Transcript Carbon Trust Presentation - E

Support for Energy Efficiency
Donagh Moorehead – Client Manager
Potential for significant
cost effective energy efficiency improvement
Energy Efficiency
improvement
potential
(% current use)
40%
37%
35%
30%
24%
21%
20%
10%
0%
Industry
Source: Performance & Innovation Unit, February 2002
Services
Domestic Transport
How the Carbon Trust can help your
business
Understand your carbon footprint
Identify saving opportunities
Access the best knowledge
Finance your energy plan
Energise your employees
Achieve sustained energy
reductions
Show your carbon commitment
Implemented Site Survey Savings by
Technology
Our primary method for delivering cost effective Energy/Carbon savings to
businesses right now are a range of free technical surveys carried out by
independent specialist consultants approved and sourced by the Carbon Trust.
Other
15%
Energy
management
26%
Motors & drives
3%
Office equipment
3%
Instrumentation &
control
3%
Operation &
maintenance
3%
Air conditioning
4%
Process heating &
cooling
6%
Compressed air
7%
Source: Carbon Trust survey analysis 2008
Lighting
17%
Heating
13%
Site Survey Case Study – Local
Engineering Company
Utility
Purchased Energy
Cost
CO2
emissions
kWh/ year
%
£ / year
%
tonnes
Grid Electricity
1,670,132
45.7%
150,930
73.1%
718
Fuel Oil
1,961,989
53.7%
53,946
26.1%
510
23,684
0.6%
1,556
0.8%
5
LPG
Total Energy
3,655,805
206,432
1,233
Site Survey Case Study – Local
Engineering Company
Estimated Annual Savings
Recommendations and Key
Priority Actions
Financial
Savings
CO2
Savings
Energy
Savings
Estimated
Cost of
Measure
£
tonnes
kWh
£
Suggested
Payback Timescale
period
for
(years) completion
1
Energy Policy Development
0
0.0
0
0
-
0 - 3 Months
2
Raise Staff Awareness
0
0.0
0
0
-
0 - 3 Months
3
Implement Training & Awareness
Programme
10,322
61.7
182,790
10,000
0.97
3 - 6 Months
4
HP Air Compressor System Leakage
3,268
14.5
33,006
2,500
0.76
0 - 3 Months
5
Steam Boiler Plant - Heating &
DHWS
8,092
76.5
294,989
0
-
0 - 3 Months
6
Factory Lighting - Upgrading
14,848
64.5
149,983
15,000
1.01
0 - 3 Months
7
Lighting Considerations - Sensors
260
1.2
2,868
350
1.35
0 - 3 Months
8
Factory Extraction System Drive
Motor - VSD
9,652
42.0
97,495
5,000
0.52
0 - 3 Months
9
ICT - General Awareness
-
Total
46,442
260.5
761,131
32,850
0.71
Site Survey Case Study – Local
Engineering Company
Priority 4
Cost Saving
£3,268
per year
H.P. Air Compressor – System Leakage
CO2 Savings
14.52
Tonnes/year
Energy Savings
33,006
kWh/year
Cost
£2,500
(estimate)
Payback
0.76
Years
Detail:
The main air compressor units and associated drier are sited in a dedicated area in an outbuilding to the side of the manufacturing area.
The system provides compressed air at 7bar gauge via a piped delivery system that does not form a complete ring-main.
Two in number compressors supply the system:
1 x Mattei 350, 55kW constant speed machine – currently only used as back up in the event of failure.
1 x VS Electra saver, 75kW variable speed drive unit. This unit provides for the normal daily supply of compressed air.
Leak Checking
Leak checking is not carried out currently as a pro-active maintenance regime. Consideration needs to be given to addressing this issue
in the immediate future as significant leakage was identified on the compressed air systems - these are a high cost to the operation
and seriously reduce the overall system efficiency.
Most compressor systems can save upwards of 30% in energy by simple measures such as identifying and fixing leaks. Reference:
Energy Consumption Guide (ECG 41)
Industry leakage can be as much as 40% - For the purposes of calculation 30% leakage is assumed - and reduced by survey and
repairs as required to 10%. Calculation above considers the variable speed machine at an average 65% utilisation and repair costs of
£1000. A leak survey can be completed within 1-2 days on a site of this type and size would cost within £750 - 1500, due to access
and safety requirements. Successful leak management requires a strict cleaning and maintenance regime in order to sustain the
significant savings. Plant/process air leakage was evident throughout the manufacturing areas - in particular on the use of flexible
connections and air tools and filter/regulator units on machines.
Rationale:
Leaks represent a significant waste of energy. Leak surveys and the subsequent repair of those leaks should be part of a pro-active
maintenance regime. Pressure regulation is a fundamental ‘good practice’ requirement of compressor management.
Compressed air is expensive’ – it costs the equivalent of c50p/kWh.
Risks:
Increased costs and poor control of a very expensive commodity.
H.P. air is a very useful process tool but requires significant investment in its upkeep and ongoing maintenance.
Plant access to equipment may be difficult due to operational needs.
Next Step:
Carry out full leak survey.
Identify and log issues.
Develop action plan within shutdown/quite periods to fix leaks.
Subsequent to this it is recommended that the systems be considered for 3 -monthly air audits by on site staff.
Obtain publications from the Carbon Trust.
Relevant
Publications:
Energy Consumption Guide 40 – Compressing Air Costs, Generation
Energy Consumption Guide 41 – Compressing Air Costs, Leakage
Energy Consumption Guide 42 – Compressing Air Costs, Treatment
Site Survey Case Study – Local
Engineering Company
Priority 6
Cost Saving
£14,848
per year
Factory Lighting Considerations
CO2 Savings
64.5
Tonnes/year
Energy Savings
149,983
kWh/year
Cost
£15,000
(estimate)
Payback
1.01
Year
Detail:
Upgrades to the factory lighting have been carried out in recent years (actual date not known due to change of staff but believed to be within past 1-2 years). The upgrade
information (fine detail) is not fully documented so comments are made in respect to what is currently existing against what could be attained through re-visiting this
project and further enhancing the savings.
Original upgrade scope was to replace old fittings in operational bays only i.e. bays 2,3 and 4; with High Frequency twin and single open batten fluorescents utilising
Triphosphor colour 840 lamps. In addition to fit 6 in number photocells to allow interaction of daylight factor into the lighting scheme.
Total energy savings predicted where £16,109 with a payback of 1.48 years.
Currently the lighting scheme is as stated above with the following exceptions;
1.Daylight control via the sensors is not operational – and is stated as having never been operational. 2 Fitting of twin lights to some areas i.e. end rows where skylights are
not fitted – this is considered as extra lighting possibly due to the closed roof area however it is considered that single reflected units could have been used here and
interacted with some daylight that presents itself from the glazed walling areas at the end of the factory. 3. Zoning of the lighting scheme is effectively none existent with
several large areas being lit when no/intermittent occupancy (and in some cases redundant areas) occurs. 4. Adjacent areas such as washrooms and link corridors have not
been included in the upgrade and remain lit with mains frequency controlled twin fittings etc. These issues need to be corrected in order to ensure full and effective control
is achieved and predicted savings are identified, achieved and sustained.
Rationale:
T8 fluorescent tubes use 8% less energy compared to the older T12 fluorescent tubes.
T5 tubes can offer up to 50% energy savings plus increased lumens/watt (light output). Retrofit upgrade option by replacement of internal gear, single lamp, high frequency
control gear and reflector provide savings estimated as: Lighting controls will provide at least 20% saving in this factory if applied through correctly applied lux sensors,
occupancy detectors and a centralised controller correctly set and with ease of operation.
Risks:
Lighting needs to be considered in respect of lux levels etc. this will obviously have to be a managed and controlled in full consideration of both area task and Health and
safety requirements. A project of this nature would need operational, technical and quality control approval in line with the business function. It may well be an option to
have a mixed lighting scheme, which can still deliver savings.
Costs are not quotes. It is worthy of note at this point to state the ever increasing costs of electricity will have a impact on this calculation and hence the project. Savings
originally predicted for the photocell operation have increased from £3,826 to £5,740 at current prices. Savings shown include for converting existing twins to singles
(reflected with HF control gear). Considers T8 lamps as existing – T5 could be used with adaptors currently available to the market OR new units incorporating T5 lamps;
the latter option would extend paybacks and would possibly be the least favoured option due to expenditure already incurred. Savings do not include energy saved by
switching off circa 15% of the detailed lights that are illuminated above no/reduced occupancy areas e.g. old machine stores by bay 1, occupancy sensors for overhead
lighting for integral open ceiling stores etc. A further ‘Full’ lighting survey will allow firm quotes to be generated (e.g. check condition of lamp fittings and assess suitability
for twin to single upgrade, confirm lighting design layouts are appropriate for area functions, re-design options considered from an energy efficiency perspective may offer
additional benefits in respect of lighting levels, etc.)
Next Step:
Contact Author / Lighting professional to have lighting schemes reviewed.
Contact proprietary owner (Chalmor) or original contractors to re-instate lux controllers and set up central controller. Claims against the original contractor may be difficult
without sufficient evidence and facts re original specification etc. The controller is open circuited in several out stations and from on-site discussions (CT Consultant with
proprietary Technical Support Engineer) it would appear that the original settings have been tampered with or where never set correctly hence no control exists for daylight
factor integration. The position of the lux sensors also requires investigation as excellent daylight is available via the roof lights and current sensors do not appear to be
placed in a representative layout to maximise control. Lighting equipment is included in the ECA Energy Technology List. Contact author for further information and/or go
to: www.eca.gov.uk. Section 5.5 provides further information on ECA.
Relevant
Publications:
CIBSE (Chartered Institution of Building Services Engineers) offer lighting guides for refurbishment & new build options, i.e. LG1 – industrial Lighting.
Some case study literature from the Carbon Trust may be of relevance to this sites operation.
HSE (Health & Safety Executive) publication, ‘lighting for work’. Lighting Guide 006 – Carbon Trust
Energy Efficiency - Cutting carbon now
Key achievements in Northern Ireland include:
Saving our customers over £70m per annum through reduced energy bills
Reducing carbon emissions by over 685,000 tCO2 per annum
Stimulated over £100m of investment in energy efficiency and low carbon
technologies
Identified a further £100m+ pa of energy savings and associated carbon
savings of nearly 1mtCO2
Awarded over £11m in interest-free loans to enable 212 local companies to
invest in energy and carbon saving technologies that will reduce their energy
costs by over £5m pa
Over 6,300 delegates have attended 115 low carbon skills and knowledge
transfer seminars and workshops
Interest-Free Loan Scheme
The objective of the Carbon Trusts loan scheme is to encourage end-user
investment in energy efficiency & renewable energy projects.
Key features of the NI Loan Scheme:
£3,000 to £400,000
0% Interest
No other fees
Unsecured
Repayment period reflects energy payback – up to max 48 month
Minimum ‘red tape’
Loan offers can be made in 2 weeks from
receipt of a complete application
Loan Scheme Project Type
CHP VSD
3% 2%
Boilers
10%
General
4%
Lighting
21%
Biomass
18%
Refrigeration
7%
Renewable
3%
•212 loans offered
New Process
Equipment
15%
•£11.7m dispersed
•£5 m saving
•Over £27m total project costs
Comp Air
17%
Significant potential for cost effective
energy efficiency improvement
Case Study : NI compressed
air initiative
Electricity Spend = £7.6m
Cost savings = £2.3 pa
Implementation costs = £3.0m
Payback = 16 months
Percentage savings = 31%
tCO2 savings = 26,409 pa
Electricity savings = 42 GWh pa
Ref: CTS010, Mar 06
Energy effective lighting case studies
Montupet – new lighting scheme T12 to
T5. Capex of £110,000 offers annual
savings of £130,000 and reduces CO2
emissions by 1,022 tonnes pa.
Armaghdown Creameries – more
efficient metal halide lamps, repositioned
with daylight control. Capex of £4,000
offers annual savings of £1,000 and
reduces CO2 emissions by 3 tonnes pa.
Ref: CTS011, Mar 06
Refrigeration & Lighting case study:
Henderson Group (Retail)
Bespoke partnership with familyowned business incorporating five
companies and 400 independent
retailers and 55 company-owned
convenience retail outlets and petrol
stations throughout Northern Ireland
Lighting
– Typical energy savings of 25%
– Payback on additional cost was
0.8 years
“Given the continual increase in energy costs, we
have made a conscious effort to reduce our
energy consumption and CO2 emissions. With the
support of the Carbon Trust and the conclusive
findings of the energy audits, we have been able
to implement energy-efficient corporate
refrigeration and lighting specifications which
satisfy our objectives and provide an enhanced
retail environment at reduced operating costs.”
Philip Wright - Senior Property Manager
Refrigeration
– Typical energy savings of 17%.
– Payback was immediate
CHP & Energy Management:
Ryobi Aluminium Castings Ltd
Highly successful partnership with a
global corporation.
Projects to date include:
–
–
–
–
“Ryobi’s senior management has been
very supportive of the various projects
that we’ve initiated to reduce energy
costs. Each success opens our eyes to
further opportunities.”
Edwin Turner – Facilities Manager
1.4MWe CHP
Process EMS
Compressed air modifications
Expert plant utilisation study
Annual electrical and thermal energy
savings of more than £250,000
Emissions savings of approximately
1,150 tonnes CO2 per annum
Nearly £1m investment in energy
efficiency over the past three years,
offering a simple payback of about
3.3 years
Heat Recovery: Ulster Carpets
Consumption of heavy fuel oil has
been cut by over 300,000 litres pa
The time required for dyeing was cut
by over 10%, increasing the
throughput
The water to be discharged is now
cooler, so additional cooling is no
longer needed
Annual cost savings of £68,000
Payback <10 months
CO2 savings of ~1,000 t pa
“Ulster Carpets places great importance on managing its environmental impact.
The company has been delighted by the energy saving results of this project.”
George Ussher – Technical Service Manager
Bombardier
Aerospace
Metering monitoring & targeting
New natural gas boiler installation
Lighting upgrades
CDA optimisation
New boilers
Cultural transformation
Gas consumption
Reduced by 7%
Electricity consumption
Reduced by 8%
HFO consumption
Reduced by 100%
Pritchitts
New high efficiency steriliser unit
Heat recovery
Dew point sensing control to CDA system
Staged evaporative condenser installation
Magnetic bearing turbo compressor installation
Capital Cost
£1,000,000
Annual Cost Savings
£2,000,000
Company Perspective
‘I can honestly say that we have never
lived to regret any of our investments
in energy efficiency.’
Alan Flack,
Engineering Manager, Pritchitts
LaFarge
Cookstown
Centralised air compressors
Variable speed drive compressor
Increase the size of CDA pipework
Zero purge desiccant dryer
Reduced maintenance
Interest free loan
Enhanced capital allowances
Capital cost
£295,000
Interest free loan
£200,000
Annual cost savings
£80,000
Annual CO2 savings
566 tCO2
Simple Payback
3.7 years
Company Perspective
‘Specialist implementation advice, an interest free loan and Enhanced Capital Allowances combined
with and significant energy and maintenance savings made this project a an all-round winner.’
David Kelly, Energy Manager at LaFarge Cookstown
3Y Group
Replacement dual fired
heating system.
Modern process extraction.
1,400 kW waste wood
& dust boiler
Saving 2,000 MWh
Replacement process
equipment
Single new machine replacing
3 old inefficient machines
Reduced energy consumption
of 200,000 kWh
Capital cost
£270,000
Capital cost
£90,000
Interest free loan
£270,000
Interest free loan
£60,000
Annual cost savings
£72,576
Annual cost savings
£18,076
Annual CO2 savings
502 tCO2
Annual CO2 savings
90 tCO2
Simple Payback
3.7 years
Simple Payback
3.3 years
FP McCann
Insulated Silo for recycled
product
Installation of aggregate
sheds to ensure drier product
Capital cost
£36,500
Interest free loan
£36,500
Annual cost savings
£14,424
Simple Payback
2.7 years
Company Perspective
‘These projects will help make FP McCann more energy efficient and commercially
competitive through the significant reduction of unnecessary energy consumption.
We take our responsibility to the environment very seriously and strive to reduce
carbon emissions.
The Carbon Trust has been most helpful in highlighting and implementing a number
of energy saving projects that benefit both the environment and our company’
Don Mulholland, Financial Director – FP McCann Limited
Dale Farm
Replacement of existing chilling
system with a single energy
efficient unit utilising high
efficiency motors and heat
recovery.
Capital cost
£250,000
Interest free loan
£200,000
Annual cost savings
£50,000
Annual CO2 savings
323 tCO2
Simple Payback
5 years
Upgrading of thermal insulation
at both the Pennybridge and
Dunman sites to current best
practice standard.
Capital cost
£30,000
Annual cost savings
£60,000
Annual CO2 savings
1,900 tCO2
Simple Payback
2 years
Company Perspective
As a leading dairy, Dale Farm strives to be best in class in all its activities.
The company has an ongoing programme of continuous improvement, which includes
a strong focus on energy efficiency to both reduce utility costs and respond to the threats
posed by sustainability issues around hydrocarbon energy sources.
We appreciate the assistance of the Carbon Trust in the outworking of this programme
and will continue to work closely with them in the future.
Gary Shields, Energy Manager – United Dairy Farmers
Carbon Trust Publications
Making Business Sense
of Climate Change
For further advice and to access the services from the
Carbon Trust, visit our website at:
www.carbontrust.co.uk
or ring our customer centre on:
0800 085 2005
The contents of this presentation are the copyright of the Carbon Trust and may not be copied or republished without the
prior written consent of the Carbon Trust. The trade marks, service marks and logo used in this presentation are the
property of the Carbon Trust and no licence or right is granted to use any such marks or logo.
Summary
Improving resource efficiency - business opportunity
– Makes business sense
– CSR
– Competitive advantage
Carbon Trust has the experience and expertise to help
– opportunity identification and quantification
– implementation assistance
– financing.