-energy-management
DESCRIPTION
Energy-Management.TRANSCRIPT
Energy Reduction and Sustainability through
Total Energy Management (TEM)
Santiago [email protected]
Sean [email protected]
November 2009
2
Agenda
• Energy reduction and sustainability through implementation of “Total Energy Management”program
• Assisting our injection molders to achieve sustainability through “TEM” program
3
Manufacturing Advisory Services
Provide operational consulting, design and
project management services to support our existing and prospective customers
1. Consulting and Advisory Services
• Comprehensive plant & operational assessment
• Operational performance improvement & implementation
• Facility planning and optimization
• Total Energy Management Program
2. Building and Infrastructure Planning and Design
3. Project Management and Turnkey services
4
CO2 Emission due to Electricity Production
83% of total emissions is CO2 related
40% of CO2 emissions is due to producing electricity
forecasted global CO2 is expected to increase by 36% over 1990 levels by 2010
1900 1910 1920 1930 1940 1950 1960 1980 1990 2000 2008
Source: US Energy Information Administration
5
Carbon Cap-and-Trade
United States:
• New carbon cap-and-trade program calls for 14% below 2005 levels by 2020 and 83% below by 2050
• Energy intensive manufacturers would be forced to identify energy reduction opportunities (compliant with ISO 50001)
Canada:
• Reduce greenhouse gas emissions by 20% from 2006 levels by 2020
• In Ontario, 6,300 MW reduction in peak demand by 2025 (most ambitious target in North America)
Legislated Actions to Reduce Carbon Footprint
6
Costs Breakdown in Typical Molding Plants
• “Energy” could be the same or more than “Direct labor” *
• Approximately 70% of cost savings are focused on direct labor
* Costs vary based on markets, number of machines, geographical location, etc..
- Consumer manufacturer in US - Bottle manufacturer in US
Material
59%
Direct labor
6%
Indirect labor
9%
Maintenance
2%
Energy
6%
Other controllable
expenses
2%
Payroll benefits
7%
Occupancy
4%
Depreciation
5%
Material78%
Labor
3%Energy
5%
Primary Equipment10%
Building & Infrastructure
3% Maitenance1%
7
Two Approaches to Reduce Cost
1. Reduce the cost of energy used through acquisition to reduce the $/ kWh
• Numerous consulting firms provide “Negotiation and risk mitigation” services
• Alternative Energy generation
2. Reduce the amount of energy used (KW/lb):
• Certain utility companies offer programs that provide molders rebates towards the purchase and installation of qualified equipment that improves their facility’s energy efficiency
The two approaches alone without an “Energy Management Program” is not sustainable
8
• Implementation of policies and procedures to measure, set targets, and monitor energy related KPIs to continuously reduce and sustain energy consumption
Total Energy Management
9
Magnitude of Savings
• Energy cost can be reduced by up to 30% for most plastics processing plants
• Savings can be achieved through a combination of No-cost, Low-cost, and Investment actions
30% Energy cost savings
Organizational /Management
MaintenanceCapital
Investment
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1 - Estimate and verify site energy profile
2 - Understand your “Base” and “Process” loads
3 - Understand when and how much energy is used
4 - Monitoring and Targeting
– Understand Where energy is used
5 - Data analysis and reporting energy KPIs (Energy dashboard) by department
6 - Identify, Quantify, and Prioritize opportunities
7 - Eliminate waste and reduce consumption through
Implementation of selected energy reduction projects
8 - Conduct internal and external benchmarking
9 - Repeat the steps – Continuous improvement
Husky Total Energy Management Program
11
1- Estimate and Verify Site Energy Profile
• Estimated site energy profile based on audited equipment
• Verify estimated energy profile through actual on-site measurements
Estimated consumption break down
Plant Lighting
9.6%
Injection Molding
Machine
56.1%
Cranes
0.1%
Feed Systems
1.7%
Printers
4.2%
Compressed air
5.8%
Wrapping Machines
0.0%
Handle Machines
1.3%
Process Water system
16.9%
Thermoformer
2.3%
Film Extruder
2.1%
Measured consumption break down
Film Extruder
4.5%Thermoformer
2.5%
Process Water system
16.5%
Handle Machines
1.3%
Wrapping Machines
0.0%
Compressed air
8.7%
Printers
4.4%
Feed Systems
1.6%
Cranes
0.1%
Injection Molding
Machine
51.5%
Plant Lighting
8.9%
12
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000
Production volume (Kg or Lb)
En
erg
y u
sag
e (
KW
h)
• Energy has variable and fixed costs and both can be affected
• Performance Characteristic Line (PCL) provides an operational signature of the plant that is closely related to the way the plant management runs the plant
2 - Identify Base & Process Loads
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Performance Characteristic Line (PCL)
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000
Production volume (Kg or Lb)
Energ
y u
sage (K
Wh)
Base load
• Base load is effectively your “Energy overhead” and is the energy consumption with No production output
• Base loads are typically 10% to 40% of the average total load . The less the better
• Base loads energy usage reduction are generally easy to make, low in cost, and have rapid payback (low hanging fruits)
14
Performance Characteristic Line (PCL)
• Slope of the line indicates the average plant process load (Kwh/ Kg or Lb). The less the better
• Plant process loads are typically in the region of 0.6 to 1.6 Kwh/Kg (0.36 to 0.72 KWh/ Lb)
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000
Production volume (Kg or Lb)
Energ
y u
sage (KW
h)
Base load
Slope = 1.57
R2 = 0.96
• Correlation coefficient (R2) indicates linearity between energy usage and production volume
– High R2 (low scatter) means good correlation between energy usage and production volume
15
3 – Understand “When” and “How much”
Peak at 1,700KW
Base load at 300KW (25% of average load)Goal to be @ 10% of average load
Average PF of 0.84Goal to be above 0.9
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• Monitoring & Targeting - Sub-metering to understand Where energy is used
– Husky’s installed three main meters and fifteen sub-meters in one building
4 – Monitoring & Targeting - Understand “Where”
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– SPC analysis for energy usage
– Energy profile
– Cost allocation and budgeting
– Forecasting energy consumption per department
– Variance analysis (Deviation between actual and predicted energy)
5 – Data Analysis and Energy KPIs
-40,000
-30,000
-20,000
-10,000
0
10,000
20,000
30,000
40,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Month
De
via
tio
n f
rom
pre
dic
ted
(K
Wh
)
-100000
-50000
0
50000
100000
150000
200000
250000
300000
350000
400000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Month
CU
SU
M (
KW
h)
Target CUSUM
Original CUSUM
18
Reporting energy KPIs (Energy dashboard) by department– Electrical cost as % of production cost
– Monthly deviation from predicted and target energy usage
– Cumulative deviation from predicted and target energy usage
– Electricity cost and production volume by month
– Status of energy reduction projects
Energy on Management Agenda
Electrical cost as % of production cost
Monthly deviation from predicted and target energy usage
Cum. deviation from predicted and target energy usage
Electricity cost and production volume by month
19
1 - Estimate and verify site energy profile
2 - Understand your “Base” and “Process” loads
3 - Understand when and how much energy is used
4 - Monitoring and Targeting
– Understand Where energy is used
5 - Data analysis and reporting energy KPIs (Energy dashboard) by department
6 - Identify, Quantify, and Prioritize opportunities
7 - Eliminate waste and reduce consumption through
Implementation of selected energy reduction projects
8 - Conduct internal and external benchmarking
9 - Repeat the steps – Continuous improvement
Husky Total Energy Management Program
20
Machines
50%
Lighting
3%
Mold cooling
12%
Dryers
20%
HVAC
8%
Air compressors
6%Others
1%
Typical Part Cost Break Down
ENERGYENERGY
Resin
86%
Labour
2%Energy
3%
Equipment
5%
Infrastructure
2%Maintenance
2%3% to 5%
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Mold Cooling - Chiller Types
Machines
50%
Others
1%
Air compressors
6%HVAC
8%
Dryers
20%
Mold cooling
12%
Lighting
3%
0.00
5.00
10.00
15.00
20.00
40 41 42 43 44 45 46 47 48 49 50 51
Leaving chilled water temperature
% i
ncre
ase i
n C
hil
lers
' C
OP
Absorption
Reciprocating
Centrifugal
Screw
(F)
• Typically every 1oF increase in leavingwater temperature from chillers results to 1% to 1.5% reduction in energy
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Free Cooling
23
Free Cooling – Case Study – Middlesex, UK
Effect of Chilled Water Temperature on free Cooling:PET mold, 50oF vs. 43oF LWT:
• 15% of the year with 40oF (4.5C) (including dry cooler and heat exchanger approach)
• 4% of the year with 33oF (0.5C) (including dry cooler and heat exchanger approach)
• Estimated savings around $40k / year vs. $11K / year
Temperature vs. Time - Middlesex UK
0
5
10
15
20
25
11/14/2007 1/3/2008 2/22/2008 4/12/2008 6/1/2008 7/21/2008 9/9/2008 10/29/2008 12/18/2008 2/6/2009
Date
Tem
pera
ture
(d
eg
C)
15% of the year is colder than 4.5°C,
compared to 4.26% of the year
colder than 0.5°C
40F
33F
24
Dehumidification – Case Study - Middlesex, UK
Dew Point vs. Time - Middlesex UK
-10
-5
0
5
10
15
20
11/14/2007 1/3/2008 2/22/2008 4/12/2008 6/1/2008 7/21/2008 9/9/2008 10/29/2008 12/18/2008 2/6/2009Date
Tem
pe
ratu
re (
de
gC
)
72% of the year the dew point is less
than 10°C, compared to 42% of the
year below 6°C
Effect of Chilled Water Temperature on mold dehumidification:PET mold, 50oF vs. 43oF LWT:
• 72% of the year dew point is less than 50oF• 42% of the year dew point is less than 43oF
50F
43F
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Turbocor – Micro Centrifugal Compressors
• New compressor technology
• Oil-free, variable speed drive compressor
– No oil management hardware, controls or downtime costs
– Improved heat transfer efficiency
• Uses centrifugal compression technology, previously limited to large chillers 2,000KW + (250 Ton+)
– COP (KWth/ KWe) of 6 to 10 or (0.55 kwh/Ton).
Better energy consumption than scroll compressors
– Similar capital costs to a regular air cooled chiller
• Quiet operation
– 70dBA sound with virtually no vibration
• Compact– 50% less footprint and 1/4 to 1/5 the weight of traditional compressors
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Machine Cooling Options
Cooling Towers
• Contamination in water
• Scale and oxidation in pipes
• High water and chemical consumption
• Cost of water disposal
Dry Coolers
• Clean water to process
• No scale or corrosion
• Minimal maintenance
• Reduced energy consumption
• No water disposal
• No water treatment chemical consumption
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Dry Coolers
1. Adiabatic Cooling – Maintains ability to deliver cool water even in HOT ambient conditions with minimal water consumption, little maintenance.
2. Self-Draining - Freeze protection without requirement for Antifreeze/Glycols. Works in all climates.
3. DC Variable Speed Fans – Extremely low energy consumption
4. Less than 20 times less water than tower
-
0.50
1.00
1.50
2.00
100806040200O U T D O O R T E M P . ( C )
kW / fan
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Cascading Use of Energy
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1. Traditional systems
– Roof top DX units
– Central chillers and air handling units
2. Displacement ventilation
Air Conditioning
Machines
50%
Others
1%
Air
compressors
6%
HVAC
8%
Dryers
20%
Mold cooling
12%
Lighting
3%
30
Air Conditioning
1,194
879 315
0 200 400 600 800 1,000 1,200 1,400
Cooling Size (kW)
26% lessDisplacementVentilation
TraditionalVentilation
1,194
879 315
0 200 400 600 800 1,000 1,200 1,400
Cooling Size (kW)
26% lessDisplacementVentilation
TraditionalVentilation
2,272
1,154 1,118
0 500 1,000 1,500 2,000 2,500
Chiller Thermal Energy Use / Year (MWH/Yr)
49% lessDisplacement
Ventilation
TraditionalVentilation
2,272
1,154 1,118
0 500 1,000 1,500 2,000 2,500
Chiller Thermal Energy Use / Year (MWH/Yr)
49% lessDisplacement
Ventilation
TraditionalVentilation
Up to 26% less capital cost
Up to 49% less operational cost
Traditional air conditioning Displacement Ventilation
31
Advanced Technology Resin Dryer
• Variable throughput feature– Controlled residence time
– Optimized air flow
• Energy recovery system– Up to 25% of the required
temperature rise for free
• Energy efficient– < 0.08kWh/kg all electric
$28,000/ Year
Estimated Savings
0.040.063Energy
New
(kWh/Lb)
Traditional (kWh/Lb)
2200Lb/hr
$0.07/kWh , 8000hrs/yr
$28,000/ Year
Estimated Savings
0.040.063Energy
New
(kWh/Lb)
Traditional (kWh/Lb)
2200Lb/hr
$0.07/kWh , 8000hrs/yr
Machines
50%
Lighting
3%
Mold cooling
12%
Dryers
20%
HVAC
8%
Air
compressors
6%Others
1%
32
Machines
50%
Lighting
3%
Mold cooling
12%
Dryers
20%
HVAC
8%
Air compressors
6%
Others
1%
Compressed Air
• Compressors are only 5-15% efficient
• Compressed air is expensive energy– At point of use compressed air costs 10
times more than equivalent quantity of electrical power
• Most of the cost of a compressor is in the energy it uses
Energy cost, 75%
Capital cost, 15%
Maintenance, 10%
33
Operating Conditions Influence Energy Costs
• Part load operation– 40–80% of full kW at part load
• System pressure – each 5psi = up to 5% more power
• Air inlet temperature– each 7oF lower = 1% more air
• Pipe sizing – Each 5psi drop = 2% more energy
• Leaks commonly constitute 25% of total compressed air use
Size CFM HP $/Yr
1/4” 104 26 $15,300
One 1/4" leak is equal to 300 60-watt lamps!
34
Lighting
Machines
50%
Others
1%
Air compressors
6%HVAC
8%
Dryers
20%
Mold cooling
12%
Lighting
3%
Fluoresce T5 (0.2 KW) Metal Halide (0.4 KW)
Functioning MH Consumes 400WLight level: 400 LUX
80% burnt MH Consumes 400WLight level: 100 LUX
Dirty MH Consumes 400WLight level: 150 LUX
Burnt MH Consumes 60WLight level: 0 LUX
35
Effect of Cycle Time on Energy
Machines
50%
Lighting
3%
Mold cooling
12%
Dryers
20%
HVAC
8%
Air compressors
6%Others
1%
Base Line Exit Temperature Faster Cycle Exit Temperature
36
• 6% overall reduction in cycle times and energy consumption (KW/ Kg)
Equipment DescriptionMeasured
Power (kW)
Power Factor
480V
Cycle
Time
(sec)
Part
Weight
(g)
Number of
Parts per
Cycle
Machine
Process Load
(kW/kgHr)
Before Husky-HL160RS55/50 30.440 0.76 13.4 174 1 0.651
After Husky-HL160RS55/50 30.811 0.76 12.6 174 1 0.613
Percent improvement 6% 6%
Effect of Cycle Time on Energy
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Power Conditioning
Corrects power quality problems:• Balances voltage across all three phases
• Balances current across all three phases
• Decrease voltage fluctuations
• Mitigates harmonics
• Corrects power factor
• Suppresses surges and transient to reduce
the chance of equipment damage
• Protects equipment from brownouts (option)
• Protects equipment from intermittent supply
failure
38
• Thermolators
• Raising chilled water above ambient wet bulb temperature
• Chillers
• Un-optimized water temperature
• Air compressors
• Leakage
• A/C
• Setting temperature too low
• Leaving doors open
• Grinders
Examples of Contributors to Base Load
39
• Start with auditing your plant– Most utility providers offer financial incentives to cover
portions or all of the audit cost
– Some utility providers offer programs that provide rebates towards the purchase and installation of qualified equipment that improves their facility’s energy efficiency
• Implement an “Energy Management Program”
• Husky’s “Manufacturing Advisory Services” team can assist you in developing and implementing a TEM program for your facility
Action Plan
40
• Santiago Archila, – [email protected]
– 905-951-5000, Ext. 3810
• Sean Golzarian,– [email protected]
– 905-951-5000, Ext. 3550
• Husky website: www.husky.ca
Contacts
Energy Reduction and Sustainability through
Total Energy Management (TEM)
Santiago [email protected]
Sean [email protected]
November 2009