Energy Efficiency Methodology
Download
1 / 72

Energy Efficiency Methodology Energizing Cleaner Production Management Course - PowerPoint PPT Presentation


  • 160 Views
  • Uploaded on

Energy Efficiency Methodology Energizing Cleaner Production Management Course. Company Energy Efficiency methodology. Training Agenda: Company Energy Efficiency methodology. Introduction to the methodology Methodology step by step Purpose, outputs and tasks Company examples

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Energy Efficiency Methodology Energizing Cleaner Production Management Course' - etana


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
Slide1 l.jpg

Energy Efficiency Methodology

Energizing Cleaner Production

Management Course

Company Energy

Efficiency methodology


Slide2 l.jpg

Training Agenda: Company Energy Efficiency methodology

  • Introduction to the methodology

  • Methodology step by step

  • Purpose, outputs and tasks

  • Company examples

  • Worksheets

  • Energy focus

Company Energy

Efficiency methodology


Slide3 l.jpg

Introduction

The “Company Energy Efficiency Methodology” (Methodology) has been developed for Asian industrial companies to help them improve energy efficiency through Cleaner Production.

Company Energy

Efficiency methodology


Slide4 l.jpg

Benefits from Energy Efficiency

  • Cost reductions through efficient use of energy

  • Reduced exposure to fluctuating energy supply and prices and blackouts

  • Increase in productivity and product quality

  • Improved reputation with customers and society through environmental protection

  • Improved employee motivation, health and safety

  • Compliance with legislation and ISO 14001 targets

  • Increased profits and shareholder value

Company Energy

Efficiency methodology


Slide5 l.jpg

The Methodology

  • Is tailored to energy-intensive industrial companies in developing Asian countries

  • Focuses on energy, which is less visible than waste, water and raw materials

  • Explains

  • what should be done in theory

  • how it is done in practice in different companies

Company Energy

Efficiency methodology


Slide6 l.jpg

The Methodology is based on:

  • The Cleaner Production (CP) strategy:

  • Prevention of waste

  • Systematic approach

  • Integrated into business processes

  • Aimed at continuous improvement

  • Existing CP and energy audit methodologies

  • Real practice experience from energy assessments carried out as part of the GERIAP project in more than 40 Asian industrial companies

Company Energy

Efficiency methodology


Slide7 l.jpg

6-Step Cleaner Production Approach

Company Energy

Efficiency methodology


Slide8 l.jpg

Information under each Step

Several tasks: what a company should do as a minimum

Company examples: how the task was applied at different companies and lessons learnt

Worksheets: to assist completing the task

Remember: apply the methodology flexibly as long as energy efficiency is improved because each company is different.

Company Energy

Efficiency methodology


Slide9 l.jpg

Step 1: Planning and Organization

  • Purpose:

  • Obtain top management commitment

  • Plan and organize an energy assessment

  • Output:

  • Written proposal with selected steps and tasks to improve the company’s energy efficiency

  • Approved by top management.

Company Energy

Efficiency methodology


Slide10 l.jpg

Step 1: Continued

  • Time: 3 – 6 days

  • Tasks include:

  • Task 1a: Meeting with top management (1-2 hours)

  • Task 1b: Form a Team and inform staff (0.5-1 day)

  • Task 1c: Pre-assessment to collect general information (1-3 days)

  • Task 1d: Select focus areas (0.5-1 day)

  • Task 1e: Prepare assessment proposal for top management approval (2-3 days)

Company Energy

Efficiency methodology


Slide11 l.jpg

Task 1a: Meeting with Top Management (1 – 2 hours)

  • Purpose of first meeting:

  • Top management:

  • Get commitment of company middle managers, staff and/or external facilitators to carry out a pre-assessment

  • Write a proposal for a detailed energy assessment

  • Company middle manager or external facilitator:

  • Get top management’s approval for a pre-assessment

  • Write a proposal for a detailed energy assessment

Company Energy

Efficiency methodology


Slide12 l.jpg

Task 1a: Meeting with Top Management (continued)

  • Discuss at this 1-2 hour first meeting:

  • If/Why top management is interested in energy efficiency

  • Energy areas of interest or concern

  • Where the company is now

  • Other factors of influence on the assessment

  • Time needed for pre-assessment and writing proposal for feasible options

  • Team composition and management representative

  • How staff will be informed to ensure cooperation

Company Energy

Efficiency methodology


Slide13 l.jpg

Worksheet 1: Reasons for Energy Efficiency

Company Energy

Efficiency methodology


Slide14 l.jpg

Worksheet 2: Energy Management Matrix

Company Energy

Efficiency methodology


Slide15 l.jpg

Worksheet 3: Factors influencing the energy assessment approach

Company Energy

Efficiency methodology


Slide16 l.jpg

Task 1b: Form a Team and inform staff approach(0.5 – 1 day)

  • The Team should consist of:

  • Someone who knows the main energy uses and environmental impacts, e.g. the Environment Manager or Energy Manager

  • Someone who knows the production process, e.g. the Head of Production

  • Someone with access to general company information and energy cost data, e.g. the company’s Accountant or Finance Manager

  • A communications or training person

  • A top management representative

Company Energy

Efficiency methodology


Slide17 l.jpg

Energy approach

Focus

Task 1b: Form a Team and inform staff (cont.)

  • Team should have

  • Knowledge of energy equipment

  • Energy intensive production processes

  • Access to energy data

  • Typical positions

  • Utilities Manager

  • Energy Manager

  • Maintenance Engineer

Company Energy

Efficiency methodology


Slide18 l.jpg

Worksheet 4: Team Members and Roles approach

Company Energy

Efficiency methodology


Slide19 l.jpg

Task approach1c: Pre-assessment to collect general information(1 – 3 days)

  • Information collected should include:

  • General company details

  • Organization chart

  • General production flow chart

  • Production data for the past 3 years

  • Energy, resource consumption data and costs for the past 3 years

  • Inventory of major equipment

  • Overview of information collected for each process step / department

  • Company greenhouse gas (GHG’s) emissions

Company Energy

Efficiency methodology


Slide20 l.jpg

Energy approach

Focus

Task 1c: Pre-assessment to collect general information(cont.)

  • Include auxiliary sections in the general production flow chart

    • Water treatment

    • Boiler and steam systems

    • Compressed air systems

    • Air conditioning / refrigeration

    • Ventilation

Company Energy

Efficiency methodology


Slide21 l.jpg

Energy approach

Focus

Task 1c: Pre-assessment to collect general information(cont.)

  • Production and resource data should also include

    • Fuel consumption rates and costs

    • Electricity consumption and costs

    • Fuel mix

    • Electricity bills from utility

Company Energy

Efficiency methodology


Slide22 l.jpg

Energy approach

Focus

Task 1c: Pre-assessment to collect general information(cont.)

  • Inventory of major equipment

    • Name of equipment: motor

    • Numbers: 50

    • Capacity: 1 with 100 HP, 39 with >25 HP, 10 with <10 HP

    • Type: AC motor

    • Supplier: General Electric

    • Rated parameters: e.g. load

    • Operating parameters (if available)

Company Energy

Efficiency methodology


Slide23 l.jpg

Worksheet 6: General Production Flow Chart approach

Company Energy

Efficiency methodology


Slide24 l.jpg

Worksheet 7: Production and Resource Data approach

Company Energy

Efficiency methodology


Slide25 l.jpg

Worksheet 8: Inventory of Major Equipment approach

Company Energy

Efficiency methodology


Slide26 l.jpg

Task approach1d: Select focus areas (0.5 – 1 day)

  • A focus area can be:

  • Entire plant

  • A department, production line, or process step

  • Specific (energy) equipment or resources

  • The process for selecting focus areas:

  • Identify possible focus areas

  • Determine selection criteria

  • Rate each focus areas High, Medium, Low for each criteria

Company Energy

Efficiency methodology


Slide27 l.jpg

Energy approach

Focus

Task 1d: Select focus areas (cont.)

  • Different focus areas can be selected when energy is considered

    • An auxiliary system instead of a production step

    • - Steam system

    • - Compressed air

    • Specific major energy equipment

    • - Boiler house (not just the boiler!)

Company Energy

Efficiency methodology


Slide28 l.jpg

Worksheet 10: Selection of Focus Areas approach

Company Energy

Efficiency methodology


Slide29 l.jpg

Task 1e: Prepare assessment proposal for top management approval (2 – 3 days)

  • It is important to obtain top management commitment

  • The assessment proposal should include:

  • Objective, scope (i.e. focus areas)

  • Outputs

  • Approach (step 2, 3 and 4 of the Methodology)

  • Team

  • Time & budget

Company Energy

Efficiency methodology


Slide30 l.jpg

Step 2: Assessment approval

Purpose:assess where energy is lost/wasted for the focus area(s)

Output: overview of how much energy is lost and how much money this costs for the focus area(s)

Then it becomes easier to identify options to improve energy efficiency in step 3!

Company Energy

Efficiency methodology


Slide31 l.jpg

Step 2: Assessment approval

  • Time: minimum 3 days

  • Tasks include:

  • Task 2a: Staff meeting and training (>0.5 day for staff meeting only)

  • Task 2b: Prepare focus area flow charts (>2 hours per focus area)

  • Task 2c: Walkthrough of focus areas (> 0.5 day per focus area)

  • Task 2d: Quantify inputs and outputs and costs to establish a baseline (time required depends on data available)

  • Task 2e: Quantify losses through a material and energy balance (0.5 – 1 day per focus area)

Company Energy

Efficiency methodology


Slide32 l.jpg

Task 2a: Staff meeting and training approval

  • Staff meeting (0.5 day)

  • Inform staff about assessment and their roles

  • Get their support

  • Staff training

  • Importance of energy efficiency

  • How to carry out an assessment

  • Energy equipment & monitoring instruments

  • Financing, GHG Indicator, other…

  • Information:

  • Posters, newsletters, meetings

Company Energy

Efficiency methodology


Slide33 l.jpg

Task 2b: Prepare focus area flow charts approval (>2 hours per focus area)

  • Flow chart for each focus area

  • Different steps of the focus area

  • Most important inputs (resources) for each step

  • Most important outputs for each step

  • Intermediate and final products between the steps

Company Energy

Efficiency methodology


Slide34 l.jpg

Energy approval

Focus

Task 2b: Prepare focus area flow charts (cont.)

  • Different types of focus areas require different types of charts:

    • Production step: process flow diagram

    • Auxiliary systems: layout chart for steam or compressed air distribution system

    • Specific major equipment: major equipment and all auxiliary equipment

Company Energy

Efficiency methodology


Slide35 l.jpg

Task 2c: Walkthrough of focus areas approval (>0.5 day per focus area)

  • Purpose of the walkthrough(s)

  • Better understand the focus area

  • Get feedback from production staff about problems…

  • Write down visible losses of energy and materials

  • Obtain information about quantities and costs

Company Energy

Efficiency methodology


Slide36 l.jpg

Worksheet 14: Walkthrough observations approval

Company Energy

Efficiency methodology


Slide37 l.jpg

Task 2d: Quantify inputs and outputs and costs to establish a baseline

  • Time required depends on information available

  • Why a baseline?

  • Measure improvements after implementing options

  • Management only convinced to continue if you can show savings

  • Collect the following information:

  • Quantities (e.g. tons of coal per day)

  • Costs (e.g. $ per ton of coal)

  • Other characteristics (e.g. temperature of water going in and out of the boiler, pressure)

Company Energy

Efficiency methodology


Slide38 l.jpg

Worksheet 13: Process flow chart, inputs/output, energy balance

Company Energy

Efficiency methodology


Slide39 l.jpg

Energy balance

Focus

Task 2d: Quantify inputs and outputs and costs to establish a baseline (cont)

  • Examples of material-related parameters for the boiler house

  • Fuel and electricity

  • Water

  • Blow down

  • Ash

  • Steam produced

  • Condensate recovered

Company Energy

Efficiency methodology


Slide40 l.jpg

Energy balance

Focus

Task 2d: Quantify inputs and outputs and costs to establish a baseline (cont)

  • Examples of energy-related parameters for the boiler house

  • Pressure

  • Temperature

  • Flue gas composition

  • Draft

  • Radiation

  • Note: specific monitoring equipment may be needed

Company Energy

Efficiency methodology


Slide41 l.jpg

Energy balance

Focus

Company Energy

Efficiency methodology


Slide42 l.jpg

Task 2e: Quantify losses through a material and energy balance (0.5 – 1 day per focus area)

  • Try to “balance” inputs and outputs (what goes into a process must come out!)

  • Identify “losses”: energy, products, materials

  • Calculate costs of losses

  • Be practical: this is the most difficult task!

Company Energy

Efficiency methodology


Slide43 l.jpg

Energy balance

Focus

Task 2e: Quantify losses through a material and energy balance

Company Energy

Efficiency methodology


Slide44 l.jpg

Step 3: Identification of Options balance

  • Purpose: identify opportunities to improve energy efficiency for the selected focus areas

  • Output: list of options that will be investigated on their feasibility in step 4

  • Tasks and minimum time:

  • Task 3a: Determine causes of losses (0.5 day per focus area)

  • Task 3b: Identify possible options (0.5 day per focus area)

  • Task 3c: Screen options for feasibility analysis (0.5 day)

Company Energy

Efficiency methodology


Slide45 l.jpg

Task 3a: Determine causes of losses balance (0.5 day per focus area)

  • Brainstorm session with staff and others

  • Ask the question: Why are these losses occurring?

  • Keep asking until you found the “root cause”

  • Look for different causes:

  • Man

  • Method

  • Machine

  • Material

Company Energy

Efficiency methodology


Slide46 l.jpg

Task 3a: Determine causes of losses balance (cont.)

Fishbone diagram

Company Energy

Efficiency methodology


Slide47 l.jpg

Energy balance

Focus

Task 3a: Determine causes of losses (cont.)

  • Material losses with an energy-related cause

    • Low dye exhaustion caused by low temperatures

    • Scale losses caused by cold air infiltration in rolling mills

  • Energy losses with an energy-related cause

    • High electricity use in rollers caused by overheating of bars in rolling mills

    • High transmission and distribution losses caused by low power factor

Company Energy

Efficiency methodology


Slide48 l.jpg

Energy balance

Focus

Task 3a: Determine causes of losses (cont.)

  • Energy losses with a material-related cause

    • Inefficient combustion caused by improper sizing of coal

    • High steam consumption in dyeing process caused by too high liquor-to-cloth ratio

  • Poor product quality with an energy-related cause

    • Thin zinc layer caused by high temperature of zinc bath in galvanizing

    • Uneven strength of forged products caused by low/non-uniform temperature in furnace

Company Energy

Efficiency methodology


Slide49 l.jpg

Energy balance

Focus

Task 3a: Determine causes of losses (cont.)

  • Other examples

    • Low boiler efficiency caused by operating at <50% capacity

    • High electricity consumption due to compressed air leaks

    • High steam consumption caused by un-insulated flanges

    • High electricity consumption due to motor operating at varying loads

Company Energy

Efficiency methodology

Do you know of any other examples?


Slide50 l.jpg

Task 3b: Identify possible options balance (0.5 day per focus area)

  • Brainstorm session with staff and others

  • Ask the question: What can we do to reduce energy losses?

  • Options can fall in the following categories:

  • Good housekeeping

  • Improved process management

  • Production process / equipment modification

  • New technology / equipment

  • Input material substitution

  • On-site reuse / recovery

  • Production of useful by-product

  • Product modification

Company Energy

Efficiency methodology


Slide51 l.jpg

Energy balance

Focus

Task 3b: Identify possible options (cont.)

  • A combination of options is likely

  • Poor bleaching can be solved by:

    • Reducing the liquor-to-cloth ratio

    • thereby increasing the bleaching bath temperature

Company Energy

Efficiency methodology


Slide52 l.jpg

Task 3c: Screen options for feasibility analysis balance (0.5 day)

  • Put identified options in three groups:

  • Options that can be implemented directly

  • Options that require further analysis

  • Options that can be considered at a later stage

Company Energy

Efficiency methodology


Slide53 l.jpg

Worksheet 15: Causes, identify options and screening balance

Company Energy

Efficiency methodology


Slide54 l.jpg

Step 4: Feasibility Analysis of Options balance

  • Purpose:

  • Determine which options are technically, financially and environmentally feasible

  • In what order feasible options should be implemented

  • Output: proposal that is approved by top management with:

  • Recommended options for implementation

  • How to do this

  • List of options that require further investigation

Company Energy

Efficiency methodology


Slide55 l.jpg

Step 4: Feasibility Analysis of Options balance

  • Tasks:

  • Task 4a: Technical, economic and environmental evaluation of options

  • Task 4b: Rank feasible options for implementation (0.5-1 day)

  • Task 4c: Prepare implementation and monitoring proposal for top management approval (2-3 days)

Company Energy

Efficiency methodology


Slide56 l.jpg

Task 4a: Technical, economic and environmental evaluation of options

  • The Team should (time depends on options):

  • Investigate which options are technically, economically and environmentally feasible

  • Identify other possible reasons for implementing the option

  • Think of possible barriers to implementing the option

Company Energy

Efficiency methodology


Slide57 l.jpg

Worksheet 16: Option analysis and implementation options(part for feasibility analysis)

Company Energy

Efficiency methodology


Slide58 l.jpg

Energy options

Focus

Task 4a: Technical, economic and environmental evaluation of options

  • Technical

  • Location of power, steam, compressed air lines

  • Handling capacity of existing system for new equipment

  • Environmental

  • Fluorescent tube lights use less electricity than incandescent lamps but contain toxic materials

  • Bag filter reduces dust but uses electricity

Company Energy

Efficiency methodology


Slide59 l.jpg

Task 4b: Rank feasible options for options

Implementation

  • Team meeting to give each option a

  • Rank (0.5 – 1 day):

  • Implementation in short term (e.g. <1 year)

  • Recommended for implementation but in the longer term (e.g. 2-3 years)

  • Recommended for further investigation or consideration at a later stage

  • Unfeasible options

Company Energy

Efficiency methodology


Slide60 l.jpg

Task 4b: Rank feasible options for options

Implementation (cont.)

  • For options to be implemented (rank = 1)

  • (time depends on options):

  • Implementation and monitoring tasks

  • Who is responsible

  • Completion dates

  • How much staff time required

  • Comments

Company Energy

Efficiency methodology


Slide61 l.jpg

Worksheet 16: Option analysis and implementation options(part for implementation)

Company Energy

Efficiency methodology


Slide62 l.jpg

Worksheet 17: Ranking of options options

Company Energy

Efficiency methodology


Slide63 l.jpg

Task 4c: Prepare implementation and monitoring proposal for top management approval

  • Prepare Implementation and Monitoring

  • Plan

  • Introduction

  • Number of options identified, options investigated for feasibility, feasible options, options requiring further investigation, and unfeasible options

  • Options recommended for implementation in the short term

  • Worksheets for each option

  • Obtain management approval

Company Energy

Efficiency methodology


Slide64 l.jpg

Step 5: Implementation and Monitoring of Options top management approval

  • Purpose

  • Implement feasible options in order of priority

  • Monitor results

  • Discuss findings with top management

  • Output

  • Improved energy efficiency, reduced costs and reduced GHG emissions

  • Agreement with top management about the next steps

  • Tasks

  • Task 5a: Implement options and monitor results (time depends on options)

  • Task 5b: Evaluation meeting with top management (0.5 day)

Company Energy

Efficiency methodology


Slide65 l.jpg

Task 5a: Implement options and monitor results top management approval

  • Carry out the Implementation and

  • Monitoring Plan

  • Record results for each option:

  • Economic results

  • Environmental results

  • Other results: e.g. any other benefits from the option and barriers encountered

  • Communicate results to staff

Company Energy

Efficiency methodology


Slide66 l.jpg

Worksheet 16: Option analysis and implementation top management approval(part for feasibility analysis)

Company Energy

Efficiency methodology


Slide67 l.jpg

Task 5b: Evaluation meeting with top management approval

top management (2-4 hours)

  • Purpose:

  • Close the first round of energy efficiency projects

  • Gain management commitment to continue with energy efficiency

  • Discuss the following:

  • Results

  • How to communicate results internally and externally

  • How to continue

    • Additional options for implementation / investigation

    • New focus areas to carry out more assessments

    • How to integrate energy management throughout the company’s systems

Company Energy

Efficiency methodology


Slide68 l.jpg

Step 6: Continuous Improvement top management approval

  • Purpose: ensure that the company continues improving energy efficiency in a systematic way that is integrated in company processes

  • (these are the key components of Cleaner Production!!)

  • Output:

  • Continuation of implementing energy efficiency options

  • Integration of energy management into company processes

  • Task 6a: Prepare proposal to continue with energy efficiency (2-3 days)

Company Energy

Efficiency methodology


Slide69 l.jpg

Task 6a: Prepare a proposal to continue with energy efficiency for top management approval

  • Write a proposal

  • Based on what was agreed with top management at the evaluation meeting

  • Considering new focus areas and options identified for later implementation / investigation

  • Include how to integrate energy management into company processes!!

  • Seek top management approval

Company Energy

Efficiency methodology


Slide70 l.jpg

In Summary: efficiency for top management approval

  • The Company Energy Efficiency Methodology helps companies to:

  • Save energy

  • Reduce costs

  • Protect the environment

  • Now and in the future!

Company Energy

Efficiency methodology


Slide71 l.jpg

Training Session on the Company Energy Efficiency methodology

How to become Energy Efficient

THANK YOU

FOR YOUR ATTENTION

Company Energy

Efficiency Methodology


Slide72 l.jpg

Disclaimer and References methodology

  • This training session was prepared as part of the development and delivery of the course “Energizing Cleaner Production” funded by InWent, Internationale Weiterbildung und Entwicklung (Capacity Building International, Germany)and carried out by the United Nations Environment Programme (UNEP)

  • The session is based on materials from the “Energy Efficiency Guide for Industry in Asia” developed as part of the GERIAP project that was funded by the Swedish International Development Cooperation Agency (Sida)

  • The textbook chapter is available on www.energyefficiencyasia.org

Company Energy

Efficiency Methodology