Industrial Energy Saving Solutions. Barry Paschali

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1 Industrial Energy Saving Solutions Learn how your business can save money through efficient use of compressed air, efficient use of motors & drives, heat recovery, more efficient lighting, voltage optimisation and power factor correction Barry Paschali Tel:

2 T: Barry Paschali BSc CEng MCIBSE GDBM Chartered Engineer Corporate Member of CIBSE 25yrs + experience in M&E design, project & business management Specialising in low cost energy solutions and smarter greener working Founder of PASCHALI Greener Working Solutions 1.1m savings identified in last 3 years Independent clear advice to full solutions Employed by Atkins & Arup 20+ yrs (10 yrs as director) BREEAM Consultancy (Auditor In-Use) Joint author Arup Existing Building Survival Strategies Guide (Mar 09)

3 Contents 1. Energy Audit/Monitoring 2. What does energy audits/monitoring mean? 3. Identification of priorities 4. Compressed Air 5. Lighting 6. Voltage Optimization and Power Factor Correction 7. Heat Loss Recovery 8. Motor Use 9. Employee Greener Working Engagement 10. Generate your own

4 Energy Audit/Monitoring Identify which type of energy audit/ monitoring fits your company needs. Typical things that are included: - Lighting Levels - Temperature - Energy consuming equipment - Business processes - Where energy escapes - Current energy tariffs IF YOU CAN T MEASURE IT, YOU CAN T CONTROL IT

5 What do Energy Audits do? Energy Audits are one off exercises which identify: CO2 Emissions kwh consumption Lack of control Ways to protect the environment Ways to improve marketability How to save Savings up to 66% identified Typical 23% average

6 What is Energy Monitoring? Energy Monitoring is continuous... Collecting consumption data (24hrs a day for 365days a year) Analyse & understand Present in a clear format Do something about it quickly Various methods Manual or web-enable Saves at least 10-15% of Costs with Paybacks of 1-3 years.

7 Identification of Priority Areas Typical industrial priorities include: Compressed Air Lighting Voltage optimization & Power Factor Correction Heat Loss Recovery Motor Use Employee engagement Building fabric and or air leakage

8 Things to consider: Compressed Air Size of compressor Is it working too hard Type of distribution Operational Patterns Leak Identification Lack of maintenance No system control or monitoring Typical Savings per outlet 10% to 20%

9 Things to consider: Lighting Levels Types of Lighting - SONS, LED, Fluorescent Controls - Presence Detection - Dimming - Operational control Roof lights Internal Lighting

10 Don t forget natural lighting (It s free) Client saves 2780 annually (60%) from using roof lights

11 Lighting Comparison Existing Upgrade Fitting Type 36nr SONS 36nr Fluorescent T5 s Annual Running Cost ( ) 3,600 2,100 Cost of Upgrade ( ) - 5,400 Savings ( ) - 1,500 Payback (years) years % Savings - 41%

12 Low cost solution: External Lighting 1. Audit identified 4K pa spend 2. Reviewed operational & lighting up times (complying with security and H&S needs) 3. Revised external lighting policy 4. Reset timers & added additional controls. 5. Communicated & implemented.

13 Results Policy Existing: External lighting on Building exterior lighting on Recommended Policy 1: External lighting off Building exterior lighting off Recommended Policy 2: External lighting off Building exterior on kwh Consumption Cost per annum ( ) Savings ( ) Percentage Savings 41, , % 25, % The company operates 80 sites which means a potential saving of 100k+ could be realised with little investment.

14 Power Factor Correction Power Factor is the proportion of electricity that is being used to do useful work. It is defined as the ratio of active power (kw) to apparent power (KVA) Power factor = Active power (kw)/apparent power (KVA) The typical uncorrected industrial power factor is 0.5 to 0.8. This means that 1000KVA transformer can only supply between 500 to 800kW or that a consumer can only draw useful amps from 100Amp supply. The Utility company has to generate much more current than is theoretically required. This results in increased charges

15 Reactive Power (KVAR) Power Factor Correction Active Power (kw)

16 Power Factor Correction Utility companies charge for reactive power Up to 1/3 is free of charge More than 1/3 considered as excess PFC equipment uses capacitors to reduce the difference between apparent & active power Means no excess charges Payback is balance of savings on excess vs capital cash

17 Voltage Optimisation Electricity supplied at this voltage Historic UK voltage UK Nominal Voltage Equipment designed to operate at this voltage (Extract taken from PowerStar Brochure) Controlled reduction in Voltage Used to save energy & power Typically installed in series Not applicable to all Loads Savings based a reduction of overvoltage Can be expensive Paybacks: 1.5 to 7 years Research has shown +/ 1% = 0.25% kw

18 Type of Equipment Voltage Optimization Vs Power Factor Correction Voltage Optimization Power Factor Correction DC Motors and Drives X X AC Motors and Drives Incandescent lighting Fluorescent T8 s Fluorescent T5 s X X Laptops X X Resistance loads e.g. ovens X X Refrigeration (Industrial) Air conditioning Typical savings range from 5-20%

19 Heat Recovery Where can companies utilise this? - Warm air heating systems - Ventilations systems - Heat recovery in processes Example: Industrial yarn washing process cost 75k in heating oil Implement heat recovery/exchanger system: 43% saving = 32k & 170 CO2e tonnes Payback: 1.5 years!

Motor Use Ways to reduce energy consumption of motors: Minimising motor loads - Ventilation systems (poor fan efficiency, unnecessary bends, etc) - Pumps and hydraulic systems (poor pump

20 Motor Use Ways to reduce energy consumption of motors: Minimising motor loads - Ventilation systems (poor fan efficiency, unnecessary bends, etc) - Pumps and hydraulic systems (poor pump efficiency, excessive pipe lengths) Correct motor sizing and selection - Over sizing of motors (lowers efficiency) Controlling the Motor Load - Variable speed drives - Variable flow control

21 Water Bore Holes What are they? Alternative to a mains water supply Own personal private water supply Free use for your organisation Are you making use out of them? Do they need upgrading? Typical cost: 8k to 250K

22 Bore Hole Case Study Industrial company, Leeds based (water intensive usage) Spending 1/m 3 for water Wanted to reduce costs Invested in on site borehole (170 metres) to tap into local ground water supply Capital Cost circa 100k Hours of consumption Savings per Annum Payback Period months months months

23 Employee Greener Working Engagement Physical Energy audit/monitoring Lighting Voltage Optimisation Power Factor Correction Heat Loss Recovery Motor Use Renewable Energy Etc Greener Working in Industry Behaviour Top Level Commitment Engage Develop Embed Role creation Staff training Consultation Incentives

24 What s next? Generate your Own Electricity: Heat: Hydro Wind Solar PV/Thermal Ground Source Heat Pumps Solar (PV) A bit of both! Biomass Get paid for generating electricity/heat through the feed in tariff & renewable heat incentive

25 Get Paid for Power and Heat Generation: Feed In Tariffs Feed-in-tariff (FIT) is a rate per kwh that your electricity supplier pays you for generating electricity from a renewable source. Renewable Heat Incentive Renewable Heat Incentive (RHI) is a rate per kwh that The Treasury will pay you for generating heat from a renewable source. The recently published tariffs are only for the commercial sector. PV Electricity Generating Technology Proposed tariffs (p/kwh) Up to 21p Wind Up to 35.8p Sale of Electricity back to Grid Heat Generating Technology Ground Source heat Pumps 3.1p Proposed tariffs (p/kwh) Up to 4.7p Biomass Boilers Up to 8.3p Solar Thermal 8.9p

26 Support/Funding Funding can come from multiple sources: The Green Deal Leasing Agreements

27 1. Audit & Identify 7. Monitor & Action 2. Prioritise 6. Generate Your Own 7 Steps: Industry Energy Saving Solutions 3. Reduce Usage 5. Educate & Change Behaviour 4. Efficient Solutions

28 Industrial Energy Saving Solutions Thank you Barry Paschali Tel:

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