faith mkhacwa ncpc
DESCRIPTION
NCPC Energy Audits Program for Industry Faith Mkhacwa, Project Specialist, Industrial Energy Efficiency Project National Cleaner Production Centre of SATRANSCRIPT
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration1
The Case Study: Industrial Energy Efficiency Improvement Project
IDC11 June 2013
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Project Component• Effective National Policy Framework: Providing
support 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
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Energy Management Standard: ISO 50001• Purpose: Enable organizations to establish systems and processes necessary to improve energy
performance
• Applicable to all organizations
• Does NOT prescribe specific performance criteria with respect to energy
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Other ISO StandardsDifferent standards → All critical → One CANNOT replace the other
Energy ManagementISO 50001
Environmental Management
ISO 14000
Quality Management
ISO 9001
Other Management Systems
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Industrial 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?
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Barriers 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 operating budgets
• Sustainability Risk
• Defensiveness
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Ad hoc approach to managing energy
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Structured approach to managing energy
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Savings: 4 Small – Medium Chemical companies5 Medium – Large Textiles, leather & footwear companies
Option 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 maintenance
324 200 126 500 1.0
46 900 kg Low Sulphur Oil
3 kL/yr heavy fuel oil750kL Water
158 700
Compressor Controli. Air leak maintenanceii. Vairable speed controliii. Pressure controliv. Flow control (Accumulator)
177 232 329 975 1.9 267 641kWh 156 982
Energy Managementi. Washbath covers (insulation)ii. Washbath Insulation
37 295 n/a n/a31 116kWh303kg LPG
32 500
Lighting Retrofittingi. Replacement of bulbsii. Retrofit of Electronic Control Geariii. Natural lightingiv. Task lighting
479 937 753 511 1.6423 695 kWh
1.8kVA154 552
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
EnMS ResultsIndustrial enterprises
that implemented EnMSBusiness as usual Organisations new to
energy management
2-3% Annual energy intensity reductions
1% Annual energy intensity reduction
10-20% savings during the first 2 years
•EnMS accelerate adoption of EE best-practices and technology upgrades, enhances productivity and competitiveness.
•Improve enterprises’ bottom line.
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
EnMS Implementation VictoriesCompany Sector kWh Savings Comments
2011/12 2012/13
Arcelor mittal-Saldanha Works
Metals 81 325 527 10 600 000 Primarily no cost investments
Toyota- SA Automotive 4 484 533 1 717 511 Compressed Air, Lighting, Pumps, etc..
Gelvenor Textiles
Textiles 996 670 Tbc Only 3 projects
Saint-Gobain ConstructionProducts
917 916 Tbc Excludes ongoing water gauge project
87 724 646 12 317 511
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Our approach to systems optimisation
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Start with what you have...
...then look to address technology and capital intensive options...
Leakages in compressed air systems
Heat Exchanger fouling
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Energy Systems Optimisation (ESO)Component Approach Systems Approach
- Segregate components- Analyse performance of each in isolation
- Look at how the entire group functions together
- How will changing one impact the other?
May result from education by a specific technology sales engineer (e.g.: VSD or steam trap)
More knowledge of system and its interactions required
2-5% efficiency gains on the total energy consumption
10-50% average efficiency gains
Shifting FOCUS from Component optimization to systems optimization!!!
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Systems Approach
15 kW MotorEfficiency = 91%
Combined Motor & Pump Efficiency = 59%
System Efficiency = 13%
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
ESO Example
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
ESO Implementation VictoriesCompany Energy
SystemSavings Comments
Annualized
Rhodes Foods Group-Franchhoek
Steam R881 794 0.2 year payback (Not implemented)
Da Gama Textiles Steam R9 267 000 2.3 year payback (Implementation underway)
SAB Maltings Steam R6 603 028 1.0 year payback (Started system optimisation)
Arcelor Mittal-Saldanha Works
Pump R1 108 851 Cooling system Pump throttle settings changed.
Impala Platinum Pump R285 205 Switching off cooling system pump and fan.
Kraft Foods Electricity R223, 304 Switching off idle machines. Savings over shutdown.
R18 369 182
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Sector Distribution of SME’s Audited
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Participating companies
Industrial Energy Efficiency Project
● Policy Framework ● Introduction of Standards ● Capacity Building ● Demonstration
Thank youFaith Mkhacwa: Regional Project Manager-IEE
Telephone: +27(0)12 841 4097 Email: [email protected]
Websites: www.ncpc.co.za/www.iee-sa.co.za
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