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Energy Efficiency Methodology Energizing Cleaner Production Management Course

Energy Efficiency Methodology Energizing Cleaner Production Management Course. Company Energy Efficiency methodology. Training Agenda: Company Energy Efficiency methodology. Introduction to the methodology Methodology step by step Purpose, outputs and tasks Company examples

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Energy Efficiency Methodology Energizing Cleaner Production Management Course

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  1. Energy Efficiency Methodology Energizing Cleaner Production Management Course Company Energy Efficiency methodology

  2. Training Agenda: Company Energy Efficiency methodology • Introduction to the methodology • Methodology step by step • Purpose, outputs and tasks • Company examples • Worksheets • Energy focus Company Energy Efficiency methodology

  3. Introduction The “Company Energy Efficiency Methodology” (Methodology) has been developed for Asian industrial companies to help them improve energy efficiency through Cleaner Production. Company Energy Efficiency methodology

  4. Benefits from Energy Efficiency • Cost reductions through efficient use of energy • Reduced exposure to fluctuating energy supply and prices and blackouts • Increase in productivity and product quality • Improved reputation with customers and society through environmental protection • Improved employee motivation, health and safety • Compliance with legislation and ISO 14001 targets • Increased profits and shareholder value Company Energy Efficiency methodology

  5. The Methodology • Is tailored to energy-intensive industrial companies in developing Asian countries • Focuses on energy, which is less visible than waste, water and raw materials • Explains • what should be done in theory • how it is done in practice in different companies Company Energy Efficiency methodology

  6. The Methodology is based on: • The Cleaner Production (CP) strategy: • Prevention of waste • Systematic approach • Integrated into business processes • Aimed at continuous improvement • Existing CP and energy audit methodologies • Real practice experience from energy assessments carried out as part of the GERIAP project in more than 40 Asian industrial companies Company Energy Efficiency methodology

  7. 6-Step Cleaner Production Approach Company Energy Efficiency methodology

  8. Information under each Step Several tasks: what a company should do as a minimum Company examples: how the task was applied at different companies and lessons learnt Worksheets: to assist completing the task Remember: apply the methodology flexibly as long as energy efficiency is improved because each company is different. Company Energy Efficiency methodology

  9. Step 1: Planning and Organization • Purpose: • Obtain top management commitment • Plan and organize an energy assessment • Output: • Written proposal with selected steps and tasks to improve the company’s energy efficiency • Approved by top management. Company Energy Efficiency methodology

  10. Step 1: Continued • Time: 3 – 6 days • Tasks include: • Task 1a: Meeting with top management (1-2 hours) • Task 1b: Form a Team and inform staff (0.5-1 day) • Task 1c: Pre-assessment to collect general information (1-3 days) • Task 1d: Select focus areas (0.5-1 day) • Task 1e: Prepare assessment proposal for top management approval (2-3 days) Company Energy Efficiency methodology

  11. Task 1a: Meeting with Top Management (1 – 2 hours) • Purpose of first meeting: • Top management: • Get commitment of company middle managers, staff and/or external facilitators to carry out a pre-assessment • Write a proposal for a detailed energy assessment • Company middle manager or external facilitator: • Get top management’s approval for a pre-assessment • Write a proposal for a detailed energy assessment Company Energy Efficiency methodology

  12. Task 1a: Meeting with Top Management (continued) • Discuss at this 1-2 hour first meeting: • If/Why top management is interested in energy efficiency • Energy areas of interest or concern • Where the company is now • Other factors of influence on the assessment • Time needed for pre-assessment and writing proposal for feasible options • Team composition and management representative • How staff will be informed to ensure cooperation Company Energy Efficiency methodology

  13. Worksheet 1: Reasons for Energy Efficiency Company Energy Efficiency methodology

  14. Worksheet 2: Energy Management Matrix Company Energy Efficiency methodology

  15. Worksheet 3: Factors influencing the energy assessment approach Company Energy Efficiency methodology

  16. Task 1b: Form a Team and inform staff (0.5 – 1 day) • The Team should consist of: • Someone who knows the main energy uses and environmental impacts, e.g. the Environment Manager or Energy Manager • Someone who knows the production process, e.g. the Head of Production • Someone with access to general company information and energy cost data, e.g. the company’s Accountant or Finance Manager • A communications or training person • A top management representative Company Energy Efficiency methodology

  17. Energy Focus Task 1b: Form a Team and inform staff (cont.) • Team should have • Knowledge of energy equipment • Energy intensive production processes • Access to energy data • Typical positions • Utilities Manager • Energy Manager • Maintenance Engineer Company Energy Efficiency methodology

  18. Worksheet 4: Team Members and Roles Company Energy Efficiency methodology

  19. Task 1c: Pre-assessment to collect general information(1 – 3 days) • Information collected should include: • General company details • Organization chart • General production flow chart • Production data for the past 3 years • Energy, resource consumption data and costs for the past 3 years • Inventory of major equipment • Overview of information collected for each process step / department • Company greenhouse gas (GHG’s) emissions Company Energy Efficiency methodology

  20. Energy Focus Task 1c: Pre-assessment to collect general information(cont.) • Include auxiliary sections in the general production flow chart • Water treatment • Boiler and steam systems • Compressed air systems • Air conditioning / refrigeration • Ventilation Company Energy Efficiency methodology

  21. Energy Focus Task 1c: Pre-assessment to collect general information(cont.) • Production and resource data should also include • Fuel consumption rates and costs • Electricity consumption and costs • Fuel mix • Electricity bills from utility Company Energy Efficiency methodology

  22. Energy Focus Task 1c: Pre-assessment to collect general information(cont.) • Inventory of major equipment • Name of equipment: motor • Numbers: 50 • Capacity: 1 with 100 HP, 39 with >25 HP, 10 with <10 HP • Type: AC motor • Supplier: General Electric • Rated parameters: e.g. load • Operating parameters (if available) Company Energy Efficiency methodology

  23. Worksheet 6: General Production Flow Chart Company Energy Efficiency methodology

  24. Worksheet 7: Production and Resource Data Company Energy Efficiency methodology

  25. Worksheet 8: Inventory of Major Equipment Company Energy Efficiency methodology

  26. Task 1d: Select focus areas (0.5 – 1 day) • A focus area can be: • Entire plant • A department, production line, or process step • Specific (energy) equipment or resources • The process for selecting focus areas: • Identify possible focus areas • Determine selection criteria • Rate each focus areas High, Medium, Low for each criteria Company Energy Efficiency methodology

  27. Energy Focus Task 1d: Select focus areas (cont.) • Different focus areas can be selected when energy is considered • An auxiliary system instead of a production step • - Steam system • - Compressed air • Specific major energy equipment • - Boiler house (not just the boiler!) Company Energy Efficiency methodology

  28. Worksheet 10: Selection of Focus Areas Company Energy Efficiency methodology

  29. Task 1e: Prepare assessment proposal for top management approval (2 – 3 days) • It is important to obtain top management commitment • The assessment proposal should include: • Objective, scope (i.e. focus areas) • Outputs • Approach (step 2, 3 and 4 of the Methodology) • Team • Time & budget Company Energy Efficiency methodology

  30. Step 2: Assessment Purpose:assess where energy is lost/wasted for the focus area(s) Output: overview of how much energy is lost and how much money this costs for the focus area(s) Then it becomes easier to identify options to improve energy efficiency in step 3! Company Energy Efficiency methodology

  31. Step 2: Assessment • Time: minimum 3 days • Tasks include: • Task 2a: Staff meeting and training (>0.5 day for staff meeting only) • Task 2b: Prepare focus area flow charts (>2 hours per focus area) • Task 2c: Walkthrough of focus areas (> 0.5 day per focus area) • Task 2d: Quantify inputs and outputs and costs to establish a baseline (time required depends on data available) • Task 2e: Quantify losses through a material and energy balance (0.5 – 1 day per focus area) Company Energy Efficiency methodology

  32. Task 2a: Staff meeting and training • Staff meeting (0.5 day) • Inform staff about assessment and their roles • Get their support • Staff training • Importance of energy efficiency • How to carry out an assessment • Energy equipment & monitoring instruments • Financing, GHG Indicator, other… • Information: • Posters, newsletters, meetings Company Energy Efficiency methodology

  33. Task 2b: Prepare focus area flow charts (>2 hours per focus area) • Flow chart for each focus area • Different steps of the focus area • Most important inputs (resources) for each step • Most important outputs for each step • Intermediate and final products between the steps Company Energy Efficiency methodology

  34. Energy Focus Task 2b: Prepare focus area flow charts (cont.) • Different types of focus areas require different types of charts: • Production step: process flow diagram • Auxiliary systems: layout chart for steam or compressed air distribution system • Specific major equipment: major equipment and all auxiliary equipment Company Energy Efficiency methodology

  35. Task 2c: Walkthrough of focus areas (>0.5 day per focus area) • Purpose of the walkthrough(s) • Better understand the focus area • Get feedback from production staff about problems… • Write down visible losses of energy and materials • Obtain information about quantities and costs Company Energy Efficiency methodology

  36. Worksheet 14: Walkthrough observations Company Energy Efficiency methodology

  37. Task 2d: Quantify inputs and outputs and costs to establish a baseline • Time required depends on information available • Why a baseline? • Measure improvements after implementing options • Management only convinced to continue if you can show savings • Collect the following information: • Quantities (e.g. tons of coal per day) • Costs (e.g. $ per ton of coal) • Other characteristics (e.g. temperature of water going in and out of the boiler, pressure) Company Energy Efficiency methodology

  38. Worksheet 13: Process flow chart, inputs/output, energy balance Company Energy Efficiency methodology

  39. Energy Focus Task 2d: Quantify inputs and outputs and costs to establish a baseline (cont) • Examples of material-related parameters for the boiler house • Fuel and electricity • Water • Blow down • Ash • Steam produced • Condensate recovered Company Energy Efficiency methodology

  40. Energy Focus Task 2d: Quantify inputs and outputs and costs to establish a baseline (cont) • Examples of energy-related parameters for the boiler house • Pressure • Temperature • Flue gas composition • Draft • Radiation • Note: specific monitoring equipment may be needed Company Energy Efficiency methodology

  41. Energy Focus Company Energy Efficiency methodology

  42. Task 2e: Quantify losses through a material and energy balance (0.5 – 1 day per focus area) • Try to “balance” inputs and outputs (what goes into a process must come out!) • Identify “losses”: energy, products, materials • Calculate costs of losses • Be practical: this is the most difficult task! Company Energy Efficiency methodology

  43. Energy Focus Task 2e: Quantify losses through a material and energy balance Company Energy Efficiency methodology

  44. Step 3: Identification of Options • Purpose: identify opportunities to improve energy efficiency for the selected focus areas • Output: list of options that will be investigated on their feasibility in step 4 • Tasks and minimum time: • Task 3a: Determine causes of losses (0.5 day per focus area) • Task 3b: Identify possible options (0.5 day per focus area) • Task 3c: Screen options for feasibility analysis (0.5 day) Company Energy Efficiency methodology

  45. Task 3a: Determine causes of losses (0.5 day per focus area) • Brainstorm session with staff and others • Ask the question: Why are these losses occurring? • Keep asking until you found the “root cause” • Look for different causes: • Man • Method • Machine • Material Company Energy Efficiency methodology

  46. Task 3a: Determine causes of losses (cont.) Fishbone diagram Company Energy Efficiency methodology

  47. Energy Focus Task 3a: Determine causes of losses (cont.) • Material losses with an energy-related cause • Low dye exhaustion caused by low temperatures • Scale losses caused by cold air infiltration in rolling mills • Energy losses with an energy-related cause • High electricity use in rollers caused by overheating of bars in rolling mills • High transmission and distribution losses caused by low power factor Company Energy Efficiency methodology

  48. Energy Focus Task 3a: Determine causes of losses (cont.) • Energy losses with a material-related cause • Inefficient combustion caused by improper sizing of coal • High steam consumption in dyeing process caused by too high liquor-to-cloth ratio • Poor product quality with an energy-related cause • Thin zinc layer caused by high temperature of zinc bath in galvanizing • Uneven strength of forged products caused by low/non-uniform temperature in furnace Company Energy Efficiency methodology

  49. Energy Focus Task 3a: Determine causes of losses (cont.) • Other examples • Low boiler efficiency caused by operating at <50% capacity • High electricity consumption due to compressed air leaks • High steam consumption caused by un-insulated flanges • High electricity consumption due to motor operating at varying loads Company Energy Efficiency methodology Do you know of any other examples?

  50. Task 3b: Identify possible options (0.5 day per focus area) • Brainstorm session with staff and others • Ask the question: What can we do to reduce energy losses? • Options can fall in the following categories: • Good housekeeping • Improved process management • Production process / equipment modification • New technology / equipment • Input material substitution • On-site reuse / recovery • Production of useful by-product • Product modification Company Energy Efficiency methodology

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