HRL provides energy cost reduction and optimisation services for large industrial plants. They have expertise in reducing costs from natural gas, electricity, and process heating through engineering solutions like equipment modifications, process improvements, and securing government incentives. Their services include energy auditing to identify savings opportunities, measuring current performance, evaluating opportunities, and implementing solutions to deliver 5-10% energy cost savings with less than 2 year paybacks for customers.

1. Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au
Energy Cost Reduction and Optimisation
Specialising in large industrial plants with high natural gas, electricity and process heating demands

2. expertiseinaction
2
Energy Market: Rapidly Escalating Energy Costs
• The prices of natural gas, electricity, coal and other fuels are rapidly escalating
• Cost increases are impacting the commercial viability of many Australian manufacturing
businesses
• Action is needed to maintain sustainable margins and profitability
• hrl: offers specialist engineering solutions to reduce energy costs
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

3. expertiseinaction
3
What makes hrl: different?
• Expert engineers with decades of experience in
the energy industry delivering tangible results
• Practical outcomes not limited to changing light
bulbs - partnering with hrl: delivers material
commercial results
• A complete offering – from energy auditing,
process modelling and design, through to turn-
key implementation or ‘owners engineer’
support
• Commitment to sustainable on-going results
Energy Cost Reduction Service Overview
Our Offer
• Targets Australian industry with large natural gas,
electricity, fuel and process heating demands
• We identify, quantify and implement significant
opportunities to improve your operations
• We deliver cost reductions to your bottom line
• Examples include 5 to 10% + energy cost savings
with less than 2 year payback
• Our customers have saved millions of dollars
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

4. expertiseinaction
4
• Waste heat recovery
• Co-generation
• Equipment modification
• Process improvement
• Combustion optimisation
• Voltage optimisation and power factor correction
• Fuel switching
• Biomass and waste utilisation
• Asset reliability and integrity improvements
• Securing government incentives and rebates
• Typical results of Facility Energy Audits: 5-10%+ savings, <2 year
payback
HRL has delivered successful energy cost savings with:
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

5. expertiseinaction
5
Identify
• Energy auditing to identify, quantify and prioritise opportunities
Measure and Evaluate
• Specialist plant performance testing to measure current and optimised plant performance
• Process modelling to evaluate identified opportunities
• Design of equipment improvements
• Develop capital and operating cost estimates
• Evaluate technical and economic feasibility of opportunities
Deliver Solution
• Develop business case
• Assist in securing government funding and rebates
• Project management – turn-key implementation or ‘owners engineer’ support
Sustain Benefits
• On-going partnership - increase savings over time
• Maintain and improve asset reliability and integrity
• Assistance with regulatory reporting, approvals and incentives
Our Unique Approach
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

6. expertiseinaction
6
External funding and/or rebates are available for energy efficiency and energy/greenhouse gas
reduction.
hrl: assists with securing funding for clients under programs such as:
• Victorian Energy Upgrades
• South Australian Energy Productivity Program (SAEPP);
• NSW Energy Efficient Business Program (EEB);
• Emissions Reduction Fund (ERF);
• Renewable Energy Target (RET) and Renewable Energy Certificates (REC);
• NSW Energy Savings Scheme (ESS);
• NSW Major resource recovery infrastructure grants program
Securing Rebates and Funding
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

7. expertiseinaction
7
hrl: delivers material commercial solutions:
• Detailed evaluation, costing and specification of process modifications and upgrades
• Turn-key project implementation
• Owners engineer support to project manage and implement solutions
Specific solution offerings include:
• Voltage Optimisation and Power Factor Correction: to significantly reduce electricity consumption
• Digital Monitoring: Development of digital on-line plant monitoring systems to enable
plant performance optimisation and increase plant efficiency
• VSD’s: for fans, pumps and other motors to increase equipment energy efficiency
Delivering Solutions
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

8. expertiseinaction
8
• An energy audit of a major industrial facility including boilers, dryers, mills,
distillation towers, etc.
• Identified energy savings opportunities equal to ~9% of the total fuel and
electricity use with average payback of <2 years, including:
• Boiler Optimisation: Insulation, Economiser repair, and O2 trimming
• Waste Water Heat Recovery for Process Heating
• Voltage Optimisation
• HRL were subsequently engaged to design the Waste Heat Recovery Plant:
• Process modelling and integration with existing plant
• Equipment specifications and cost estimates
• Design verification
• Installation scheduled by end of 2017
Case Study: Energy Audit and Waste Heat Recovery
Value: Waste heat recovery Project >$3M/yr savings, $3M capital project, payback of less than one year
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

9. expertiseinaction
9
• An energy audit of a brick production facility
• Identified savings opportunities amounting to 5% of the site
total energy use with average paybacks of <3 years
• Waste heat recovery to reduce fuel use;
o Process design, equipment specification and costing
• Power factor correction upgrade
• Variable Speed Drive (VSD) installation on large motors
• Air Compressor upgrade – replace multiple air compressors
with a single VSD compressor
Case Study: Energy Audit and Waste Heat Recovery
Value: $285k/yr savings identified, $300k capital projects, payback approximately one year
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

10. expertiseinaction
10
• A detailed technical and economic feasibility study of replacing large gas
(>1.5 PJ Natural Gas p.a.) boilers with a technology utilising the client’s
waste biomass, including:
• Data collection and evaluation
• Technology evaluation (e.g. solid-fuel boilers, co-firing biomass with
natural gas, anaerobic digestion, etc.)
• Process modelling, technology selection and evaluation
• Liaising with project stakeholders
• Review of technology options
• Develop equipment specifications
• Economic modelling and assessment
Case Study: Natural Gas Fuel Switching and Bioenergy
Value: Robust techno-economic basis for decision-making on future site energy strategy
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

11. expertiseinaction
11
Operating steam generation and process heating systems is
increasingly costly for industrial sites.
hrl: draws on our deep experience with steam raising and power
generation plant to assist clients to optimise their combustion
processes.
hrl: has delivered energy savings results through:
• Combustion tuning / oxygen trimming
• Economisers / feedwater heating
• Combustion air pre-heating / flue gas heat recovery
• Burner management and control systems
• Insulation / steam trap maintenance / leak repairs
Case Study: Boiler and Combustion Optimisation
Value: For one of our food industry clients, boiler combustion tuning provided immediate results
and a 6.8% reduction in annual fuel bill
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

12. expertiseinaction
12
Case Study: Co-generation and Alternative Fuels
• Evaluation of technical and economic feasibility of
cogeneration and fuel switching to aid our client with setting
their future energy strategy
• Process modelling and design using Thermoflow (leading
power and cogeneration thermal engineering software) to
develop design specifications for the plant
• Feasibility studies from preliminary concept studies through
to detailed Front End Engineering Design (FEED)
• Owner’s Engineering support to clients for major capital
projects
Value: long-term energy strategy, finance plan and KPIs established
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

13. expertiseinaction
13
On-going technical support for Waste Heat Boiler (WHB) steam turbine
• Tube erosion reduced efficiency and availability. Computational Fluid Dynamic (CFD) modelling designed baffles to reduce
peak gas velocities. Installation of baffles eliminated the erosion problem improving availability and electrical (MWh) output.
• Further CFD modelling examined the effects of substantially increased plant throughput and resulting gas flow rates. Design
modifications to the economiser were made which decreased erosion and increased electrical output by ~10%.
Case Study: Plant Reliability and Energy Improvements
Velocity contours at tube bank entrance are high & unbalanced Modified baffle design: velocity contours at tube bank entrance are lower
and balanced
Value: < 2 week project payback, reduced maintenance costs, increased availability
Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

14. expertiseinaction
14
Laboratory
testing
• Chemical testing
• Mechanical and metallurgical testing
• Niche thermal testing
• Laboratory outsourcing
HRL Technology Group: Our Services
Specialised
engineering solutions
• Asset integrity, reliability, and materials
engineering
• Power and combustion performance
engineering
• Process and energy efficiency
engineering
• Specialist capital
project implementation
•
Expert technical
advisory
Trusted, discrete and industry-renowned
expert technical advice and witness to
Legal, Insurance, and Banking firms for
failure investigations, loss-adjusting,
warranty claims, due-diligence etc
Innovation
partnerships
• Feasibility, scale-up and
commercialization
• R&D collaborations
• Global technology partnerships

15. expertiseinaction
15
HRL Technology Group: Energy Efficiency Contacts
David Shoesmith
Principal Chemical Engineer, CPEng, RPEQ
Telephone +61 7 3243 4319
Mobile +61 417 004 683
Email dshoesmith@hrl.com.au
Glenn Innes
Senior Chemical Engineer, CPEng, RPEQ
Telephone +61 3 9565 9932
Mobile +61 439 100 704
Email ginnes@hrl.com.au
Sam Clayton
Senior Chemical Engineer
Telephone +61 3 9565 9864
Mobile +61 407 015 763
Email sclayton@hrl.com.au