Auf in neue Märkte! Energy Efficiency in the South Afican Industry Viable applications and Trends Sashay Ramdharee, 30 June 2017 Sandton
Presentation Content o SA Industrial Energy Efficiency Project o Energy Efficiency - National Landscape o Case Study Evidence o SA s Energy Efficiency Business Case TT.MM.JJJJ Seite 2
Industrial Energy Efficiency Project
Industrial Energy Efficiency A Global Programme
IEE Project Approach
Energy Systems Optimisation Resources
Training Format National Experts National Trainees Candidate Plant Host Plant Candidate Plant
Training Results 220 Training workshops 3 200 Professionals trained 155 National Experts qualified 53 National Trainers 40 ISO 50001 Lead Auditors
Project ~ Industrial Footprint Iron and Steel Automotive Engineering Agro Processing Chemicals Clothing and Textile Cement Pulp and Paper Commercial Bldngs Mining By Sector 0 2 4 6 8 10 Annual Energy Consumption Small: 8 700 45 000 Medium: 45 001 2.6M Large: > 2.6M Large Medium Small By Company Size 0 10 20 30
Project Outcomes 384 77 2 153 108M 1.9 m 55 Industrial plants engaged Demonstration plants GWh energy saved Energy cost avoided tonnes CO 2e mitigated Case studies
ISO 50001 Certification ~ Early Adopters Compressed air system optimization assessment The SABS certification audit team were: Graduates of the IEEP Lead Auditor training, Graduates of the EnMS Expert Programme Conducted 3 EnMS training workshops on site EnMS Expert conducted internal audit EnMS candidate plant Energy Manager trained by IEEP IEEP supported EnMS implementation IEEP conducted the stage 1 audit. EnMS candidate plant IEEP supported implementation Conducted internal audit Auditor a graduate of IEEP lead auditor training. EnMS candidate plant Energy Manager trained by IEEP EnMS candidate plant Energy Manager trained by IEEP EnMS candidate plant in Cape Town Energy Manager trained by IEEP EnMS candidate plant in Energy Manager trained by IEEP
Project Beneficiaries
Energy Efficiency ~ National Landscape and Drivers
Pre 2008 Energy Conditions o Cheap electricity. 2.2 euro cents/kwh o Abundant power supply capacity 15-20% safety margin o Low annual tariff escalation ave. 5.4% pa since 2000 o Generally poor energy management practices low awareness o Energy efficiency, co-gen and waste heat recovery projects are unattractive > 4 year payback o Small energy services sector
Electricity Tariff Escalation
Post 2008 Energy Conditions o Electricity 300% more expensive approx. 7.0 euro cents/kwh o Critical power safety margins 0-5% o High annual tariff escalation 10-20% pa and set to continue o Co-gen and WHR project feasibility at tipping point o Wider evidence of industrial energy efficiency awareness in all sectors o Renewable / alternative energy interest growing Solar-PV, Biogas, Biomass, etc,
Energy Efficiency Drivers: Supporting Standards o o o o o o o ISO 50001:Energy Management ISO 50002: Energy Audits ISO 50003: Auditor Requirements ISO 50004: Guidelines for Implementation ISO 50006: Energy Baseline and EnPI s SANS 50010: Measurement & Verification ISO 50015: Measurement & Verification
EE Drivers: Regulatory Landscape o Energy White Paper - 1998 o National Energy Efficiency Strategy (NEES)- 2004/2015 o Renewable Energy White Paper 2003 o Electricity Basic Services Support Tariff Policy - 2003 o Biofuels Industrial Strategy - 2007 o National Climate Change Response Strategy (NCCRS) o National Energy Act No. 34 of 2008 o Integrated Resource Plan for Electricity 2010-2030 (IRP2) o Integrated Energy Plan (IEP) (not yet promulgated) o Income Tax Act Amendments (12i/l/k) Tax allowances for EE savings o SANS 941 Energy Efficiency of Electrical and Electronic Apparatus o 2nd National Communication to the United Nations Framework Convention on Climate Change (UNFCCC) o Energy Efficient Leadership Network (EELN)
Regulations on Energy Consumption Reporting and Energy Management Plans Government (DoE) Notice R259 of the National Energy Act 2008 published for comment on 27Mar2015: All industrial facilities, mines, commercial & public buildings consuming more than 180 Terra Joules (50 GWh) pa shall submit to the Department annual energy consumption figures and all consuming >400 Terra Joules (110 GWh) shall submit a 5 year energy management plan signed by the accounting officer, to guide, manage and implement their energy efficiency initiatives;
Case Study Evidence
Case Study Steel Mill Arcelormittal Saldanha Works South Africa COREX Electricity demand : 160 MW Steel shop Manpower: 548 permanent employees Sales output: 1.2M ton HRC/annum Mills RHF DR-Plant Energy Efficiency Achievements 2011 Energy Management System Implemented No. of Projects/Measures 11 Total Capital Investment 0 2011 Gross Financial Savings 3.75M Overall Payback Period 0 years 2011 Energy Savings 80 GWh 2011 GHG Reductions (tons CO 2 ) 77,000 Energy Savings in 2012 > 100 GWh Success Factors Plant Director & Energy Manager Leadership Training, communication and innovative strategies to secure employees commitment Collaboration between different departments
Case Study ~ Automotive OEM Johnson Matthey South Africa Manufacturing plant in the automotive sector Started implementation of EnMS in 2012 Target ISO 50001 certification Johnson Matthey 2012-2013 Annual Electricity Savings Annual cost savings - Cost savings from projects - Cost savings from behavior changes & operational efficiency 9.4 GWh 630,000 370,000 260,000 Total annual investments 500,000 Payback Period ISO 50001 Certified - 2014 0.8 yrs Completed implementation in 9 months 4 large projects implemented: Compressors optimisation; optimising chillers; calcining ovens, process optimisation Success Factors Full support and resources from top management (appointed Energy Team) Energy Manager Leadership Weekly meetings of Energy Team Adjusting existing structures to energy specifics (policies, procedures & reporting)
Case Study ~ Automotive Assembly 700 000 m 2 7 500 employees Toyota SA 153 000 units / year 105 000 MWh / year 309 000 GJ (Gas) Energy Cost = 122M per annum Toyota improvements 2010-2013 Energy Management System Implemented No. of Measures/Projects 73 Total Capital Investment Gross Monetary Savings Overall Payback Period 5.2M 9.1M 0.6 years Annual Energy Savings (MWh) 15,603 2011 GHG Reductions (tons CO 2 ) 13,058
SA s Energy Efficiency Business Case
SA s Power Generation Profile
Industrial Business Case for Renewable Energy o o o o o o Biofuels Food vs fuel debate Biogas founding of SA Biogas Association (SABIA) in 2013, The GEF/UNIDO 4 year SMME biogas project, +50 industrial plants operational including 7 large biogas plants under construction Biomass wood chips and bagasse widely used for industrial steam and power generation, Ocean Renewable Energy - blue economy, wave energy Solar PV solar atlas in progress Wind Power existing wind atlas
Bioenergy Projects in South Africa TT.MM.JJJJ Seite 27
Vielen Dank für Ihre Aufmerksamkeit sramdharee@csir.co.za +27 (0) 74 254 3488 ahartzenburg@csir.co.za +27 (0) 83 779 2871 www.iee-sa.co.za TT.MM.JJJJ Seite 28