Eletrobrás

Vienna, Austria – March 2007Vienna, Austria – March 2007

BRAZILIAN INDUSTRIAL ENERGY BRAZILIAN INDUSTRIAL ENERGY EFFICIENCY PROGRAM: FOCUS ON EFFICIENCY PROGRAM: FOCUS ON

MOTOR DRIVEN SYSTEMS.MOTOR DRIVEN SYSTEMS.

BRAZILIAN INDUSTRIAL ENERGY BRAZILIAN INDUSTRIAL ENERGY EFFICIENCY PROGRAM: FOCUS ON EFFICIENCY PROGRAM: FOCUS ON

MOTOR DRIVEN SYSTEMS.MOTOR DRIVEN SYSTEMS.

INDUSTRIAL ENERGY EFFICIENCY AND ENERGY MANAGEMENT STANDARDS - UNIDOINDUSTRIAL ENERGY EFFICIENCY AND ENERGY MANAGEMENT STANDARDS - UNIDO

D.Sc. George Alves Soares – Eletrobrás - Brazil

Eletrobrás

Content Motor system importance in Brazil; Background; Learned Lesson; Industrial Energy Efficiency Program; Results; Learned lessons after 4 years of

implementation; Industrial EM Standard; Other related activities.

Eletrobrás

ELECTRICITY CONSUMPTIONELECTRICITY CONSUMPTION

Electric power consumption in 2006:

347 TWh

Residential25%

Industrial44%

Others15%

Commercial16%

Residential

Industrial

Commercial

Others

Eletrobrás

IMPORTANCE OF ELECTRIC MOTORS IN THE IMPORTANCE OF ELECTRIC MOTORS IN THE CONSUMPTION OF ELECTRIC POWERCONSUMPTION OF ELECTRIC POWER

49%

0%10%

7%

32%

Motor Drive

Lighting

Boiler

Eletrochemical

Furnace

Eletrobrás

CONSUMPTION OF ELECTRIC ENERGY FOR INDUSTRIAL CONSUMPTION OF ELECTRIC ENERGY FOR INDUSTRIAL SEGMENTSEGMENT

Cement

Iron-cast and steel

Iron-Alloys

Mining e pelletization

Non-Ferrous and Others Metals

Chemical

Food and Beverages

Têxtil

Paper and cellulose

Cerâmic

Others

0

5000

10000

15000

20000

25000

30000

GWh

Source: BEN-2003

Eletrobrás

ELECTRIC POWER CONSUMPTION SHARE OF MOTORS, BY ELECTRIC POWER CONSUMPTION SHARE OF MOTORS, BY INDUSTRIAL SEGMENTINDUSTRIAL SEGMENT

Iron-Steel

Ferroalloy Mining

Aluminum

Chemistry

Food and Beverages

Textile

Paper Others0

10

20

30

40

50

60

70

80

90

100

Cement

Pelletizing

NonFerrous

Sugar

Ceramics

Source: BEU-93

Eletrobrás

• PROCEL – National Program of Energy PROCEL – National Program of Energy Conservation created in 1985 and carried out by Conservation created in 1985 and carried out by ELETROBRÁS;ELETROBRÁS;• Until 2002Until 2002

• Some energy studies and survey;Some energy studies and survey;• Hundreds of energy audits in industry;Hundreds of energy audits in industry;• Hundreds of trained professionals;Hundreds of trained professionals;• Monitoring and target project implementations;Monitoring and target project implementations;• Demonstration projects in some industrial Demonstration projects in some industrial sectors like automobile;sectors like automobile;• Several publications, seminar and conferences;Several publications, seminar and conferences;• Web-sites, campaigns and softwares;Web-sites, campaigns and softwares;• Processes and motors actionsProcesses and motors actions• Low tariffs and cultures barriers;Low tariffs and cultures barriers;• No guarantee of real energy savingsNo guarantee of real energy savings

BACKGROUNDBACKGROUND

Eletrobrás

Learned Lessons

Lack of knowledge about the motor system integrated performance; The motor driven systems are complex and quite different; There’s no engineering that focus all components of the motor system and its integrated performance; Few interactions between the universities and the industries;

Eletrobrás

Computational tools / training / course do not meet all expected targets;

Few interactions between the buying sector and the technical staff;

Energy is never the core business; Inflation culture; The need of management commitment; Absence of structured plan to installed

motor driven systems;

Learned Lessons

Eletrobrás

Started in 2003Started in 2003

OBJECTIVESOBJECTIVES

Minimizing losses in motor-driven systems already Minimizing losses in motor-driven systems already installed in the Brazilian industryinstalled in the Brazilian industry; Increasing the market penetration of high-efficient Increasing the market penetration of high-efficient three-phase induction motors and efficient motor three-phase induction motors and efficient motor loads;loads; Strengthening the technical support in this areaStrengthening the technical support in this area

PROCEL PROCEL INDÚSTRIA INDÚSTRIA INDUSTRIAL ENERGY EFFICIENCY PROGRAMINDUSTRIAL ENERGY EFFICIENCY PROGRAM

Eletrobrás Training and analysis tools

for several levels

Financing forequipment andinstrumentation

Self Energy Audit and implementation

industry

Universities andResearch Institutes

Manufacturers

CONCEPTIONCONCEPTION

COMMITMENT

COMMITMENT

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

Eletrobrás

AWARENESSAWARENESSAWARENESSAWARENESS

ELETROBRÁSELETROBRÁSFEDERATIONSFEDERATIONSASSOCIATIONSASSOCIATIONS

SKILLS BUILDINGSKILLS BUILDINGSKILLS BUILDINGSKILLS BUILDING

RESEARCHERSRESEARCHERSCONSULTANTCONSULTANT

FINANCINGFINANCINGFINANCINGFINANCING

FEDERAL FEDERAL BANKBANK

LABELLABELLABELLABEL

CERTIFIERS & CERTIFIERS & MACHINES MACHINES

ASSOCIATIONASSOCIATION

IMPLEMENTATIONIMPLEMENTATIONIMPLEMENTATIONIMPLEMENTATION

INDUSTRYINDUSTRYINDUSTRYINDUSTRY

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

Eletrobrás

CONVINCING CONVINCING THE INDUSTRYTHE INDUSTRY

CONVINCING CONVINCING THE INDUSTRYTHE INDUSTRY

AWARENESS

FINANCIAL FINANCIAL RESOURCES RESOURCES

(BNDES)(BNDES)

FINANCIAL FINANCIAL RESOURCES RESOURCES

(BNDES)(BNDES)

FINANCING

LABELLABELLABELLABEL

CERTIFICATION

EDUCATION.EDUCATION.MATERIALMATERIAL

EDUCATION.EDUCATION.MATERIALMATERIAL

SKILLS BLDG.

FEDERATIONSFEDERATIONSFEDERATIONSFEDERATIONS

ASSOCIATIONSASSOCIATIONSASSOCIATIONSASSOCIATIONS

1111

4444

4444MULTIPLIERSMULTIPLIERSCAPACITYCAPACITY

MULTIPLIERSMULTIPLIERSCAPACITYCAPACITY

AGENTS AGENTS TRAININGTRAINING AGENTS AGENTS TRAININGTRAINING

2222

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

AGENTS=EMPLOYEES FROM INDSTRY

COMMITMENT

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AGENTAGENTAGENTAGENT

INDUSTRYINDUSTRYINDUSTRYINDUSTRY

IMPLEMENTATION IMPLEMENTATION ENERGY AUDITENERGY AUDIT

IMPLEMENTATION IMPLEMENTATION ENERGY AUDITENERGY AUDIT

LABELING MACHINESLABELING MACHINESLABELING MACHINESLABELING MACHINES

FINANCIALFINANCIALRESOURCESRESOURCESFINANCIALFINANCIAL

RESOURCESRESOURCES

ENERGY SAVINGSENERGY SAVINGSENERGY SAVINGSENERGY SAVINGS

4444

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

COMMITMENT

Eletrobrás

ELETROBRÁS/PROCEL & FEDERATIONS AGREEMENTELETROBRÁS/PROCEL & FEDERATIONS AGREEMENT

AWARENESS OF INDUSTRY MANAGERSAWARENESS OF INDUSTRY MANAGERS& TRAINING OF MULTIPLIERS& TRAINING OF MULTIPLIERS

• WORKSHOPS FOR TOP & MIDDLE MANAGEMENT & WORKSHOPS FOR TOP & MIDDLE MANAGEMENT & TECHNICAL-OPERATIONAL LEVELS IN INDUSTRYTECHNICAL-OPERATIONAL LEVELS IN INDUSTRY

• SPECIALIZATION COURSE FOR MULTIPLIERSSPECIALIZATION COURSE FOR MULTIPLIERS

SKILLS BUILDING FOR INDUSTRY AGENTSSKILLS BUILDING FOR INDUSTRY AGENTS• MIDDLE AND HIGHER LEVEL SPECILIZATION COURSEMIDDLE AND HIGHER LEVEL SPECILIZATION COURSE

SETTING UP OF BEST PRACTICESETTING UP OF BEST PRACTICE• IMPLEMENTATION AT THREE INDUSTRIAL IMPLEMENTATION AT THREE INDUSTRIAL

PLANTS IN DIFFERENT SUBSECTORSPLANTS IN DIFFERENT SUBSECTORS

FOLLOW-UP OF IMPLEMENTATIONSFOLLOW-UP OF IMPLEMENTATIONS AND RESULTS DIVULGINGAND RESULTS DIVULGING

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PROGRAM GOALS - 1st PHASE -2007

To reach 800 industries (large and medium);To reach 800 industries (large and medium); 0,8 billion KWh / year ( 13% of Brazil’s potential);0,8 billion KWh / year ( 13% of Brazil’s potential); 270 multipliers;270 multipliers; 3,700 agents;3,700 agents; 12 federations;12 federations; Interaction among different agents, division of costs and Interaction among different agents, division of costs and

responsibilities.responsibilities.

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

Eletrobrás

MÓD. DISCIPLINE H/LI. ELECTRIC POWER CONCEPTS, POWER QUALITY AND TARIFFS 8hII. ELECTRIC MOTOR 16hIII. ELECTRONIC ADJUSTABLE SPEED DRIVE 16hIV. PUMPS 16hV COMPRESSORS 16hVI. FANS AND EXHAUST FANS 16hVII. CONVEYOR BELTS 8hVIII MOTOR-LOAD COUPLING 8hIX. INSTRUMENTATION AND CONTROL 8hX. ECONOMIC ANALYSIS OF INVESTMENTS 8hXI. ORIENTED PEDAGOGY 8hXII. MARKETING AND SALES 8hXIII. INDUSTRIAL SAFETY 8hXIV. MONITORING AND TARGET 8h

XV. METHODOLOGY FOR ENERGY AUDIT ON THE MOTOR DRIVEN

SYSTEM8h

XVI. TECHNICAL VISIT AND EVALUATION 8HXVII. CASE STUDY 8h

176hTOTAL

BUILDING CAPACITY FOR MULTIPLIERS

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Under way: 10 states

•Current SituationCurrent Situation

MG

BA

SC

SP

MS

MT

PAAM

PE

CE

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Dissemination of E.E. motor systems techniques in Dissemination of E.E. motor systems techniques in involved engineering;involved engineering;

Technical support of federations agreements and Technical support of federations agreements and industries;industries;

Simulation of the several operating conditions of main Simulation of the several operating conditions of main motor-driven systems;motor-driven systems;

12 Universities already contemplated in 10 states.12 Universities already contemplated in 10 states.

ELETROBRÁS/PROCEL AND UNIVERSITIES AGREEMENT

Eletrobrás

Multiplyer Agent Industry Laborat. scholars.MW 35 495 74 3 33

S 18 126 46 1 11SE 41 679 199 2 22N 43 536 166 3 28

NE 43 330 206 3 30Total 166 2132 550 12 124

INDUSTRIAL ENERGY EFFICIENCY PROGRAM

RESULTS

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INDUSTRIAL ENERGY EFFICIENCY PROGRAM

RESULTS

Region State Scholar-ships

Bachelor’s Degree

Master’sDegree

Doctor’sDegree

North

Amazonas 11 7 3 1

Amazonas 7 4 3 -

Pará 9 5 3 1

Northest

Ceará 11 7 4 -

Pernambuco 11 7 3 1

Bahia 8 7 1 -

Midwest

Mato Grosso 11 7 3 1

Mato Grosso 11 7 3 1

Mato Grosso do Sul

11 7 3 1

Southest

São Paulo 4 2 2 -

Minas Gerais 11 7 3 1

Minas Gerais 11 7 3 1

South Santa Catarina 8 6 2 -

TOTAL124 80 36 8

Eletrobrás

Learned Lessons after 4 years of implementation

The Brazilian state industry federations were more concerned with political issues. The Program pushed them to get closer by gathering data and industrial managers awareness activities. This approach led to identify engineering services opportunities to be offered by the federations to the industries. This is one of the sustainability aspects of the program.

The existing gap between the universities and the industries was reduced through the professors’ acting as multiplier, teaching the agents from the local industry and providing technical assistance.

The agents frequently have reported some difficulties such as lack of time and measurement equipments to identify energy efficiency opportunities in their plants. As a result the implementation phase has been delayed. They have claimed for more support from their managers.

Eletrobrás

Learned Lessons after 4 years of implementation

Lack of facility engineers and existence of large number of technicians in the maintenance and buying sectors → rewrite all the material taking into account their education and the suitable didactical methodology.

The first energy audits reports were focused basically on motor replacements → high index of energy audit rejection and they have to redo these audits.

Either the consultants changed their mind through out the program.

In order to enhance multipliers’ confidence, a complementary practical training in plants was added to the 176 hours original training. As a result they were better prepared to support energy audits. This also took extra time.

Eletrobrás

Industrial EM Standards

There is no brazilian standards; There are several industries that

manage their energy consumptions (electricity intensive);

More than 2500 Companies with ISO 14001 Certification;

Working Group to analyze the existent standards will start in September of 2007.

Eletrobrás

Other related activities

MEPS for induction motors– Only high efficient motors after 2009;

Labeling for pumps– Residential water pump

Mounting independent laboratory capacities for compressors and pumps;

Common agenda with National Industry Confederation;

Projects demonstration and courses for small industries.

Eletrobrás

THANK YOU FOR THE ATTENTION

D.Sc. GEORGE ALVES SOARES

ELETROBRÁS / PROCEL

e-mail: georgesoares@eletrobras.com

www.eletrobras.com/procelwww.eletrobras.com/procelwww.eletrobras.com/procelwww.eletrobras.com/procel