Energy Efficiency at Vale
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Transcript of Energy Efficiency at Vale
Energy Efficiency at Vale
ITEMS
Goal
Energy Management: Energy Efficiency
Plant Assessments
Energy Saving Needs in Brazilian Industry
Conclusion
GOAL
Present the form of action from Vale regarding energy efficiency, share experiences in plant assessment, as well as provide an insight into potential energy savings in industry
ENERGY MANAGEMENT AT VALE
ENERGY MANAGEMENT
Value Criation Optimization
of Supply Costs
Supply Secutiry
Social-Environmental Responsibility Energy
Efficiency
* There is no hierarchy among the pillars
WHAT IS CONSIDERED ENERGY EFFICIENCY?
Energy Efficiency
Reduction of unitary
prices
Contractual Arrangements
Energy quality
Optimization of industrial
assets
Consumption Reduction
Productivity increase
Change in energy
transport alternative
Energy – any sort, and
not only electricity
Energy Efficiency -
Optimization of energy
expenses
Energy Efficiency Projects - Projects or
activities that lead to
reductions in energy
spending, which are
crucial for the economic
viability of investments
ENERGY MANAGEMENT – ENERGY EFFICIENCY
PERFORMANCE
Expenses
Energy End-use
Unitary price
• Energy service (heat,
driving force)• Energy evaluation and
selection (demand,
availability, unitary price)• Supply choice (self
production, market)
• Contracts• Tariffs• Taxes• Transport
• Corrections and improvements• Process changes• Energy recovery• Technology development
Operations
Energy
End- Use
Unitary Price
Projects
Plant Assessments Contractual Renegotiations and RevisionsImprovements, Replacements and Corrections
Project Validation (FEL)New Energy ContractsProject Revisions and Adjustments
ENERGY MANAGEMENT – ENERGY EFFICIENCY
Standards
TGEE
Energy Management
Operations
Current Projects
Capital Projects
Energy Policy / Technical Standards for projects and equipments
Local and Global Energy Committees / Evaluation of results and sharing of best practices
Monitoring of specific consumption and costs of operations
Plant Assessments, measurement and verification of results
Exploration, engineering and project implementation
Analysis of energy efficiency through the steps of FEL
ENERGY MANAGEMENT – ENERGY EFFICIENCY
PLANT ASSESSMENTS
Falhas de equipamentos apontadas no OEE
Energy Management (Specific Consumption)
Problemas PotenciaisTGEE – Technical
Groups
Gestão da Mudança Innovates Vale
(Stock ideas)
Mapeamento da Cadeia de Valor (Assessment)Plant Management
(Strategy)
Emissão de SEPsCurrent Projects
Estudos KaizenSES – System of
Engineering Standards
Estudos de Confiabilidade
APS – Action Plan Sustainability
ENTRADAINPUT PROCESSOPROCESS
Outras alternativasDepartment of Energy /
Alternatives
TCIEnergy DepartmentFase 1 - Avaliação do impacto
econômico ou risco associado a cada um das preocupações
identificadas
Technical and economic analysis Decides on performing
broad or specific assessment
Geração de lista de estudos priorizada pelo impacto/risco,
dificuldade de execução e estimativa de investimento
Gerência IndustrialPlantsFase 2 - Priorização dos estudos
a serem conduzidosProvide the infrastructure and validate stages of assessment
TCIDep. of Energy / PlantsFase 3 – Endereçamento dos
estudos e formação das equipes de trabalho
Addresses the improvements /Incorporate the
opportunities in the budget
SAÍDAOUTPUT
ROM/RNC - Estudos de Engenharia
Lean Six Sigma Department
Performs contracting company service provider and makes management of contracted
PLANT ASSESSMENTS PIMS
Energy Management System – Brucutu Plant
Superior PerformanceNormal PerformanceAverage PerformanceBad Performance
MotorsSystem
Ventilation andExhaust
Lighting
Compressed Air
Thermal Systems /
Cogeneration
Instrumentation and Control
Conveyor Belts
Pumps
SYSTEMS
PLANT ASSESSMENTS
SCOPE
Analysis and measurements of electrical and mechanical systems
Analysis of systems the utilities area
Analysis of processes that interact on the plants
Energy Management
Incorporation of technology
Creation of control parameters
Performance evaluation
PLANT ASSESSMENTS
SYSTEMS AND EQUIPMENTS ANALYZED
PLANT ASSESSMENTS
Couplings Solar heating Pumps Boilers Chillers Cogeneration Compressors Variable speed drive Capacitors Conveyors Effluent treatment plant Exhaust Filters Energy management Lighting Thermal insulation
Hot water lines Power transmission lines Steam lines Measurement of electric
and magnetic fields Mills Motors Industrial water system Compressed air system Ventilation system Chilled water system Transformers Pneumatic conveyors Heat exchangers Turbines
SYSTEMS AND EQUIPMENTS ANALYZED
PLANT ASSESSMENTS
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL CASE
Total Electric Energy
% Savings per system
Plant AssessmentPumping
Compressed air
Motors
Lighting
Variable speed drive
VENTILATION AND EXHAUST Elimination of head losses Reduction of power exhaust fans Use of variable speed drive in motors Use of thermal energy from exhaust gases
COMPRESSED AIR Elimination of leakage and drainage of condensate Reduced pressure losses Classification and division of compressed air lines Sizing of compressors in accordance with the appropriate application Suitable arrangement of the house of compressors Optimization of the air intake system in order to reduce the temperature Automation of the operation of the compressor (load / idle)
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONS
MOTORS SYSTEMS Sizing of motors Use of energy efficient motors Use of variable speed drive Automation control systems to reduce no-load operation
PUMPING (Water, pulp ou vacuum) Elimination of leaks Use of variable speed drive for variable flow demands Reduction of the Head by dividing reservoirs Proper selection of the pump to the point of maximum efficiency Elimination or reduction of pumping due to the route optimization Reduction of friction in the pump shaft seals Control of temperature and water flow sealing vacuum pumps
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONS
LIGHTING, AIR CONDITIONING AND HEATING WATER Proper specification and distribution of equipment in environments Integration of natural resources to the solution of thermal comfort and light Promotion of adequate and regular maintenance of equipment Automation and suitable actuation of system Using solar energy to heat the water used for washing parts, restaurants and
clothing room
ELECTRIC POWER SYSTEM Evaluation of the load transformers Evaluation of power factor and installation of capacitors and filters Monitoring of power quality
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONS
TRANSPORT Implementation of measurement system Relocation of supply points Automatic calibration of tires Training of operations focused on efficient driving Reduction of MDT (Middle Distance Transport) Maintenance plans focused on energy efficiency Auxiliary systems to operate the equipment (on-board computers connected to the
dispatch system) Maintenance of roads running Replacement trucks for pumping pulp or conveyor belts, where applicable
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONS
THERMAL SYSTEMS Preheating of the combustion gases Improved insulation and reducing losses of hot gases Evaluation of the steam distribution system Analysis of the refrigeration system (cooling towers and others) Use of additives to improve fuel combustion in motors Evaluation of cogeneration systems
NEW TECHNOLOGIES Trolley Trucks Studying application of electrical energy for supply of locomotives to replace
diesel Truckless system for mines
ENERGY SAVING NEEDS IN INDUSTRY
TYPICAL ACTIONS
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCY
STRENGTHS
Electricity from low carbon sources
Wide range of energy (electricity, gas, fuels, biomass and others)
Energy matrix is converted to energy from renewable sources
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCY
WEAKNESSES
Imposition of non-energy costs on the tariff Lack of technical courses for industrial energy
efficiency (technical and superior levels) Lack of tax and credit incentives for thermal systems Low investment in instrumentation and control Lack of knowledge on energy laws
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCY
OPORTUNITTIES
PNE (National Energy Efficiency Plan) ISO 50001 (Energy Management Standard) Expansion of investment in instrumentation Certification in Measurement & Verification
processes Strong performance in thermal systems Effective fiscal and credit incentives Increase the importance of PROCEL and CONPET
programs
CONCLUSION
SWOT ANALYSIS – ENERGY EFFICIENCY
THREATS
Importing solutions not suitable to the Brazilian reality
Dissociation of efficiency incentives for different energy sources
CONCLUSION
EVOLUTIONARY VISION – ENERGY EFFICIENCY
Management Maturity
Impa
ct o
f act
ions
Continuous monitoring (power + indicators)
Contractual tariff adjustment
Adjustment of consumption profile (awareness)
Review of the production process (automation)
Technology upgrades (retrofit)
Cogeneration and Renewable
Fábio A. ChavesDINE (Energy Department)General Management of Trading and Market Solutions+55 (13) [email protected]