School of Aerospace, Mechanical and Manufacturing Engineering Climate Change Seminar: Australian Industry Group, 15 Nov 2007 RMIT-NORTHLink Greenhouse Challenge Support Program Dr John Andrews

Deep cuts (at least 60% compared to 1990) in greenhouse gas emissions by 2050 are now seen as essential to avoid catastrophic climate change globally nationally by each company/organisation individually

A Commonwealth Government cooperative program with industry to encourage greenhouse gas abatement

The Australian Greenhouse Office has provided funding over the past four years for RMIT and the northern region’s business network, NORTHLink, to help firms in Melbourne’s north reduce their greenhouse gas emissions

RMIT-NORTHLink Greenhouse Challenge Support program  Opportunity for fourth-year Bachelor of Mechanical Engineering students, and Master of Engineering (Sustainable Energy) students, to conduct research projects with companies in Melbourne’s north on cutting energy use and greenhouse gas emissions

Companies involved in 2007  Caterpillar  City of Darebin  Foster’s Brewing Group  Honda  Orica  Riotinto  South Pacific Tyres  Yarra Trams  Edlyn Foods  Hotel Sofitel  Moreland Energy Research Foundation  RMIT Property Services

Companies involved in 2006:  P&O Ports  RMIT Property Services  The Age Print Centre  Wentworth Furniture  Yarra Trams  Armstrong World Industries  Bostik  GWA Intl/Caroma  City of Hume  Greer Industries  Hilton Melbourne Airport

Companies involved in 2004 and :  Air International, Armstrong World Industries, Autoliv, ED Oates, Greer Industries, Kangan Batman TAFE, Northern Hospital, Noteprinting Australia, Original Juice Co., Sutton Tools, Venture Industries, Yarra Valley Water 2005:  Autoliv, City of Whittlesea, Marsden and McGain, RMIT (Property Services), Schiavello Commercial Interiors, Sealed Air Cryovac, Yarra Trams, Yarra Valley Water

2006 Program was a huge success! The participating firms will:  save up to $3 million/year  cut their emissions of carbon dioxide by more tonnes/year if they implement the recommendations made by the 11 B Mech Eng and 6 M Eng Sustainable Energy students involved in the program.

The Northern Hospital Epping, Victoria Student: Tom Doherty and Low Eng Wah Project Aim:  To reduce energy used for water and space heating  Solar water heating  Economisers for boilers

The Northern Hospital: Outcomes 1  Flow control valves could cut hot water consumptions by 35%, and greenhouse emissions by 70 Tonnes CO 2 -e/year  Solar water heating plus demand management would save an additional 58 tonnes/year  Total emission reduction ~1% of hospital’s total  Total investment: $  Payback period: Flow control valves - 2 years; solar water heating – just over 10 years

The Northern Hospital: Outcomes 2  Installation of an economizer on the main boiler supplying hot water for both space and domestic water heating would reduce total emissions by up to 60 Tonnes/year  Capital cost $  Payback period ~5 years

Note Printing Australia Ltd (Cragieburn, Victoria)  A global producer of currency and security products supplying Australia with polymer currency and passports.  Alex Kim project: –Reduce emissions by cutting spoilage rate –Rationalise boilers

Note Printing Australia Ltd: Outcomes  Reduce spoilage rate from 15% to 5%  Cut greenhouse gas emissions by ~ 70 Tonnes CO2-e /year, plus additional reductions due to lower usage of inks and polymer substrate  Capital cost $1.3 m, annual savings ~$3 m  Payback: less than 6 months

Sealed Air - Cryovac - International  World leader in global manufacturing of food packaging plastics.  Operate in 51 countries over 100 manufacturing plants, approximately 17,600 employees.  Inventors of Bubble Wrap ®  Students: Stuart Sisley and Brett Gillespie

Barrier Bag Manufacture Blowing /Racking Process 18 blowing / racking machines Staples used for joining

Sealed Air Cryovac: Outcomes  New heat sealing method reduces annual greenhouse gas emissions by 1900 tonnes (~2% of plant total)  Capital cost: $  Annual savings from reduced energy consumption and waste - $1.04 million  Simple payback period - 1 month

 Student: Tasman Higgins  Reducing diesel fuel consumption and greenhouse gas emissions of straddle carriers P&O Ports: West Swanson Terminal

P&O Ports: Outcomes  Limiting the over-lifting of containers reduces greenhouse gas emissions by approximately 150 tonnes annually  Installing limit switches to each machine: $7,500  Annual fuel saving $80,000  Payback period: just over one month

ORICA LAVERTON PLANT  Produces chlorine through electrolysis –High electricity consumption –Emissions well over tonnes/y –produces hydrogen gas as a by-product  Student: Andrew O’Dea  Using vented hydrogen for electricity prodcution and heat

Greenhouse gas reduction options Utilise wasted hydrogen to offset electricity and gas consumption by: Utilise wasted hydrogen to offset electricity and gas consumption by: –producing electricity through:  a fuel cell, or  a gas turbine generator –reducing natural gas usage by fuelling the boiler with hydrogen

PEM hydrogen fuel cell  Electrochemical device (no burning)  Latest technology  No CO 2 emissions  Produces electricity and hot water

Hydrogen-fuelled gas turbine generator  Turbo shaft engine driven AC generator  2000 kg/h steam generation  Electricity generation  No CO 2 emissions

Potential savings Annual CO 2 reduction Payback period Fuel cell ~ tonnes ~ 5 years Gas turbine ~ tonnes ~ 3 years

Solar Lighting at Tram Stops for Yarra Trams: Student: Andrew Devene

Yarra Trams: Outcomes Environment Environment  Potential Greenhouse Gas Emission savings:  328 kg CO 2 -e/yr/light  335 tonnes CO 2 -e/yr (60% of Network) Financial Financial  Estimated Annual energy bill savings ($0.08/kWh):  $60/year/light  $60,373/year (60% of network) Social Social  Increased community awareness of Sustainable Energy Options  Increased security & safety Yarra Trams

To participate in the RMIT- NORTHLink Greenhouse Challenge Support program next year  Must be a Greenhouse Challenge Plus member  Contacts: Dr John Andrews, SAMME RMIT University Ph:  John Wyett, Australian Greenhouse Office: ;  Mick Butera, NORTHLink, ;