Energy Resource Efficiency

MAS/ERE-Workshop
Newcastle upon Tyne
May 2008
Agenda for the day

 Structured approach to Energy Management

 Requirements in international standards (IS393 etc.)
 SEIs Energy MAP
 Review of Energy Aspects
 Energy Analysis Techniques
 Significant Energy Users
 Onion Diagram/Energy Services
 Delta-T hunting
 Integration Approach
 Energy Efficient Design
 Energy Management and KPIs
 Lean, Six Sigma etc.
 Summary and recommendations

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International Standards - History

 DS2403 (Danish Standard) launched 1996

 To secure management focus on energy savings
 To strengthen focus on processes (vs. utilities)
 Swedish Standard SS 62 77 50 launched 2001
 Irish Standard IS393 launched 2006
 Dutch and German specifications available
 Ongoing UK-preparations

All standards based on EMAS and ISO-standards regarding

environmental management and continued improvements
(Dr. Demings TQM-circle)

Standards mostly address “management” – not “techniques”

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Continued Improvements

Dr. Deming’s Principles for TQM

Plan

Act Do

Check

 Identify saving options

 Implement saving projects
 Follow-up on achieved savings
 Corrective actions
 New initiatives
 Etc.

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UK Standard

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Requirements in International Standards

 Demonstrate progress regarding energy efficiency

 Implemented savings
 Documented savings
 Demonstrate holistic approach
 Process vs. utilities
 Broad mix of measures
 Short term vs. long term saving projects (special investigations)
 Use of M&T
 Design, purchase and maintenance etc.
 Demonstrate data platform
 Pie charts & diagrams etc.
 Demonstrate annual management review
 To secure “top-down” approach
 To integrate with “company life”

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IS393 – Review of Energy Aspects - example

 The company shall establish its current position regarding

energy usage by means of an initial review
 The review should identify the equipment and processes
which account for the greatest energy usage or which offer
the most potential for energy savings
 The review shall address:
 Past and present energy usage
 Equipment having significant energy usage
 Opportunities for improvement
 Identification of personnel whose work may have an impact on
significant energy usage

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IS393 – Review of Energy Aspects - example

 Past and present energy usage

 Energy inputs based on distribution of electricity, oil, natural gas or
other
 Final use estimations (drying, pumping, air conditioning, lighting or
other)
 Energy supply/energy usage of each location should be reviewed
individually
 Trends in energy usage over previous years should be reviewed and
form basis for setting targets

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IS393 – Review of Energy Aspects - example

Equipment having significant energy usage:

 Energy aspects that use the most energy

 Energy aspects that determine energy use or the core energy
requirement
 Energy aspects that offer the most potential for saving

By example:
Processes, plants, equipment, fixtures, fittings, buildings and
Building services, raw materials, water use (energy associated),
other services, such as transport

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IS393 – Review of Energy Aspects - example

 The identification of opportunities for improvement

 Opportunities from the review should form the basis for setting
targets and energy management programmes
 No cost housekeeping measures such as turning off equipment,
training of personnel and promotion of energy efficiency may offer
greatest opportunity
 The identification of personnel whose work may have an
impact on significant energy usage
 Roles, responsibilities and authority should be clarified
 Include personnel who have an indirect impact such as purchasing,
design and training staff
 Company should consider updating the review annually

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IS393 – Review of Energy Aspects - example

A special investigation shall be planned and

described in terms of:
• Aim of project
• Expected saving potential
• Activities to be carried out
• Organization and responsibilities
• Time schedule
• Budget and resources

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Ongoing Work CEN/CLC BT/TF189/PT

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UK Standard

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SEI Energy MAP – 5 pillars

 Commit
 Identify
 Plan
 Take Action
 Review

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SEI Energy MAP – 20 Steps (1)

1. Appoint senior manager to Energy MAP

2. Appoint energy manager
3. Establish energy policy Commit
4. Communicate policy to employees
5. Annual review by management of Energy Map

6. Develop and overview total energy consumption

7. Identify key factors that influence energy consumption
8. Survey energy use & identify significant energy users Identify
9. Identify energy saving opportunities

10. Set objectives and targets

11. Establish Energy MAP plan Plan
12. Allocate Adequate Resources

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SEI Energy MAP – 20 Steps (2)

13. Promote energy efficiency awareness and practices among employees

14. Train key personnel in energy efficient practices Take
Establish an energy savings register
15.
Action
16. Efficient design, purchase, operation and maintenance

17. Develop and monitor energy performances indicators (EPIs)

18. Establish a measuring and monitoring system Review
19. Review Energy MAP actions annually and identify improvements
20. Management review of Energy MAP

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Inspiration

Inspiration and examples:

 Ireland: SEI Energy Map (www.sei.ie/energymap)

 EU: IPPC BREF document on Energy Efficiency Techniques
(version 2 July 2007)
 BAT-documents (BREF)

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 Review of Energy Aspects:
Data and mapping
Significant Energy Users
Significant Persons

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Past and present energy consumption

 Energy consumption from past 3 years should be known

 Production figures from 3 years should be known
 But often overall EPI’s are difficult to use:
 Production logistics might change from year to year
 New products or product qualities influence energy consumption
 New equipment and production processes are introduced
 Etc.
 So what is the benefit ?
 To establish an overview
 To secure EPI’s and input for the management follow-up
 To understand the context – what is on the agenda in the company

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SEC for ”CO2-world class” company
kWh/ton
140

120

100

80
Series1
60

40

20

0
1 3 5 7 9 11 13 15 17 19 21 23 25
1980 2006

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Significant energy users

 Energy aspects that use most energy

 equipment, machine etc.
 Energy aspects that determine the energy usage or the core energy
requirement
 chemical process, a raw material requiring large energy cons. etc.
 Energy aspects with high saving potentials
 Old equipment

Plant Manufacturer Plant principle Rated Annual run- Etc.

& year performance hours
Evaporator,li Atlas 1982 4-effect 2 tonnes of 2-shift, 4000
ne 2 steam/hour hours

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Persons influencing Energy Consumption

Energy Management

Process Utilities Operators

- Fermentation - Cooling - Processes
- Drying - Compressed air - Building
- Evaporation - Heating/CHP - Logistics
- Etc. - Etc. - Etc..

Process Engineers/chemists have Mechanical engineers/techn-cians Operators have the responsibility

the capabilities and responsibilities have the capabilities to maintain of operating processes and utility
to change important process and optimize the operation of systems during daily operation
parameters utility systems

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Significant persons

 Operators operating major processes and equipment

 Technical department responsible for maintenance
 Facilities management responsible for buildings
 Design engineers responsible for new facilities
 External companies responsible for cleaning
 Service companies owing and operating utilities
 Production planning department
 QA-department
 FDA
 Etc.

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Plenum discussion

 Your significant energy users?

 You significant persons?

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Principle diagrams/flow sheets

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The Next step: Mapping by End-user

Misc.
Vacuum Kortlægning, el: 25A+29B Pumps
Diverse
Pumpning og
Proces/produktion 0%
Lighting 10%
cirkulation

Vakuum
9%
Cooling
Køling
1%
13%
Compressed airTrykluft
19%

Belysning og EDB Ventilation

13% 35%

Ventilation Production

Separate mappings for electricity and thermal energy

use should be presented – if relevant also for water

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Pie charts – how and why ?

 By end-use or by section ?
 Most often metering structure is by section
 Detailed methodology might be needed
 To overview the energy balance of the company
 To discover not-seen energy usage
 “Speak with data”
 Data is the platform for decisions

…there are always surprises !

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Hot water consumption can be hidden usage

Ready Meals:
 Need for hot water for cleaning
purposes was estimated to be 40
m3 per day
 Measurements showed a need for
> 150 m3 hot water per day
 New data initiated investigations
of options for heat recovery.
 Annual cost saving
Euro 200,000
Pay-back = 1½ years

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Mapping of end-user consumption

Motor-ID Installed Estimated load Annual run- Annual power Etc.

capacity (kW) (%) hours consumption
(kWh)

The same methodology might be applied for:

 Heat

 Electricity

 Water

 Etc.

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Conversion losses should be mapped

Steam boilers without economiser might have efficiencies

below 70% and including distribution losses, efficiencies as
low as < 50% have been observed in Irish industry (2006)

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End-users

Thermal end-users Electrical end-users Water end-users

(steam, hot water etc.)
- drying - refrigeration - process (additives)
- process heating - natural cooling - steam injection (heating)
- evaporator lines - compressed air - water for injection (WFI)
- boiling - process air - RO-plants
- distilling - fans/HVAC - humidification of air
- kilns & furnaces - air-conditioning - cleaning of premises
- building heating/HVAC - production machinery - CIP/SIP
- CIP/SIP - pumps - condensate losses
- water heating - hydraulics - cooling towers
- conversion losses - small motors - showers
- distribution losses - lighting - accommodation
- etc. - etc. - etc.

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Example: Mass Balance for Cooling System

Principle diagrams can most often be found in BMS or monitoring systems

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Example 1

Significant Energy Users

Significant persons
Fermentation Process
Agigator

Fermentor
Cooling tower

NH3

Cooling compressor

Compressed air compressors

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 Review of Energy Aspects:
Onion Diagram
Energy Balances
Composite Curves and delta-T
Review design/operating parameters
Value Stream Mapping

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Typical Savings from an Energy Review

 Concrete projects
 Savings that can be implemented with just minor efforts
 Investment projects
 Improved maintenance
 Change of process parameters
 Changed operation of equipment and processes
 Etc.
 Special investigations
 Savings that requires more detailed investigations
 Due to technical complexity
 Due to cross-organisational involvement
 Due to required input from external specialists
 Etc.
 Identified KPI’s and energy management-routines
 New purchase and design procedures
 Etc.

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 Energy efficiency is many things

= don’t go to the boiler station !!!

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The ”Onion” Diagram – Energy Demand
Good
Housekeping

Operation &
Maintenance

Control

Plant

Process

Energy
Service

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From Energy Service to Energy Bill

1. Reduce the ”Energy Service”

2. Use energy efficient technology
3. Optimise efficiency of plant and technology
4. Ensure a correct operation of the plant
5. Re-use waste/excess energy

Energy Energy
Service Consumed

Energy is used twice – and can be saved twice !!!

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 Example: Removal of Dust from Cement-Bags

1. ”Energy Service” = removal of dust

2. Technology = compressed air vs. ”mechanical” solution
3. Efficiency = minimize pressure need etc.
4. Operation = minimize idle load etc.
5. Re-use of waste = utilise excess heat for building heating

7% 100%

Energy Service Electricity bill

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Example: Tray Washing Machine at Abatoir

Energy- og waterconsumption:
 Steam = 50.000 Euro/year
 Vand = 100.000 Euro/year
 Totalt = 150.000 Euro/year

Water- and heat-recovery (?) :

 Saving = 50%
 Large investments

Filled trays
Operation according to need (!):
 Saving = 90%
 Small investments

The ”vets” have to approve

Cold water 82°C Cold water
water vand
Empty trays

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Energy Balances/Sankey Diagrammes

90
80
70
60
50
40
30
20
10
0
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

An energy balance can explain the overall efficiency of a process

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 Furnace for Coating of Metal Alloys
Flue gas (300C)

Exhaust Stack
from doors

Hot
surface
approx.
130C

Product Conveyor Product

entering the leaving the
furnace furnace

Air
3 natural
gas burners Natural gas

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Composite Curves
The ”composite”-
principle identifies:
Temperature - Improved supply
- Heat recovery

Hot composite

The ”composite”-
Cold composite principle can be
applied also for:
- Compressed air
- Water/waste water
Energy Content
Behovsanalyse godtgør at 95% af kølebehov ligger over 10 C - Etc.
- men frikøling er for varmt til temperering af produktionsområder

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Example: Heat Recovery

 Large waste heat ammounts in most industrial

sectors
 In food sector, pharmaceutical sector etc. large

ammounts of waste heat has temperatures < 100C

 The most easy solutions might be utilised already

(building heating)
 ...but large hidden energy demands might be found

in heating of water for processes and cleaning

purposes etc.

 Use the composite-principle

 Establish water/heat storage (70 C)

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Benefits of Composite Principle

 What is “worst-case” utility design ?

 Can heat be recovered ?

 What is “best-case” utility design ?

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Example: Delta-T hunting

 What is efficiency of heat exchangers ?

 Design criteria
 Fouling
 How is delta-T in cooling systems
 Is low-temperature brine used for high-temperature cooling ?
 How is delta-T in heating systems ?
 Is steam used for low temperature heating
 Building heating
 Heating of water for cleaning/CIP and production purposes

Heat exchangers might have delta-T’s as low as 2C – often

delta-T of 15-20C is seen in Irish industry requiring more
utility and recovering less energy (worst case delta-T = 138C)

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Delta-T’s in extraction process
Ekstraktion: Procesforløb ved rapsdrift

Faststof "skrå"
29
Miscella
60S
18S Rapsolie
Tank 17 22DD
20A Hexan/damp
21A
22A/B Hexan/vand
21B 19
Hexan

Kondensat/vand
24 B1 24 B2
G18S 23A
Damp

18A Luft
23B

G22B
G8 G60
81A
58P19
Kældertank
KT5 i Møllen

Centrifuge

G22DD Siloloft
X1 70SC
Toaster
20A G19
H4
Mixer
Procesvand
Filter 16 F
RD 290 G1

32/34
Ekstraktør (3)
49P1 Flash-
Koger 45 & damp
zero effluent
anlæg
G32B

EV5 RD 103
Køleluft

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Review of Design Parameters

Food Ingredients:
 Need for ventilation in
packaging area
was before audit 10
times per hour
 Review of product
requirements and change of
equipment reduces
ventilation to 4 times
per hour
 Annual cost saving
Euro 25,000
Pay-back = 0 years

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 Value stream mapping

Glucose-/sucrosetanks NH3,
yeast,
Etc.

Agitators

Sterile plant
Water, salts
etc.
Cooling

37C
Final cooling

6C
Recovery

Mixing tanks Sterile plant Substrate tanks Fermentors

Process air

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Example 2

Onion diagram for an autoclave

Autoclave in Healthcare Industry

Sterilisation of
6 compressors of products at 100%
each 150 kW humidity and 120C
delivering 8.5 bar Trays with
plastic tubes in for 50 min.
compressed air
bags with
sterile water

8 bar
steam

10C
water
Compressed air 20 autoclaves of each 15 meter
reciever at 8.5 bar length and 2 meter diameter

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