Download Global Energy Consulting Improving Efficiency, Reducing Costs

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Responding to the
Challenge of Climate
Change
Energy
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Workshop Session - Energy
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Introductions
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The Drivers (reminder)
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How can …
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Now let’s talk about your experiences …
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Practical Opportunities & Real Issues
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… how they were realised and how they were overcome
Business and Energy - 3 Drivers
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Rising energy costs
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World oil, gas, coal prices all rising
Prices will remain high and volatile for foreseeable future
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High demand - China, supply side instabilities, shortages of capacity
 Increasing reliance on imports – links gas prices more closely to oil
 No return to historic norms
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Environmental compliance
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Carbon management
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Increasing raft of rules and regulations relating to emissions
IPPC provides legal framework to drive improvement
Slow start but growing inducements to reduce carbon emissions
Climate Change Levy (carbon tax) moving to EU ETS II
And …. Rising energy costs
It’s everywhere …
Energy Intensity vs Energy Consumption (US)
Energy Intensity (Consumption per $
value added kBtu)
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1000
Petroleum
Refining
Cement
100
Iron & steel
Alumina &
Aluminium
Pulp & Paper
Chemicals
10
Metal Casting
Food
Manufacturing
Metal Fabrication
1
1
10
100
1000
Energy Consumption (TBtu)
Source: Energy Trends in Selected Manufacturing Sectors: Opportunities and Challenges for
Environmentally Preferable Energy Outcomes”, U.S. Environmental Protection Agency, March 2007
10000
Know where it goes … (?)
Others
9%
Other Electrical
12%
Process Heating
43%
Process Cooling
17%
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Fans System
6%
Air Compression
7%
Pump System
6%
Step by step …
ENERGY
SAVING
ALTERNATIVE PROCESS
PROCESS INTEGRATION
PROCESS MODIFICATION
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CONTROL SYSTEMS
HOUSEKEEPING
COST OF IMPLEMENTATION
Just motors …
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Electric motors use 65% of electricity in industrial
facilities
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Focus on the larger motors on the site
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Eliminate / reduce idle (no load) time
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Challenge sizing of motor (starting load / running load)
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Challenge duty of motor (pumps, agitators, grinding, fans,
compressors)
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Consider use of variable speed drives (pumps & fans in
particular)
Case study: Energy savings - PVC production
Client: Major PVC Producer, UK
Background
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Major UK PVC producer seeking reductions in
energy costs
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Solution
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Analyse energy consumption on across the site
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Numerous opportunities for cost reduction
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Tariff management
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Improving efficiency of steam generation,
distribution and use
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Improved electrical efficiency across the motor
portfolio
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Improving heat recovery – “thermo-crime”
Benefits
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Reduction of ~10% in site utility bill
Discussion and Debate – Suggested Focus
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Global issue but local challenge
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What does it mean for my business?
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Sales
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Operating Costs
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Availability of Resources (sustainability)
Opportunities as well as Threats