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EMPOWERING YOU
Slide | 2
ENERGYMAESTRO – PRESENTATION OUTLINE
1. Challenges in energy management today 2. ENERGYmaestro methodology 3. ENERGYmaestro examples of implementation
Ulrika Wising – VP Sales & Marketing
Slide | 3
INDUSTRY HAS ALREADY SAVED A LOT
But we can still do more! • 2010 McKinsey
report : There is still a potential to reduce energy consumption up to 25% by improved energy management
Slide | 4
WE ALL WANT TO SAVE ON ENERGY COSTS
Energy Cost
Savings
Procurement
Investments
Operations
Slide | 5
• Operations are production-oriented, not cost optimization-oriented
• Few actionable parameters for operators
• Problem solving is based on opinions and experience rather than on facts
ENERGY MANAGEMENT CHALLENGES
• Reduce energy costs while maintaining production levels
• Secure already made investments for increased energy efficiency
• Increase sustainability
Slide | 6
EFFECTIVE ENERGY MANAGEMENT
• Is integrated in the overall management of production, quality and energy
• Is part of a continuous improvement activity • Perform Audit • Install necessary measurements • Install a Data historian • Implement the “management” part of an energy
management system (targets, responsibilities, models)
• Improve (training, audit, projects)
Slide | 7
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 8
GAP ANALYSIS
TARGET
NOW
Design
1. Assess where you
are
2. Target where you want to be
time
KPI
3. Analyze and close the gap
Maintenance
Variability
OEE
Waste = Opportunity
Energy projects are rarely pure energy projects
Slide | 9
NA Europe
BAT
GAP ANALYSIS
Slide | 10
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 11
KPI DEFINITION
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
Slide | 12
KPI DEFINITION (SMART)
• WHO? WHAT? WHEN? HOW? the right decision-making support to the right people, at the right time
Role of KPI • related to business goals • linked to relevant targets • assigned to people that are
accountable • actionable • visually adapted to user • easy to interpret • in limited number (<5)
Slide | 13
KPI DEFINITION
Slide | 14
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 15
DATA COLLECTION – EXAMPLE
It all starts with a very simple question: What makes the natural gas consumption at the furnace vary?
Slide | 16
What makes the natural gas
consumption at the furnace vary?
Slide | 17
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 18
steam per ton of paper
VARIABILITY ANALYSIS
The causes for variability in steam use is not clear
Slide | 19
Step 1: Quantifying variability
VARIABILITY ANALYSIS
Low consumption
Medium consumption
Peak consumption
≈ + 2.5 €/t
≈ + 3 €/t
Slide | 20
VARIABILITY ANALYSIS
0
5
10
15
20
25
30
A B C D E F G H I J K L M N O P
%
Parameters
Pareto chart Step 2: Root cause data analysis
Slide | 21
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 22
TARGETING AND MODELING
KPI: Dirty Steam/MW USER CASE
Slide | 23
TARGETING AND MODELING
Valve opening < 15%
Heating tower temp.
> 85 °C
Heating tower temp.
< 85 °C
Valve opening > 15%
KPI >1.1
KPI <1.1
KPI
1
1
2
Best performance when steam valve is open <15% and heating tower outlet temp is >85°C
1 Most of the bad performance occurs when steam valve is open more than 15%
2
USER CASE
Slide | 24
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 25
MONITORING
Actual value of KPI
Predicted regimes
> 1.1
< 1.1
KPI>1.1 KPI<1.1
A: Performance is good and we know
why
C: Performance is good “but we do not know why”
B: Performance is bad “but we do not know why”
D: Performance is bad and we know
why
Insight to solve the problem 1. CO pre-heater < 15% 2. Temp heating tower > 84,5°C
Previously unseen situation! Operator alerts energy improvement team for more investigations
USER CASE
$600,000!
PER YEAR!
OF RECURRENT!
SAVINGS!
Slide | 26
METHODOLOGY
NO
W
Targ
et
GA
P Gap Analysis
Level 3: Monitoring of specific equipment / process
Level 1: Monitoring of total GJ/day of steam consumed Is there a problem with the mill steam consumption?
Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not,
Is it because of the steam users or the steam recovery?
Recovery Reboiler
Heat exchanger Water recirculation
Users Tempering
Pickling Water / Air heating
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
KPI definition Data collection
Variability analysis Targeting + modeling Monitoring
Implementation
Slide | 27
IMPLEMENTATION
• An energy management system should be an integral part of the manufacturing management system – not a stand alone separate system
ENERGY, PRODUCTIVITY AND QUALITY SHOULD BE MANAGED
TOGETHER WITH A COST
OPTIMIZATION FOCUS
Cost
Energy
Slide | 28
IMPLEMENTATION
“Turning everyone into a decision maker. Push decision-making down to the lowest level.
Our experience strongly suggests that when you ask employees to make most of the decisions, they become more productive”
- Nucor
Ope
rato
rs
Supe
rvis
ors
M
anag
ers
Impa
ct o
f dec
isio
n on
day
-to-d
ay e
nerg
y co
st
Slide | 29
IMPLEMENTATION
USER CASE
Slide | 30
Ulrika Wising u.wising@pepite.be - www.myenergymaestro.com - +32 478 170 193
A PEPITe Technology
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