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Presented by the

Industrial Energy Efficiency Project

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The best approach?

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Energy Systems Optimisation

Systems Optimisationapproach requires:

Observation of the industrial system

as a whole, not just at the

individual pieces of equipment

Analysis of both the supply

and demand sides of the system

and how they interact

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The IEE Project equips companies to systematically target selected systems within their processing facilities and

interrogate their performance and effectiveness.

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Did you know?

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The Systems Approach

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Electric UtilityFeeder

Transformer

Motor Breaker/Starter

AdjustableSpeed Drive(electrical)

Motor Coupling Pump FluidSystem

UltimateGoal

Slide Courtesy of Oak Ridge National Laboratory

• At each interface, there are inefficiencies.• The goal should be to maximize the overall

cost effectiveness of the pumping, or how much flow is delivered per unit of input energy.

Matching Process and Generation Needs

Approach Methodology

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o What does the user need?o Consider variations, e.g. seasonal, occupancy, production schedules,

alternative services, etc.

o Optimise use of the serviceo How is it used, operations, controls, etc.

o Optimise distribution of the serviceo Leaks, pressure drops, insulation, etc...

o FINALLY optimise the generation of the serviceo Boilers, Chillers, Air Compressors, Pumps, etc.

Optimisation process

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Candidate Plant 1

Trainers and Co-facilitators

Host Plant

National EnMS EXPERT Trainees

Candidate Plant 2

IEE Project Training Approach

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What CAN be achieved?

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1. Minimise user requirement2. Shut bypasses3. Determine actual flow and pressure requirement4. Reselect motor and pump5. Replace 150m3/h with 25m3/h6. Save 75% or 176MWh pa

28kW

6kW

Example of Systems Approach

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Cummulative SavingsCompany System Optimisation kWh Tonnes CO2 Rands

ArcelorMittal-Saldanha Pumps 6,651,000 6,372 3,324,000

Gledhow Sugar Steam 65,616,000 21,750 11,700,000

Sockit Manufacturing General Energy 276,000 270 420,000

Precision Press General Energy 351,300 242 198,768

Techniplate General Energy 1,264,032 1,211 518,253

Klein Karoo International Steam 405,010 388 657,200

At Source Foods General Energy 275,326 264 226,000

Gastro Foods General Energy 267,618 256 252,514

Impala Platinum Pumps 2,034,177 2,028 1,222,305Idwala Lime Process Heating 356,562,222 354,780 213,937,334AMKA Products Steam 2,805,554 2,792 1,683,332Weet-Bix Compressed Air 1,250,000 1,244 750,000

Consol Glass – Wadeville Fans 2,117,650 1,905 1,800,000

Pioneer Foods - PE Wheat Mill Fans 103,000 98 82,000

Durbanville Hills Wines General Energy 156,000 149 342,000

Solomons Coatings Compressed Air 54,000 62 160,000

ABI Premier Place   336,000 321 265,000

    440,524,889 394,132 237,538,706

ESO Implementation Savings Reported

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1

8

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3

4

56

7

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8

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4

56

7

PUMP SYSTEM OPTIMISATION:

ARCELOR-MITTAL

SALDANHA BAY

Case Study

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System 1:Melt Shop Con Arc/LHF Shell and Duct Cooling

System Description• Hot water, returned from the machines, is cooled via an air- cooled heat exchanger system.• 8 pumps – 2 standby:• Make: KSB ETA 250-50• Capacity: 1085 m3/h• Head: 66m• Motor: 280kW (3.3kV motors)

Process Parameters:• Total flow rate: 6 500 m3/h• Controlled pressure: 750 kPa• Inlet temperature: 23oC• Outlet temperature 34oC

12 3 12 3

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Case Study Results

1. One pump can be safely turned off whilst maintaining operational requirements.

2. Pump efficiencies have degraded since the pumps were installed and refurbishing one or more of the pumps may be cost effective.

3. Pump C has an impeller that is larger than needed. Could be trimmed.4. It might be possible to automate the system, so the operators are

prompted to run pumps as a function of temperature.5. Implemented - Savings achieved: 6,651,000 kWh 6,372 tonnes CO2

and R3,324,000.

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www.ncpc.co.zaIndustrial Energy Efficiency Project

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