novo ets improving your organizations’ environmental, health and safety performance energy...
TRANSCRIPT
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IMPROVING YOUR ORGANIZATIONS’
ENVIRONMENTAL, HEALTH AND SAFETY
PERFORMANCE
ENERGY MANAGEMENT ENERGY MANAGEMENT IN THE CONTEXT OF IN THE CONTEXT OF
GREEN PRODUCTIVITYGREEN PRODUCTIVITY
ENERGY MANAGEMENT ENERGY MANAGEMENT IN THE CONTEXT OF IN THE CONTEXT OF
GREEN PRODUCTIVITYGREEN PRODUCTIVITY
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SCOPESCOPE
• Productivity & Energy ManagementProductivity & Energy Management
• Green ProductivityGreen Productivity
• Energy Efficiency ConceptsEnergy Efficiency Concepts
• Case StudiesCase Studies
• ConclusionConclusion
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ENVIRONMENT
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ENVIRONMENT
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PRODUCTIVITYPRODUCTIVITY
INPUT
OUTPUTProductivity =
OUTPUTINPUT
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PRODUCTIVITYPRODUCTIVITY
OUTPUT
INPUTWastes
Productivity = OUTPUT
INPUTNatural
Resources
Resource Productivity
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What is Green Productivity ?
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What is Energy Management?What is Energy Management?What is Energy Management?What is Energy Management?
Energy Management is: The systematic process
of achieving the most efficient and effective use of energy
Production of the same level of goods or services with less energy or expanded levels with the same amount of energy
Energy Management is: The systematic process
of achieving the most efficient and effective use of energy
Production of the same level of goods or services with less energy or expanded levels with the same amount of energy
Energy Management is not:
Rationing Doing without Sacrificing quality,
productivity, safety, or environmental standards -- in fact, it often results in better performance in these areas
Energy Management is not:
Rationing Doing without Sacrificing quality,
productivity, safety, or environmental standards -- in fact, it often results in better performance in these areas
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Energy Management Provides Numerous Energy Management Provides Numerous BenefitsBenefitsEnergy Management Provides Numerous Energy Management Provides Numerous BenefitsBenefits
Reduced operating costs and Reduced operating costs and increased competitivenessincreased competitiveness
Improved productivityImproved productivity Attractive returns on investmentAttractive returns on investment Environmental benefits Environmental benefits Organisation becomes more Organisation becomes more
resilient towards increasing fuel resilient towards increasing fuel pricesprices
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BARRIERS
Staff time Access to capital Decision made based on imperfect
information Lack of motivation
– Invisibility of energy and energy efficiency– Small contribution on energy to total cost
Split incentives – e.g. landlord vs tenant
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HOW TO IMPROVE RESOURCE PRODUCTIVITY
Innovation Advances in Science and Technology New ideas New business models Smarter form of production and consumption Improving ways goods are designed, made,
delivered, used and disposed
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GP MethodologyGP MethodologyGP MethodologyGP Methodology
Getting StartedGetting Started
PlanningPlanningPlanning
Generation and Evaluation
of GP Options
Generation andEvaluation ofGP Options
Generation andEvaluation ofGP Options
Sustaining GPSustaining GP
Monitoring and Review
Monitoring and Review
Implementation of GP Options
Implementation ofGP Options
Implementation ofGP Options
I
II
IIIIV
V
VI
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Energy Efficiency ConceptsEnergy Efficiency ConceptsThree broad measures can be used to improve
the energy efficiency of an organisation:
Reduce the time of use
Improve equipment/process
efficiency
Energy Efficiency
Reduce energy loads (heating and cooling)
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GP OptionsGP Options GP OptionsGP Options
1. Keep It Maintained1. Keep It Maintained Clean it
Seal it
Adjust it
Lubricate it
Keep it unobstructed
Recalibrate it
Check control settings
Check speeds
Check flows
Keep valves, dampers, etc operating smoothly
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2. Reduce cooling and heating loads2. Reduce cooling and heating loads Change temperature setting Change temperature setting
Reduce minimum outside air quantities Reduce minimum outside air quantities
Turn equipment off when not in useTurn equipment off when not in use
Maintain hot medium set point as low as Maintain hot medium set point as low as possiblepossible
Maintain cold medium set point as high as Maintain cold medium set point as high as possible possible
GP OptionsGP Options GP OptionsGP Options
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3. Turn it off when not in use3. Turn it off when not in use
GP OptionsGP Options GP OptionsGP Options
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4. Reduce flows and resistance Reduce fan flows commensurate with reduced
heating and cooling loads/or due to over design
Reduce pump flows commensurate with reduced heating and cooling loads/or due to over design
Reduce resistance of air distribution systems
Reduce resistance of piping systems
GP OptionsGP Options GP OptionsGP Options
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5. Improve equipment/system efficiency5. Improve equipment/system efficiency Low kW per ton for chillers
High Coefficient of Performance (COP)
Low equipment pressure drops
Keep refrigerants at efficient levels
Stage compressors
Avoid oversized equipment, especially chillers
GP OptionsGP Options GP OptionsGP Options
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6. Cooling energy improvements Raise chilled water temperature leaving
evaporator
Clean condenser tubes
Stage one large chiller operating at an efficient part load to two or more chillers running at full loads
Replace old chillers at high COP such as 0.9 kW/ton to more efficient chillers at 0.6 kW/ton
Use VSDs for chilled pumping system
Use efficient staging - operate one or several compressors at full load before starting second
GP OptionsGP Options GP OptionsGP Options
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6. Cooling energy improvements6. Cooling energy improvements Install proper controls such that one chiller is Install proper controls such that one chiller is
running full load before the next chiller is running full load before the next chiller is activatedactivated
Lower cooling tower condenser temperature Lower cooling tower condenser temperature returning to chillersreturning to chillers
Increased heat exchangers area to increase Increased heat exchangers area to increase efficiency of chiller systemefficiency of chiller system
Avoid allowing cooling towers on standby. Use Avoid allowing cooling towers on standby. Use VSDs to run all cooling towers if possible.VSDs to run all cooling towers if possible.
GP OptionsGP Options GP OptionsGP Options
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7. Heating energy improvements7. Heating energy improvements
Check combustion efficiency and adjustCheck combustion efficiency and adjust
Clean soot, scale from tubes and firewallsClean soot, scale from tubes and firewalls
Schedule boiler blow down on a required basis Schedule boiler blow down on a required basis rather on a regular basisrather on a regular basis
Set hot water temperature as low as possibleSet hot water temperature as low as possible
Set boiler operating pressure as low as possibleSet boiler operating pressure as low as possible
Avoid one large boiler operating only at part Avoid one large boiler operating only at part load; use smaller boilers insteadload; use smaller boilers instead
Have proper insulation (boiler, steam and Have proper insulation (boiler, steam and water pipe, feed tank)water pipe, feed tank)
GP OptionsGP Options GP OptionsGP Options
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7. Heating energy improvements7. Heating energy improvements Convert to more efficient fuel?Convert to more efficient fuel?
Install energy efficient burnersInstall energy efficient burners
Use proper chemicals, demineralise and Use proper chemicals, demineralise and deaerate waterdeaerate water
Use, maintain steam trapsUse, maintain steam traps
Recover energy if possibleRecover energy if possible
GP OptionsGP Options GP OptionsGP Options
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Heat Recovery SystemHeat Recovery SystemHeat Recovery SystemHeat Recovery System
Feed water
30oC - 70oC
Steam
Combustion air
30 oC Exhaust gas (220 - 280oC) discharged to atmosphere
Boiler
Without heat recovery systemWithout heat recovery system
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Heat Recovery SystemHeat Recovery SystemHeat Recovery SystemHeat Recovery System
With heat recovery systemWith heat recovery system
Exhaust gas (220 - 280oC)
and/or
Preheated combustion air
Feed water
30 - 70 oC
Preheated
Feed water
Combustion air
30 oC
SteamExhaust gas
120 -140 oC
Boiler
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VacuumVacuumInner surface Inner surface of heat pipeof heat pipe
Outer surface Outer surface of heat pipeof heat pipe
Working fluidWorking fluid
Sealed Sealed at both at both endsends
Heat PipesHeat PipesHeat PipesHeat Pipes
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Heat PipesHeat PipesHeat PipesHeat Pipes
Condensing Condensing endend
Gap
betw
een
heat
pip
eG
ap
betw
een
heat
pip
e
Flue gasFlue gas
EvaporatinEvaporating endg end
Flue gasFlue gas
CombustioCombustion air/feed n air/feed waterwater
CombustioCombustion air/feed n air/feed waterwater
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Heat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat Exchangers
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Heat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat Exchangers
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Heat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat ExchangersHeat Pipe Heat Exchangers
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Basic operation information of food industry company
Description Parameters1 boiler 30 ton/hr
Current running capacity Full
Temperature of boiler feedwater inlet
80C
Temperature of flue gasdischarge
530C
Operation 24 hrs/day &340 days/yr
Case Study ICase Study ICase Study ICase Study I
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Description Before AfterTemperature ofboiler feed waterinlet
80C 112C
Temperature offlue gas
530C 195C
Temperature offresh air inlet
33oC 101.5oC
Yearly Savings - US$350,000
Before and after installation of heat recovery system
Case Study ICase Study ICase Study ICase Study I
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Case Study ICase Study ICase Study ICase Study I
Before and after installation of heat recovery system
Description Before AfterFuel oil saving perday
- 7,742litre/day
Heat loadreduction
- 1014 J /yr
Carbon dioxidereduction
- 8,300tonnes/yr
Sulphur reduction - 47 tonnes/yr
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Description Parameters2 boilers 8 T/hr each
Current running capacity 70%
Temperature of boilerfeedwater inlet
60C
Temperature of flue gas 230C
Operation 24 hrs/day &26 days/ mth
Basic operational information of a packaging company
Case Study IICase Study IICase Study IICase Study II
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Case Study IICase Study IICase Study IICase Study II
Description Before AfterTemperature ofboiler feedwaterinlet
60C 94C
Temperature offlue gas
230C 140C
Yearly Savings - US$38,000
Before and after installation of heat pipe heat exchanger
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Description Before AfterWaste heatrecovered
- 6x1012 J /yr
Carbon dioxidereduction
- 570tonnes/yr
Sulphur reduction - 3.3 tonnes/yr
Before and after installation of heat pipe heat exchanger
Case Study IICase Study IICase Study IICase Study II
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ConclusionsConclusionsConclusionsConclusions
Less Energy, More Wealth
Good for the Environment,
Good for the Bottomline !