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U.S. Brazil Collaborative Program E3

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What is E3

• E3 stands for Energy, Economy, Environment• E3 is a coordinated initiative that is designed to

help communities work with their manufacturing base to focus on and offer solutions for improved sustainability.

• E3 provides manufacturers with customized hands on assessments of production processes which identify opportunities in the areas of:– energy consumption reduction– carbon footprint minimization– pollution prevention – production efficiency – business growth – business costs

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Typical E3 Schedule

• 11 Weeks to complete assessment

• 6 months of follow up to facilitate implementation metrics

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PILOT COMPANIES AGGREGATED RESULTS

Identified recurring savings - Annualized

Energy Savings - $1.7 MM

Environmental Savings - $2.6 MM

Lean Savings - $1.033 MM

Water pollutants avoided – 257,000 pounds

CO2 emissions avoided – 19,000 tonnes

SOx Reduction – 215 tonnes

Solid waste reduction – 24,000 pounds

Realized savings – Annualized

$1,050,000 implemented or committed since project began – about $175,000 per company

9,457 tonnes of GHG avoided annually

E3 Results: Columbus Ohio Pilot

TechSolve has conducted six additional assessments since the beginning of 2010 and has received a contract for as many as 25 additional assessments

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GROUPS involved in 2010 E3 Assessment

Evaluation Methods / Templates

Contacts for program continuation

E3 Training

Initial E3 Evaluations

Program Guidance

E3 Program Continuation

in Brazil

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E3: BRIC Observation Exercise

During the week of September 27th, a total of eight individuals [delegation], four from Eletrobras, two of the Federal Universities and two of the SEBRAEs (similar to US SBA) observed an E3 evaluation at Vertis Communications [manufacturer], a 220 employee commercial printing facility with a demand of 3000Kw, served by AEP Ohio.

The evaluators were from the DOE’s Industrial Assessment Center located at the University of Dayton and the DOC’s Manufacturing Extension Partnership, TechSolve.

During the October 1st meeting, participants included representatives from the delegation, USEPA, USDOE, AEP, Duke Energy, Vertis Communications and NIST MEP.

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E3: Vertis Communications - Energy

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Observing, Analyzing, Brainstorming…The Brazilian Delegation partakes in an E3 evaluation at Vertis Communications

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E3: Vertis Communications - Energy

Exemplary practices identified: 8

Energy savings opportunities identified: 23

Key potential savings:– Use compressor waste heat for seasonal heating– Install variable speed drives on trim collector fans to reduce

motor energy and heating costs– Use existing heat exchanger and cooling tower to reduce chiller

run time in cold weather– Use heated regenerative thermal oxidizer exhaust

• vent air for dryers• power generation using organic Rankine cycle

– Filter and return trim exhaust air to building

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E3: Vertis Communications Economy and Environment

Two day value stream map event

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E3: Vertis Communications Economy and Environment

Waste walk

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E3: Vertis Communications Economy and Environment

Improvement opportunities: 39

Just do its: 11

Key potential savings:– Improve paper acquisition logistics– Reduce packaging losses – Improve layout and material handling – Improve dust control– Investigate key process changes

• UV inks• Digital press for small runs

Brazilian delegation became part of assessment team and offered suggestions and recommendations

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Premise & method: Energy evaluations will identify savings available from energy efficiency improvements and waste minimization. This is accomplished through using data, engineering methods and detailed analysis. Manufacturers will be provided performance improvement estimations and payback times.

Delegation experiences & conclusions:

•Multi skill set integrated approach (University perspective)

•Quick solution for manufacturers

•Manufacturer was engaged

•Combination of utility, university, consulting company worked well

•Focus on client needs and perspective

•Integrated several engineering disciplines

E3: Energy Evaluation (feedback)

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Premise & method: Energy evaluations will identify savings available from energy efficiency improvements and waste minimization. This is accomplished through using data, engineering methods and detailed analysis. Manufacturers will be provided performance improvement estimations and payback times.

Manufacturer experiences & conclusions:

•Facilitation was a plus

•Participation of delegation from Brazil

•Trained and experienced facilitators was invaluable

•Fresh set of eyes was beneficial

•Financial results appear consistent with pilot values

E3: Energy Evaluation (feedback)

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Premise & method: This review evaluates a manufacturer for potential areas of waste in manufacturing processes. This is accomplished through reviews performed by walkthroughs, interviews and process mapping.

Delegation experiences & conclusions:

•Collaborative approach including manufacturer

•Done with customer not to customer•Motivation for implementation – ownership of results

Manufacturer experiences & conclusions:•Helping Vertis to help itself•Enabled Vertis to see the waste•Limited staff – normally no resources for this type of event

•Lean and clean opportunities consistent with pilot results

E3: Lean and Clean Review (feedback)

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Premise & method: A third component of the E3 evaluation is the training of the manufacturer on how to calculate their GHG emissions. In addition to the training, documents are provided to assist the manufacturer in planning the reduction of these emissions.

Baseline carbon footprint will be done post event.

Delegation experiences & conclusions:

The GHG Emissions training portion of the E3 evaluation was not observed by the delegation.

•Considered absolutely important•Need training on tools•Needs adaptation, but tool is very flexible

Manufacturer experiences & conclusions:

•Is an important component that requires follow up and subsequent calculations & data entry into EPA spreadsheets

E3: GHG Emissions Training (feedback)

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•The delegation, with Eletrobras as both a company and the Brazilian agency mandated for Energy Efficiency program implementation, believes E3 BRIC will be a valuable addition to its portfolio of actions to improve its commercial and industrial electricity users’ efficiency and environmental performance.

•Eletrobras sees this as an opportunity to gather partners and further expand energy efficiency policies and activities in Brazil.

•Vertis Communications is pleased to know how it can become more energy efficient and reduce its environmental footprint. Vertis recommends that other Commercial and Industrial electricity users participate in the E3 program.

•US Federal agencies recognize this week’s progress and will assist and support the furtherance of E3 programs as appropriate.

Conclusions – Vertis Assessment

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Delegation Questions Addressed During October 1st Meeting

1. What is the E3 business model:- what are the costs? Who pays what and whom?- what are the results to date?- what is the overall cost-effectiveness?- what is the overall E3 workflow?Brazil already has the technical expertise.

2. What is the relevance of E3 in the E8?

3. Can you suggest ways for funding for the pilot project in Brazil?

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Overall view of E3

• Integrates multiple approaches.

• Clearly benefits all the players involved (a win-win relation).

• E3 is technically feasible in Brazil with some adjustments to the local reality.

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• E3 evaluation observation by Duke team in Ohio – June

• E3 evaluations by Duke/Eletrobras team in Brazil – August

• Additional training as necessary for Eletrobras team – August

• E3 program continuation by Eletrobras

E3: BRIC Next Steps

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• Kelly Kissock – University of Dayton• Perry Stephens – Duke Energy • Greg Hume – TechSolve, Inc.

5 August, 2011

E3 Assessment of

Whirlpool - Manaus Facility

E3 Assessment of

Whirlpool - Manaus Facility

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E3 Timeline

2009: Pilots in Ohio and Texas

2010: Brazilian delegation observes E3 assessment in US

2011: Programs in 21 states

2011 Pilot assessment in Manaus, Brazil

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Project Team

Senior Engineers

Carlos Aparecido Ferreira, Eletrobras

Carlos Henrique Moya, Eletrobras

Marcella Fuchs Salmao, Eletrobras

Fernando Pinto Dias Perrone, Eletrobras

Marcio Americo, Sebrae-RJ

Jurimar Collares Ipiranga , Eletrobras Amazonas Energia

Sergio Meirelles Pena, Cepel

Greg Hume, TechSolve

Perry Stephens, Duke Energy

 

University Energy Engineers

Rogerio Diogne de Souza e Silva, Federal University of Para

Vitor da Silva Kataoka, Federal University of Para

Antonio Carlos Picanco Jr, Federal University of Para

 

Energy Team Leader

Kelly Kissock, University of Dayton

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Energy Assessment Methodology

• Establish Energy Baseline

• Identify Savings Opportunities

• Quantify Savings Opportunities Using Measured Data and Energy Engineering

• Report Results

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Annual Savings by System

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Overall Simple Payback: 7 months

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Total Savings: 18.6% of Plant Energy

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Lessons Learned

• Teams of energy engineers with University students can work with manufacturers over a short period to identify and quantify significant energy savings with good returns on investments.

• Most energy saving opportunities are in energy end-uses, not motors and electrical systems.

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Lean and Clean Process Review

Work with plant operations

personnel to identify:

•Process steps

•Material & energy input

•Process wastes

•Process issues

•Improvement ideas

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Exemplary Practices

Kaizen Shop

Visual management

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Exemplary Practices

Robust recycling programWastewater management

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Observations

Distribution piping

Disposition of EPS

Excessive conveyor wear

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Value stream map

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Economy & Environment recommendations

Annual savings GHG reduction - tonnes

090 Reconfigure shop floor into U shape x

100 Recuperative burners on paint oven x x

100 Solar hot water for wash water and sanitary uses x x

100 Use waste heat from oven exhaust to preheat cleaning solution x x

110 Capture H2 N2 test gas x Indirect

110 Eco-friendly refrigerant Puron, R410A ? x

130 Evaluate better handling technology to replace conveyor x X

130 Limit switch to stop conveyor motor x

990 Design for disassembly x x

990 DEVap process ? 350,000 tonnes

990 Redesign of packaging - assume 50% savings on first cost Very large

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NREL: Desiccant-Enhanced eVaporative (DEVap)

Timeline:•2010: Technology announced

- Membrane based- Uses liquid desiccant – no CFC/HCFC- 50-80% energy reduction vs. refrigeration technology

•2011: Prototypes in production•2015: Large CO2 reduction?

Recommended action:•Contact DOE to determine availability of technology

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Whirlpool Reaction

The Whirlpool Plant Manager expressed his appreciation for the energy savings identified by Dr. Kissock’s team and noted that this was a welcome roadmap to help Whirlpool, Manaus continue to compete in the global marketplace.

He also noted that the DEVap technology might be a way for Brazil to move much of the manufacturing work back to Manaus from China.

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FOR MORE INFORMATION

www.procelinfo.com.br

THANK YOU

FERNANDO PERRONE