Transcript industrial energy efficiency energy audit

industrial
energy
efficiency
energy audit
case TBM fortaleza
M&V - measurement and
verification protocol
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
TBM fortaleza - features
•products:
textile yarn - carded yarns, open-end yarns, yarns
compacted, fancy yarn
natural and synthetic fibers - cotton - viscose polyester - micro fiber - nylon - bamboo - linen-silk Lyocell - modal.
filaments - elastane - various filaments
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
energy savings
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
energy audit 2007
net present value-NPV (R$)
Elétricos
Motores
motors
electric
prompt replacement
1.305.097
1.400.000
gradual replacement
1.200.000
910.140
1.000.000
734.062
800.000
691.535 677.863
636.903
549.690
600.000
386.494
400.000
200.000
0
15 anos
eficiência energética i
10 anos
8 anos
6 anos
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
executive summary
effects on plant productivity:
•due to a better control over Temperature & Humidity in every area, the
productivity growth through the reduction of wire breakage.
•substantial reduction of product losses.
chillers specific
efficiency
power
measurement
kW
thermal load
removed by
chillers
kW
thermal load
removed/power
kW
year 2007
1.079
3.517
3,26
year 2010
853
3.903
4,58
rise of specific
efficiency
45 %
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
eficiência energética i
6
M&V
TBM fortaleza
executive summary
annual power consumption
(mWh)
system
measurement
in 2007
measurement
in 2010
reduction of power
consumption
(2007»2010)
energy savings
in 2010 only
chiller system - U1
9.320,0
7.370,0
20,9%
R$390.000,00
US$249,894.00
chiller system – U2
7.921,2
7.754,4
2,1%
R$33.360,00
US$21,350.000
comp. air system
3.793,0
2.528,9
33,3%
R$252.360,00
US$161,510.00
lighting system
3.621,0
3.503,5
3,2%
R$23.500,00
US$15,040.00
total
24.655,2
21.156,8
14,2%
R$ 699.680,00
US$447,795.00
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
M&V
TBM fortaleza
executive summary
energy audit
estimated values.
investments
savings
payback
[months]
eficiência energética i
M&V
report results
R$ 316.683,51
R$ 333.543,43
US$ 201,664.00
US$ 212,401.00
R$ 635.761,50
R$ 699.680,00
US$ 404,854.00
US$447,795.00
5,98
5,72
+5,1 %
+9,1 %
-4,5 %
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
industrial
energy
efficiency
panel
large industries
2005 - 2011
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
energy audit in industries.
systems-thinking methodology
- sectors of a an industrial plant are not
isolated bodies, the use of energy
requires an integrated management.
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
energy audit in industries.
preliminary
steps
analysis of the energy
consumption and rates
analysis of energy flow
audit planning
preliminary review of diagrams
analysis of
individual devices
(eg electric motors)
analysis of
auxiliary systems
analysis of
production
processes
analysis of
energy
management
technical / economical
report
eficiência energética i
PROGRAMA
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
petrochemical industry
annual savings
payback
R$ 4.773.912,07 (31.7% of current power
consumption)
12.6 months.
R$ 2.500.000,00
use of steam
and cogeneration.
R$ 2.000.000,00
R$ 1.500.000,00
R$ 1.000.000,00
cooling
system
electric
motors
motor
couplings
R$ 500.000,00
boilers
lighting
use of steam and cogeneration
eficiência energética i
PROGRAMA
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
automotive industry.
annual savings
payback
R$ 2.812.848,00 ( 23,3 % of current power
consumption).
7,0 months.
compressed air
R$ 1.000.000,00
R$ 900.000,00
R$ 800.000,00
lighting
R$ 700.000,00
cooling
system
R$ 600.000,00
energy
management.
R$ 500.000,00
R$ 400.000,00
R$ 300.000,00
R$ 200.000,00
boilers
electric
motors
R$ 100.000,00
net200 Hz
chiller Ala 4
management / air leakage and decentralization
eficiência energética i
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
textile industry
annual savings
payback
R$ 976.053,00 ( 8,1 % of current power
consumption).
16,3 months.
R$ 400.000
electric
motors
chillers:
re-establish the
project
specifications
R$ 300.000
compressed
air
R$ 200.000
lighting
replacement
of chilled
replacement
water pumps
of water
pumps - U2
R$ 100.000
chillers: re-establish the project
specifications
eficiência energética i
PROGRAMA
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
18 plants, average payback - 13.2 months.
fertilizer manufacture
chemical industry-ammonia
liquid gas plants
automobile industry
cleaning products
automobile industry
car tire factory
petrochemical
mining company
petrochemical
cellulose and paper
mining company
automobile industry
textile industry
truck tire factory
photographic Papers
cosmetic factory
manufacturer of metal strings
0
5
10
15
20
25
30
feedback industries
actions proposed in the audits actually
performed:
1. actions with the binomial payback & investment
close to Ø (zero), e.g. option to always use the
equipment with lower power consumption,
2. change in operational procedures of production
areas, e.g. automatic shutdown of machines
that remain running without production,
3. return the equipment settings at original
project values,
eficiência energética i
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
feedback industries
actions proposed in the audit actually
performed:
4. install energy management system, e.g.
to allow the decentralization of utility
area,
5. change in acquisition procedures for new
equipment also considering the specific
energy consumption,
6. base load reduction, complete or partial
scheduled shutdowns for loss
measurements.
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
beenchmarks - shows errors, when we compare
similar plants
Industrial Water Cooling System
best solution - comparison the values of specific
consumption
facilities served by
the cooling water
system
thermal
load
electric
power
water flow to
remove heat
[kW]
[m3/h/TR]
power utilized to
remove heat
[kW/TR]
A
air compressors
3.420,0
1.300,0
271,0
0,4
0,1
B
air compressors
and chillers
1.900,0
1.175,0
180,0
0,6
0,1
C
air compressors
and chillers
582,0
800,0
205,6
1,4
0,4
D
air compressors
and chillers
112,0
136,5
46,3
1,2
0,4
E
chillers and
others
721,0
1.038,0
473,6
1,4
0,7
2.284,2
4.111,4
1.559,3
1,8
0,7
industrial
plant
air compressors
plant “X” and chillers
eficiência energética i
[TR]
water flow
[m3/h]
PROGRAMA
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CONSERAÇÃO DE
ENERGIA ELÉTRICA
average contribution of each system obtained from
18 large industrial plants energy audits.
industrial water system and pumps
26.4%
compressed air system and compressors
23.3%
boilers and steam system
14.6%
re-sizing of electric motors
9.4%
energy management
7.8%
chilled water system
6.9%
lighting system
6.9%
ASD and motor coupling
2.4%
other
2.3%
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA
edson szyszka
[email protected]
www.eletrobras.com/procel
eficiência energética i
PROGRAMA
NACIONAL DE
CONSERAÇÃO DE
ENERGIA ELÉTRICA