INDUSTRIAL ENERGY EFFICIENCY

PROJECT CASE STUDIES

SUSTAINABILITY CONFERENCE 2014

Faith Mkhacwa: Regional Project Manager B Eng., MBL, EnMS Expert (UNIDO)

EnMS - ISO 50001 - ESO

UNIDO EnMS Programme Operational in 13 countries

on-going & planned activities in more than 30 countries

Operational

South Africa Moldova Russia Turkey Iran Malaysia

Thailand Vietnam Philippines Egypt Indonesia Ecuador

Total UNIDO Funds Total Co-Funding Total Project Funding

US$ 58M US$ 456M US$ 514M

EnMS Victories

Implementation Highlights

Company

kWh Savings Comments 2011/12 2012/13

ArcelorMittal Saldanha

81 325 527 92 676 882

No/low cost investments.

Toyota SA 4 484 533 11 131 462 73 Projects; Compressed Air, Lighting, Pumps, etc..

Gelvenor Textiles

996 670 996 670 3 projects; switched off generator & chillers and fitted VSD’s to 9 circulation fans.

Saint-Gobain Construction Products

917 916 917 916 Combustion efficiency improvement, lighting, compressed air, water gauge.

87 724 646 105 722 930

EnMS Implementation Outcomes

Company kWh Savings Energy Systems

Mercedes Benz 1 400 000 Compressed Air System

Kraft Foods 2 915 912 pF, Lighting, idle machines

PPC Cement PE 51 531 Axial sampling of grinding media

Tenneco Emission Control 301 564 Lighting

Tenneco Ride Control 1 181 844 Oven, Knives, Induction Geyser, VSD

Willard Batteries 2 817 649 Curing time, wet scrubbers, chargers

Distell – Adam Tas Winery 298 554 Lighting, Compressors

Sappi Cape Kraft 184 722 Peak clipping

Polyoak Packaging CT 194 400 Lighting retrofit

BMW 8 850 000 Paintshop ovens, driers

Consol Glass - Wadeville 2 084 392 Lighting, Compressor

ACSA Durban 393 148 Lighting

Feltex 1 305 804 Cooling, Comp , Lights, idle Mach

Richards Bay Minerals 3 919 687 Pumps, Compressed Air, Lighting

Total 25 899 207

Energy Management Standard

ISO 50001

• Purpose: Enable organizations to establish systems and processes necessary to

improve energy performance

• Applicable to all organizations

• Does NOT prescribe specific performance criteria with respect to energy

Source: SWEDAC

Other ISO Standards Different standards → All critical → One CANNOT replace the other

Energy

Management

ISO 50001

Environmental

Management

ISO 14000

Quality Management

ISO

9001

Other Management Systems

ISO 50001 CERTIFIED

COMPANIES

Tenneco Ride Control & Emission Control

ISO 50001 Certified!!!

Intervention Capital Cost

ZAR

Savings

ZAR

Energy saving

Compressed air systems

Compressed air optimisation

R 1 023 265.30 R 425 595 766 305 kWh

Lighting initiatives

Factory, Offices, Sensors, Daylight Harvesting

R 1 076 695.40 R 780 131.49 926 064 kWh

Paint shop burner submersion tube R 35 000 R 16 284 15 366 kWh

Automatic metering.

Electricity, LPG, Shielding gas weight

R 149 011 - Better energy

management.

New Chrome Planting oven R 750 000 R 634 508 829 444 kWh

Power Factor correction at Tenneco – Emission Control. To be

done at Tenneco - Ride Control

R 69 079 R 142 776 127 kVA

Procedures – Shutdown, SEU training - - Better energy

management.

TOTAL R 3 103 050.70 R 1 999 294.49 2 537 179 kWh

ENERGY SYSTEMS

OPTIMISATION

Energy Systems Optimisation

(ESO)

Component Approach Systems Approach

- Segregate components - Analyse performance of each in isolation

- Look at how the entire group functions together

- How will changing one impact the other?

May result from education by a specific technology sales engineer (e.g.: VSD or steam trap)

More knowledge of system and its interactions required

2-5% efficiency gains on the total energy consumption

10-50% average efficiency gains

Shifting FOCUS from Component optimization to systems

optimization!!!

ESO Implementation Victories

Company Energy System Savings Comments

Annualized

Rhodes Foods Group-Franchhoek

Steam R881 794 0.2 year payback (Not implemented)

Da Gama Textiles Steam R9 267 000 2.3 year payback (Implementation underway)

SAB Maltings Steam R6 603 028 1.0 year payback (Started system optimisation)

Arcelor Mittal-Saldanha Works

Pump R1 108 851 Cooling system Pump throttle settings changed.

Impala Platinum Pump R285 205 Switching off cooling system pump and fan.

Kraft Foods Electricity R223, 304 Switching off idle machines. Savings over shutdown.

R18 369 182

SME SUCCESS STORIES

Techniplate- Silverton, Pretoria

Implementation Statistics Implementation Detail and Actions

Trigger: Plating tanks- temperature variations, excessive temp and excessive energy usage Energy Savings : • 19.3% or 421 344kWh/annum • 23.5% or R172 751/annum Investment Cost: R46 200 Payback Period: 4 months

* Better process control → Better products.

Background: Temperature was manually controlled on plating tanks • Average of 6°C higher than required=

4.4kWh

Optimisation Detail: Temperature controller & Energy Meter installed (42 tanks in total)

Measurement and Data Analysis: Manual vs Auto control resulted in • 4.7°C hotter tank temperature. • Higher variability • Higher energy consumption as per

temperature profile.

Precision Press - Cape Town

Energy Reduction Opportunity

Capital Cost (ZAR )

Savings per annum (ZAR )

Payback Months

Environmental Benefit per annum

Switching-off electrical equipment hydro-boils, lights & motors (presses) when not in use)

793.20

37,699

0.25

55,000 kWh

Compressed air (leak tagging, awareness & sustainable system)

0 28,566

- 62 100 kWh

TOTAL R 793.20

R 66,265

0.14 117 100 kWh

UNIDO Training

EnMS ESO

PSO

CASO

SSO

PHSO

MSO

FSO

UNIDO Training

1 day Awareness Workshop

Target Group:

Process engineers, Energy consultants, Equipment vendors and Service providers.

Objective:

To buy into EnMS, ESO and the IEE project

2 day Users Training

Target Group:

Process engineers, Energy consultants, Equipment vendors and Service providers.

Objective:

To share in-depth technical information on undertaking system energy assessment

Experts Training

Target Group:

EE consultants, ESCO’s, Specialists and others

Objective:

Experts that deliver energy performance improvements and best practices that are sustainable

Elements, Target Groups and Objectives

Some of the participating companies

fdaba@csir.co.za

Thank you