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.