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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 supplyand demand
sides of the systemand 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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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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Industrial Energy Efficiency Project
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