IMPROVING YOUR ORGANIZATIONS

1
ENERGY MANAGEMENT IN THE CONTEXT OF GREEN
PRODUCTIVITY

• IMPROVING YOUR ORGANIZATIONS
• ENVIRONMENTAL, HEALTH AND SAFETY
• PERFORMANCE

2
SCOPE

• Productivity Energy Management
• Green Productivity
• Energy Efficiency Concepts
• Case Studies
• Conclusion

3
ENVIRONMENT
4
ENVIRONMENT
5
PRODUCTIVITY

• Productivity Output / Input
• Output economic or consumption
• Input natural resources
• Resource Productivity
• Energy productivity
• Output economic or consumption
• Input energy
• Increasing productivity better results without
  more people, more resources, more money, more
  time or more energy.

OUTPUT
Productivity
INPUT
6
PRODUCTIVITY
INPUT
OUTPUT
7
PRODUCTIVITY
INPUT
Resource Productivity
OUTPUT
Natural Resources
8
What is Green Productivity ?
9
What is Energy Management?

• Energy Management is
• The systematic process of achieving the most
  efficient and effective use of energy
• Production of the same level of goods or services
  with less energy or expanded levels with the same
  amount of energy

• Energy Management is not
• Rationing
• Doing without
• Sacrificing quality, productivity, safety, or
  environmental standards -- in fact, it often
  results in better performance in these areas

10
What is Energy Management?

• Ultimate aim of an energy management programme is
  to enhance an organisations energy efficiency.
• This is different from energy conservation
• Energy conservation only means using less energy
  without any notion about productivity or
  production
• Energy efficiency means using less energy while
  maintaining the same amount of production
• Productivity

Using less energy to do the same amount of work
will mean more productive!
11
Energy Management Provides Numerous Benefits

• Reduced operating costs and increased
  competitiveness
• Improved productivity
• Attractive returns on investment
• Environmental benefits
• Organisation becomes more resilient towards
  increasing fuel prices

12
BARRIERS

• Staff time
• Access to capital
• Decision made based on imperfect information
• Lack of motivation
• Invisibility of energy and energy efficiency
• Small contribution on energy to total cost
• Split incentives e.g. landlord vs tenant

13
HOW TO IMPROVE RESOURCE PRODUCTIVITY

• Innovation
• Advances in Science and Technology
• New ideas
• New business models
• Smarter form of production and consumption
• Improving ways goods are designed, made,
  delivered, used and disposed

14
GP Methodology
15
Energy Efficiency Concepts
Three broad measures can be used to improve the
energy efficiency of an organisation
Reduce the time of use
Energy Efficiency
Improve equipment/process efficiency
Reduce energy loads (heating and cooling)
16
Energy Efficiency Concepts

• All energy saving techniques or programmes can be
  categorised under these three broad categories
• Some techniques will require no or low cost
  these are simple and quick to implement
• Others require substantial investment these
  usually require time to implement
• Typical GP energy saving options are summarised
  in the following slides

17
GP Options

• 1. Keep It Maintained
• Clean it
• Seal it
• Adjust it
• Lubricate it
• Keep it unobstructed
• Recalibrate it
• Check control settings
• Check speeds
• Check flows
• Keep valves, dampers, etc operating smoothly

18
GP Options

• 2. Reduce cooling and heating loads
• Change temperature setting
• Reduce minimum outside air quantities
• Turn equipment off when not in use
• Maintain hot medium set point as low as possible
• Maintain cold medium set point as high as
  possible

19
GP Options

• 3. Turn it off when not in use

20
GP Options

• 4. Reduce flows and resistance
• Reduce fan flows commensurate with reduced
  heating and cooling loads/or due to over design
• Reduce pump flows commensurate with reduced
  heating and cooling loads/or due to over design
• Reduce resistance of air distribution systems
• Reduce resistance of piping systems

21
GP Options

• 5. Improve equipment/system efficiency
• Low kW per ton for chillers
• High Coefficient of Performance (COP)
• Low equipment pressure drops
• Keep refrigerants at efficient levels
• Stage compressors
• Avoid oversized equipment, especially chillers

22
GP Options

• 6. Cooling energy improvements
• Raise chilled water temperature leaving
  evaporator
• Clean condenser tubes
• Stage one large chiller operating at an efficient
  part load to two or more chillers running at full
  loads
• Replace old chillers at high COP such as 0.9
  kW/ton to more efficient chillers at 0.6 kW/ton
• Use VSDs for chilled pumping system
• Use efficient staging - operate one or several
  compressors at full load before starting second

23
GP Options

• 6. Cooling energy improvements
• Install proper controls such that one chiller is
  running full load before the next chiller is
  activated
• Lower cooling tower condenser temperature
  returning to chillers
• Increased heat exchangers area to increase
  efficiency of chiller system
• Avoid allowing cooling towers on standby. Use
  VSDs to run all cooling towers if possible.

24
GP Options

• 7. Heating energy improvements
• Check combustion efficiency and adjust
• Clean soot, scale from tubes and firewalls
• Schedule boiler blow down on a required basis
  rather on a regular basis
• Set hot water temperature as low as possible
• Set boiler operating pressure as low as possible
• Avoid one large boiler operating only at part
  load use smaller boilers instead
• Have proper insulation (boiler, steam and water
  pipe, feed tank)

25
GP Options

• 7. Heating energy improvements
• Convert to more efficient fuel?
• Install energy efficient burners
• Use proper chemicals, demineralise and deaerate
  water
• Use, maintain steam traps
• Recover energy if possible

26
Heat Recovery System

• Without heat recovery system

Steam
Boiler
Feed water 30oC - 70oC
Combustion air 30 oC
Exhaust gas (220 - 280oC) discharged to atmosphere
27
Heat Recovery System

• With heat recovery system

Steam
Exhaust gas 120 -140 oC
Boiler
Combustion air 30 oC
Preheated combustion air
and/or
Preheated Feed water
Feed water 30 - 70 oC
Exhaust gas (220 - 280oC)
28
Heat Pipes
Vacuum
Inner surface of heat pipe
Sealed at both ends
Outer surface of heat pipe
Working fluid
29
Heat Pipes
Combustion air/feed water
Combustion air/feed water
Gap between heat pipe
Condensing end
Evaporating end
Flue gas
Flue gas
30
Heat Pipe Heat Exchangers
31
Heat Pipe Heat Exchangers
32
Heat Pipe Heat Exchangers
33
Case Study I

• Basic operation information of food industry
  company

34
Case Study I

• Before and after installation of heat recovery
  system

35
Case Study I

• Before and after installation of heat recovery
  system

36
Case Study II

• Basic operational information of a packaging
  company

37
Case Study II

• Before and after installation of heat pipe heat
  exchanger

38
Case Study II

• Before and after installation of heat pipe heat
  exchanger

39
Conclusions
Less Energy, More Wealth
Good for the Environment, Good for the
Bottomline !