Presented by the Industrial Energy Efficiency Project

The best approach?

Energy Systems Optimisation Systems Optimisation approach 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

The IEE Project equips companies to systematically target selected systems within their processing facilities and interrogate their performance and effectiveness.

Did you know?

The Systems Approach + the pump + distribution system

Electric Utility Feeder TransformerMotor Breaker/ Starter Adjustable Speed Drive (electrical) MotorCouplingPumpFluid System Ultimate Goal 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

o What does the user need? o Consider variations, e.g. seasonal, occupancy, production schedules, alternative services, etc. o Optimise use of the service o How is it used, operations, controls, etc. o Optimise distribution of the service o Leaks, pressure drops, insulation, etc... o FINALLY optimise the generation of the service o Boilers, Chillers, Air Compressors, Pumps, etc. Optimisation process

10 Candidate Plant 1 Trainers and Co-facilitators Host Plant National EnMS EXPERT Trainees Candidate Plant 2 IEE Project Training Approach

What CAN be achieved?

Minimise user requirement 2. Shut bypasses 3. Determine actual flow and pressure requirement 4. Reselect motor and pump 5. Replace 150m3/h with 25m3/h 6. Save 75% or 176MWh pa 28kW 6kW Example of Systems Approach

Cummulative Savings CompanySystem Optimisation kWhTonnes CO2Rands ArcelorMittal-SaldanhaPumps6,651,0006,3723,324,000 Gledhow SugarSteam65,616,00021,75011,700,000 Sockit ManufacturingGeneral Energy276, ,000 Precision PressGeneral Energy351, ,768 TechniplateGeneral Energy1,264,0321,211518,253 Klein Karoo InternationalSteam405, ,200 At Source FoodsGeneral Energy275, ,000 Gastro FoodsGeneral Energy267, ,514 Impala PlatinumPumps2,034,1772,0281,222,305 Idwala LimeProcess Heating356,562,222354,780213,937,334 AMKA ProductsSteam2,805,5542,7921,683,332 Weet-BixCompressed Air1,250,0001,244750,000 Consol Glass – WadevilleFans2,117,6501,9051,800,000 Pioneer Foods - PE Wheat MillFans103, ,000 Durbanville Hills WinesGeneral Energy156, ,000 Solomons CoatingsCompressed Air54, ,000 ABI Premier Place 336, , ,524,889394,132237,538,706 ESO Implementation Savings Reported

PUMP SYSTEM OPTIMISATION: ARCELOR- MITTAL SALDANHA BAY Case Study

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 Capacity:1085 m 3 /h Head:66m Motor:280kW (3.3kV motors) Process Parameters: Total flow rate: m 3 /h Controlled pressure:750 kPa Inlet temperature:23 o C Outlet temperature34 o C

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 CO 2 and R3,324,000.

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