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Energy Efficiency in the Industrial SectorCase Studies from Lebanon

Nader Hajj ShehadehSenior Energy & Sustainability Consultant

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?


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


Energy Audit Levels

0. Preliminary Energy Audit

1. Walkthrough

2. Energy Survey & Analysis

3. Detailed Survey & Analysis


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?


Energy Load Breakdown – WHERE?


Monthly Energy Demand – WHEN?


Energy Demand Analysis – WHY?


Energy Distribution – HOW?


CASE STUDIES FROM

LEBANON

Carton Production Food & Beverage Food & Beverage

The Sites

CASE STUDIES FROM LEBANON

1 2 3

Energy Breakdown


kW kWh

Energy Breakdown


Energy by Source


Energy by Type


Energy Saving Potential


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



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



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



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



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



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



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



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



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



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



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



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



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



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



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)



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



EXHAUST GAS BOILER Heat Recovery $200k - $500k 5% - 15% Thermal 3 - 7


exhaust by the installation of a heat

exchanger on the engines jacket

water coolant to produce hot water

Generator Heat Recovery – Jacket Water



HEAT EXCHANGER (JACKET) Heat Recovery $20k - $120k 1% - 15% Thermal 1 - 5


exhaust to be used in an absorption

chiller to generate chilled water and

save on electricity expenses

Absorption Chiller



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

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