EMPOWERING YOU

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ENERGYMAESTRO – PRESENTATION OUTLINE

1.  Challenges in energy management today 2.  ENERGYmaestro methodology 3.  ENERGYmaestro examples of implementation

Ulrika Wising – VP Sales & Marketing

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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

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WE ALL WANT TO SAVE ON ENERGY COSTS

Energy Cost

Savings

Procurement

Investments

Operations

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•  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

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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)

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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

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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

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NA Europe

BAT

GAP ANALYSIS

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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

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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)

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KPI DEFINITION

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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

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DATA COLLECTION – EXAMPLE

It all starts with a very simple question: What makes the natural gas consumption at the furnace vary?

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What makes the natural gas

consumption at the furnace vary?

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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

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steam per ton of paper

VARIABILITY ANALYSIS

The causes for variability in steam use is not clear

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Step 1: Quantifying variability

VARIABILITY ANALYSIS

Low consumption

Medium consumption

Peak consumption

≈ + 2.5 €/t

≈ + 3 €/t

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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

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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

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TARGETING AND MODELING

KPI: Dirty Steam/MW USER CASE

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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

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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

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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!

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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

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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

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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

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IMPLEMENTATION

USER CASE

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Ulrika Wising u.wising@pepite.be - www.myenergymaestro.com - +32 478 170 193

A PEPITe Technology