Transcript Energy Efficiency through Product & Process Design

This project has been assisted by
the New South Wales Government
through its Energy Efficiency Training Program
Energy Efficiency
through Product & Process
Design
Prepared by
Prepared by Plastics Industry Manufacturers of Australia (PIMA)
in partnership with Australian Management Academy (AMA);
executed in collaboration with EcoProducts
Copyright and disclaimer
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used, reproduced and adapted, provided the meaning is unchanged and its source, publisher and
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this document are factual and free of error. However, the State of NSW and the Office of Environment
and Heritage shall not be liable for any damage which may occur in relation to any person taking
action or not on the basis of this document.
Office of Environment and Heritage, Department of Premier and Cabinet
Phone: (02) 9995 5000 (switchboard)
Email: [email protected]
Website: www.environment.nsw.gov.au
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Energy Efficiency
through Product & Process
Design
Module 7 – Energy Efficient
Manufacturing Process Optimisation
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Products Agency
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Key Points
1.
2.
3.
4.
5.
Where is energy used in manufacturing?
Measuring energy use
Analyzing energy use
Benchmarking
Process optimization
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Energy Efficiency
• Measure
– Understand your energy use
– Compare with benchmarks
– Identify opportunities for energy saving
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Energy Use
• Key energy uses in plastics processing are:
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–
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Drying materials prior to processing
Heating materials up to the processing temperature
Cooling products after processing
Building services
• Heating, cooling, lighting
– Ancillaries
• Compressors, granulators
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Energy Use
auxilliary
equipment
2%
dryers
8%
building
services
9%
injection
moulders
61%
cooling
tower &
chillers
20%
Energy use in a typical injection moulding plant
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Energy Use
• Measuring energy use
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Electricity and gas bills
Sub-metering by area or machine
Short term monitoring of key equipment
Estimate % on-time x power rating x duty factor
• Analysis
– By plant production volume
– By process
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Energy Use by Production
Volume
production volume
(tonnes)
energy use
(MWh)
Jan
202
550
Feb
392
890
Mar
360
700
Apr
290
630
May
350
720
Jun
380
550
Jul
280
500
Aug
330
580
Sep
358
620
Oct
375
720
Nov
344
650
Dec
360
610
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Energy Use by Production
Volume
Monthly ENergy Consumption
(MWh)
1000
900
800
700
Process Characteristic Line (PCL)
600
500
400
Base Load
300
200
100
0
-50
50
150
250
350
450
Monthly Production Volume (tonnes)
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Energy Use by Production
Volume
• Base load should be <30% of max load,
preferably <10%
• Scatter indicates potential waste
• Investigate variances and trends
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Energy Use by Process
• Energy use in a process or process line can be
characterized by the Specific Energy
Consumption (SEC)
• Unit of material is usually kg or tonne
• But could also be number of parts
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Energy Use by Process
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Energy Use by Process
• Larger throughputs are more energy efficient
– Less waste heat
– Lower drive losses
• Injection & blow moulding have higher SEC
– energy for opening and closing tools and other
actions
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Benchmarking
• Compare SEC with best practice for similar
processes and throughputs
• May be misleading due to:
– Different types of products
– Different size operations
• Benchmark like-for-like if possible
• Internal benchmarking of similar operations can
be powerful
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Benchmarking
• Typical energy use for plastics processing
SEC (kw.hr/kg)
Injection moulding
0.9 – 1.6
Blow moulding
1.4 – 2.5
Extrusion
0.4 – 0.6
Sheet extrusion/thermoforming
0.9 – 1.6
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Summary
• The use of simple financial tools enables
comparison of costs and benefits for energy
efficiency investments
• No single financial tool is best for all uses
• Non-financial benefits should also be
considered when assessing options
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Energy Management
• Manage energy as carefully as labour
• Startup and shut down procedures
• Job scheduling to avoid running equipment that
is not in use
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Dryers
Granulators
Moulding machines
Lights
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Adjusting Process
Conditions
• Process temperatures as low as possible
• Cycle times and rates as high as possible
• Cooling water temperatures no lower than
necessary
• Minimize rejects
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Maintenance
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Eliminate compressed air leaks
Insulate cold water lines
Minimize downtime
Minimize rejects
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Summary
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Understand where energy is being used
Measure energy use in detail
Analyze by production volume and SEC
Compare to benchmarks
Identify key opportunities
Process Optimization
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Products Agency
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