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Energy Management that makes TenCate Thiolon different.
Group 1
Ahme AbunadaCarlos Diaz
Jo-Ting HuangRafia Abdul-Samii
Xuan Gui
Master of Energy and Environmental Management, University of Twente
Energy Specilisation Case Study
Outline of the Presentation• Overview and analysis of energy management
• Energy management matrix and SWOT Analysis• Baseline data• Technical review
• Energy saving options• Renewable energy possibilities
• Energy saving action plan• Housekeeping options• Management review—planning at management level• Roadmap
Energy Management Matrix
Energy Management Matrix
SWOT AnalysisStrengths Clear visions: quality, sustainability,
well-being and safety A core energy management team CEO’s commitment and top
management’s support Technical review and baseline data of
energy consumption Open attitude to innovations,
research and development
Weaknesses Lack of long-term energy investment Machinery investment does not
consider energy efficiency High annual energy bill (1.7 million
Euro) High electricity consumption share in
total energy consumption
Opportunities Good image because of quality Market leader Energy audit and investment
appraisal data suggest that many energy efficiency opportunities exist which offer savings of 10% to 20% in energy use
Threats High consumption in energy and the
danger of increase of future electricity price (2011: 7.1 cents/kWh and 2012: 7.7 cents/kWh)
No plans for reducing GHG emissions might influence the image or market competitiveness
Production may have to stop for one year due to possible break-down of the transformer
Energy Consumption & Monofilament Lines
Energy Consumption and Costs
Source: Own elaboration based on TenCate data.
Monofilament and TapeTable: Correlation Analysis
Electricity - Tape 0.39Electricity - Monofilament 0.62
Graph: Energy Loads of Transformers (kWh)
Source: Own elaboration based on TenCate data.
-100000
100000
300000
500000
700000
900000
1 2 3 4 5 6 7 8 9 10 11
Transformer J1 Transformer J3 Transformer I1
Transformer I2 Transformer W1
Monofilament Production Line: 670 KW
Alternatives for the Hot Bath:
Alternatives for the Hot BathProposal 1: Proposal 2:
Actual Situation
Gas Fired Water Heater
Hot Bath Machinery Upgrade
Electricity Consumption (KWh) 3,110 1,112Gas Consumption (KWh) 3,110Daily Costs (Euros) 240 80 85Annually Costs (Euros) 87,407 29,200 31025Savings (Year) 58,207 64754Savings (Percentage) 70 65Payback (Years) 4 Unknown
Source: Own elaboration
Not enough!•Previous proposals imply only 3% of the total amount of expenditures in energy.
•We need to do more!•To much electricity consumption: 1.5 millions
Costs of energy consumption: Electricity and Natural Gas
Source: Own elaboration based on TenCate data.
Actual Situation Energy Demand (MJ)
Percentage(%)
Costs(Euros)
Electricity 76,792,172.4 71.3 1,529,444.1Gas 3,757,583.0 3.5 27,187.6
Steam and Compressed Air 27,187,197.8 25.2 204,404.3Total 107,736,953.1 100.0 1,761,035.9
New Situation Energy Demand (MJ)
Percentage(%)
Costs(Euros)
Electricity 3,757,583.0 3.5 74,838.5Gas 76,792,172.4 71.3 555,621.1
Steam and Compressed Air27,187,197.8 25.2 204,404.3
Total 107,736,953.1 100.0 834,863.9
Proposal: Gas Fired CHP Unit
Gas Fired CHP Unit: Inputs and Outputs
Source: Own elaboration.
CHP Unit100%
• 2000 kW• 48.000 KWh (day)
Electricity Generation
30%
• 600 KWe• 14.400 KWh (day)
Heat Generation
60%
• 1200 KWth• 28.800 KWh (day)
Losses10%
Situation with CHP Unit
Electricity Generation
600 KW
Monofilament Production
500 KW
HeatGeneration
1200 KW
Hot Baths (10)650 KW
Other Processes100 KW
Space Heating Water HeatingTenCate (TCP)
550 KW
Savings from CHP
Source: Own elaboration.
Annual Savings: Euros Actual Situation Electricity for Monofilament Production (1 line) without Hot Baths: 500 KW
337,260
Electricity for Hot Baths (10): 650 KW 438,000 Gas Consumption for Heating: 1.270.332 KWh (Year Average) 27,188 Total Actual Situation 802,448 CHP Situation Gas Consumption of CHP: 2000 KW 479,975 Operation and Management of CHP 175,200 Total CHP Situation 655,175 TOTAL SAVINGS 137,273
Finally…
•This proposal has to be seen not only in terms of money but also in terms of energy efficiency.
•A CHP unit for TenCate Thiolon will represent a responsible energy management in accordance to our times where the society, the economy and the environment are the track for a better future.
More Energy Saving Options—New design of cooling system and reusing cooling water
Cooling Unit
TCP
Heat Exchanger
Heat Exchanger
Ground Water
Cooling System ‘Current Situation’
Heat Exchanger
Heat Exchanger
H. E.
Cooling Unit
H. E.
13o
12o 18o
16.5o
15o
17o
19o
12o
13o
12.5o 21o
27o
35o
15o
20o
33o
24o
Compounding LoopExtrusion Loop
G.W. Line
Lennox WP01 WP02€ 0
€ 10,000
€ 20,000
€ 30,000
€ 40,000
€ 50,000
€ 60,000
Energy Costs of Water Cooling Machines 2011
Cos
t
Machine KWH Mj Cost €
Lennox 295,650 1,064,340 22,765
WP01 689,938 2,483,775 53,125
WP02 637,290 2,294,244 49,071
Total 1,622,878 5,842,359 124,962
Lennox WP01 WP020
100,000200,000300,000400,000500,000600,000700,000800,000
Energy Consumption of Wa-ter Cooling Machines 2011
kWh
Calculations
Annual Cooling Energy Consumption = 1,622,878 kwh
Annual Cooling Energy Costs = 125,000 € = 7 % of total energy costs
Each ton of water cooling machine (chiller) capacity with energy consumption of about 0.6 to 0.8 kw/ton.
In NL, the average temperature throughout the whole year is 10 Co
Is there a better solution?
TCPHeat
Exchanger(1)
Heat Exchanger
(2)
Ground Water
Cooling System ‘Proposed Situation’
Condensationor/and
Cooling Unit
H. E.
13o
19o
14o
25o
Compounding LineExtrusion Line
G.W. Line
H. E.
Extrusion Compounding
12o
31o
23o
15o
30 kg/s
25 kg/s
30 kg/s
Or to extrusion baths… is it possible ?
Free Cooling System
Reference:
Counter Flow-Cooling Tower
Comparison System Component Standard Sys.
(kw)Free Cooling
(kw)
Consumption Rate per ton 0.6-0.8 kw 0.2 kw
Chiller 116 -
Heat Exchanger 20 20
Condensor Water Pump 10 10
Additional Piping 15 15Total 161 45
By using Free Cooling System:Annual energy consumption = (energy consumption per year)*(0.2/0.7) = 1,622,878 * (0.2/0.7) = 463,680 kwh.
Annual energy savings = 1,622,878 - 463,680 = 1,159,200 kwh Annual cost savings = 1,159,200 * 0.077 = 90,000 €
2011 2012€ 0
€ 20,000
€ 40,000
€ 60,000
€ 80,000
€ 100,000
€ 120,000
€ 140,000
Expected Cost Reduction 2012
Cos
t
Conclusions
* Reduction of energy cost by 50%* Shorter cycling of water process, lower operational costs.* Lower maintenance costs.* Lower Carbon Dioxide emissions.
Renewable Energy Possibilities
Solar PV Installation
Formula: Cost per kWh= (lifetime expenses for capital + financing + installation + maintenance) / lifetime energy production
Note: calculation done based on European Commission’s Photovoltaic Geographical Information System
Nominal power of the PV system 10 kW Location TwenteTotal electricity production from the given system (kWh) for a year
8300 kWh
Requiring Area 70 square-meter
Lifetime 25 years
Other benefit: annual carbon reduction up to 5,000 kgs of carbon dioxide
Investment and total expenses 37000 Euro Cost per kWh= 37000 Euro / (8300 kWh x 25 years) = 18 cents/ kWhInvestment per year: 1480 Euro (0.05% total energy bill)
Roof top wind turbines
Roof top wind turbineTechnical Specifications
Performance Annual Energy ProductionInstantaneous Rated Power 12kW Assuming Wind
Capture10,512 kWh - 42,000 kWh Annually
Rated Wind Speed 29 mph (13 m/s) 10 - 40% of the time at rated speedCut-In Speed 6 mph (2.7 m/s)Maximum Wind Speed 111 mph (49.6 m/s)
Physical Parameters
Size 19'8" (6m) Rotor Diameter X
20'4" (6.2m) Blade Length
Tower Height 18' (5.5m)
Gross Weight 4190 lbs (1905kg) Excluding Tower
Cost: 31600 Euro (fully equipped, shipping and installation)
Financial FeasibilityCost (fully equipped, shipping and installation)
31600 Euro
Lifetime 20 years
Average wind speed in Twente 12 km/h (equivalent to 3.3 m/s)
Power production 0.8kW
Calculations of Cost per kWh
0.8kW x 24 hours = 19.2 kWh per Day
365 days x 19.2 kWh = 7008 kWh annually
Cost per kWh = 31600 Euro / (7008 kWh x 20 years) = 22.5 cents/kWh
Investment per year: 1580 Euro (0.04% of total energy bill)
Other Benefits of Renewable Energy
• Showcase• Sustainable image• Possible subsidy from feed-in tariffs• Without paying energy tax• Carbon reduction
Energy Management Action PlansMeasure Description Total Cost
(Euro) Energy Savings (kWh) per year
Cost Savings (Euro) per year
Payback Time year
1 Gas fired water heater for hot baths in monofilament production
8000 0 29,000 4 years
2 Upgrade hot bath machinery in monofilament production
Based on the price
714,670 32,485 Based on the price
3 Cogeneration heat and power unit
750,000 1,314,000 165,000 5 years
4 New design of cooling system and reusing cooling water
63,000 1,160,000 90,000 1 year
5 Roof top wind turbines installation
31,600 7008 - 721 None
6 PV installation 37,000 8300 - 855 None Total energy saving: 3,203,978 kWh per year (53% of total energy consumption)Total cost savings: 314,909 Euro per year (18% of yearly the energy bill)
Good Housekeeping Options
Good housekeeping checklist•Start today!• Buildings Turn down the thermostat Switch off lights Install dimmer switches• Water• Machinery and equipment•Long-term savings Insulation jacket Monitor energy use Install an energy star-rated ceiling fan
Cost and EffectivenessHousekeeping option
Cost/unit (euro) Effectiveness
Programmable thermostat
20 Save 1% energy for heating by 1 degree lower for 8 hours
Motion sensor 15 Smart to save energy
Plug load monitor 20 and up Monitor energy consuming, could cut power automatically
Ceiling fan 23 Save up to 40% space heating and cooling costs
Barrel Insulation jacket
60 (100mm X 100mm) Up to 40% energy saving; 15,000kWh/day (MF)
Organizational culture and energy management
• Corporate culture: market culture• Focus: productivity and achievements• Planning: short-term. Investment: 3-4 years or even shorter
The responsibilities of who are accountable for energy management in the organization:• Monitoring consumption,• Setting targets,• Identifying and correcting faults,• Motivating staff to conserve energy,• Identifying and implementing energy saving measures.
Organizational culture and energy management
• Overlap two sets of aims “senior managers on the one hand, and energy managers on the other”
• providing appropriate manage information on energy consumption to senior managers
• demonstrating effective performance of the energy management function to senior and top managers, budget holders and end users.
The strategies of energy management for Thiolon’s market culture• Assign accountability for energy budgets to line managers• Performance improvement arises from• responsibility for energy budget• required information on energy performance• Identify: mapping sub-metering schemes on organizational
structure• Management of energy = management of finances• Requires use of MT&R (Monitoring Targeting and
Reporting) techniques
Management review—
planning at management level
Energy policy•Sustainability:• 20% E.R. By 2020. EE, reuse, recycle• Include environment factor (GHG, Ecological footprint)• Invest in RE and environmental sound technique
•Quality:• Invest in technology and Good maintenance culture
•Safety: • Pleasant working environment promoting collaboration, integration and generate
innovative ideas to improve energy efficiency.
•Well being:• Ensure constant training, workshop and support system
Step-by-step Energy Management
Top management Commitment
Strategic Methodology (focus on a selected action)
Create an energy Team &
Develop Energy Policy
Implement action plan
Evaluate, control and monitor the
performance
Recognize and Review
achievement
Marketing(productivity & achievement)
Integrating EMS in Energy Management Objective: To ensure a sound management by employing quality,
sustainability, safe and good well being in all production operations leading to good trade balance in our market and more competitive.
•Economic factors Long-life span of machineReduce energy cost
•Environmental factorReduce GHG emissionEnsure sound environment with low exploitation
•Sustainable and ReputationContinuous productionPositive attribute from the public
Environmental Management Monitoring Plan
Implementing and Reviewing PlansProgress Reports on Outcomes
Review of Energy Saving Action Plan
Putting a Plan TogetherManagement Actions and Technical Actions
Determine opportunities to reduce energy useTechnical Review
Planning at management levelManagement Review
Determine how much energy is usedBaseline Data
Roles and Responsibilities•Director:Motivate and support idea generation.Participate in policy generation,
•Energy Manager:Identify and plan energy programHave the strong ability to influences behaviour change, not a dictator Execute , Monitor and control activities
•Environmental ManagerGHG inventory plan, Technology, Regulation, Reporting on emission,
• Intern:Accurate systematic and scheduled recording Logging of all measure on a programmed software,Reporting of trend to Emission measurement
•Employees: Motivated to achieving industrial goalsCollaborate, integrate and generate ideas
Roadmap
Thank you! Questions, discussion and comments
are welcome!
