karsten visby-kjærgaard dept. man. - project management energy responsible
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Karsten Visby-Kjærgaard Dept. Man. - Project Management
Energy responsible
Aalborg Portland 2004• Net turnover 1,716,000,000 DKK• Profit for the year 201,000,000 DKK• Production capacity 2,900,000 tons• Domestic 53%• Exports 47%
Aalborg Portland 2004• Plant area 75 ha/185 acres• Chalk Pit area 400 ha/1120 acres• Total area 1420 ha/3500 acres• Employees 602
Chalk QuarryDrum washer Chalk slurry
Raw mill
Sand Quarry
Sand mills
Kaolin/Alu-silicate
Kiln slurry
Fuel
Wet KilnPrecipitator
Clinker storage
Gypsum
Roller-press Cement mills
Cement silos
Heat Recovery
Aalborg Portland 2004
• Energy consumptions: • Electricity 361,000 Mwh• Coal 408,000 tons• Oil 22,000 tons• CEM fuel 101,000 tons
• (Water 3,548,000 m3)
Production Costs 2004
22,7%
19,2%
10,9%4,9%
13,7%
0,3%
3,3%
16,4%
8,6%
Fuel
Electricity
Materials
Wages
Salaries
Others
Environm.tax
Contractors
Spare parts
”Energy history”
• 2 energy inspections (1992 and 1996)
• 3-year agreements with the Danish Energy Agency since 1992
• Latest agreement:- Period: 2003 - 2005- Updating of energy mapping- Annual report to the Danish Energy Agency- Establishment and verification of an energy management system according to DS2403.
Certifications
• ISO 9002: Quality• ISO 14001: Environment, energy and working
environment- Energy management verified by “Dansk
Standard” (DS 2403)
• EMAS: Environment, energy and working environment
• OHSAS 18001: Working environment
Energy Management
General headlines• Mapping and updating of mapping• Energy policy, goal-setting and goals• Operational control• Maintenance of energy consuming plants• Energy conscious engineering and procurement• Information and training• Assessment
Energy Management
Mapping and updating of mapping
• Basic mapping (energy inspection)• Annual updating of the mapping (block diagrams)• Screening of potential energy savings• Special investigations• Environmental registration teams
Energy Management
Example of a block diagram
Energy Management
Typical Special investigations:
• Heat recovery from the surface of a cement kiln.• Draining of water from sand slurry• Plant for dry or moistened iron additive• Production of new cement types with less heat
consumption
Energy Management
Energy policy, goal-setting and goals
• Management tools :
Environment and Energy Group: Group management and environmental manager
• Publication in Environmental Report• About 10 annual follow-up meetings
Energy Management
Energy management• Key persons
Persons with influence on the energy consumption
• Key figuresMonthly reports to the energy responsible person
• Follow-up meetings (quarterly)Review of reportsCorrective actions?Development of key figures?
Energy Management
Maintenance of energy consuming plants
• Approved list of preferred components• PC-based maintenance system• Procurement and stocking of energy-saving
motors
Energy ManagementEnergy conscious engineering and procurement
Procurement- Uses standard text in
relation to energy conscious procurement when inviting offers.
- Assists project managers and draws up commercial conditions / negotiates prices.
Project manager- Makes the real energy
assessment.
- Contacts suppliers.
- Drawn up the technical basis of the purchase.
Energy ManagementEnergy conscious engineering and procurement
Overall energy assessment:
• Statement of energy demands
• Possible alternative process arrangements
• Possibility of recovery of e.g. waste heat from/to other plants
Energy ManagementEnergy conscious engineering and procurement
Basic registration of data:
Plant no.Machine typePurpose of machineCapacityWorking timePower consumptionMotor sizeAnnual energy consumption
Energy ManagementEnergy conscious engineering and procurement
Energy study – at energy costs more than 20,000 £/year
• Description of the result of the energy study
• Statement of annual energy savings achieved
Energy ManagementEnergy conscious engineering and procurement
Further assessment - conclusion
Is the energy-saving alternative a cheaper investment:”Natural choice”.
Is the alternative more expensive:- At pay-back time < 4 years it must be chosen.- At pay-back time > 4 years assessment is made in every single case.
Energy Management
Information and training
• Information about energy-saving projects• Information about the co-operation with the
Danish Energy Agency• At the annual personnel appraisal: Discussion of
potential courses in a.o. energy savings
Energy Management
Assessment• Internal audits• Annual audit by “Dansk Standard”• The management’s assessment
Once annually:
Performance during the year
Setting up goals for the coming year
Energy Management
Final observations
• The organisation being more focused on energy issues.
• Employee attitude: More work, but will eventually become routine tasks.
• It is a good idea having a standardised method for reduction of the energy consumption.
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