091105 Energy Management

8/9/2019 091105 Energy Management

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Energy Reduction and Sustainability through

Total Energy Management (TEM)

Santiago [email protected]

Sean Golzarian

[email protected]

November 2009


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2

Agenda

Energy reduction and sustainability throughimplementation of Total Energy Managementprogram

Assisting our injection molders to achievesustainability through TEM program


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Manufacturing Advisory Services

Provide operational consulting, design and

project management services to support ourexisting and prospective customers

1. Consulting and Advisory Services

Comprehensive plant & operational assessment Operational performance improvement & implementation

Facility planning and optimization

Total Energy Management Program

2. Building and Infrastructure Planning and Design

3. Project Management and Turnkey services


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4

CO2 Emission due to Electricity Production

83% of total emissions is CO2 related

40% of CO2 emissions is due to

producing electricity

forecasted global CO2 is expected toincrease by 36% over 1990 levels by 2010

1900 1910 1920 1930 1940 1950 1960 1980 1990 2000 2008

Source: US Energy Information Administration


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Carbon Cap-and-Trade

United States:

New carbon cap-and-trade program calls for 14% below 2005 levelsby 2020 and 83% below by 2050

Energy intensive manufacturers would be forced to identify energyreduction opportunities (compliant with ISO 50001)

Canada:

Reduce greenhouse gas emissions by 20% from 2006 levels by 2020 In Ontario, 6,300 MW reduction in peak demand by 2025 (mostambitious target in North America)

Legislated Actions to Reduce Carbon Footprint


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Costs Breakdown in Typical Molding Plants

Energy could be the same or more than Direct labor * Approximately 70% of cost savings are focused on direct

labor

* Costs vary based on markets, number of machines, geographical location, etc..

- Consumer manufacturer in US - Bottle manufacturer in US

Material

59%

Direct labor

6%

Indirect labor

9%

Maintenance

2%

Energy

6%

Other controllable

expenses

2%

Payroll benefits

7%

Occupancy

4%

Depreciation

5%

Material

78%

Labor

3%Energy

5%

Primary Equipment

10%

Building &

Infrastructure

3% Maitenance

1%


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Two Approaches to Reduce Cost

1. Reduce the cost of energy used through acquisition toreduce the $/ kWh

Numerous consulting firms provide Negotiation and riskmitigation services

Alternative Energy generation

2. Reduce the amount of energy used (KW/lb): Certain utility companies offer programs that provide molders

rebates towards the purchase and installation of qualifiedequipment that improves their facilitys energy efficiency

The two approaches alone without an Energy ManagementProgram is not sustainable


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Implementation of policies and procedures to

measure, set targets, and monitor energyrelated KPIs to continuously reduce andsustain energy consumption

Total Energy Management


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Magnitude of Savings

Energy cost can be reduced by up to 30% for most plasticsprocessing plants

Savings can be achieved through a combination of No-cost,Low-cost, and Investment actions

30% Energy cost savings

Organizational /Management

MaintenanceCapital

Investment


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1 - Estimate and verify site energy profile

2 - Understand your Base and Process loads

3 - Understand when and how much energy is used4 - Monitoring and Targeting

Understand Where energy is used

5 - Data analysis and reporting energy KPIs (Energy dashboard) by

department6 - Identify, Quantify, and Prioritize opportunities

7 - Eliminate waste and reduce consumption through

Implementation of selected energy reduction projects

8 - Conduct internal and external benchmarking9 - Repeat the steps Continuous improvement

Husky Total Energy Management

Program


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1- Estimate and Verify Site Energy Profile

Estimated site energy profile based on audited equipment Verify estimated energy profile through actual on-site

measurements

Estimated consumption break down

Plant Lighting9.6%

Injection Molding

Machine

56.1%

Cranes

0.1%

Feed Systems

1.7%

Printers

4.2%

Compressed air

5.8%

Wrapping Machines

0.0%

Handle Machines

1.3%

Process Water system

16.9%

Thermoformer

2.3%

Film Extruder

2.1%

Measured consumption break down

Film Extruder

4.5%Thermoformer

2.5%

Process Water system

16.5%

Handle Machines

1.3%

Wrapping Machines

0.0%

Compressed air8.7%

Printers

4.4%

Feed Systems

1.6%

Cranes

0.1%

Injection Molding

Machine

51.5%

Plant Lighting

8.9%


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-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000

Production volume (Kg or Lb)

Energyusage(KWh)

Energy has variable and fixed costs and both can be affected Performance Characteristic Line (PCL) provides an operational signature

of the plant that is closely related to the way the plant management runs

the plant

2 - Identify Base & Process Loads


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Performance Characteristic Line (PCL)

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000


Energyusage(KWh)

Base load

Base load is effectively your Energy overhead and is the energyconsumption with No production output

Base loads are typically 10% to 40% of the average total load . The less thebetter

Base loads energy usage reduction are generally easy to make, low in cost,and have rapid payback (low hanging fruits)


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Performance Characteristic Line (PCL)

Slope of the line indicates the average plant process load (Kwh/ Kg or Lb).The less the better

Plant process loads are typically in the region of 0.6 to 1.6 Kwh/Kg (0.36 to0.72 KWh/ Lb)

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

- 50,000 100,000 150,000 200,000 250,000 300,000 350,000 400,000


En

ergyusage(KWh)

Base load

Slope = 1.57

R2 = 0.96

Correlation coefficient (R2) indicates linearity between energy usage andproduction volume

High R 2 (low scatter) means good correlation between energy usage andproduction volume


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3 Understand When and How much

Peak at 1,700KW

Base load at 300KW

(25% of average load)Goal to be @ 10% of average load

Average PF of 0.84Goal to be above 0.9


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Monitoring & Targeting - Sub-metering to understand Where energy isused Huskys installed three main meters and fifteen sub-meters in one building

4 Monitoring & Targeting - Understand Where


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SPC analysis for energy usage

Energy profile

Cost allocation and budgeting

Forecasting energy consumption per department

Variance analysis (Deviation between actual and predictedenergy)

5 Data Analysis and Energy KPIs

-40,000

-30,000

-20,000

-10,000

0

10,000

20,000

30,000

40,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Month

Deviationf

romp

redicted(KWh)

-100000

-50000

0

50000100000

150000

200000

250000

300000

350000

400000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Month

CU

SUM(KWh)

Target CUSUM

Original CUSUM


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Reporting energy KPIs (Energy dashboard) by department

Electrical cost as % of production cost

Monthly deviation from predicted and target energy usage Cumulative deviation from predicted and target energy usage

Electricity cost and production volume by month

Status of energy reduction projects

Energy on Management Agenda

Electrical cost as % ofproduction cost

Monthly deviation frompredicted and targetenergy usage

Cum. deviation frompredicted and targetenergy usage

Electricity cost andproduction volume bymonth


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1 - Estimate and verify site energy profile

2 - Understand your Base and Process loads

3 - Understand when and how much energy is used4 - Monitoring and Targeting

Understand Where energy is used

5 - Data analysis and reporting energy KPIs (Energy dashboard) by

department6 - Identify, Quantify, and Prioritize opportunities

7 - Eliminate waste and reduce consumption through

Implementation of selected energy reduction projects

8 - Conduct internal and external benchmarking9 - Repeat the steps Continuous improvement

Husky Total Energy Management

Program


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Machines

50%

Lighting

3%

Mold cooling

12%

Dryers

20%

HVAC

8%

Air compressors

6%Others

1%

Typical Part Cost Break Down

ENERGYENERGY

Resin

86%

Labour

2%Energy

3%

Equipment5%

Infrastructure

2%Maintenance

2%3% to 5%


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Mold Cooling - Chiller Types

Machines

50%

Others

1%

Air compressors

6%HVAC

8%

Dryers

20%

Mold cooling

12%

Lighting3%

0.00

5.00

10.00

15.00

20.00

40 41 42 43 44 45 46 47 48 49 50 51

Leaving chilled water temperature

%

increaseinChillers

'COP

Absorption

Reciprocating

Centrifugal

Screw

(F)

Typically every 1o

F increase in leavingwater temperature from chillers resultsto 1% to 1.5% reduction in energy


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Free Cooling


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Free Cooling Case Study Middlesex, UK

Effect of Chilled Water Temperature on free Cooling:

PET mold, 50oF vs. 43oF LWT:

15% of the year with 40oF (4.5C) (including dry cooler and heat exchanger approach) 4% of the year with 33oF (0.5C) (including dry cooler and heat exchanger approach)

Estimated savings around $40k / year vs. $11K / year

Temperature vs. Time - Middlesex UK

0

5

10

15

20

25

11/14/2007 1/3/2008 2/22/2008 4/12/2008 6/1/2008 7/21/2008 9/9/2008 10/29/2008 12/18/2008 2/6/2009

Date

Temperature(degC)

15% of the year is colde r than 4.5C,

compared to 4.26% of the year

colder than 0.5C

40F

33F


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Dehumidification Case Study - Middlesex, UK

Dew Point vs. Time - Middlesex UK

-10

-5

0

5

10

15

20

11/14/2007 1/3/2008 2/22/2008 4/12/2008 6/1/2008 7/21/2008 9/9/2008 10/29/2008 12/18/2008 2/6/2009Date

Temperature(degC)

72% of the year the dew point is less

than 10C, compared to 42% of the

year below 6C

Effect of Chilled Water Temperature on mold dehumidification:

PET mold, 50oF vs. 43oF LWT:

72% of the year dew point is less than 50oF 42% of the year dew point is less than 43oF

50F

43F


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Turbocor Micro Centrifugal Compressors

New compressor technology

Oil-free, variable speed drive compressor No oil management hardware, controls or downtime costs

Improved heat transfer efficiency

Uses centrifugal compression technology, previously limitedto large chillers 2,000KW + (250 Ton+)

COP (KW th/ KWe) of 6 to 10 or (0.55 kwh/Ton).

Better energy consumption than scroll compressors

Similar capital costs to a regular air cooled chiller

Quiet operation

70dBA sound with virtually no vibration

Compact 50% less footprint and 1/4 to 1/5 the weight of traditional compressors


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Machine Cooling Options

Cooling Towers

Contamination in water

Scale and oxidation inpipes

High water and chemicalconsumption

Cost of water disposal

Dry Coolers

Clean water to process No scale or corrosion Minimal maintenance Reduced energy

consumption

No water disposal

No water treatmentchemical consumption


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Dry Coolers

1. Adiabatic Cooling Maintains ability todeliver cool water even in HOT ambientconditions with minimal water consumption,little maintenance.

2. Self-Draining - Freeze protection withoutrequirement for Antifreeze/Glycols. Works in

all climates.

3. DC Variable Speed Fans Extremely lowenergy consumption

4. Less than 20 times less water than tower

-

0.50

1.00

1.50

2.00

100806040200O U T D O O R T E M P . ( C )

kW / fan


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Cascading Use of Energy


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1. Traditional systems Roof top DX units Central chillers and air handling units

2. Displacement ventilation

Air Conditioning

Machines

50%

Others

1%

Air

compressors

6%

HVAC

8%

Dryers20%

Mold cooling

12%

Lighting3%


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Air Conditioning

1,194

879 315

0 200 400 600 800 1,000 1,200 1,400

Cooling Size (kW)

26% lessDisplacementVentilation

TraditionalVentilation

1,194

879 315

0 200 400 600 800 1,000 1,200 1,400

Cooling Size (kW)



2,272

1,154 1,118

0 500 1,000 1,500 2,000 2,500

Chiller Thermal Energ y Use / Year (MWH/Yr)



2,272

1,154 1,118

0 500 1,000 1,500 2,000 2,500

Chiller Thermal Energ y Use / Year (MWH/Yr)



Up to 26% less capital cost

Up to 49% less operational cost

Traditional air conditioning Displacement Ventilation

Air


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Advanced Technology Resin Dryer

Variable throughput feature Controlled residence time

Optimized air flow

Energy recovery system Up to 25% of the requiredtemperature rise for free

Energy efficient < 0.08kWh/kg all electric

$28,000/Year

Estimated

Savings

0.040.063Energy

New

(kWh/Lb)

Traditional

(kWh/Lb)

2200Lb/hr

$0.07/kWh , 8000hrs/yr

$28,000/Year

Estimated

Savings

0.040.063Energy

New

(kWh/Lb)

Traditional

(kWh/Lb)

2200Lb/hr

$0.07/kWh , 8000hrs/yr

Machines

50%

Lighting

3%

Mold cooling

12%

Dryers

20%

HVAC

8%

Air

compressors

6%Others

1%


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Machines

50%

Lighting

3%

Mold cooling

12%

Dryers

20%

HVAC

8%

Air compressors

6%

Others

1%

Compressed Air

Compressors are only 5-15%efficient Compressed air is expensive energy

At point of use compressed air costs 10

times more than equivalent quantity ofelectrical power

Most of the cost of a compressor isin the energy it uses

Energy cost, 75%

Capital cost, 15%

Maintenance, 10%

O i C di i I fl


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Operating Conditions Influence

Energy Costs Part load operation

4080% of full kW at part load

System pressure each 5psi = up to 5% more power

Air inlet temperature

each 7o

F lower = 1% more air

Pipe sizing Each 5psi drop = 2% more energy

Leaks commonly constitute 25% of total compressed air use

Size CFM HP $/Yr

1/4 104 26 $15,300

One 1/4"

leak is equal to 300 60-watt lamps!

Air compressors

6%


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Lighting

Machines

50%

Others

1%

6%HVAC

8%

Dryers

20%

Mold cooling

12%

Lighting

3%

Fluoresce T5 (0.2 KW) Metal Halide (0.4 KW)

Functioning MH

Consumes 400WLight level: 400 LUX

80% burnt MH


Dirty MH


Burnt MH


HVAC

Air compressors

6%


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Effect of Cycle Time on Energy

Machines

50%

Lighting

3%

Mold cooling

12%

Dryers

20%

HVAC

8%

6%Others

1%

Base Line Exit Temperature Faster Cycle Exit Temperature

C


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6% overall reduction in cycle times and energy consumption (KW/ Kg)

Equipment DescriptionMeasured

Power (kW)

Power Factor

480V

Cycle

Time(sec)

Part

Weight(g)

Number of

Parts perCycle

Machine

Process Load(kW/kgHr)

Before Husky-HL160RS55/50 30.440 0.76 13.4 174 1 0.651

After Husky-HL160RS55/50 30.811 0.76 12.6 174 1 0.613

Percent improvement 6% 6%

Effect of Cycle Time on Energy

P C di i i


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Power Conditioning

Corrects power quality problems: Balances voltage across all three phases

Balances current across all three phases Decrease voltage fluctuations Mitigates harmonics

Corrects power factor

Suppresses surges and transient to reducethe chance of equipment damage

Protects equipment from brownouts (option)

Protects equipment from intermittent supplyfailure

E l f C t ib t t B L d


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Thermolators Raising chilled water above ambient wet bulb temperature

Chillers Un-optimized water temperature

Air compressors Leakage

A/C Setting temperature too low

Leaving doors open

Grinders

Examples of Contributors to Base Load


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Contacts


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Santiago Archila,

[email protected], Ext. 3810

Sean Golzarian,[email protected], Ext. 3550

Husky website: www.husky.ca

Contacts


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Energy Reduction and Sustainability through

Total Energy Management (TEM)

Santiago [email protected]

Sean [email protected]

November 2009

091105 Energy Management

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