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Maik winges

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Cross Cutting Presentations

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Maik winges

  1. 1. NCPC-SA Industrial Efficiency Conference 2017 Cape Town 14 September Improving Resource Efficiency in the Manufacturing Sector in the Eastern Cape
  2. 2. Idea and Approach – Target group: SMMEs + champion companies that share and attract – Main objective: low hanging fruits + awareness creation – Main approach: assisted peer learning – ECOPROFT: methodical process to increase resource efficiency and thus save money and protect the environment via: • reviewing resource efficiency in manufacturing • developing evaluating, implementing and reviewing measures that increase resource efficiency and reduce costs • using tools consistent with ISO management systems 2
  3. 3. Elements – thematic workshop: basic information – individual company on-site visits: identification of potential measures – working material that is ISO 14001/50001 compatible and visit protocols -> identification of measures based on cost-benefit- analyses -> implementing monitoring system -> Networking and peer learning 3
  4. 4. 4 Structure
  5. 5. 5 A 3-1 Energy-Inputs/CO2-Emissions A 3-2 Significant Energy Uses (SEUs) A 3-3 Compressed Air A 3-4 Ventilation and Air-Conditioning A 3-5 Refrigeration A 3-6 IT and Workstations A 3-7 Lighting A 3-8 Machines, Motors and Drives A 3-9 Heat Generation A 3-10 Measurement Concept A 3-11 Monthly Energy Input Worksheets table of content
  6. 6. MAP of Participating companies 6
  7. 7. 7 Company Measure Saving in kWh/a Cost Savings in ZAR/a Implementatio n Cost in ZAR Payback period Autopipe Switching off compressor at night 80,000 54,000 0 immediately Fixing compressed air leakages 22,000 15,000 15,000 1 year Switching parts washer to blower 2,000 150 0 < 1 year Isri Repair and upgrade of heat pumps 28,000 19,000 ?? < 3 years Reduction of temperature in degreasing tank 2,000 1,400 0 < 1 year Testing of powder paint with lower curing temperatures To be assessed 0 < 1 year Prism Suggested use of removal barrel insulation blankets on five machines 75,000 51,000 50,000 < 1 year Suggested retrofit of VSDs on three machines 90,000 61,000 150,000 < 3 years Repair of air leaks 24,000 16,000 0 immediate Installation of motion detectors in sanitary units 500 400 400 1 year Yenza Optimizing operating time of compressor 40,000 52,000 0 immediately Fixing compressed air leakages 20,000 26,000 2,000 < 1 year Removing/replacing broken fluorescent tubes 12,000 15,600 10,000 < 1 year Sum 395,500 311,550 227,400
  8. 8. Yenza Manufacturing Port Elizabeth – established in 1997 and employs 15 people – spinning and pressing stainless steel components for Tier 1+2 companies of the automotive industry by spot and robotic welding and assembly 8
  9. 9. Yenza Manufacturing Port Elizabeth – 60 broken but yet glowing fluorescent tubes were replaced or switched off -> 7,000 kWh/a – Air leakages have been detected, new regulators, clamps and fittings have been installed – 55 kW screw compressor was running at very low load of 39 %. – compressor is now switched off completely during nights and week ends -> 59,600 kWh/a 9
  10. 10. Case Study 3 – … 10
  11. 11. Case Study 3 – … 11
  12. 12. Case Study 3 – … 12
  13. 13. Yenza Manufacturing Port Elizabeth – … 13
  14. 14. Yenza Manufacturing Port Elizabeth – … 14
  15. 15. Yenza Manufacturing Port Elizabeth 15 ECOPROFIT savings measures Measure Annual Resource Saving Annual Cost Saving Implementati on Cost Payback period Optimizing operating time of compressor 40,000 kWh R 52,000 R 0 immediat ely Fixing compressed air leakages 20,000 kWh R 26,000 R 2,000 < 1 year Removing/replacing broken fluorescent tubes 12,000 kWh R 15,600 R 10,000 < 1 year
  16. 16. Yenza Manufacturing Port Elizabeth “Ecoprofit has been successful project for us. It has been a first step towards our ISO 14001 certification.“ Themba Mtati 16
  17. 17. Lessons learned – Better together: Group setting leads to exchange and generation of ideas and ensure lasting effect – Keep it short and simple: Work material has to be simple and adjustable – No sweet without sweat: Investing time in resource monitoring requires convincing 17
  18. 18. For further information please contact: Dr Maik Winges maik.winges@giz.de 082 950 6264 Thank you very much!
  19. 19. Worksheets 19 A 3-1 Energy-Inputs/CO2-Emissions A 3-2 Significant Energy Uses (SEUs) A 3-3 Compressed Air A 3-4 Ventilation and Air-Conditioning A 3-5 Refrigeration A 3-6 IT and Workstations A 3-7 Lighting A 3-8 Machines, Motors and Drives A 3-9 Heat Generation A 3-10 Measurement Concept A 3-11 Monthly Energy Input Worksheets table of content
  20. 20. Worksheets 20 Company: Use Rated Power [kW] Average load factor [%] Hours/ Day Days/ Year Hours/ Year Consumption [kWh/ a] Share of Total Electricity uses Compressed Air 60% 0 0 #DIV/0! Ventilation and Air Conditioning 40% 0 0 #DIV/0! Refrigeration 70% 0 0 #DIV/0! IT and servers 50% 0 0 #DIV/0! Lighting 100% 0 0 #DIV/0! Workstations 30% 0 0 #DIV/0! Machines 70% 0 0 #DIV/0! Kitchen/ Canteen 80% 0 0 #DIV/0! Heating pumps 40% 0 0 #DIV/0! Electrical motors and drives 70% 0 0 #DIV/0! 0 0 #DIV/0! 0 0 #DIV/0! Significant Energy Uses (SEUs) ECOPROFIT Date: Author: Version:

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