This document discusses the systems optimization approach to improving industrial energy efficiency. It advocates observing industrial systems holistically rather than focusing on individual equipment. This approach involves analyzing both energy supply and demand within the system. The document provides an example of optimizing a pumping system which reduced energy usage by 75% through minimizing requirements, adjusting pumps and flow rates. It also shares case studies of numerous South African companies that achieved energy and cost savings through system optimization implemented with support from the Industrial Energy Efficiency Project.

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Presented by the
Industrial Energy Efficiency Project

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The best approach?

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Energy Systems Optimisation
Systems Optimisation
approach requires:
Observation of the
industrial system
as a whole,
not just at the
individual pieces
of equipment
Analysis of
both the supply
and demand
sides of the system
and how they
interact

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The IEE Project equips companies to systematically
target selected systems within their processing facilities and
interrogate their performance and effectiveness.

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Did you know?

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The Systems Approach

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Electric Utility
Feeder
Transformer
Motor Breaker/
Starter
Adjustable
Speed Drive
(electrical)
Motor Coupling Pump Fluid
System
Ultimate
Goal
Slide Courtesy of Oak Ridge National Laboratory
• At each interface, there are inefficiencies.
• The goal should be to maximize the overall
cost effectiveness of the pumping, or how
much flow is delivered per unit of input
energy.
Matching Process and Generation Needs
Approach Methodology

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o What does the user need?
o Consider variations, e.g. seasonal, occupancy, production
schedules, alternative services, etc.
o Optimise use of the service
o How is it used, operations, controls, etc.
o Optimise distribution of the service
o Leaks, pressure drops, insulation, etc...
o FINALLY optimise the generation of
the service
o Boilers, Chillers, Air Compressors, Pumps, etc.
Optimisation process

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10
Candidate Plant 1
Trainers and Co-facilitators
Host Plant
National EnMS
EXPERT Trainees
Candidate Plant 2
IEE Project Training Approach

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What CAN be achieved?

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1. Minimise user
requirement
2. Shut bypasses
3. Determine actual flow
and pressure requirement
4. Reselect motor and pump
5. Replace 150m3/h with 25m3/h
6. Save 75% or 176MWh pa
28kW
6kW
Example of Systems Approach

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Cummulative Savings
Company System Optimisation kWh Tonnes CO2 Rands
ArcelorMittal-Saldanha Pumps 6,651,000 6,372 3,324,000
Gledhow Sugar Steam 65,616,000 21,750 11,700,000
Sockit Manufacturing General Energy 276,000 270 420,000
Precision Press General Energy 351,300 242 198,768
Techniplate General Energy 1,264,032 1,211 518,253
Klein Karoo International Steam 405,010 388 657,200
At Source Foods General Energy 275,326 264 226,000
Gastro Foods General Energy 267,618 256 252,514
Impala Platinum Pumps 2,034,177 2,028 1,222,305
Idwala Lime Process Heating 356,562,222 354,780 213,937,334
AMKA Products Steam 2,805,554 2,792 1,683,332
Weet-Bix Compressed Air 1,250,000 1,244 750,000
Consol Glass – Wadeville Fans 2,117,650 1,905 1,800,000
Pioneer Foods - PE Wheat Mill Fans 103,000 98 82,000
Durbanville Hills Wines General Energy 156,000 149 342,000
Solomons Coatings Compressed Air 54,000 62 160,000
ABI Premier Place 336,000 321 265,000
440,524,889 394,132 237,538,706
ESO Implementation Savings Reported

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PUMP SYSTEM
OPTIMISATION:
ARCELOR-
MITTAL
SALDANHA BAY
Case Study

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System 1:
Melt Shop Con Arc/LHF Shell and Duct Cooling
System Description
• Hot water, returned from the machines, is cooled via an air- cooled heat exchanger system.
• 8 pumps – 2 standby:
• Make: KSB ETA 250-50
• Capacity: 1085 m3/h
• Head: 66m
• Motor: 280kW (3.3kV motors)
Process Parameters:
• Total flow rate: 6 500 m3/h
• Controlled pressure: 750 kPa
• Inlet temperature: 23oC
• Outlet temperature 34oC
2 32 3

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Case Study Results
1. One pump can be safely turned off whilst maintaining operational
requirements.
2. Pump efficiencies have degraded since the pumps were installed and
refurbishing one or more of the pumps may be cost effective.
3. Pump C has an impeller that is larger than needed. Could be trimmed.
4. It might be possible to automate the system, so the operators are
prompted to run pumps as a function of temperature.
5. Implemented - Savings achieved: 6,651,000 kWh 6,372 tonnes CO2
and R3,324,000.

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www.ncpc.co.za
Industrial Energy Efficiency Project
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