Best Practices Energy Effeciency Masonite Chile March 2011

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Masonite Chile

Best Practices

Energy Efficiency

March 2010

Francisco Mora AmsticaMechanical Engineer

Engineering Department of Masonite Chile


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Masonite Chile S.A. BestPractices Energy Efficiency

F.M.A. March 2011 2

Masonite Chile BestPractices

Energy Efficiency

Energy can be neither created nor destroyed, it can only be misused

Summary

The need to increment energy generation and use efficiency, generates opportunities of

cooperation among companies. Best Practices also allow sharing continuous improvement

programs experiences, contribute with energy policies, participate in sustainable energy

development and lead companies into a socially responsible operation.

For Masonite Chile applying an Energy Efficiency program has allowed a 40% reduction in

the electric energy consumption, granting a financial benefit over 500.000 US$ annually.

Energy Efficiency must not only be related with electric energy consumption, but it must

be a part of a global concept for Industrial Best Practices.

Introduction

Energy is a topic of significant relevance for industrial activity; it is a strategic supply for

any company, so Energy Efficiency must be an integral part of any company performance

optimization effort. The industrial sector consumes 23% of the total energy in Chile

(Source: C.N.E.)

Energy can be defined from a variety of approaches; anyway all of them have some kind of

relationship. Energy allows transforming different raw material into final product and by

being properly used; it contributes to generate a non contaminated, emission free

environment. In the panel manufacturing process, energy is associated to the physical

mechanic transformation, such as raw material washing, transport and refining or to

physical chemical changes as resin curing in the press and paint curing in finishing

process. Energy is also use in the waste water treatment process, such as physical

chemical changes in the cells electrocoagulation during Primary Treatment. Appendix N5shows energy consumption distribution in Masonite Chile S.A.

Nevertheless, Energy is found interrelated with equipment and machinery that turn

energy into a final product. These equipments have certain efficiency due to thermal or

mechanical irreversibilities, internal or external. The efficiency is the ration between

useful works obtained and consumed work, so for producing the same product, same


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F.M.A. March 2011 3

quality, you could manufacture it consuming more o less energy depending on the

operation and the equipment used.

All the actions that allow optimizing the relationship between amount of consumed

energy and the final products obtained are called Energy Efficiency(E.E.).

Masonite Chile S.A. has chosen to develop and openly inform the Best Practices concerning

the efficient use of Energy.

Benefits of an E.E. program are well-known, such as, environmental benefits by reducing

greenhouse gases emissions; economic benefits by reducing specific costs; strategic

benefits at national levels by reducing dependency from foreign energy sources and

commercial benefits by producing environmental friendly assets which allow entering into

most demanding markets.

The Best Practices task must be undertaken by a multidisciplinary group of people withinthe industry. Maintenance, production, finances, engineering and general management

areas, should not be away from this task, and should compromise to apply this E.E.

management methodology.

Taking into consideration that fundamental energy flows are heat cycles and mechanical

power, the issues to concentrate on an E.E. program, can be divided into two areas:

thermal area (ex.: combustion control, steam generation, heat exchanger, thermal

equipment insulation, air conditioning system, etc.) and the area of power transmission

equipment (ex. Turbo machinery, mechanical transmission equipments, compressed air,

etc.)

Motor-driven equipment accounts for 64 percent of the electricity consumed in the

industrial sector (Source: U.S. Department of Energy)


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F.M.A. March 2011 5

Projects from EE Program used in Masonite Chile

Working with a multidisciplinary team along with the utilization of an EE Program led us to

develop a series of projects and optimizations in the process.

The next chart shows a summary of projects carried out. Savings are expressed in reducedpower in kW and also in US$/year. Examples of the main projects development are shown

in appendix No.1

ID Project Improvement Power Saving Investment Savings Payback

1Process Optimization: fiber transport fan in forming

line

Suction fan damper head loss decreased (change

speed of rotation by pulley) 20 kW 780 US$ 12.624 US$ 0,06

2Process Optimization: induced circulating fan (flue

gases from heat exchanger chamber)

Suction fan damper head loss decreased (change

speed of rotation by pulley) 10 kW 1.240 US$ 6.312 US$ 0,20

3Decreased Consumption: Optimizing air conditioning

system for office

Timer installation to turn on & off air conditioning

equipments. 3 kW 250 US$ 1.894 US$ 0,13

4Process Optimization: painting booth extractionsystem

Elimination of one filter bag. Joint of the extractionsystem into only one filter bag. 18 kW 2.160 US$ 11.361 US$ 0,19

5Process Optimization: fan detention After several industrial trails, stop some

equipments did not alter normal production 104 kW 0 US$ 65.327 US$ 0,00

6Decreased Consumption: compressed air Reduction in air compressed consumption

100 kW 6.000 US$ 63.118 US$ 0,10

7Equipment s efficiency increasing: Lightning study Upgrade to high efficiency lightning

49 kW 5.000 US$ 30.928 US$ 0,16

8Process Optimization Press hydraulic pumps units Operational and press control changing

50 kW 0 US$ 31.559 US$ 0,00

9Process Optimization: Cleaning system in forming line Fiber dust extraction system modification

50 kW 4.500 US$ 31.559 US$ 0,14

10Process Optimization: panel humidification process Water diminishing consumption. Pump changing

17 kW 2.500 US$ 10.730 US$ 0,23

11Rotation velocity reduction: Dust extraction system

Door assembly plant

Recalculation extraction system. Calibration

extraction system 40 kW 2.000 US$ 25.247 US$ 0,08

12Process Optimization: Cooling system press hydraulic

unit

Recalculation coolant flow for hydraulic oil. Pump

replacement. 11 kW 2.500 US$ 6.943 US$ 0,36

13Process Optimization: belt conveyors in coating line Unification in a drive system.

8 kW 10.000 US$ 5.049 US$ 1,98

14Process Optimization: Dryer fan Control system change. A variable-frequency drive

(VFD) installation 100 kW 10.000 US$ 63.118 US$ 0,16

15Process Optimization: Electrical motor efficiency study Oversized or under load motor changing

15 kW 10.000 US$ 9.468 US$ 1,06

16Process Optimization: ADI screen cleaning water

pumps

Piping modification, use only one pump7 kW 2.000 US$ 4.418 US$ 0,45

17Process Optimization:

Eliminate Z-Sifter & Forming using only one Pendistor

Engineering study to eliminate one Pendistor & Z-

Sifter 125 kW 50.000 US$ 78.898 US$ 0,63

18Process Optimization: Compressed air equipment Operational air pressure decreasing, use a VFD air

compressed equipment 38 kW 10.000 US$ 23.985 US$ 0,42


Refiner main motor

Change 1.6 MW motor for 2 x 250 kW in s eries

motors 40 kW 25.000 US$ 25.247 US$ 0,99


Several equipment rotation speed reducing

A variable-frequency drive (VFD) installation55 kW 40.000 US$ 34.715 US$ 1,15

21Alternative energy usage: from LPG oven to thermaloil oven

From LPG oven change to thermal oil exchangeroven 80 kW 35.000 US$ 30.000 US$ 1,17

22Process Optimization: water consumption reduction Water flow optimization

5 kW 500 US$ 3.156 US 0.16


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Results of EE Program in Masonite Chile

The results of an EE Program, must be clearly identified in the financial balance sheet of the

company.

An EE Program savings, usually have tangible results expressed in a reduction of the unitary cost of

production. In the case of electric energy, there must be a diminishing in the recorded consumed

energy and a reduction in the monthly electricity invoice. A representative from Finance area must

verify and assess reported savings. An EE Program, however, not only delivers hard savings, but

also gives soft savings, like improving environment and safety, equipment improved designs, lead

time optimizing, organizational improvement, etc.

For Masonite Chile, the EE program gave a US$666.626 savings for 2008 and a US$542.501 for

2009 in electrical energy, US$30.000 additional saving in LPG fuel. The difference in the saving

amount is due to the variation in the cost of the electrical energy for those years. (See the electric

energy cost variation in appendix No.2)

The following box plot charts show a reduction over 40% in the electrical energy consumption and

a 20% decrease in the specific energy consumption (kW-hr/skin). These variables are the main

metrics used in the result evaluation.

201020092008200720062005200420032002

2.5

2.0

1.5

1.0

0.5

ElectricalEnergyGW-hr

1.26 GW-hr

1.03 GW-hr

1.10 GW-hr

1.56 GW-hr

2.02 GW-hr2.10 GW-hr

2.07 GW-hr

1.92 GW-hr

1.88 GW-hr

Electrical Energy Consumption

Chart No.1: Annual Electrical Energy Consumption


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The box plot chart N2 shows the energy consumed per produced unit (skin). A decrease

of this factor during 2005, 2006 and 2007, is explained due to the high production level,

reaching 7,4 million units for 2006, so the specific energy differs in comparison with a 4,9

million units manufactured during 2009, so the use of specific energy significantlyimproved even with lower production. (See Annual Production appendix No.6)

It is clear that operational continuity of a plant, improves the energy demand per

produced unit. During 2008 and 2009, due to low sales and continuous press dressing

changes, it was not possible to run continuously, nevertheless specific energy

consumption still decreased.

201020092008200720062005200420032002

7

6

5

4

3

2

SpecificEnergyConsumptionkW-hr/skin

2.57

2.72

2.60

3.063.31

3.71

4.104.154.92

Specific Energy Consumption

Chart No.2: Specific Energy Annual consumption


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Conclusions

The principle saying that Energy can neither be created nor destroyed, it can only be

misused, fully applies to all projects carried out in Masonite Chile under the Energy

Efficiency Program. Inefficient use of energy can be attributed to oversized equipment

designs, unnecessary equipment, incorrect operational procedures, operational pressures

and temperatures over requirements and technological updates of equipment.

An EE Program is a task requiring continuous development, clear objective and actions

which require joint participation of government, industry and educational area.

Francisco Mora [email protected] (+56) (43) 404 400
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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APPENDIX No.1

Practical Cases Analysis

Project ID : #16

Type : Mechanical Power Transmission Process Optimization

Name : Eliminate Z-Sifter & Forming using only one Pendistor

Strategic Opportunity: Reduces energy consumption. Optimizes the process,

reduces or eliminates equipments (fans) in z-sifter area and

forming line.

Project description

The Z-Sifter is installed as an integrated part of the fiber transport system between the

fiber bin and the forming stations (Pendistor).

Z-Sifter was originally designed by the MDF industry for removal of foreign particles, such

as resin lumps, latex and wood splinters from the fiber stream. It was also designed for

separating fine and coarse fiber to feed two different forming stations.

Also, two forming stations (Pendistor) were originally designed for our plant, one for fine

fiber and the other one for coarse fiber.

After numerous laboratory analysis (fiber length analysis), it was concluded that the Z-Sifter does not separate fibers and Pendistors had the same fiber quality.

In the same way, after field tests, it was concluded that if we re-use the reject of the Z-

Sifter, there is no quality problems.

Justification.

Z-Sifter is a very convenient system for MDF process, but not necessary for primed boards,

primed hide foreign particles.

Due to elimination of Z-Sifter and associated components, we expect to save energy,

maintenance cost reduction and have extra spare parts such as frequency converters,

electrical motors, fire detection components, fans, etc., coming from eliminated

equipment.


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F.M.A. March 2011 10

Process Diagram

Original Improved

Implementacin de las mejoras.

Improvements implementation.


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Statistical verification of electrical energy savings


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Project ID : #18 - #19 - #20

Type : Mechanical Power Transmission Process Optimization

Name : Refiner main motor optimization. Compressed air equipment & fans

optimization

Strategic Opportunity: Reduce energy consumption.

Project description

The energy saving projects were developed in the refiner main motor, air compressor and

fans.

A speed-torque study and a starting timing for the 1,6 MW refiner main motor, was

carried out. It is concluded that it is oversize in relation to real charge load. The alternative

was replacing the 1,6 MW motor by a lower power capacity, matching the demands of the

process. A solution to install two 250 kW motor, mechanically connected in series, is

proposed and carried out.

An analysis concerning real power (kW) and air flow (lt/s) consumption for the air

compressors was carried out. The two originally installed air compressors, with an 802

(lt/s) nominal air flow and a 294 kW installed power, were not working according to their

nominal capacity, so working with only one compressor was enough. Additionally the

alternative to acquire an air compressor including a VFD (90 kW @ 284 lt/s) came up,

which was used to replace one of the old existing air compressors.

Finally all improvements implemented allowed to reduce the operating air pressure from

7.5 bar to 6.2 bar, thus reducing energy consumption.

Installing VFD in the motor was the option taken for the process controlled by damper or

throttle. Using VFD allows controlling fans or pumps rotation speed thus eliminating the

pressure drop caused by damper action.

Justification

Reduction of energy consumption and maintenance costs


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Improvements implementation.

Before After

Energy consumption KW-hr.

Before After Reduction

Compressed air 63.653 34.440 46%

Main motor 39.101 15.570 60%

VFD 50.210 22.801 55%

Total 155.829 73.269 53%

Statistical verification of electrical energy savings.


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Appendix No.2

Variation in the cost of electric energy

The electric energy cost for Masonite Chile until end of 2006, was 50 US$/MW-hr,

however from that date forward, the cost increased by 6 times by the end 2008 and has

varied according to the attached chart that shows the marginal cost tariffs and spot

pricing in the Chilean electric power sector in US$/MW-hr.

The electric energy cost has decreased due to new power supplier contracts; however is

still a main valuable input for our production.

0

50

100

150

200

250

300

350

Jun-05

Ago-05

Oct-05

Dic-05

Feb-06

Abr-06

Jun-06

Ago-06

Oct-06

Dic-06

Feb-07

Abr-07

Jun-07

Ago-07

Oct-07

Dic-07

Feb-08

Abr-08

Jun-08

Jul-08

Sep-08

Nov-08

Ene-09

Mar-09

May-09

Jul-09

Sep-09

Nov-09

Ene-10

Mar-10

May-10

Jul-10

Sep-10

Nov-10

US$/MW-hr


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Appendix No.3

Methods of the generation of Energy Efficiency Program

Previous actions:

Update process flow diagrams (PI&D) Selection of EE work team Select a Project Leader who reports directly to the GM and define responsibilities of areas.1. Definition

a. Making interdisciplinary meetingb. Establish clear and attainable objectivesc. Diagram analysis search process opportunities (VSM)d. Establish communication and information plane. Project planning (Gantt chart)f. Review progress of each stage

2. Measurementa. Develop a plan for collecting data and information. (power consumed by areas

and equipment, fuel consumption, etc.).

b. Definition of a metric (kW-hr/units, kW, etc.)c. Defining a baseline against metrics (average monthly consumption, etc.).d. Review progress of each stage

3. Analysisa. Identify, select and summarize the potential causesb. Prioritize the major causes (Pareto, FMEA)c. Identify and assess the impacts on processes because of the potential

improvements

d. Process capability analysise. Review progress of each stage


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4. Improvementsa. Development and evaluation of potential solutions for improvementb. Developing an implementation plan for improvementsc.

Balances of the process and engineering studies

d. Implement improvementse. Review progress of each stage

5. Controla. Information transfer production linesb. Standard Operating Proceduresc. Controlling and monitoring plan and process variablesd. Statistical Controle. Feedback session of the teamf. Review progress of each stage


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ANEXO No.4

Ideas for energy savings

Thermodynamics Area

Insulation of piping & equipment Insulating tanks and reactors Condensate steam recovering Regulatory purging of steam generators or boilers Analysis of amount of excess combustion air Continuous controls thermal efficiencies of equipment Review of the production process parameters (set point) Turning off equipment not in use Optimizing HVAC equipment Lightning Control Reducing processes operating temperatures Optimization of reverse osmosis plants Using alternative fuels

Power transmission area

oversized electric motors (less than 50% load) Control variable speed fans and pumps Changing transport system of raw materials (pneumatic conveyors systems for mechanical

conveyors)

Optimization of pneumatic conveying system Reduction of process pressures Reducing compressed air consumption Reducing process water consumption Improved suction pump system (pressure drop)


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Appendix No.5

Energy Data Masonite Chile S.A.

Installed electrical power : 6,271 MW.

Energy Plant : 16,07 MW 13,84 Gcal/hr.

The pie charts below shows the distribution of energy consumption in Masonite Chile


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Best Practices Energy Effeciency Masonite Chile March 2011