INDUSTRIAL ENERGY EFFICIENCY PROJECT CASE STUDIES SUSTAINABILITY CONFERENCE 2014 Faith Mkhacwa: Regional Project Manager B Eng., MBL, EnMS Expert (UNIDO)
EnMS - ISO 50001 - ESO
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
EnMS Victories
Implementation Highlights Company ArcelorMittal Saldanha kwh Savings 2011/12 2012/13 Comments 81 325 527 92 676 882 No/low cost investments. Toyota SA 4 484 533 11 131 462 73 Projects; Compressed Air, Lighting, Pumps, etc.. Gelvenor Textiles Saint-Gobain Construction Products 996 670 996 670 3 projects; switched off generator & chillers and fitted VSD s to 9 circulation fans. 917 916 917 916 Combustion efficiency improvement, lighting, compressed air, water gauge. 87 724 646 105 722 930
EnMS Implementation Outcomes Company kwh Savings Energy Systems Mercedes Benz 1 400 000 Compressed Air System Kraft Foods 2 915 912 pf, Lighting, idle machines PPC Cement PE 51 531 Axial sampling of grinding media Tenneco Emission Control 301 564 Lighting Tenneco Ride Control 1 181 844 Oven, Knives, Induction Geyser, VSD Willard Batteries 2 817 649 Curing time, wet scrubbers, chargers Distell Adam Tas Winery 298 554 Lighting, Compressors Sappi Cape Kraft 184 722 Peak clipping Polyoak Packaging CT 194 400 Lighting retrofit BMW 8 850 000 Paintshop ovens, driers Consol Glass - Wadeville 2 084 392 Lighting, Compressor ACSA Durban 393 148 Lighting Feltex 1 305 804 Cooling, Comp, Lights, idle Mach Richards Bay Minerals 3 919 687 Pumps, Compressed Air, Lighting Total 25 899 207
Energy Management Standard ISO 50001 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
Other ISO Standards Different standards All critical One CANNOT replace the other ISO 14000 Energy Management ISO 50001 ISO 9001 Environmental Management Other Management Systems Quality Management
ISO 50001 CERTIFIED COMPANIES
Tenneco Ride Control & Emission Control Intervention Capital Cost Savings Energy saving ZAR ZAR Compressed air systems R 1 023 265.30 R 425 595 766 305 kwh Compressed air optimisation Lighting initiatives R 1 076 695.40 R 780 131.49 926 064 kwh Factory, Offices, Sensors, Daylight Harvesting Paint shop burner submersion tube R 35 000 R 16 284 15 366 kwh Automatic metering. R 149 011 - Better energy Electricity, LPG, Shielding gas weight management. New Chrome Planting oven R 750 000 R 634 508 829 444 kwh Power Factor correction at Tenneco Emission Control. To be R 69 079 R 142 776 127 kva done at Tenneco - Ride Control Procedures Shutdown, SEU training - - Better energy management. TOTAL R 3 103 050.70 R 1 999 294.49 2 537 179 kwh ISO 50001 Certified!!!
ENERGY SYSTEMS OPTIMISATION
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!!!
ESO Implementation Victories Company Energy System Savings Comments Rhodes Foods Group- Franchhoek Annualized Steam R881 794 0.2 year payback (Not implemented) Da Gama Textiles Steam R9 267 000 2.3 year payback (Implementation underway) SAB Maltings Steam R6 603 028 1.0 year payback (Started system optimisation) Arcelor Mittal-Saldanha Works Pump R1 108 851 Cooling system Pump throttle settings changed. Impala Platinum Pump R285 205 Switching off cooling system pump and fan. Kraft Foods Electricity R223, 304 Switching off idle machines. Savings over shutdown. R18 369 182
SME SUCCESS STORIES
Techniplate- Silverton, Pretoria Implementation Statistics Trigger: Plating tanks- temperature variations, excessive temp and excessive energy usage Energy Savings : 19.3% or 421 344kWh/annum 23.5% or R172 751/annum Investment Cost: R46 200 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.
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) 793.20 37,699 0.25 55,000 kwh Compressed air (leak tagging, awareness & sustainable system) 0 28,566-62 100 kwh TOTAL R 793.20 R 66,265 0.14 117 100 kwh
UNIDO Training PSO CASO EnMS ESO SSO PHSO MSO FSO
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
Some of the participating companies
fdaba@csir.co.za
Thank you