1. NOVO ETS IMPROVING YOUR ORGANIZATIONS’ ENVIRONMENTAL, HEALTH AND SAFETY PERFORMANCE ENERGY MANAGEMENT IN THE CONTEXT OF GREEN PRODUCTIVITY

2. 2 SCOPE Productivity & Energy Management Productivity & Energy Management Green Productivity Green Productivity Energy Efficiency Concepts Energy Efficiency Concepts Case Studies Case Studies Conclusion Conclusion

3. 3 ENVIRONMENT

4. 4

5. 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. Productivity = OUTPUT INPUT

6. 6 PRODUCTIVITY OUTPUT Productivity = OUTPUT INPUT

7. 7 PRODUCTIVITY OUTPUT INPUT Wastes Productivity = OUTPUT INPUT Natural Resources Resource Productivity

8. 8 What is Green Productivity ?

9. 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: 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 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. 10  Ultimate aim of an energy management programme is to enhance an organisation’s 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 = Output Input Input Using less energy to do the same amount of work will mean more productive! What is Energy Management?

11. 11 Energy Management Provides Numerous Benefits Reduced operating costs and increased competitiveness Reduced operating costs and increased competitiveness Improved productivity Improved productivity Attractive returns on investment Attractive returns on investment Environmental benefits Environmental benefits Organisation becomes more resilient towards increasing fuel prices Organisation becomes more resilient towards increasing fuel prices

12. 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. 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. 14 GP Methodology

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

16. 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. 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. 18 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 GP Options

19. 19 3. Turn it off when not in use GP Options

20. 20 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 GP Options

21. 21 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 GP Options

22. 22 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 GP Options

23. 23 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. GP Options

24. 24 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) GP Options

25. 25 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 GP Options

26. 26 Heat Recovery System Feed water 30 o C - 70 o C Steam Combustion air 30 o C Exhaust gas (220 - 280 o C) discharged to atmosphere Boiler s Without heat recovery system

27. 27 Heat Recovery System s With heat recovery system Exhaust gas (220 - 280 o C) and/or Preheated combustion air Feed water 30 - 70 o C Preheated Feed water Combustion air 30 o C Steam Exhaust gas 120 -140 o C Boiler

28. 28 Vacuum Inner surface of heat pipe Outer surface of heat pipe Working fluid Sealed at both ends Heat Pipes

29. 29 Heat Pipes Condensing end Gap between heat pipe Flue gas Evaporating end Flue gas Combustion air/feed water

30. 30 Heat Pipe Heat Exchangers

31. 31 Heat Pipe Heat Exchangers

32. 32 Heat Pipe Heat Exchangers

33. 33 t Basic operation information of food industry company Case Study I

34. 34 t Before and after installation of heat recovery system Case Study I

35. 35 Case Study I t Before and after installation of heat recovery system

36. 36 t Basic operational information of a packaging company Case Study II

37. 37 Case Study II t Before and after installation of heat pipe heat exchanger

38. 38 t Before and after installation of heat pipe heat exchanger Case Study II

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