Assessment of Energy Efficiency Measures Recommended for Industrial Facilities: Environmental, Economic, and Life Cycle Perspectives

This study assesses the economic, environmental, and life cycle impacts of more than 800 industrial Energy Efficiency Measures (EEMs) identified in manufacturing facilities across Nebraska. These EEMs are notable for their rapid implementation and minimal disruption to the facility’s building structure or core processes. The research evaluates the financial viability of EEMs by analyzing utility savings, implementation costs, and payback periods. It also examines their cost-effectiveness in reducing greenhouse gas (GHG) emissions, including calculations of net cost and cost of mitigated CO₂-eq. Key findings indicate that adding insulation to hot pipes and buildings, replacing personal fans with High-Volume, Low-Speed (HVLS) fans, and installing economizers on boilers are among the most cost-effective and environmentally beneficial EEMs. Additionally, lighting upgrades, occupancy sensors, and leak detection in compressed air systems were found to significantly reduce initial GHG emissions. Sector-specific equipment upgrades—such as the electrification of steam shrink tunnels—were also identified as effective decarbonization strategies, particularly when implemented at the end of the equipment’s useful life. These upgrades offered substantial GHG reductions and shorter payback periods. Conversely, measures such as motor replacements, especially when implemented before the equipment has reached the end of its efficient life, were found to be less cost-effective. A Life Cycle Assessment (LCA) was conducted to identify potential burden shifting, where reductions in GHG emissions may be offset by increases in other environmental impacts. LCA results generally aligned with reductions in Scope 1 and 2 operational emissions but also revealed instances of burden shifting. This was particularly evident in equipment-intensive measures such as motor and boiler replacements and the replacement of personal fans with HVLS fans, where high capital investment and the embodied emissions of new equipment materials led to increases in certain environmental impacts. Advisor: Bruce I. Dvorak