Several estimates   Preventive maintenance is estimated to reduce fuel consumption by 0.09 GJ/t-product and electricity consumption by 0.05 GJ/t-product.

  Emissions reductions are estimated to be around 15 g CO₂/t-product.

Annual operating and retrofit costs are estimated to be 0.03/t-product and $0.02/t-product, respectively.

 Cumulative energy savings of around 20130 TJ/y have been enabled in various plants with the use of these tools.

 Approximately 1.5 million tons of CO₂/y savings have been realized with the use of such tools.

  Use of these tools have enabled cumulative savings in excess of US $101 million/y in various plants.

Insulation can typically reduce energy losses by 90%.

 Payback times between 10 to 13 months have been reported In one steel plant it was found that for every 100 feet of piping insulated, energy savings could be upto $19,000 each year (Worrell, et al., 2010. p. 52).

Depending on the pressures involved, the flash steam contains approximately 10% to 40% of the energy content of the original condensate.

The economics of heat recovery projects are most favorable when the waste steam heat content is high and the flow is continuous. Average payback time for this measure is around 9 months.

  Energy saving potential is estimated to be 0.02GJ/t-product (US EPA, 2010)
Electricity savings are estimated to be between 20 – 50% of pump energy consumption (Worrell, et al., 2010. p. 64).

 A plant in Germany saved 3.2 GWh/y and 325 GWh/y with the installation of VSDs (IPPC, 2009). 

Implementation costs are estimated between $1.3/t-product (APP, 2010) to $2.0/t-product.

  Investment costs for the German plant was €67 thousand. It provided annual savings of €32.5 thousand, giving a payback time of 2.1 years, and a RoI of 48%. (IPPC, 2009)

  In one plant installation of a smaller vent blower resulted in electricity savings of 896 MWh/y.

 The smaller fan system enabled cost savings of $35,840/y and had a payback time of 5 months.

Correcting pump oversizing can save 15% to 25% of electricity consumption for pumping on average for the U.S. Industry.

By reducing the impeller diameter from 320 mm to 280 mm, energy savings between 25 to 30% have been realized in plants in the US and the UK.

Maintenance costs were reduced by impeller trimming.

Energy savings depend on how the pumps are operated.  A reduction of 20-30% in electricity use is estimated.

$63,000-$65,000/year reduction in power costs.