Efficiency Opportunities. Compressed Air Energy. LeapFrog Energy Technologies Inc. 11 June McMaster University CDM Conference

Transcription

1 Compressed Air Energy Efficiency Opportunities 11 June McMaster University CDM Conference LeapFrog Energy Technologies Inc.

2 About LeapFrog Energy Technologies Inc. 2 LeapFrog is a Professional Services company providing: Independent and objective advice Practical strategies lower risk Solutions to improve energy and environmental performance Incorporated in 2006 Completed projects across Canada and 11 countries Licensed by PEO Energy and Water Audits Training and Handbooks CDM Measurement & Verification Emerging Energy Technology Research & Development Field Trials, Software Models

3 What is Compressed Air? 3 Stored energy Operates machinery, equipment, or processes Common in manufacturing and some service industries Used where it is impractical or hazardous to use electrical powered equipment Worst Compressed Air Award Winner

4 Transformation Process 4 Heat of Compression 7-8 Cubic Units of Air at Atmospheric Pressure Air Compressor + ENERGY 1 Cubic Unit of Air at approximately 7-8 Times Atmospheric Pressure Moisture

5 Compressed Air Energy Losses HP Energy Input Heat of Compression and Compressor Losses (~80 HP) Air Dryer (~3 HP) Filters and Leaks (~6 HP) Pneumatic to Mechanical Conversion (~2 HP) Useful Energy Output (9 HP) For every 100 kwh input, fewer than 9 kwh end up being converted into useful work

6 Compressed Air A Significant EE Opportunity 6 Sometimes called the fourth utility Most expensive and often the most inefficient utility in many plants About ¾ of lifetime cost is for electricity Lifetime Cost of Compressed Air (Source: US Department of Energy) Energy Maintenance 73 Capital Cost Installation

7 #2 Recommended E.E. Opportunity 7 IAC Program completed 15,400 Industrial Energy Audits DEMAND MANAGEMENT 2% BUILDING ENVELOPE 3% STEAM 3% BOILERS 4% HEAT CONTAINMENT 4% 100,800 Total Recommendations OTHER 14% LIGHTING 23% EQUIPMENT CONTROL HEAT 5% RECOVERY 6% COMPRESSED AIR 18% Average Payback 0.6 years SPACE CONDITIONING 6% Source: IAC Database June 5, 2012 MOTORS (Pumps, Fans) 12%

8 Annual Operating Electricity Costs 8 Compressor Size 1 Shift (2,250 Hrs) 2 Shifts (4,250 Hrs) 3 Shifts (8,400 Hrs) 10 HP $1,720 $3,250 $6, HP $2,580 $4,880 $9, HP $4,300 $8,130 $16, HP $8,600 $17,260 $32, HP $17,120 $32,330 $63,900 Based on $0.10 per kwh

9 Supply Side System Components 9 Supply Side

10 Air Intake and Filters 10 Use cool (outdoor) air intakes Clean and replace inlet and end use filters regularly

11 Moisture Separators and Drains 11 Moisture separators remove entrained liquids from the air. Zero Loss Drains save about $450/year for 2 shift operation

12 Demand Side System Components 12 Demand Side

13 Compressed Air Receiver 13 Supplies peak demands Radiates heat Helps water and lubricant to settle out Reduces compressor cycling Improves control

14 Pressure Losses 14 Supply 115 psig 100 psig Compressor Operating Range, Aftercooler, Separators Dryer and Filter Pressure Drop Demand 90 psig 85 psig Distribution Piping Pressure Drop FRL, Hose, Disconnects Figure: Adapted from Compressed Air Challenge psig Regulated End Use

15 Ultrasonic Leak Detection 15 Air leaks emit inaudible sound (Ultrasound ~40 khz) Unaffected by background noise Can pin point leak location quickly

16 16 Common Types of Leak Repair Programs Leak Tag Program Tag identifies location, size, and description of the leak to be repaired. Seek and Repair Program Find the leak and repair it immediately Best approach depends on the type, size, and the culture/work practices of the facility Employee Awareness 10 minute discussion at safety meeting Location Date Location Priority Low Medium High Date Priority Low Medium High AIR LEAK

17 BC Hydro 17 A Pioneer Compressed Air Testing & Audits since 1989 Compressed Air Program Components Self Directed Assessment Online Tools Feasibility Studies Financial Incentives Employee Awareness Customer Recognition

18 Manitoba Hydro 18 Systems Approach Lower end use requirements Minimize distribution losses Optimize supply Use effective controls Compressed Air Performance Optimization Scoping Study Feasibility Study Financial Incentives Training (CAC)

19 Efficiency Nova Scotia 19 Established in 2009 Independent Agency Financial Incentives for: Feasibility Studies Capital Incentives Compressed Air Prescriptive Incentives Cycling Refrigerated Air Dryers VSD Compressors Air-Entraining Air Nozzles Zero Loss Drains Receiver Tanks

20 Efficiency New Brunswick 20 Opportunity Identification Develop Business Case Project Implementation (Incentives) Measurement & Verification Customer Master Energy Plans Training & Awareness Feasibility Studies Financial Incentives Leveraging ASME EA Standard

21 ASME EA Standard 21

22 Compressed Air Challenge 22 Voluntary North American Consortia Source of product-neutral compressed air information Introductory and Advanced Compressed Air Auditing Sponsors: BC Hydro Compressed Air & Gas Institute (CAGI) Compressor Distributors Association Iowa Energy Center Manitoba Hydro National Grid USA New York State Energy Research & Development Authority (NYSERDA) Northwest Energy Efficiency Alliance Northeast Utilities NSTAR Gas & Electric Corporation Pacific Gas & Electric U.S. Department of Energy

23 USA - Compressed Air Challenge 23 US Dept. of Energy Improving Compressed Air System Performance Compressed Air Challenge Best Practices (Second Edition)

24 Xcel Energy 24 Program Elements Compressed Air Challenge >50 HP Compressors Subsidized Feasibility Study Customized Incentives up to $400/HP Prescriptive incentives for zero loss drains

25 Tacoma Power 25 Free Walk Through energy audit Program Elements 50% of Demand side components Minimum efficiency standards for Supply side Training Cash Incentives Zero interest loans Compressed Air Challenge

26 UK - Carbon Trust 26 National Agency to promote energy efficiency Information Resources Training Some Incentives UK Carbon Trust - GPG385 Energy Efficient Compressed Air Systems

27 Summary and Conclusions 27 Each jurisdiction is taking a customized approach Compressed Air Efficiency should be a priority for ongoing Energy Efficiency Offers quick payback CDM results Eliminate Inappropriate Use 6% Reduce Discharge Pressure 20% Optimize Compressor Size 3% Upgrade Controls 3% Coolest Location for Air Intake 26% Reduce / Eliminate Leaks 39%

28 Compressed Air References 28 NRCan Compressed Air Energy Efficiency Guide Sustainable Air Leak Management Ontario Mining Association

29 Questions and Discussion Compressed Air Energy Efficiency Opportunities 11 June McMaster University CDM Conference LeapFrog Energy Technologies Inc.