Polymer Processing Cost Saving Workshop - 03 Sustainable Development

SustainableDevelopmentPolymer Processing ‐ Cost Savings Potential in the Process

Ciaran O'Reilly Chartered Engineer

Process

Chartered Engineer

Technical AdviserSustainable DevelopmentSustainable Development

M i i iMaximisingEfficiencies 5 ProgrammersEfficiencies

(1) Resource Efficiency Audit (2) P j t M t F k(2) Project Management Framework (3) Energy Efficiency Loan Scheme (4) Capital Grants for SME’s of up to £40 000(4) Capital Grants for SME s of up to £40,000 (5) Industrial Symbiosis

Sustainable Development

M i i iMaximisingEfficiencies

Progress Last 3 YearsEfficiencies Last 3 Years

850 Audits Completed

£60,000,000

of Identified SavingsSustainable Development

CostCost Savings Hidden Potentialdde o e a

Polymer Processing ‐ Cost Savings Potential in the Process

Areas of High Process Energy ConsumptionAreas of High Process Energy Consumption.

Actions that can be taken to reduce Consumption.

S t i bl D l t

Indicative Potential Investment Costs and Cost Savings


EnergyEnergy Process Energy v Carbon

Manufacturing Factory Polymer Processing

80%

100%

120%

80%

100%

120%

Polymer Processing

40%

60% Heating

Electric

40%

60%

80%

Heating

Electric

S t i bl D l t

0%

20%

Carbon Energy0%

20%

Carbon Energy


CostCost Savings Energy used in an

t d b iextruder business

66% Processing

Manufacturing business16% Processing equipment

10%

5%5% 2%1%

66% Processing equipment

11% Chillers

10% Compressed Air

16%

5%

10%

5% Chillers

10% Compressed Air

66%

11%

5% Water Pumps

5% Lighting

2% Factory & office

5%

10%

5%

34%

5% Water Pumps

20% Lighting

S t i bl D l t

yheating

1% Offices20% 34% Factory & office heating

10% Offices


CostCost Savings

Extrusion Blow MouldingInjection Stretch Moulding

45%

16%

8%45% Extruder

31% Hydrulics

3% 3%

94% Infra Red Lamps

31%

16% Heat

3% Ventilation

3% Motion

S t i bl D l t

8% Granulator94%


CostCost Savings

Process 325 KW1 000 kg/h

Specific energy to raise the temperature of the plastic is typically 0 16 kWh/k f i t lli l ti (lik PE PP)

1,000 kg/h

• 0.16 kWh/kg for semi-crystalline plastics (like PE or PP)• 0.10 kWh/kg for amorphous plastics (e.g., PVC, PS).

The actual specific energy consumption will be higher because of losses in the motor, gearbox,thrust bearings cooling the feed housing and extruder barrelthrust bearings, cooling the feed housing and extruder barrel,

• 0.20 to 0.25 kWh/kg semi-crystalline plastics• 0.15 to 0.20 kWh/kg for amorphous plastics

d i i t t li d i l ti t t k

S t i bl D l t

• a dryer, resin conveying system, water cooling and circulation system, take-up0.20 to 0.25 kWh/kg


Energy 55 KW / HEnergy Savings

55 KW / Hour£7.70 / Hour

Process powerExtruder 125kw

/

Extruder 125kwHeat per hour 160kwCooling 40kwTotal 325kwTotal 325kw

Heat recovery 25% 40kwProduct stored at 30C 16kw

S t i bl D l t

Product stored at 30C 16kwEnergy Savings 56kw

17%


WhatNo 1Energy Efficiency

WhatWorks Energy Efficiency

Plant ReplacementInsulationInduction HeatingInduction HeatingHeat RecoveryM&TM&T

FinanceFinanceAvailable

No and Low InterestInterest

Interest free Loans Invest-NIGrowth Loan Fund Invest-NIE h d C i l AllEnhanced Capital AllowanceROC’s & RHI for RenewablesRegulator Grants through the Utility providersRegulator Grants through the Utility providers

S t i bl D l tSustainable Development

Top 10 Investments All SPB

Less 24 months


RenewablesRenewablesEconomics Appraisal:PV Array 50kWCAPITAL COST £65,000 PV Array 50kW SPB 2 yearsSupply and install 50kWp system

EXISTING ELECTRICITY COSTS

Existing electricity consumption 1,387,040kWh

Existing electricity consumption cost £194 186Existing electricity consumption cost £194,186

TOTAL COST SAVINGS

Estimated annual output of PV system 41,080kWh

INCOME

Electricty generated and used on site 90% 36,972kWh

(36,972 kWh X £0.14/p/kWh) £5,176

ROC's payment (41,080 kWh X £0.1696) £6,984

E t U it 10% (4 108 kWh X £0 0559) £246Export Units 10% (4,108 kWh X £0.0559) £246

TOTAL SAVINGS £12,406

Simple pay back 5.24 Years

Enhanced Capital Allowance £30,000

Sustainable DevelopmentIntrest Free Loan Invest‐NI (by CT) £13,063

CAPITAL OUTLAY SPB 2 Years £21,937

SustainableSustainableDevelopment What Are We Doing

Next For YouNext For You

Implementation AuditsPolymer Sector Studyy y

Special Energy Task GroupISO 50001 W k hISO 50001 Workshops


Sustainable MaximisingSustainableDevelopment

Maximising Efficiencies

Next EventsInvest-NI Sustainex 9th &10th April La Mon Hotel

Bombardier June Joint SeminarISO 50001 Workshops


Polymer Processing Cost Saving Workshop - 03 Sustainable Development

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