Abstract: Given the fact that most of plants in
various industries currently do not manage their energy poorly, and the fact
that in the 13th Five-Year Plan, Chinese government stressed on
energy structure optimization, this paper introduces a comprehensive solution
to industrial plants that is aimed to improve the energy efficiency in the
plants, and create savings in terms of energy for the plants.
Key words: Energy; efficiency; management;
1. Current Status of Energy Management for Industry
Currently, most industrial plants
manage their energy incorrectly. Plant owners are focusing on production,
product quality, safety and environment. I definitely agree that these fields
are very important, but that is not enough. In mid-sized plants, annual energy
consumption may total $30-50 million and even more, which is a great deal of
money. Therefore, it would be appropriate to emphasize the energy issue
accordingly. Moreover, energy efficiency may improve production output,
environment, product quality and safety.
To verify the fact that the
attention put to energy is currently inadequate is most plants, I would like to
suggest an experiment. Ask the plant manager whether he
knows or has a summarizing document indicating the amount of money paid for
energy consumption in the past year and what was the consumption of all types of
energy used in the past year. I can assure you that 90% of the respondents will
not be able to provide such a document, which shows that energy management at
the plant is deficient and requires immediate improvement. On the opposite, if you ask about the amount of production last
year, you will get a quick and precise answer with all the relevant details.
We are aiming to improve the energy management on the site. How can we achieve this goal? To manage the energy on the site properly, we have to understand
the energy consumption and how much we pay. To do this, we need a quality
system to measure the total consumption or supply of energy, in order to
understand the overall situation on the site. Afterwards, we would be able to
examine every detail and choose the area we need to focus on. First, we should focus on the main consumers with high energy cost and then the process begins.
We need to examine the efficiency of
large consumers by using smart tools that can help us see an even bigger
picture and derive smart ideas to increase efficiency and save energy. It should be noted that the senior management must believe in the
process and be committed to it, and lead it while allocating resources and
evaluating performance throughout the process.
One of our main problems is
awareness to efficient work. There are many ways to raise awareness among
employees, such as energy training, establishment of a performance evaluation
system, which can be a software continuously displayed in the control rooms,
establishment of incentives for success, as well as addition of an energy
supervisor for the entire site.
In addition, it is possible and even
recommended to involve the employees in the process of evaluating performance
on the site in terms of energy and efficiency, while using sophisticated tools,
thus achieving the involvement and curiosity of the staff on the front line,
who are also the majority – do not forget this.
2. Technology Application in the Solution
efficiency technology that we bring is based on an organized methodology, which
includes the use of smart tools and involves the managers and employees of the
plant, meaning that it is based on joint work.
a general data collection is needed, which means the amounts of various
categories of energy that the plant purchase, such as coal, electricity, steam,
water, fuels, etc. need to be metered and collected. Based on that, we then
need to build a list that include how much of which kind of energy had been
distributed to which consumer. After that, additional tools will be adopted to
measure the energy efficiency. Next, analyses will be conducted based on the
results from the tools and ideas will be generated according to the analyses.
After that, we need to filter all of the ideas and finally stay with a limited
number of ideas. A idea ticket will be created for each idea that passed the
filtration, including information such as saving calculation, investment
required, payback period, etc. Afterwards, we decide together with the plant
management on when and how to implement each idea. Finally, we can build a
savings plan and streamline energy efficiency for over five years. In the
course of the project, we are required to build performance tests for each
process, while others are built on software, while others are on control room
boards, allowing all employees to be exposed to performance and even take part
in their examination.
program is suitable for any industrial plant needing energy efficiency
improvement. The benefits of the program are: raising awareness and changing
energy behavior both among employees and managers. In addition, the energy
status of the plant can be organized, and all the issues with energy will be
also discussed. There will be a lot of ideas of improvement, some of which even
without any investment. From this point on, the plant does not return to its
previous state, but progresses and becomes more efficient both in awareness and
behavior and in their processes.
we recommend to establishment of an energy department that could initially
include just one person who is solely responsible for collecting all the
information. In addition, he constantly conducts performance tests according to
the goals set by the plant and always thinks ahead and examines improvements
and introduction of new technologies.
3. Examples and Analysis
3.1 Cost and Load Analysis
As an example, we shall use an
application tool called Cost and Load Analysis to
examine the compressed air system at the plant.
Prepare a table of compressors at
the plant. The table should include the amount of compressors, name of each
compressor, flow rate of each compressor and possible pressure of each
compressor, and after measurements – the cost per compressed air unit of each
compressor. In addition, prepare a list of consumers and build a long-term consumption
distribution. A simple analysis will allow us to see that some compressors
should be activated before the others, and we will probably find that we do not
need to activate all the compressors, which will enable saving energy. This is
one of many examples of using the tools.
3.2 Losses Reflected by Unit Consumption
example of examining the process energy efficiency by looking into unit
Take the most energy-intensive
equipment and start to examine the energy consumption according to the manufacturer
per ton of product, i.e. the technology we chose. What is the actual energy
consumption per ton of product? In most cases, the actual consumption will be
higher that the consumption provided by the manufacturer, and this is where the
engineering work begins by examining the source of gaps, and for each gap, we
should find a solution, thereby contributing to increased efficiency and energy
Many other important tools can be
used to achieve maximum efficiency.
Summary and Future Enlightenment
The government provides grants and
launches information projects aimed to present the Chinese industry with the
possible value of streamlining industrial energy processes. The main reason the
government focuses on energy efficiency in Chinese industry is that most of the
energy is wasted due to poor management of energy and electricity consumption
at plants and industrial workplaces.
The program, which aims to streamline
and economize energy cost on industrial plants in an intensive manner, is a
system-wide program that lists a long list of steps arranged within a
methodology that touches the entire energy chain on the site. The plan defines
expected savings, expected investments and priorities. In addition, the plan
presents the things that must be done and the means of implementation, while
defining milestones until completion, and even performs performance tests
according to the defined goals.
Energy efficiency saves money - it's
a fact. Most of the businesses that have already entered the process did not
necessarily have to do so for reasons of environmental thinking, but out of
recognition of the return that investment generates in streamlining. And if it
is out of the environmental reasons and can make profits, it will be an even better thing to do, too. According to previous experience, a program as such can reduce around 10% of the annual energy cost for a plant.
4.2 Future Enlightenment
For proper energy management, the
following are required:
Commitment of the management,
defining the energy policy, setting goals and objectives, conducting work
procedures, reporting and training employees, testing energy efficiency of
various processes and taking corrective actions, constantly updating and
improving, defining the required energy indicators.
Defining the energy indicators
required at the plant, while taking into consideration the following aspects:
· Reduction of environmental impacts.
· Identification and detection of energy efficiency potential.
· Benchmarking – comparisons with similar enterprises vs. sector
· Establishment of indicators to examine energy efficiency.
Energy Efficiency Design
· At the planning stage, prior to implementing any new project or
installation, energy considerations should be taken into account.
· Optimal efficiency of energy
between various systems.
Monitoring & Measurement
· Implementation of monitoring and measurement systems in order to
verify savings and find new sources for efficiency.
· Installation of technologies that will lead to energy efficiency.