energy efficiency in industrial and commercial facilities 2003 energy and environmental conference...
TRANSCRIPT
Energy Efficiency in Industrial and Commercial Facilities
2003 Energy and Environmental ConferenceSeptember 16, 2003
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Energy management
Effective use of energy to maximize profits (minimize costs) and enhance competitive positions
Reduce energy use per unit output
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Energy Management
Use energy wiselyOptimizeImplement selected projectsMaintenanceBe proactiveHave energy efficiency program
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Energy Efficiency Program
Management EndorsementForm a TeamEstablish ObjectivesDevelop the Communications PlanImplement The ProgramTrack ProgressEvaluate
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Benefits
Reduced energy and operating costs. Full understanding of energy usage, requirements, and savings.Prolonged Life of Equipment
Reduced Operational & Maintenance Expense
Reduced Consumption of Natural Resources
Improved Air Quality and the Environment
Reduce Emissions
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Energy Baseline
Establish the baseline for the energy elements• Electric • Gas• Water• Others
Establish data collection guidelinesPerform Statistical AnalysisDetermine the cost per unit energy consumed
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Implementation
Conservation Program• Weekend and Holiday Shutdowns• Demand limiting shutdowns (manual or automatic)
Facility Improvement Program• Energy conservation projects• Pay-backs on energy savings alone
frequently provide only marginal justification for a project
• Planning energy conservation projects in conjunction with major renovations
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0
50
100
150
200
250
300
350
1000 B
tu/sq f
t
Commercial Buidings-Annual Energy Usage
1000 Btu/sq ft 86.8 172.9 308.6 150 111.7 113.3 52.1 51.3
EducationFood
ServicesHealth Care
Lodging OfficePublic
AssemblyReligious Worship
Warehouse &
Storage
Data obtained from U.S. DOE
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Space Heating
35%
Miscellaneous
13%
Office Equipment
4%
Lights
21%
Hot Water
16%
Space Cooling
11%
Commercial Energy Use
Data obtained from U.S. DOE
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Industrial Energy Use
Steam
31%
Cogeneration
13%Mach.
Drive/Electric
19%
Heat
37%
Data obtained from U.S. DOE
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Energy Saving Opportunities
Lighting Systems Upgrade• Fluorescent T12 vs. T8• 400 W MH vs. 360 W MH• Controls (sensors or programmable panels)
HVAC• Install controls for more efficient operation• Reduce conditioned air leakage• Utilize free cooling during spring & fall months• VFD for large fans• Shut down units when facility is unoccupied• Minimize exhaust
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Annual Cost of LightingEnergy Cost of 200 Watt light
HRS/ Day 12 24Days/ Week 4 5 6 7 4 5 6 7Cost/ kWh
$0.01 $5 $6 $7 $9 $10 $12 $15 $17$0.02 $10 $12 $15 $17 $20 $25 $30 $35$0.03 $15 $19 $22 $26 $30 $37 $45 $52$0.04 $20 $25 $30 $35 $40 $50 $60 $70$0.05 $25 $31 $37 $44 $50 $62 $75 $87$0.06 $30 $37 $45 $52 $60 $75 $90 $105$0.07 $35 $44 $52 $61 $70 $87 $105 $122$0.08 $40 $50 $60 $70 $80 $100 $120 $140$0.09 $45 $56 $67 $79 $90 $112 $135 $157$0.10 $50 $62 $75 $87 $100 $125 $150 $175
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2002 Degree Days
0
200
400
600
800
1000
1200
Deg
ree
Day
s
Heating D.D. 992 891 929 480 342 21 0 0 38 481 766 1119
Cooling D.D. 0 0 0 30 23 203 364 257 161 23 0 0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Free Cooling Period
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Energy Saving Opportunities (continued)
Compressed air systems Upgrade• Install controls to eliminate blow-offs• Reduce system pressure• Repair leaks
Utilization of waste heat • Pre-heat boiler make-up water• Space heating
Insulation• Building (walls, roofs, doors etc.)• furnaces, ovens or parts washers• Exposed Steam & Condensate pipes
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$0
$50,000
$100,000
Ann
ual
Loss
es
Hole Diameter, in
Comressed Air Leak Losses at 100 psig(24 hr/ day, $0.17/ MCF)
Losses $580 $2,323 $9,293 $20,908 $37,081 $83,455
1/ 16 1/ 8 1/ 4 3/ 8 1/ 2 3/ 4
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Energy Saving Opportunities (continued)
Steam leak reductions
• Steam traps• Condensate return stations
Boiler Systems
• Increasing Condensate Return• Eliminating leaks to make-up systems• Reduction in blow downs
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(Gas $5/MCF, Coal $45/ton)
$0
$10,000
$20,000
$30,000
$40,000
A
nn
ual
Loss
es
Hole Diameter, in
Steam Leak Losses at 100 psigFor Gas & Coal Boilers
Gas Boiler $621 $2,482 $9,929 $22,341 $39,717
Steam Boiler $265 $1,060 $4,239 $9,537 $16,955
1/ 16 1/ 8 1/ 4 3/ 8 1/ 2
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Quality Management System
Commitments to energy efficiency initiatives can be included in QMS ISO 9000 and ISO 14001 QMS are effective in the implementation of energy efficiency program since the QMS has; • Procedures• Continuous improvement• Corrective and Preventative Actions• Root Cause Analysis
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Energy Efficiency and the Environment
The wise energy use help protect the environment• Reduce carbon dioxide (CO2)emissions• CO2 is the key greenhouse gas responsible for global
warming • CO2 emissions comes from burning fossil fuels, such
as oil, coal and gas• Burning fossil fuel causes emissions of other
greenhouse gases, such as• Methane (CH4) and• Nitrous oxide (N2O)
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Case Studies
Energy Efficiency projects for selected • Manufacturing, • Commercial buildings and • Power plant
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Manufacturing A
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Power Factor Correction $3,600 $4,565 1.27Compressed Air Pressure Reduction $1,400 $0 0.00
Compressed Air Leaks $2,800 $500 0.18
Lighting $7,689 $41,625 5.41
Total $15,489 $46,690 3.01
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Manufacturing B
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Lighting Replacement, Admin Bldg $52,824 $205,529 3.89
Lighting Fixtures Reduction $59,615 $0 0.00
Water Consevation $82,500 $0 0.00
Air Conditioning Units Retrofits $149,061 $620,000 4.16
Totals $344,000 $825,529 2.40
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Manufacturing C
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Install blower system to replace compressed air header $36,000 $44,300 1.23
Replace and retrofit plant lighting (T12 to T8) $42,473 $293,030 6.90
Totals $78,473 $337,330 4.30
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Manufacturing D
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Replace 74 HID lamps with 2-lamp fluorescent $6,638 $9,408 1.42Install four VFD control on multi-pump configuration. $223,913 $60,000 0.27
Totals $230,551 $69,408 0.30
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Hotel
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Lighting $25,180 $11,330 0.45
Steam Trap Replacements $32,459 $64,500 1.99
Heating & Cooling $256,670 $690,000 2.69
Totals $314,309 $765,830 2.44
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Office Building A
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Electric Curtailments $179,222 $0 0.00
Lighting Fixtures Replacements $63,487 $212,733 3.35
HVAC $163,266 $239,242 1.47
Totals $405,975 $451,975 1.11
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Power Plant
Project DescriptionTotal
savingsProject
Cost
Simple Payback (years)
Lighting Curtailments $10,200 $0 0.00
Replace T12 to T8 fluorescent fixtures $25,575 $93,750 3.67Reduce control air header pressure from 100 psig to 85 psig. $12,750 $0 0.00
Repair compressed air leaks $33,750 $7,000 0.21
Night Setback $2,000 $1,000 0.50
Totals $84,275 $101,750 1.21
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The Importance of Energy Efficiency Program
Effective management toolCommunicates:• scope, • structure, • budget, benefits and timing to management
and peersEstablishes the energy baselineDocuments growth expectationsReduce raw material and energy use per unit output
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Energy Efficiency Means
Doing the Same ~or More~
With Less Energy
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