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POWER MANAGEMENT IN INDUSTRY

POWER MANAGEMENT IN INDUSTRY. GENERAL RULES POWER FACTOR CORRECTION (PF) INSTAL CAPACITOR BANKS PF MUST BE 95% OR BETTER MAXIMUM DEMAND CONTROL SWITCH-OFF NON ESSENTIAL LOADS TO MAINTAIN MAXIMUM DEMAND BELOW SET TARGET (ONLY POSSIBLE IF PROCESS IS NOT CONTINEOUS).

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POWER MANAGEMENT IN INDUSTRY

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  1. POWER MANAGEMENT IN INDUSTRY • GENERAL RULES • POWER FACTOR CORRECTION (PF) • INSTAL CAPACITOR BANKS • PF MUST BE 95% OR BETTER • MAXIMUM DEMAND CONTROL • SWITCH-OFF NON ESSENTIAL LOADS TO MAINTAIN MAXIMUM DEMAND BELOW SET TARGET (ONLY POSSIBLE IF PROCESS IS NOT CONTINEOUS). • SEVERAL AUTOMATIC CONTROLLERS ARE AVAILABLE ON THE MARKET. • SHIFT PRODUCTION TO OFF PEAK PERIODS – UTILISE LOWER TARRIF.

  2. REPLACE OLD EQUIPMENT WITH MORDEN EFFICIENT EQUIPMENT • ENERGY EFFICIENT MOTORS – AVOID REPETED REWINDING OF MOTORS • ELECTRONIC BALLAST FOR FLUORESCENT TUBES • 15% TO 25% MORE EFFICIENT. • GENERATES LESS INTERNAL HEAT THEREFORE REDUCED LOAD ON AIRCODITIONING SYSTEMS. • CAN POWER UPTO 4 LAMPS AS COMPARED TO TWO LAMPS FOR TRADITIONAL BALLAST • USE COMPACT FLUORESCENT LAMPS • PRODUCTION MANAGEMENT • ALWAYS RUN YOUR EQUIPMENT AS CLOSE TO THE RATED CAPACITY AS POSSIBLE.

  3. MANAGE EQUIPMENT IDLING • WORK TO REDUCE UNECCESSARY STOPS AND STARTS. THESE INCREASE ENERGY CONSUMPTION. • INTRODUCE STANDARD OPERATING PROCEDURES TO REDUCE EQUIPOMENT SHUTDOWN AND PRE-STARTUP TIMES. • ESTABLISH AN ENERGY MANAGEMENT PROGRAM • AWARENESS COMPAIGNS

  4. SPECIFIC TO CEMENT INDUSTRY • OPTIMISE BALL MILL POWER IN A CEMENT PLANT, MORE THAN 75% OF THE POWER IS USED IN GRINDING, RAW MEAL GRINDING AND CEMENT GRINDING. REQUIRED ACTION • MONITOR PRODUCTION TPH • MONITOR kWh/t • AVOID OVER GRINDING • GRINDING YOUR PRODUCTS FINER THAN NECESSARY – WASTES POWER • CHECK INSTRUMENTS AND TUNE CONTROL LOOPS • OPTIMISE BALL MILL FEED PARTICLE SIZE (BY MONITORING PARTICLE SIZE FROM CRUSHERS - 95% < 25MM)

  5. POWER MONITORING INSTALL ENERGY METERS ON ALL MAJOR ENERGY CONSUMERS – This will enable you to track power consumption patterns and take corrective action. • QUALITY IMPACT ON POWER CONSUMPTION QUALITY OF RAW MATERIALS IS CONSTANTLY MONITORED TO ENSURE THAT AFTER PROCESSING, THE CLINKER PRODUCED HAS THE CORRECT CHEMISTRY. • AVOID PRODUCING A PRODUCT THAT DOES NOT MEET SPECIFICATIONS – UNDERBURNT CLINKER, WASTAGE • HARD CLINKER IS MORE DIFFICULT TO GRIND USES MORE ENERGY.

  6. EFFICIENT GAS HANDLING • MATERIAL BUILD-UP ON IMPELLOR • FAN DESIGN • DAMPER CONDITION AND CALIBRATION • DESIGN OF DUCTWORK • USE OF DAMPER VS VARIABLE SPEED DRIVE. • MINIMISE FALSE AIR • A LOT OF INLEAKS REDUCES SYSTEM PERFORMANCE. • SEAL ALL DUCTS, HOLES etc.

  7. MINIMISE COMPRESSED AIR. • COMPRESSED AIR EFFICIENCY IS VERY LOW (10 TO 15%) – USE IT WHEN ONLY WHERE NECESSARY • SEAL ALL LEAKS • SWITCH OFF WHEN NOT IN USE.

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