Faith Mkhacwa NCPC
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NCPC Energy Audits Program for Industry

NCPC Energy Audits Program for Industry

Faith Mkhacwa, Project Specialist, Industrial Energy Efficiency Project
National Cleaner Production Centre of SA

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  • Both aspects are crucial
  • Management focus: On production NOT on energy efficiency Lack of information and understanding: Financial and qualitative benefits Lack of adequate technical skills: For developing and implementing EE measures and projects Poor monitoring systems and data Disconnection between capital and operating budgets: First costs more important than recurring costs Sustainability Risk: If EE knowledge exists, it often resides with individuals rather than with the organization Defensiveness: “I’m already doing a good job!”
  • Most industrial enterprises that have implemented EnMS achieved average annual energy intensity reductions of 2-3% against the 1% reduction of business as usual (Ireland, Netherlands, Denmark, USA). Organizations new to energy management achieved savings 10-20% during the first 2 years.
  • Component approach involves segregating components and analyzing the performance of each in isolation Can result from education by particular technology sales engineer, e.g. variable speed drive, steam trap, etc. System approach involves looking at how the whole group functions together and how changing one can help or impact another - R equires more knowledge of the system and its interactions Steam, motor-driven and related systems account for approximately 50% of final manufacturing energy use worldwide. 2-5% efficiency gains on the total energy consumption at an industrial plant for individual components against 10-50% average efficiency gains that are possible through system optimization Energy savings opportunities from systems are greater than from individual components
  • THE SYSTEMS APPROACH : - ESTABLISH current systems conditions, operating parameters & system energy use - INVESTIGATE how the total system presently operates - IDENTIFY potential areas where a system operation can be improved - ANALYZE the impacts of potential improvements to the plant system - IMPLEMENT system improvement that meets plant operational and financial criteria - Continue to MONITOR overall system performance
  • Potential KWh savings (SME’s)

Faith Mkhacwa NCPC Presentation Transcript

  • 1. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●Demonstration1The Case Study: Industrial EnergyEfficiency Improvement ProjectIDC11 June 2013
  • 2. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationProject Component• Effective National Policy Framework: Providingsupport through facilitating the review of NEES• Supportive Standards: ISO 50001• Cadre of EnMS/ESO Experts: Training• Target Industrial Clusters: Demonstration Plants,Implementation (EnMS, ESO and SME Assessments)and Case Studies
  • 3. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationEnergy Management Standard: ISO 50001• Purpose: Enable organizations to establish systems and processes necessary to improve energyperformance• Applicable to all organizations• Does NOT prescribe specific performance criteria with respect to energy
  • 4. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationOther ISO StandardsDifferent standards → All critical → One CANNOT replace the otherEnergyManagementISO 50001EnvironmentalManagementISO 14000Quality ManagementISO9001Other Management Systems
  • 5. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationIndustrial Energy Efficiency BenefitsEnergy efficiency has demonstrated, time and again, that it Saves industrial firms money Increase reliability of operations Has a positive effect on productivity and competitiveness Can offer attractive financial and economic returns Reduces exposure to rising energy prices Increases security of supply ….Why it is not happening?
  • 6. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationBarriers to Industrial Energy Efficiency• Management focus• Lack of information and understanding• Lack of adequate technical skills• Poor monitoring systems and data• Disconnection between capital and operatingbudgets• Sustainability Risk• Defensiveness
  • 7. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationAd hoc approach to managing energy
  • 8. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationStructured approach to managing energy
  • 9. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationSavings: 4 Small – Medium Chemical companies5 Medium – Large Textiles, leather & footwear companiesOption DescriptionSaving(Rand)Investment(Rand)SimplePayback (Yrs)Environmental Benefit(per year)CO2e(kg/yr)Boiler Improvementi. Steam leaksii. Pressure controliii. Insulationiv. Boiler feed air controlv. Condensate returnvi. Steam trap maintenance324 200 126 500 1.046 900 kg Low SulphurOil3 kL/yr heavy fuel oil750kL Water158 700Compressor Controli. Air leak maintenanceii. Vairable speed controliii. Pressure controliv. Flow control (Accumulator)177 232 329 975 1.9 267 641kWh 156 982Energy Managementi. Washbath covers (insulation)ii. Washbath Insulation37 295 n/a n/a31 116kWh303kg LPG32 500Lighting Retrofittingi. Replacement of bulbsii. Retrofit of Electronic Control Geariii. Natural lightingiv. Task lighting479 937 753 511 1.6423 695 kWh1.8kVA154 552
  • 10. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationEnMS ResultsIndustrial enterprisesthat implemented EnMSBusiness as usual Organisations new toenergy management2-3% Annual energyintensity reductions1% Annual energyintensity reduction10-20% savings duringthe first 2 years•EnMS accelerate adoption of EE best-practices and technologyupgrades, enhances productivity and competitiveness.•Improve enterprises’ bottom line.
  • 11. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationEnMS Implementation VictoriesCompany Sector kWh Savings Comments2011/12 2012/13Arcelor mittal-Saldanha WorksMetals 81 325 527 10 600 000 Primarily no costinvestmentsToyota- SA Automotive 4 484 533 1 717 511 Compressed Air, Lighting,Pumps, etc..GelvenorTextilesTextiles 996 670 Tbc Only 3 projectsSaint-Gobain ConstructionProducts917 916 Tbc Excludes ongoing watergauge project87 724 646 12 317 511
  • 12. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationOur approach to systemsoptimisation
  • 13. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationStart with what you have......then look to address technology and capital intensiveoptions...Leakages in compressed air systemsHeat Exchanger fouling
  • 14. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationEnergy Systems Optimisation (ESO)Component Approach Systems Approach- Segregate components- Analyse performance of each in isolation- Look at how the entire group functionstogether- How will changing one impact the other?May result from education by a specifictechnology sales engineer (e.g.: VSD orsteam trap)More knowledge of system and itsinteractions required2-5% efficiency gains on the total energyconsumption10-50% average efficiency gainsShifting FOCUS from Component optimization to systemsoptimization!!!
  • 15. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationSystems Approach15 kW MotorEfficiency = 91%Combined Motor &Pump Efficiency = 59%System Efficiency = 13%
  • 16. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationESO Example
  • 17. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationESO Implementation VictoriesCompany EnergySystemSavings CommentsAnnualizedRhodes Foods Group-FranchhoekSteam R881 794 0.2 year payback (Notimplemented)Da Gama Textiles Steam R9 267 000 2.3 year payback (Implementationunderway)SAB Maltings Steam R6 603 028 1.0 year payback (Started systemoptimisation)Arcelor Mittal-SaldanhaWorksPump R1 108 851 Cooling system Pump throttlesettings changed.Impala Platinum Pump R285 205 Switching off cooling systempump and fan.Kraft Foods Electricity R223, 304 Switching off idle machines.Savings over shutdown.R18 369 182
  • 18. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationSector Distribution of SME’s Audited
  • 19. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationParticipating companies
  • 20. Industrial Energy Efficiency Project● Policy Framework Introduction of Standards● Capacity Building● ●DemonstrationThank youFaith Mkhacwa: Regional Project Manager-IEETelephone: +27(0)12 841 4097Email: fdaba@csir.co.zaWebsites: www.ncpc.co.za/www.iee-sa.co.za?