INDUSTRIAL ENERGY EFFICIENCY PROJECT CASE STUDIES SUSTAINABILITY CONFERENCE 2014

Transcription

1 INDUSTRIAL ENERGY EFFICIENCY PROJECT CASE STUDIES SUSTAINABILITY CONFERENCE 2014 Faith Mkhacwa: Regional Project Manager B Eng., MBL, EnMS Expert (UNIDO)

2 EnMS - ISO ESO

3 UNIDO EnMS Programme Operational in 13 countries on-going & planned activities in more than 30 countries Operational South Africa Moldova Russia Turkey Iran Malaysia Thailand Vietnam Philippines Egypt Indonesia Ecuador Total UNIDO Funds Total Co-Funding Total Project Funding US$ 58M US$ 456M US$ 514M

4 EnMS Victories

5 Implementation Highlights Company ArcelorMittal Saldanha kwh Savings 2011/ /13 Comments No/low cost investments. Toyota SA Projects; Compressed Air, Lighting, Pumps, etc.. Gelvenor Textiles Saint-Gobain Construction Products projects; switched off generator & chillers and fitted VSD s to 9 circulation fans Combustion efficiency improvement, lighting, compressed air, water gauge

6 EnMS Implementation Outcomes Company kwh Savings Energy Systems Mercedes Benz Compressed Air System Kraft Foods pf, Lighting, idle machines PPC Cement PE Axial sampling of grinding media Tenneco Emission Control Lighting Tenneco Ride Control Oven, Knives, Induction Geyser, VSD Willard Batteries Curing time, wet scrubbers, chargers Distell Adam Tas Winery Lighting, Compressors Sappi Cape Kraft Peak clipping Polyoak Packaging CT Lighting retrofit BMW Paintshop ovens, driers Consol Glass - Wadeville Lighting, Compressor ACSA Durban Lighting Feltex Cooling, Comp, Lights, idle Mach Richards Bay Minerals Pumps, Compressed Air, Lighting Total

7 Energy Management Standard ISO Purpose: Enable organizations to establish systems and processes necessary to improve energy performance Applicable to all organizations Does NOT prescribe specific performance criteria with respect to energy Source: SWEDAC

8 Other ISO Standards Different standards All critical One CANNOT replace the other ISO Energy Management ISO ISO 9001 Environmental Management Other Management Systems Quality Management

9 ISO CERTIFIED COMPANIES

10 Tenneco Ride Control & Emission Control Intervention Capital Cost Savings Energy saving ZAR ZAR Compressed air systems R R kwh Compressed air optimisation Lighting initiatives R R kwh Factory, Offices, Sensors, Daylight Harvesting Paint shop burner submersion tube R R kwh Automatic metering. R Better energy Electricity, LPG, Shielding gas weight management. New Chrome Planting oven R R kwh Power Factor correction at Tenneco Emission Control. To be R R kva done at Tenneco - Ride Control Procedures Shutdown, SEU training - - Better energy management. TOTAL R R kwh ISO Certified!!!

11 ENERGY SYSTEMS OPTIMISATION

12 Energy Systems Optimisation (ESO) Component Approach - Segregate components - Analyse performance of each in isolation May result from education by a specific technology sales engineer (e.g.: VSD or steam trap) 2-5% efficiency gains on the total energy consumption Systems Approach - Look at how the entire group functions together - How will changing one impact the other? More knowledge of system and its interactions required 10-50% average efficiency gains Shifting FOCUS from Component optimization to systems optimization!!!

13 ESO Implementation Victories Company Energy System Savings Comments Rhodes Foods Group- Franchhoek Annualized Steam R year payback (Not implemented) Da Gama Textiles Steam R year payback (Implementation underway) SAB Maltings Steam R year payback (Started system optimisation) Arcelor Mittal-Saldanha Works Pump R Cooling system Pump throttle settings changed. Impala Platinum Pump R Switching off cooling system pump and fan. Kraft Foods Electricity R223, 304 Switching off idle machines. Savings over shutdown. R

14 SME SUCCESS STORIES

15 Techniplate- Silverton, Pretoria Implementation Statistics Trigger: Plating tanks- temperature variations, excessive temp and excessive energy usage Energy Savings : 19.3% or kWh/annum 23.5% or R /annum Investment Cost: R Payback Period: 4 months * Better process control Better products. Implementation Detail and Actions Background: Temperature was manually controlled on plating tanks Average of 6 C higher than required= 4.4kWh Optimisation Detail: Temperature controller & Energy Meter installed (42 tanks in total) Measurement and Data Analysis: Manual vs Auto control resulted in 4.7 C hotter tank temperature. Higher variability Higher energy consumption as per temperature profile.

16 Precision Press - Cape Town Energy Reduction Opportunity Capital Cost (ZAR ) Savings per annum (ZAR ) Payback Months Environmental Benefit per annum Switching-off electrical equipment hydroboils, lights & motors (presses) when not in use) , ,000 kwh Compressed air (leak tagging, awareness & sustainable system) 0 28, kwh TOTAL R R 66, kwh

17 UNIDO Training PSO CASO EnMS ESO SSO PHSO MSO FSO

18 UNIDO Training Elements, Target Groups and Objectives 1 day Awareness Workshop 2 day Users Training Experts Training Target Group: Process engineers, Energy consultants, Equipment vendors and Service providers. Objective: To buy into EnMS, ESO and the IEE project Target Group: Process engineers, Energy consultants, Equipment vendors and Service providers. Objective: To share in-depth technical information on undertaking system energy assessment Target Group: EE consultants, ESCO s, Specialists and others Objective: Experts that deliver energy performance improvements and best practices that are sustainable

19 Some of the participating companies

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21 Thank you