Robert Williams Chief Energy Efficiency and Climate Change Unit UNIDO Industrial System Energy Efficiency An Overview

Industrial Systems  For this discussion, the term “industrial system” refers to motor-driven or steam systems found in virtually all factories  Globally, motor-driven systems consume more than 70% of global manufacturing electricity (2564 billion kWh) annually 1  Both markets and policymakers tend to focus on motor system components, which typically offer a 2-5% efficiency improvement potential  But the optimization of motor systems offer a 20-50% efficiency improvement potential  Similar savings opportunities also exist for steam systems 1 based on analysis conducted by Lawrence Berkeley National Laboratory, Alliance to Save Energy, and Energetics July 2004, updated by LBNL 2005

Elements of System Optimization  Evaluating work requirements  Matching system supply to these requirements  Eliminating or reconfiguring inefficient uses and practices (throttling, open blowing, etc)  Applying sophisticated control strategies and variable speed drives that allow greater flexibility to match supply with demand  Identifying and correcting maintenance problems

Optimizing a Motor System 15 kW Motor Efficiency is ~ 91% Measured electrical data Nameplate data: Information courtesy of Don Casada, Diagnostic Solutions, LLC

Expanding the Box to include the pump Pump head: 36 m Flow rate: 97.6 m 3 /h => hydraulic power: 9.6 kW Combined pump and motor efficiency = 59%

Expanding the box still further – to include the discharge valve There is > 28 m pressure drop across the throttled valve Useful hydraulic power = 2.1 kW Actual System Efficiency is only 13%

Energy Wasted in Pump System

The Challenge of Energy Efficiency If you don’t have a method to measure it and you can’t see it, how can you manage it? Well-run plant responds to overheated motors caused by poorly controlled pump system

Energy savings from Systems improvements. System /facility Total Cost $US Energy savings kWh/y Payback Period Compressed air/forge plant 18,600150, years Compressed Air/machinery 32,400310, years Compressed air/tobacco 23,900150,0002 years Pump system/ hospital 18,60077,0002 years Pump system/ pharmaceuticals 150, M1.8 years Motor systems/ petrochemicals 393, M0.5 years

Why aren’t industrial systems more energy efficient?  Industrial markets focus on components, not systems  Energy efficiency is not core mission for most industries  These are supporting systems- production practices can deeply affect their operation, but are outside of the facility engineer’s control

Additional barriers to efficiency  Most industries have a budgetary disconnect between capital projects (equipment purchases) and operating expenses (energy and maintenance)  System optimization knowledge resides with the individual who has been trained- it is not institutionalized  Trained individuals leave or transfer and take this knowledge with them  Processes change over time and inefficiencies can re-occur How can system energy-efficiency be maintained in this complex, changing environment?