Post on 25-Jun-2020
Energy Efficiency in the Industrial SectorCase Studies from Lebanon
Nader Hajj ShehadehSenior Energy & Sustainability Consultant
WHY?
WHY?
Energy dominates an average of
30% of industrial facilities annual
expenses30%
Industrial facilities could save up to
20% of their energy bills through
energy management and energy
efficiency measures
20%
WHY?
Reducing energy by 20% leads to
reducing manufacturing cost by
2.5 USC on to make a 1-liter plastic
bottle, cap, & packaging
WHY?
Energy Audits are becoming
mandatory in more than 35
countries allover the world
WHY?
Rule of Thumb:
An energy audit should be
considered if energy bills exceed
$100,000 a year
WHY?
PRESENTATION
OUTLINE
o The Energy Audit Concept
o Industrial Energy Audits
o Case Studies from Lebanon
o Potential Energy Efficiency Measures in the Industrial Sector
o Monitoring & Energy Management
o Compressed Air Systems
o Steam Systems
o Heat Recovery
o How to Get an Energy Audit
Presentation Outline
ABOUT THE SPEAKER
o Senior Energy & Sustainability Consultant
o 10+ years of experience in the Lebanese Energy Sector
o Professional Energy Auditor
o Specialized in green building design, energy efficiency enhancement, and renewable energy
design
o Track record of more than 50 energy audits and sustainable building design in the past 2
years
Nader Hajj Shehadeh – BE, MS, MBA, PGDip, LEED GA
ABOUT THE SPEAKER
THE ENERGY AUDIT
CONCEPT
Definition
THE ENERGY AUDIT CONCEPT
Basic Questions
WHAT?
WHEN?
WHERE?
WHY?
HOW?
THE ENERGY AUDIT CONCEPT
o What energy is being consumed at the facility?
o When is energy most needed?
o Where is energy being drained?
o Why is that much energy needed?
o How is energy being produced, transformed, and consumed
Basic Questions
Energy Balance
Energy Patterns
Energy Density
Energy Analysis
Energy Flows
THE ENERGY AUDIT CONCEPT
Energy Audit Levels
0. Preliminary Energy Audit
1. Walkthrough
2. Energy Survey & Analysis
3. Detailed Survey & Analysis
THE ENERGY AUDIT CONCEPT
INDUSTRIAL ENERGY
AUDITS
o Step 1: Understanding the industrial operations
o Step 2: Undertaking a Preliminary Energy Audit (PEA)
o Step 3: Identification the of preliminary Energy Efficiency Measures
o Step 4: Undertaking the Detailed Energy Audit (DEA) including:
I. Preparation of measurements plans
II. Detailed analysis of existing energy end uses
III. Development of all Energy Efficiency Measures with their technical background,
savings calculations and financial analysis
IV. Preparation and presentation of the DEA report including the Action Plans
The Steps
INDUSTRIAL ENERGY AUDITS
Annual Energy Demand – WHAT?
INDUSTRIAL ENERGY AUDITS
Energy Load Breakdown – WHERE?
INDUSTRIAL ENERGY AUDITS
Monthly Energy Demand – WHEN?
INDUSTRIAL ENERGY AUDITS
Energy Demand Analysis – WHY?
INDUSTRIAL ENERGY AUDITS
Energy Distribution – HOW?
INDUSTRIAL ENERGY AUDITS
CASE STUDIES FROM
LEBANON
Carton Production Food & Beverage Food & Beverage
The Sites
CASE STUDIES FROM LEBANON
1 2 3
Energy Breakdown
CASE STUDIES FROM LEBANON
kW kWh
Energy Breakdown
CASE STUDIES FROM LEBANON
Energy by Source
CASE STUDIES FROM LEBANON
Energy by Type
CASE STUDIES FROM LEBANON
Energy Saving Potential
CASE STUDIES FROM LEBANON
ENERGY EFFICIENCY
MEASURES
o Energy monitoring system for
optimized energy utilization
(Enterprise energy management,
SCADA, etc…)
Energy Metering & Control
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
ENERGY METERING & CONTROL Monitoring & Energy Management $10k - $50k+ 5% - 35% Energy 2
o Load shifts and energy generation
source optimization based on fuel
prices and tariff structure applied at
the facility
Peak Hours Management
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
PEAK HOURS MANAGEMENT Monitoring & Energy Management $0 1% Electrical 0
o Water heating for domestic use and
process heating using solar water
heaters. Can be used to provide hot
water for use or preheated water for
steam.
Solar Water Heating
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
SOLAR WATER HEATING Water Heating $10k - $200k 10% - 50% Thermal 5
o Production of electricity through
solar photovoltaic panels. Generated
power can be used during peak hours
and fed into the grid when in surplus
Solar Photovoltaics
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
SOLAR PHOTOVOLTAICS Power $50k - $500k 10% - 40% Electrical ~10
o Use of capacitors to reduce reactive
power and improve the Power Factor
of a circuit with a large inductive load.
Power Factor Correction
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
POWER FACTOR CORRECTION Motors $10k - $80k 1% - 5% Electrical <3
o Following proper maintenance
practices, and properly sizing the
system. In addition to implementing of
good housekeeping measures
Compressed Air System Optimization
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
SYSTEM OPTIMIZATION Compressed Air System $0 - $10,000 Up to 10% Electrical <2
o Avoiding leakages and treatment of
damaged pipes, accessories, elbows,
and other leaking items that lead to
wasting compressed air
Compressed Air Leakage Prevention
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
LEAKAGE PREVENTION Compressed Air System $0 - $5,000 Up to 5% Electrical <1
o Relocating the air compressor or
installing a piping extension that
allows the inlet of outdoor air to the
air compressor
Compressed Air Temperature Optimization
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
TEMPERATURE OPTIMIZATION Compressed Air System $0 - $500 1% - 3% Electrical <1
Inlet Temperature Relative Air Delivery Power Saved
(°C) (%) (%)
10 102 1.4
15.5 100 0
21.1 98.1 -1.3
26.6 96.3 -2.5
32.2 94.1 -4
37.7 92.8 -5
43.3 91.2 -5.8
o Reduction of set pressure to the
lowest possible value. Could be
applied at the point of usage or at the
air compressor point
Compressed Air Pressure Reduction
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
PRESSURE REDUCTION Compressed Air System $0 1% - 3% Electrical 0
o Optimizing combustion efficiency by
fuel to air ratio control and oxygen
trimming, avoiding losses and
reducing fuel consumption
Steam Combustion Optimization
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
COMBUSTION OPTIMIZATION Steam System $500 - $10,000 2% - 5% Thermal 3
o Through a condensate recovery
system that recovers condensate
from steam installations in order to
maximize their overall energy
efficiency
Steam Condensate Return
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
CONDENSATE RETURN Steam System ~ $100,000 3% - 10% Thermal 3
o Recovering energy from blowdown
steam and reducing energy losses
caused by this necessary
maintenance measure
Steam Blowdown Steam Recovery
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
BLOWDOWN STEAM RECOVERY Steam System ~ $5,000 ~2% Thermal <3
o Improving insulation conditions to all
steam network elements as well as
boilers and hot mediums. This also
includes proper maintenance
practices
Steam Network Thermal Insulation Improvement
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
THERMAL INSULATION Steam System $500 - $5,000 1% - 5% Thermal ~1
o Management of steam traps including
maintenance, care, cleaning, and
replacement if the item is totally
damaged
Steam Traps Management
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
STEAM TRAPS MANAGEMENT Steam System ~$1,000 1% - 2% Thermal ~1
o Avoiding leakages and treatment of
damaged pipes, accessories, elbows,
and other leaking items that lead to
wasting steam
Steam Leakage Repair
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
STEAM LEAKAGE REPAIR Steam System $0 - $3,000 5% - 10% Thermal ~2
o Flue gas heat recovery through the
use of an economizer that reuses the
exhaust gas and uses it in a heat
exchanger
Boiler Heat Recovery (Economizer)
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
ECONOMIZER Heat Recovery $1,000 - $20,000 1% - 5% Thermal <3
o Heat recovery from generator
exhaust connecting it to a single unit
called exhaust gas boiler that
generates thermal energy for water
heating
Generator Heat Recovery - Exhaust Gas Boiler
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
EXHAUST GAS BOILER Heat Recovery $200k - $500k 5% - 15% Thermal 3 - 7
o Heat recovery from generator
exhaust by the installation of a heat
exchanger on the engines jacket
water coolant to produce hot water
Generator Heat Recovery – Jacket Water
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
HEAT EXCHANGER (JACKET) Heat Recovery $20k - $120k 1% - 15% Thermal 1 - 5
o Heat recovery from generator
exhaust to be used in an absorption
chiller to generate chilled water and
save on electricity expenses
Absorption Chiller
ENERGY EFFICIENCY MEASURES
CATEGORY CATEGORY INVESTMENT SAVING (%) ENERGY PAYBACK (YRS)
ABSORPTION CHILLER Heat Recovery $200k - $500k 5% - 15% Thermal ~5
GETTING AN ENERGY
AUDIT
1. Prepare all drawings and MEP diagrams
2. Furnish energy bills for the past 3 years
3. Hire a professional energy auditor
4. Seek financing through NEEREA
5. Expect to pay between $5,000 and $20,000
6. Expect to save $50,000 to more than $200,000 a year
How to Get an Energy Audit?
GETTING AN ENERGY AUDITOR
Ready for Questions
NADER HAJJ SHEHADEH
THANK YOU