |  |  | 10
SFI | [NAME] | Starch | Belt Dryers: [NAME] to Glycol & Surplus Steam |  | 3.Subt'd | CostRed | Ener/Wtr | 855 | TBD | Sauer | 2011-03-31 00:00:00 | 2010-11-10 00:00:00 | 12 | TBD | Waste heat used to reduce steam usage |  |  |  |  |  |  |  |  | 855
SFI | [NAME] | Refinery | Recover flash steam from refinery cond receivers |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | [NAME] | 2011-03-31 00:00:00 |  |  | TBD | New option: route flash to Malto evap, before MV (evap down) & after (evap up) MV
SFI | [NAME] | Refinery | Improve Ref CT Controls; start by installing [NAME]-Up FT |  | 5.Prop'd | CostRed | Ener/Wtr | 10 | TBD | Morehouse | 2011-03-31 00:00:00 |  | 4 | TBD | Water and electrical savings. (No change as of 10-6-2010.) |  |  |  |  |  |  |  |  | 10
SFI | [NAME] | Starch | Spray1 Dryer: [NAME] to Glycol & Hot Oil |  | 5.Prop'd | CostRed | Ener/Wtr | 575 | TBD | Sauer | 2011-03-31 00:00:00 | 2010-11-10 00:00:00 | 12 | TBD | Waste heat and coal fired steam used to reduce gas usage |  |  |  |  |  |  |  |  | 575
SFI | [NAME] | Starch | Agglomerator [NAME] |  | 5.Prop'd | CostRed | Fixed | 192 | TBD | Osterholt | 2011-03-31 00:00:00 |  | 10 | TBD | In process of internal plant review. Expect to submit AFE by 11-1-2010. |  |  |  |  |  |  |  |  | 192
SFI | [NAME] | Utilities | Heat the 180 degree water system with waste heat. |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Erny | 2011-03-31 00:00:00 |  |  | TBD | Project being defined.  (No change as of 10-6-2010.)
SFI | [NAME] | Utilities | Automate Blower Control via PLC based on basin DO |  | 5.Prop'd | CostRed | Ener/Wtr | 20 | TBD | Goodall | 2011-03-31 00:00:00 |  |  | TBD | (No change as of 10-6-2010.) |  |  |  |  |  |  |  |  | 20
SFI | [NAME] | Feed | Preheat comb. air to Steam Tube Feed Dryer |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Erny | 2012-03-31 00:00:00 |  |  | TBD | Reduce N-Gas use by PH'ing with WH or Stm. Review after completing SSD improve's.
SFI | [NAME] | Feed | Re-Prog SSD Cond PIC for [NAME] use of WH |  | 5.Prop'd | CostRed | Ener/Wtr | 0 | TBD | Erny | 2012-03-31 00:00:00 |  |  | TBD | Will pursue when users > input. Current ctl limits wtr flow if PV<14%. New ctl would limit if <1% (cond more). |  |  |  |  |  |  |  |  |  |  | 0
SFI | [NAME] | Feedhouse | Route surplus Flash Steam to SSD Cond (not HW Tower) |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Erny | 2012-03-31 00:00:00 |  |  | TBD | Will pursue once issues resolved that prevent incr. press on SH cond rec'r system
SFI | [NAME] | General | Power Factor Correction New Subs 12253 |  | 5.Prop'd | CostRed | Ener/Wtr | 75 | TBD | Titlow | 2012-03-31 00:00:00 |  | 3 | TBD |  |  |  |  |  |  |  |  |  |  |  | 75
SFI | [NAME] | Malto | [NAME] to Granular Carbon |  | 5.Prop'd | CostRed | Ingred | 1200 | TBD | Osterholt | 2012-03-31 00:00:00 |  |  | TBD | Needs definition. |  |  |  |  |  |  |  |  |  |  | 1200
SFI | [NAME] | Modified | Replace PIC Heaters w/ Waste Heat (after 180F completion) |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Osterholt | 2012-03-31 00:00:00 |  |  | TBD | Contingent on installing 180F system on wasteheat
SFI | [NAME] | Starch | Recover fines off of spray 1 collectors |  | 5.Prop'd | CostRed | Yield/Val | TBD | TBD | Cornell | 2012-03-31 00:00:00 |  |  | TBD
SFI | [NAME] | Starch | Sulfate recovery (incl. [NAME]) |  | 5.Prop'd | CostRed | Ingred | TBD | TBD | Diehl | 2012-03-31 00:00:00 |  |  | TBD | May not justify with current technology
SFI | [NAME] | Starch | Optimize starch moistures |  | 5.Prop'd | CostRed | Yield/Val | TBD | TBD | Purdue | 2012-03-31 00:00:00 |  |  | TBD
SFI | [NAME] | Steephouse | Recover Steep Evap V/C, use as Hot-Water Loop makeup |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Erny | 2012-03-31 00:00:00 |  |  | TBD | Will pursue once high alcohol in LSW mitigated (see LSW Mixer proj)
SFI | [NAME] | Steephouse | Pre-heat LSW w/ waste heat vs 50# steam |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | [NAME] | 2012-03-31 00:00:00 |  |  | TBD | Developing best process for project
SFI | [NAME] | Utilities | Replace Boiler Steam Preheat w/ Waste Heat (after 180F completion) |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Goodall | 2012-03-31 00:00:00 |  |  | TBD | Contingent on 180F system on WH; also conting on impact of re-duct FD inlet
SFI | [NAME] | Utilities | RO for Boiler Make-up |  | 5.Prop'd | CostRed | Ingred | 1200 | TBD | Goodall | 2012-03-31 00:00:00 |  | 12 | TBD | Save on boiler pre-heat cost (elev inlet temp by 20F) |  |  |  |  |  |  |  |  |  |  | 1200
SFI | [NAME] | Utilities | [NAME] |  | 5.Prop'd | CostRed | Yield/Val | TBD | TBD | Goodall | 2012-03-31 00:00:00 |  |  | TBD
SFI | [NAME] | Utilities | Switch to high sulfur coal |  | 5.Prop'd | CostRed | Ener/Wtr | 4200 | TBD | [NAME] | 2012-03-31 00:00:00 |  | 24 | TBD | Feasibility paper has been written |  |  |  |  |  |  |  |  |  |  | 4200
SFI | [NAME] | Utilities | Move FD air inlet to upper level of 31 bldg |  | 5.Prop'd | CostRed | Ener/Wtr | 50 | TBD | Market | 2012-03-31 00:00:00 |  |  | TBD | Save on boiler feedwater treatment cost |  |  |  |  |  |  |  |  |  |  | 50
SFI | [NAME] | Utilities | Other MBR re-use water |  | 5.Prop'd | CostRed | Ener/Wtr | TBD | TBD | Market | 2012-03-31 00:00:00 |  |  | TBD
SFI | [NAME] | Utilities | Utilities condensate receiver vent steam recovery |  | 5.Prop'd | CostRed | Ener/Wtr | 290 | TBD | Sauer | 2012-03-31 00:00:00 |  | 10 | TBD | $[NAME]: [NAME] condensor on roof fed by makeup wtr drain to cond tank; new low NPSHR pumps |  |  |  |  |  |  |  |  |  |  | 290
SFI | [NAME] | Utilities | Use 650# steam to keep gas boilers warm (phase1: 1 boiler) |  | 5.Prop'd | CostRed | Ener/Wtr | 300 | TBD | Goodall | 2013-03-31 00:00:00 |  |  | TBD | Route 650# to mud drum coils, How to deal w/ cond? How to control? |  |  |  |  |  |  |  |  |  |  |  |  | 300
SFI | [NAME] | Utilities | Use Softner Rinse effluent for brine tank makeup |  | 5.Prop'd | CostRed | Ener/Wtr | 160 | TBD | Goodall | 2013-03-31 00:00:00 |  |  | TBD |  |  |  |  |  |  |  |  |  |  |  |  |  | 160