Transcript www.seai.ie
Energy MAP Plastics Sector Workshop 1 Monday 16th October 2006 Athlone Alan Ryan / Elizabeth Muldowney SEI Contents • • • • • Policy and other drivers Solutions Energy Management Practical Tips SEI Assistance Why are we here? • Regulations • IPPC • EU ETS • Financial • Electricity 60% in 6 years • Fuels ?% + • Environmental • Suppliers • Corporate • Cost of Carbon • And on, and on A bit on energy costs and security of supply… Import Dependency 1990 - 2003 87% Sources Natural Gas 1999 Norwegen Großbritannien Russland 3.000 km Niederlande 1.000 km Deutschland 2.000 km Kasachstan Ukraine Usbekistan Frankreich Rumänien Aserbaidschan Turkmenistan Algerien Libyen Ägypten Sources Natural Gas 2010 Norwegen Großbritannien Russland 3.000 km Niederlande 2.000 km Kasachstan 1.000 km Ukraine Usbekistan Aserbaidschan Turkmenistan Algerien Libyen Ägypten Sources Natural Gas 2025 Russland 3.000 km 2.000 km 1.000 km Turkmenistan Still no lights… No, the Earth is not all dark at the same time…nor is it flat… 5/17/06 02/02/2006 10/21/05 07/11/2005 3/28/05 12/14/04 09/01/2004 5/20/04 02/06/2004 10/27/03 7/15/03 04/02/2003 12/19/02 09/06/2002 5/27/02 02/12/2002 10/26/01 07/10/2001 3/23/01 12/05/2000 8/21/00 05/05/2000 1/20/00 10/04/1999 6/18/99 03/04/1999 11/13/98 7/31/98 4/17/98 01/02/1998 US Dollars A bit on competitiveness Energy prices - oil Brent Crude 80 70 60 50 40 30 20 10 0 A bit on climate change… • There is real concern that human activities will change the basic conditions that have allowed life to thrive on earth. • There is an overwhelming scientific agreement on this. • This does not often happen • There is still uncertainty • Scope • Scale • Timing • Non-linearity The Kyoto Protocol • 1997 international agreement • Reduce global greenhouse gas emissions to 94.8% of 1990 levels by 2010 • EU target – 8% reduction from 1990 to 2010 • Ireland target – 13% increase • Ratified February 16th Greenhouse Gas emissions by source Whats the main objective? AIM To achieve business objectives at minimum energy cost Energy Supply Pay less per unit of energy Energy Usage Reduce energy consumed Solutions Available Energy Supply EEI / EPI’s Tender Supplies Green Electricity CHP Biofuels IS393 Energy Usage Housekeeping Energy Teams Training Energy Management Audits M&T EnergyMAP Benchmarking Planning Checklists Copyright SEI 2005 Ad hoc approach Costs high = Audit Waste cutting, some investment Costs high again: Where’s that last audit? Costs Here we go again! +5% 0 -5% Under control. -10% -15% -20% -25% 0 Years 5 Energy Management Approach Senior management commit to programme Costs +5% Initial savings sustained 0 -5% Housekeeping first – then investment -10% Becomes company culture -15% -20% Investment -25% 0 Years 3 Case Study - Example 3 key elements of successful energy management ? Organizational Management Commitment Technical Understanding your energy usage and how to control it Balance all 3 for a successful programme People Developing an energy efficient culture 5 Step Approach Review Take Action Plan Identify Commit 5 step strategy • Energy Policy – properly communicated • Appoint Senior manager sponsor • Appoint energy coordinator Commit Making the Business Case Current Year % change €3,150,000 €4,005,200 +21.4% €105,798 €154,236 +31.4% 3.36% 3.85% +12.8% €289,000 €302,000 +4.3% Energy as % of Profits 36.61% 51.07% +28.3% % increase in Profits by a 10% decrease in energy costs 3.66% 5.11% +28.3% Financial Indicators Annual Op. Costs (AOC) Total Energy Cost Energy as % of AOC Annual Profits Previous Year 5 step strategy • • • • Detail and trend past & present energy consumption Identify the main energy users Identify the main influences on energy consumption Identify saving opportunities Identify Energy Review Energy Review - Energy and emissions mapping Steam 21% Electricity Bills Production Equipment 22% Compressed Air 22% Fuel Bills Factory X HVAC 35% CIP 10% HVAC 8% Line A 7% Line B 3% Line A 5% AHU’s 8% AHU’s 9% Chill B 20% Energy Review - Step into the process - Do we need to use energy? - Can we use a cheaper form? - What are its minimum operating conditions? - Are we operating it to this operating conditions? - Then and only then - Are we distributing it efficiently? - Are we generating it efficiently? Steam Electricity Process Chilling Other Identifying opportunities • Audits • IPPC Audit Guidelines • Good Practise Guide 316 Undertaking an energy audit • You know best ! • Energy Team • Energy Wardens • Energy MAP – step 9 www.thecarbontrust.co.uk (GPG316) Pay less per Unit of Energy Negotiate Lowest Price Select Best Tariff Cost Avoidance Measures Generate Own Power Change of Fuel SEI Biofuels Programme Renewable Energy Indicative Funding Levels • Demonstration projects: up to 25% • Shared cost R&D projects: up to 45% • Public good R&D projects: up to 100% • Indicative Upper Level of Funding is 1mEuro of Eligible Costs Relevant areas of support available from RE RDD Prog • Biomass boilers - 25% of installed cost • Liquid biofuels projects (transport or heat) • Anaerobic Digesters – small to medium scale biogas plants • Large scale >10MW wood biomass CHP plant • Wind or Hydro auto production example Register of Opportunites Sample Energy Opportunities Register for XXXXXX Ltd Last Updated xx/xx/xxxx Assumptions Average Elec Day Unit Price €/kWh 0.06000 CO2 per kWh elec x gCO2/kWh Average Elec Night Unit Price €/Kwh 0.04500 CO2 per kWh gas x gCO2/kWh Average Gas Cost €/kWh 0.01900 Feasibility Analysis Energy Opportunity Person Est YearlyEstimatedEst. Yearly Simple Comment Respon kWh savings C02 savings€ savings Payback Housekeeping Actions Thermal Turn off boiler 1 at weekends Tech 1 Ongoing turn off boiler 2 at weekends Tech 2 Electrical Air Handling Turn off AHU 1 at weekends Tech 1 Turn off AHU 2 3rd Saturday off the month Tech 2 Bills management Tender gas and electricity supply Completed Enter the WPDRS Totals Capital Actions Install Economiser Eng 1 1-Jun Replace bucket trap on machine 7 Replace process 1 with process 2 Eng 2 1-Oct Items worth investigating Replace bucket traps with thermodynamic Eng 1 1-Jun Replacing machine No.7 Prod Eng CHP plant Eng 2 1-Oct Copyright SEI 2005 Totals Housekeeping Procedures & methods Technology & investment Case study 5 step strategy • Establish a programme plan Plan • Set objectives and targets • Identify & allocate resources Energy Plan XXXX Ltd Programme Plan 2005 No Objective and target € Saving CO2 SavingBudget € General 1 To train 40 key people in basic energy awareness 2 To continuously identify wastage and turn off 3 To invest 100,00 euro on energy and complete at least 20 energy saving projects 4 To identify opportunities for saving every 6 months instead of every year Significant users 1 To reduce compressed air consumption by 5% by a. installing a sequence controller b. installing heat recovery on compressor 1 c. agressively tackling leaks on machines 2 To reduce air handling units consumption by 5% by a. reviewing production monthly and turn off if NIU b. installing energy efficient motors on 5 AHU's 3 To reduce production consumption by 2% by a. replacing machine 7 with new process 4 To reduce gas consumption by 7% by a. turning off AHU's (see 2a) b. installing air fuel ratio controller Totals 57000 2500 84000 Signed ____________________ Managing Director Signed ____________________ EMAP Senior Manager Manager Responsible Training MGr Production and facilities manager Facilities manager Facilities manager Facilities supervisor HVAC supervisor Production manager HVAC supervisor Copyright SEI 2005 5 step strategy Take Action • Promote energy-efficient practices and awareness amongst employees • Train key personnel in energy efficient practices • Establish an energy savings register • Ensure the efficient operation and maintenance, design and purchase of significant energy users The bane of energy managers! Silverhill Foods • • • • • “Lunch Time Initiative” – identified all motors which have been left on during lunch hour and we also identified one line which ran 24 / 7 and was only required for 6 hrs production per day. • Total Cumulative Saving: 28193kwhrs or €2114.50 / yr Repair of Air Leaks as prompted by training discussions led to elimination of one compressor which ran for 17 hrs / day 5 days per week drawing average of 18kw. • Total Saving: 89947kwhrs or €6746 / yr Refrigeration checks showed a number of fans which were not functioning properly in blast freezers resulting in a 95kw compressor running at full load continuously. This now runs for 3 hours each morning on half load • Total Savings: 42120kwhrs €3159 A 7kw chill motor was also identified running for the weekend when it could have been switched off • Total Savings: 17472kwhrs €1310.4 / yr Condense return initiatives have also led to savings in oil of 350 Litres per week which amounts to savings of €7098 / yr. Awareness = Housekeeping • Silverhill Food • Europe’s number 1 duck supplier • Continuous energy awareness campaign • Made in Russian and English • SAVINGS OF €21,000 RESULTING DIRECTLY FROM THE ENERGYAWARENESS CAMPAIGN WITH A CAPITAL EXPENDITURE OF APPROXIMATELY €2000 + TIME. Operation and maintenance, design and purchasing • Operate what you have correctly • Learn from mistakes – design and purchase correctly Proj. Project Description Estimated Est Yearly Est. Yearly Act Yearly No. Cost € kW h saving s € savings Savings A Utility Bills - Joe, Utilities Engineer Zero Cost Savings 2 Savings over PES tariff with supplier B 0 #REF! 133,620 3 ESB MD Incentive scheme 0 ? 8,000 1 Winter rebate - items off 5pm-7pm N/A B. Air Handling/Motive power - John, A/C Tech No cost 1 Turn off AHU 11 ev/we 0 60,000 3,600 2,400 Low/Medium cost 1 Replace AHU 12 motors with Class 1 2500 15,000 900 2 An energy efficient purchasing policy TBC C. Compressed Air - Bill, Tech Zero Cost 1 Reduce generation pressure from 7.5 to 7 bar 0 230,000 13,800 3,450 Low/Med costs 2 Shutoff production line 1 CDA auto 1500 23,000 1,380 322 1 Sequence and control compressors 15000 115,000 6,900 D. General Services (Lights, PC's, office equipment) - Adam, Security Supervisor Zero Cost 1 Turn off lights from 7pm to 8am - B4 0 151,632 6,353 1,513 Jan Housekeeping 16,834 Feb 15,318 Mar 16,519 Procedures & methods 300 300 300 Technology & investment 1,150 1,150 1,150 115 115 92 529 454 529 Case study 5 step strategy Review • Develop and monitor Energy Performance Indicators (EPI) • Establish a measuring and monitoring system • Report performance with management regularly • Management Review annually Case Study • Continuous policing exercise Practical Energy Management Reality suggests: • Management commitment is not a given • Staff time is in short supply • Staff is technically, not management-oriented • Limited energy management “infrastructure” How to manage energy, with no time, no resources and no management support! SEI Supports • • • • • LIEN Training programmes Technology Promotion RD&D support Energy Awards SEI Energy Management Supports • Energy Agrements • IS393 Energy Management System • Energy Bill > €2m • In development • EnergyMAP (Energy Management Action Programme) In conclusion • • • • Ad hoc approach not sustainable Structured approach key to maintaining savings Senior management commitment pre requisite What are my next steps? • Energy review • Ongoing energy management programme • Formal energy management system • An appropriate level for every company • The business case for action is clear Where to start • Energy MAP How the support programme will work • Discussion Continual Improvement Appoint CoModel Appoint senior management sponsor Energy Policy Overview energy consumption ordinator Review Commit Identify significant users Identify key factors Identify Reporting Identify opportunities Corrective Action Plan Review Establish a plan Monitor and measure Develop key performance Operation and indicators maintenance, design, procurement Set goals and targets Take Action Project prioritization and management Appoint resources Training Culture and awareness Session 1 Topics • Step 6 “Develop and Overview total energy consumption” • Step 8 “Survey energy use and identify significant energy users” • Step 7 “Identify the key factors that influence energy consumption • Compressed Air Homework for Session 2 • Complete the “business case for action” template • Use on line tools • Collate and analysis bills – develop an overview • Use on line tools • Produce survey of significant energy users & key factors • Pie charts, flowcharts etc • Compressed Air • Undertake at least ONE energy saving action • Pat will call you two weeks before next session to mentor you and check progress Session 2 • Step 9 – Identifying energy saving opportunities • Best Practices • Plan • Setting objectives and targets • Project prioritisation • Allocating resources www.sei.ie/energymap Alan Ryansei.i 01-8082536 Silverhill Foods • • • • • “Lunch Time Initiative” – identified all motors which have been left on during lunch hour and we also identified one line which ran 24 / 7 and was only required for 6 hrs production per day. Total Cumulative Saving: 28193kwhrs or €2114.50 / yr Repair of Air Leaks as prompted by training discussions led to elimination of one compressor which ran for 17 hrs / day 5 days per week drawing ad average of 18kw. Total Saving: 89947kwhrs or €6746 / yr Refrigeration checks showed a number of fans which were not functioning properly in blast freezers resulting in a 95kw compressor running at full load continuously. This now runs for 3 hours each morning on half load Total Savings: 42120kwhrs €3159 A 7kw chill motor was also identified running for the weekend when it could have been switched off Total Savings: 17472kwhrs €1310.4 / yr Condense return initiatives have also led to savings in oil of 350 Litres per week which amounts to savings of €7098 / yr.