energy efficiency at vale. items goalgoal energy management: energy efficiency plant assessments...
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Energy Efficiency at Vale
ITEMS
GoalGoal
Energy Management: Energy EfficiencyEnergy Management: Energy Efficiency
Plant AssessmentsPlant Assessments
Energy Saving Needs in Brazilian IndustryEnergy Saving Needs in Brazilian Industry
ConclusionConclusion
GOAL
Present the form of action from Vale regarding energy efficiency, share experiences in plant assessment, as well as provide an insight into potential energy savings in industry
ENERGY MANAGEMENT AT VALE
ENERGY MANAGEMENT
Value Criation Optimization
of Supply Costs
Supply Secutiry
Social-Environmental Responsibility Energy
Efficiency
* There is no hierarchy among the pillars
WHAT IS CONSIDERED ENERGY EFFICIENCY?
Energy Efficiency
Reduction of unitary
prices
Contractual Arrangements
Energy quality
Optimization of industrial
assets
Consumption Reduction
Productivity increase
Change in energy
transport alternative
Energy – any sort, and
not only electricity
Energy Efficiency -
Optimization of energy
expenses
Energy Efficiency
Projects - Projects or
activities that lead to
reductions in energy
spending, which are
crucial for the economic
viability of investments
ENERGY MANAGEMENT – ENERGY EFFICIENCY
PERFORMANCE PERFORMANCE
Expenses
Energy End-use
Unitary price
• Energy service (heat,
driving force)
• Energy evaluation and
selection (demand,
availability, unitary price)
• Supply choice (self
production, market)
• Contracts
• Tariffs
• Taxes
• Transport
• Corrections and improvements
• Process changes
• Energy recovery
• Technology development
Operations
Energy
End- Use
Unitary Price
Projects
Plant Assessments Contractual Renegotiations and RevisionsImprovements, Replacements and Corrections
Project Validation (FEL)New Energy ContractsProject Revisions and Adjustments
ENERGY MANAGEMENT – ENERGY EFFICIENCY
StandardsStandards
TGEETGEE
Energy Management Energy Management
OperationsOperations
Current ProjectsCurrent Projects
Capital ProjectsCapital Projects
Energy Policy / Technical Standards for projects and equipments
Energy Policy / Technical Standards for projects and equipments
Local and Global Energy Committees / Evaluation of results and sharing of best practices
Local and Global Energy Committees / Evaluation of results and sharing of best practices
Monitoring of specific consumption and costs of operations
Monitoring of specific consumption and costs of operations
Plant Assessments, measurement and verification of results
Plant Assessments, measurement and verification of results
Exploration, engineering and project implementation
Exploration, engineering and project implementation
Analysis of energy efficiency through the steps of FEL
Analysis of energy efficiency through the steps of FEL
ENERGY MANAGEMENT – ENERGY EFFICIENCY
PLANT ASSESSMENTS
Falhas de equipamentos apontadas no OEE
Energy Management (Specific Consumption)
Problemas PotenciaisTGEE – Technical
Groups
Gestão da Mudança Innovates Vale
(Stock ideas)
Mapeamento da Cadeia de Valor (Assessment)Plant Management
(Strategy)
Emissão de SEPsCurrent Projects
Estudos KaizenSES – System of
Engineering Standards
Estudos de Confiabilidade
APS – Action Plan Sustainability
ENTRADAINPUT PROCESSOPROCESS
Outras alternativasDepartment of Energy /
Alternatives
TCIEnergy DepartmentFase 1 - Avaliação do impacto
econômico ou risco associado a cada um das preocupações
identificadas
Technical and economic analysis Decides on performing
broad or specific assessment
Geração de lista de estudos priorizada pelo impacto/risco,
dificuldade de execução e estimativa de investimento
Gerência IndustrialPlants
Fase 2 - Priorização dos estudos a serem conduzidos
Provide the infrastructure and validate stages of assessment
TCIDep. of Energy / Plants
Fase 3 – Endereçamento dos estudos e formação das equipes
de trabalho
Addresses the improvements /Incorporate the
opportunities in the budget
SAÍDAOUTPUT
ROM/RNC - Estudos de Engenharia
Lean Six Sigma Department
Performs contracting company service provider and makes management of contracted
PLANT ASSESSMENTS
PIMSEnergy Management System – Brucutu Plant
Superior Performance
Normal PerformanceAverage PerformanceBad Performance
MotorsSystem
Ventilation andExhaust
Lighting
Compressed Air
Thermal Systems /
Cogeneration
Instrumentation and Control
Conveyor Belts
Pumps
SYSTEMSSYSTEMS
PLANT ASSESSMENTS
SCOPESCOPE
Analysis and measurements of electrical and mechanical systems
Analysis of systems the utilities area
Analysis of processes that interact on the plants
Energy Management
Incorporation of technology
Creation of control parameters
Performance evaluation
PLANT ASSESSMENTS
SYSTEMS AND EQUIPMENTS ANALYZEDSYSTEMS AND EQUIPMENTS ANALYZED
PLANT ASSESSMENTS
Couplings Solar heating Pumps Boilers Chillers Cogeneration Compressors Variable speed drive Capacitors Conveyors Effluent treatment plant Exhaust Filters Energy management Lighting Thermal insulation
Hot water lines Power transmission lines Steam lines Measurement of electric
and magnetic fields Mills Motors Industrial water system Compressed air system Ventilation system Chilled water system Transformers Pneumatic conveyors Heat exchangers Turbines
SYSTEMS AND EQUIPMENTS ANALYZEDSYSTEMS AND EQUIPMENTS ANALYZED
PLANT ASSESSMENTS
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL CASETYPICAL CASE
Total Electric Energy
% Savings per system
Plant AssessmentPumping
Compressed air
Motors
Lighting
Variable speed drive
VENTILATION AND EXHAUST
Elimination of head losses
Reduction of power exhaust fans
Use of variable speed drive in motors
Use of thermal energy from exhaust gases
COMPRESSED AIR
Elimination of leakage and drainage of condensate
Reduced pressure losses
Classification and division of compressed air lines
Sizing of compressors in accordance with the appropriate application
Suitable arrangement of the house of compressors
Optimization of the air intake system in order to reduce the temperature
Automation of the operation of the compressor (load / idle)
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONSTYPICAL ACTIONS
MOTORS SYSTEMS
Sizing of motors
Use of energy efficient motors
Use of variable speed drive
Automation control systems to reduce no-load operation
PUMPING (Water, pulp ou vacuum)
Elimination of leaks
Use of variable speed drive for variable flow demands
Reduction of the Head by dividing reservoirs
Proper selection of the pump to the point of maximum efficiency
Elimination or reduction of pumping due to the route optimization
Reduction of friction in the pump shaft seals
Control of temperature and water flow sealing vacuum pumps
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONSTYPICAL ACTIONS
LIGHTING, AIR CONDITIONING AND HEATING WATER
Proper specification and distribution of equipment in environments
Integration of natural resources to the solution of thermal comfort and light
Promotion of adequate and regular maintenance of equipment
Automation and suitable actuation of system
Using solar energy to heat the water used for washing parts, restaurants and
clothing room
ELECTRIC POWER SYSTEM
Evaluation of the load transformers
Evaluation of power factor and installation of capacitors and filters
Monitoring of power quality
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONSTYPICAL ACTIONS
TRANSPORT
Implementation of measurement system
Relocation of supply points
Automatic calibration of tires
Training of operations focused on efficient driving
Reduction of MDT (Middle Distance Transport)
Maintenance plans focused on energy efficiency
Auxiliary systems to operate the equipment (on-board computers connected to the
dispatch system)
Maintenance of roads running
Replacement trucks for pumping pulp or conveyor belts, where applicable
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONSTYPICAL ACTIONS
THERMAL SYSTEMS
Preheating of the combustion gases
Improved insulation and reducing losses of hot gases
Evaluation of the steam distribution system
Analysis of the refrigeration system (cooling towers and others)
Use of additives to improve fuel combustion in motors
Evaluation of cogeneration systems
NEW TECHNOLOGIES
Trolley Trucks
Studying application of electrical energy for supply of locomotives to replace
diesel
Truckless system for mines
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONSTYPICAL ACTIONS
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCYSWOT ANALYSIS – ENERGY EFFICIENCY
STRENGTHSSTRENGTHS
Electricity from low carbon sources
Wide range of energy (electricity, gas, fuels, biomass and others)
Energy matrix is converted to energy from renewable sources
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCYSWOT ANALYSIS – ENERGY EFFICIENCY
WEAKNESSESWEAKNESSES
Imposition of non-energy costs on the tariff
Lack of technical courses for industrial energy efficiency (technical and superior levels)
Lack of tax and credit incentives for thermal systems
Low investment in instrumentation and control
Lack of knowledge on energy laws
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCYSWOT ANALYSIS – ENERGY EFFICIENCY
OPORTUNITTIESOPORTUNITTIES
PNE (National Energy Efficiency Plan)
ISO 50001 (Energy Management Standard)
Expansion of investment in instrumentation
Certification in Measurement & Verification processes
Strong performance in thermal systems
Effective fiscal and credit incentives
Increase the importance of PROCEL and CONPET programs
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCYSWOT ANALYSIS – ENERGY EFFICIENCY
THREATSTHREATS
Importing solutions not suitable to the Brazilian reality
Dissociation of efficiency incentives for different energy sources
CONCLUSION
EVOLUTIONARY VISION – ENERGY EFFICIENCYEVOLUTIONARY VISION – ENERGY EFFICIENCY
Management Maturity
Imp
act
of a
ctio
ns
Continuous monitoring (power + indicators)
Contractual tariff adjustment
Adjustment of consumption profile (awareness)
Review of the production process (automation)
Technology upgrades (retrofit)
Cogeneration and Renewable
Fábio A. ChavesDINE (Energy Department)General Management of Trading and Market Solutions+55 (13) [email protected]