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RECP Training National Experts August 2015

Indonesia National RECP Programme 1

RECP Training (continued)

August 2015 Module 8: Energy Efficiency 1

7. Feasibility Studies

8. RECP Options for Energy Efficiency

9. RECP Options for Materials and Waste Minimization

10. RECP Options for Water and Effluent Minimization

11. RECP Options for Chemicals Management

12. RECP Management

RECP for industrial energy efficiency


RECP& energy

Context

Approach

Act

Module 8

National Resource Efficient and Cleaner Production Programme Indonesia

Funded by Implemented by

In partnership with



Purpose


Preparation

Initial Assessment

Detailed Assessment

Feasibility Studies

Implemen-tation

Energy Assessment

Complementary assessment to expand the set of energy-specific RECP solutions


Context

Energy is of global concern in particular the ongoing increasesin its use and the reliance on fossil fuels as primary energysource. Moreover business profitability is vulnerable to energyprice fluctuations and energy supply interruptions.



Energy: a global concern• Continued rise in primary energy

consumption– 38% increase since 2000

• Energy use causes 69% of global greenhouse gas emissions

• Manufacturing and construction responsible for 39% of energy related CO2 emissions

• All energy use is associated with other environmental impacts

• Depletion of natural resources• Land use• Air and water emissions and waste

generation BP 2015 Statistical Review of World EnergyIEA 2014 CO2 emissions from fossil fuel


Industry and Climate Change• Causes 32% of global GHG

emissions – Energy use– Process related

• Vulnerable to impacts of climate change– Availability of water– Disruption of operations and

logistics– Changing market demands

• Significant mitigation potential

IPCC, AR V, 2014August 2015 Module 8: Energy Efficiency 6



Energy: a business concern • Cost to business

– Prices of fuel and energy– Unexploited productivity potential through energy efficiency

• Risk to business– Lost production due to interrupted energy supply– Volatility in fuel and energy prices, due to market and political factors

• Impact on environment– Contribution to climate change, due to emissions of Greenhouse Gas

(GHG)– Generation of smoke and other air emissions, slags, etc.


System Benefits


– One unit of friction reduction reduces fuel consumption at power station by 10 units

Lovins, A., Energy Efficiency: Taxonomic Overview.Encyclopedia of Energy, 2004: p. 383-401.



Industrial Energy Use• Energy is a utility for

industrial processes– Overall efficiency is

governed by • Energy management

– management• Energy conversion

– utility equipment• Energy distribution and

supply– system optimization

• Process parameters– process efficiency

Industrial Energy Efficiency for Sustainable Wealth Creation, UNIDO 2010


Better Business through Energy Efficiency

Direct and indirect savings

Reduce direct energy cost

Indirect savings: •Reduced maintenance •Longer life of equipment •Less materials including

toxic materials

Business security

Compliance with regulation

Reduce dependence on volatile energy

price

Improve energy security

New business opportunities

Energy efficient products

Increased potential for innovation

Better positioning on the market

Social responsibility

Climate change mitigation

Energy efficiency culture

Improved relations with comunity




Barriers to energy efficiency– Limited energy awareness

• Actual energy use and its associated costs• Impacts of behaviour and process conditions on energy consumption• Day-to-day survival mode, short-terminism

– Lack of energy knowledge• Specific energy knowledge• Lacking benchmarking • Energy saving techniques and practices

– Unfavorable economics• Low costs of energy• High costs of energy efficient technology



The root source and cause diagnosis used for optiongeneration in RECP assessment can be augmented withenergy specific technical and management tools.

Approach



RECP for Energy Efficiency• Source:

– Where is energy used for what purpose and with what losses?

• Cause:– What factors influence these energy uses and

losses?

• Option:– How to minimize these causes of energy uses

and losses?

source

cause

option


Energy Analysis1. Collect

data

• Identify all energy sources and overall consumption

2. Draw list of equipment

• Identify all electricity uses

• List all heat consuming equipment

3. Record data

• Record data on monthly basis, relate to production, weather, etc, and analyze trends

4. Benchmark consumption

• Compare with energy benchmarks for common processes

5. Record load profile and analyze

• Analyze patterns in load profile


Promoting Resource Efficiency in Small & Medium Enterprises: industrial training handbook, UNEP. 2010

source




1. Collect data

source



source 2. Draw list of equipment





source 3. Record data

Record specific energy consumption by month, week or shift for main energy users and analyze trends.

Energy Policy Toolkit: energy efficiency in industries, experiences from Denmark, Danish Energy Agency, 2014


source 4. Benchmark consumption

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

L E O M K Q G J N A H D P I F C R B

GJ/t steel

Good Practice Range

Theoretical Minimum

Energy and Resource Efficiency in Vietnamese Electric Arc Furnace Sector, UNIDO, 2010




source


5. Record load profile and analyze

Manage power load to reduce expensivepeak load charges

Power factor: ratio of maximum demand toconnected load

Control peak load by:• Rescheduling of loads• Staggering of motor loads• Storage of products • Shedding of non essential loads

Root Causes


cause

LOW energy efficiency

WASTE

PLANT PROCESS INPUTS

Technology Choice

Equipment Design

Process Control

Internal Value

External Value

PEOPLE

PRODUCT



Root Causes


cause

Root Cause Category Some examples(compressed air system)

Process Inputs Temperature at air intake

People Inappropriate use e.g. for drying, cleaning, etc.

Plant Process Control Operating pressure intervals

Equipment Maintenance status of compressor Design, dimensioning and lay out of compressed air distribution

Technology Type of compressors (compressed air supply)

Product Pressure at point of use Alternative power sources (compressed air uses)

Waste Internal Value Waste heat from compressors – replaces heating demand

External Value Waste heat from compressors – adds to air conditioning load

Technical Approach


The onion diagram aims to define a systematic“inside-out” approach to energy efficiency starting byquestioning the core reasons (“the energy service”)why a process or an area uses energy. Basic processparameters, design standards and product specificationscan define most of the energy consumptionin a facility and therefore also influence most of theenergy-saving potential.

Energy Policy Toolkit: energy efficiency in industries, experiences from Denmark, Danish Energy Agency, 2014

cause



Onion Model• Ask six times why?

• Why is this energy service needed for the production?– e.g. control contamination rather then provide clean room

• Why is this process selected to provide the energy service?– e.g. low flow/high filtration design

• Why is equipment as per these current specifications?– e.g. control of air flows, recovery of heat, fan designs

• Why is the current control adequate? – e.g. optimize performance under different load conditions

• Why are the current operations & maintenance adequate?– e.g. early failure detection and preventive maintenance

• Why is the current housekeeping adequate?– e.g. ensure standard operating practices are adhered to


cause

Option Generation


option

HIGH energy efficiency

UTILIZATION

PLANT MODIFICATION INPUT CHANGE

Technology Change

Equipment Modification

BetterProcess Control

On Site Reuse

Useful Byproduct

HOUSEKEEPING

PRODUCT MODIFICATION



Option Generation


option

RECP Practices Some examples(compressed air system)

Input Change Change air intake – cool and shielded location

Good Housekeeping Avoid unnecessary use

Plant Modification

Process Control Improved controls on operating pressure

Equipment Modification Fix all leaks, eliminate disused parts of reticulation system, minimize pressure reduction

Improve maintenance on compressorsTechnology Change Energy efficient compressor systems

Product Modification Switch to alternatives for compressed air – direct powered tools, electronic controls, etc.

Reuse On Site Reuse Recover waste heat for building heating

Useful By Product Insulate to eliminate non-useful use of heat of compressor


Act Now

Start with review of applicability of typical energy efficiencyoptions for main energy users.



Energy Applications

Compressed airCooling/freezin

g/air conditioning

Thermal systems

Electricity management

systems

Electrical motors Lighting

Buildings


Compressed Air

About 10% from the electric power is converted into compressed air. The rest is given off as heat.

About 85% of energy in the form of heat can be recovered and re-used from the cooling oil. The remaining 5% are emitted as radiation losses into the environment.

Compressed air system

Heat dissipation~ 5%

Heat dissipation

Pressured air~ 10 %

Recoverable heat fromoil cooling

~ 85 %

Energy supply(Current)

100 %

Compressor energy flow diagram




Compressed Air

Saving energy for

compressed air

Correct dimensioning of the system

Elimination of system leaks

Avoid inappropriate

use

Preventive maintenance

Control demand events

Replace poor systems

Locate in clean and cool environment

Control working pressure


Cooling Systems

Source: http://www.mpoweruk.com/heat_engines.htm




Saving energy for cooling

systems

Adjust the system to the

real needs

Replace inefficient

cooling machines

Ensure system insulation

Optimize control and regulation

Improve hydraulic pipes

Include freecooling

facility

Improve heat recovery systems

Cooling SystemsCold supply


Heat balance - Boiler energy flow diagram

Source: UNEP CP-EE Manual

Thermal Systems




Heat and warm water supply

Saving energy for thermal systems

Replacing old and inefficient

boilers and heat exchangers

Optimal combustion

(air concentration)

Condensate recovery

Maintenance of water quality control and blowdown

Insulation of boiler, heat

exchangers and pipes

Optimising hydraulic pipes

Feeding water / intake air

temperature

Thermal Systems


Waste Heat Recovery and Use • Which waste heat is available? Heat from fluegas, compressors, motors, condensers Temperature level Load profile (when and which performance, time pattern)

• What are the potential heat users? Heating/pre-heating (air, water) Necessary temperature level Load profile (which is when power needed?)

• Local conditions Distance between heat accumulation and potential heat

usersAugust 2015 Module 8: Energy Efficiency 34



Electric Motors

MotorPower Pin (w) Load

Power P (w) Power

Pout (w)

Plods

Efficiency levels (EU) :IE1 Standard Efficiency (Jun, 2011) IE2 High Efficiency (Jan, 2015) IE3 Premium Efficiency (Jan, 2017)

Motor Efficiency = Pin (w)/Pout(w)


Electric Motors

Saving energy

with motors

Replace old, inefficient motors with new motors

generation

Reduce under loading (avoid

oversized motors)

Proper ventilation and heat evacuation

Regular check on motor loading to monitor variations

Improved maintenance

Improved power input

Variable speed drivers




Lighting

• Choose the right light • Position where needed • Use only when needed • For as long as needed • And at the illumination

level needed

The lighting systems

Source: UNEP CP-EE Manual August 2015 Module 8: Energy Efficiency 37

Saving energy for

lighting system

Task lighting

Manual and decentralized

controls

Efficient light bulbs

(e.g. LED)

Periodic maintenance and cleaning

Automatic control (motion and/or

daylight sensors)

Use daylight

Lighting




Electricity Load ManagementElectricity cost:

– Energy costs in the true sense (i.e. the cost of the kWh consumed)- can be reduced primarily by reducing electricity consumption

– Costs of power demand (i.e. the cost of the peak electrical power requirement) - can be reduced by reducing peaks of power consumption

Electric load management control of maximum demand scheduling of its occurrence during

peak/off peak periods.

•


Load Management

Saving energy through load management

Rescheduling loads

Staggering of motor loads

Storage of products

Shedding of non-essential

loads




Buildings Management• Building envelope

– Walls– Floor– Roof (major source of loss)– Building materials – Insulation

• Windows • Doors

External influence– Topography and

landscaping – Exposure to sun and wind – Vegetation and trees


Buildings ManagementReducing energy for heating

– Envelope insulation – Double and triple glazing

windows – Revolving doors – Re-organizing inside

space and activities

Reducing energy for cooling

– Reduce glass area – Ensure shadowing – Reduce heat gain due to

interior activities

Heat loss Heat gain




RECP for industrial energy efficiency


RECP& energy

Context

Approach

Act

Module 8

http://crecpi.itb.ac.id/www.unido.org/cpwww.recpnet.org

August 2015 44Module 8: Energy Efficiency

Thank You ???National Resource Efficient and Cleaner Production Programme Indonesia

Funded by Implemented by In partnership with

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