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Sustainable Energy Management (SEM) June 2017

Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

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Page 1: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management (SEM)June 2017

Page 2: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Johan Ike – Team lead Process control departmentPersonal details

Sustainable Energy Management 2

• 30 years with AkzoNobel (Research & Engineering)• Senior Process Automation Engineer / Team lead P&E PC• Studies, pre-projects, projects, programs

• IT architect for industrial networks• Process control, DCS, SCADA, MES,• Validation in pharmaceutical industry• Program lead Energy Diagnostics

• Projects:• IT lead for several pharmaceutical factories in Oss,• Revamp DCS,• Energy Diagnostics,• Wireless energy metering & monitoring.• Cyber Security

• Coaching / Mentoring

Page 3: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

WhyWhy

WhatWhat

HowHow

Sustainable Energy ManagementProgram

3Sustainable Energy Management

1. Introduction

2. Program approach

3. Program execution Technical

4. Technical examples

5. Program execution Mindset & Behavior

Page 4: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Today, we are over-utilizing the earth’s resources

4Sustainable Energy Management

Number of planetEarths used each year

Today 1.6

Page 5: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Why the SEM program?

5Sustainable Energy Management

• For operational (energy) excellence

• To decrease the carbon footprint

• To engage colleagues to be more energy efficient

Page 6: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

SEM and AkzoNobel

6Sustainable Energy Management

Page 7: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Scope Operational Eco-Efficiency:Gate-to-Gate

7Sustainable Energy Management

Page 8: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Operational Eco-Efficiency:9 parameters have been defined that measure our footprint

8

• Energy

• VolatileOrganicCompounds(VOC)

• Fresh Water

• Waste

• ChemicalOxygenDemand (COD)

Indirect CO2

Direct CO2

NOx

SOx

Sustainable Energy Management

Page 9: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementAgenda

9Sustainable Energy Management

WhyWhy

WhatWhat

HowHow

1. Introduction

2. Program approach

3. Program execution Technical

4. Technical examples

5. Program execution Mindset & Behavior

Page 10: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementProgram

What is it?• Structured approach• Visualization (usage, ideas & efforts)• Knowledge sharing• Stimulation of continuous improvement• Provision of tools• Support

What is it not?• Audit• Corporate directive• One day initiative• Reinvention of the wheel

10Sustainable Energy Management

Page 11: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementEnergy target

11Sustainable Energy Management

Make conventionalenergy as green as

possible

>20% andgrowing

Priority 1:Energy savings

Common opportunities

growing

Priority 2:Renewable energy

Innovative opportunities

Page 12: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementSupport

12Sustainable Energy Management

2: Identify targets & saving ideas

3: Prioritize opportunities

4: Generate Measure cards (AR-ready)

Plan & Implementthe measures

1: Install metering to visualize energy usage

5:Stimulate Energy Continuous ImprovementContinuousImprovement

Celebrate success

>5% energy savingcan already berealized after thisstep

>10% energysaving can berealized at this step

>2% energy savingeach year can berealized at this step

Page 13: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management

13Sustainable Energy Management

WhyWhy

WhatWhat

HowHow

1. Introduction

2. Program approach

3. Program execution Technical

4. Technical examples

5. Program execution Mindset & Behavior

Page 14: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementRoadmap

14Sustainable Energy Management

Visit 1 Metering Visit 2 Tracking

Make inventoryfor a meteringplan

Investigate theenergy savingsopportunities

Identify quickwins

StimulateMindset &Behavior

Install meteringand monitor for6 months

Evaluatemetering results

Make measurecards, ready forA.R.

Extradashboards &reports

StimulatePerformanceManagement

Track progressof the projects

Put newmeasures onthe priority list

1 week 6 months 1 week Next years

(ISO 50001 compliant)

Page 15: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management3 pillars

15Sustainable Energy Management

PerformanceManagement

Mindsets andbehavior

Technicalsystem

Efficient equipmentVariable speedHeat integration

InsulationGreen energy

Lighting

KPI’s & targetsTracking

DashboardsDialogs

FeedbackDirection

Leadership

MotivationAccountability

ValuesCulture

EducationDecisionsInnovation

Each pillar is equally important

Page 16: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

16Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 17: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy KPI BreakdownOverview

17Sustainable Energy Management

PRODUCEDPURCHASED UTILITIES

UTILITY 100% eff 9,2 m3/kWh 82% eff 82% eff eff

0 kWh 0 Nm3 kwh 0 kWh 0 kWh 0 m3100%

3.409.476 Euro 354.151 Euro 39.142 Euro 13.047 Euro 62.627 Euro 573.333 Euro 2.265.025 Euro11 17 26 29 32 35

51.861.000 kWh 1.918.857 kWh 1.918.857 kWh 777.915 kWh 259.305 kWh 1.244.664 kWh 726.054 kWh 45.015.348 kWh76,5% 10

2.609.476 Euro 96.551 Euro 96.551 Euro 39.142 Euro 13.047 Euro 62.627 Euro 36.533 Euro 2.265.025 Euro

28.118.563 kWh 196.830 kWh 9.054.177 kWh 0 kWh 0 kWh 0 kWh 18.867.556 kWh 0 kWh23,5% 14

800.000 Euro 5.600 Euro 257.600 Euro 0 Euro 0 Euro 0 Euro 536.800 Euro 0 Euro

51.643 kWh 51.643 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh0,0% 30

0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro

kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh0,0% 34

Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro

Gas cooling

1,5%

Helium 100,0%

0,0%32,2% 0,0%

10,4% 1,1%

0,5%

Compressed air

0,7%Natural Gas

Electricity

Hot water

Diesel 0,0%

3,7%

Total Energy Cost Direct

3,7%

0,0%100,0% 0,0%

0,0%0,0% 0,0%

2,4% 1,4% 86,8%

0,0% 67,1% 0,0%

VSDS cooling GRU heating Compressors

0,0% 0,0% 0,0%

0,0% 0,0% 0,0%

Page 18: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy KPI BreakdownDetail 2013

18Sustainable Energy Management

Page 19: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

19Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 20: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

20Sustainable Energy Management

Wi-Pulse meter

Mesh Node(Repeater)

Energy analytics & reportingWi-LEM

meter nodes

Tbox data concentratorCommunication PLC

Gas meter

Pump

Compressor

Energy databaseServer

Page 21: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

21Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 22: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Idea list: difficult to discuss with a group

22Sustainable Energy Management

ID TitleIDcategory Phase GJ savings CO2 savings Net savings Impl. costs Impl.

Payback(y)

100 Install metering for visualization and awareness 1: High savings, Easy to implement7: Measure Defined 844,17 194920 kg € 10.787 € 15.000 Estimate 1,4

104Install a new more energy efficient chiller in stead ofthe 20 year old one. 1: High savings, Easy to implement4: MC candidate 882,00 203654 kg € 11.270 € 30.000 Guess 2,7

105 Install compressed air survey and repair service 0: Savings, Very easy to implement8: Measure Implemented474,73 109614 kg € 3.500 € 1.500 Estimate 0,4

109

Separate compressed air supply lines for WB and SBproduction. During high season block off SB areaduring second shift. 3: No high savings, Easy to implement3: Prioritized 35,60 8221 kg € 455 € 300 Estimate 0,7

111Install timer on the compressors to shut downautomatically after the shift end. 0: Savings, Very easy to implement3: Prioritized 81,00 18703 kg € 1.035 € 200 Estimate 0,2

120

Internal directive for the split heater set points forsummer and winter. A recommendation on the bestsetpoint for building 1 0: Savings, Very easy to implement3: Prioritized 49,00 9400 kg € 650 € 0 Estimate 0,0

122Re-use the heat from the compressors to heat building#5. 2: High savings, Not easy to implement3: Prioritized 395,93 29022 kg € 7.600 € 7.000 Calculation 0,9

130Insulate the Fan Coil Heater pipes going to the Fanboxes in buildings 20 and 14. 1: High savings, Easy to implement4: MC candidate 360,00 83124 kg € 4.600 € 6.000 Calculation 1,3

134Create an internal directive for computers and monitorsetc. used in the offices. Switch of when not in use. 0: Savings, Very easy to implement3: Prioritized 3,91 904 kg € 50 € 0 Guess 0,0

136Schedule cleaning of the Fan Coil Heaters to retain theefficiency 0: Savings, Very easy to implement8: Measure Implemented10,39 762 kg € 200 € 600 Guess 3,0

Page 23: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Program Tracking Tool (PTT)Idea dashboard

23Sustainable Energy Management

last ID number 129

ID no. : 100 Filter

Site : Pontiac x

Utility : All x

Subject : Other x

Source : Tim Evans x

Install metering for visualization and awareness

1: High savings, Easy to implement x

Phase : 3: Prioritized x

Net GJ savings : 3.572 GJNet CO2 savings : 593.595 kgNet savings/year : $27.491Total impl. costs : $37.000

Lead time : 6 weeksInternal FTE time : 4 days

Savings : Estimate x

Idea date : 13-apr-2012 10:50

Last update : 16-apr-2012 21:35 1,3 Payback years (Total impl. costs / net savings)

Approval date :Responsible : Tim Evans x

Remarks : 5% savings on energy use 2011 is normally assumed.

Idea category

-60.000

-40.000

-20.000

0

20.000

40.000

60.000

80.000

100.000

120.000Savings after implementation

1 year 2 years 3 years 4 years 5 years

GJ

Giga Joule Footprint

Page 24: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Program Tracking Tool (PTT)Idea dashboard

24Sustainable Energy Management

1. Standardized lay out forknowledge sharing

2. Phase definition fortracking progress of ideas

3. Prioritizing tool for ideas4. Dashboard function for

quick recognizing ofpriority

5. Automatic tracking of thelast change date

6. Filter possibilities tobrowse quickly to groupedideas

last ID number 129

ID no. : 100 Filter

Site : Pontiac x

Utility : All x

Subject : Other x

Source : Tim Evans x

Install metering for visualization and awareness

1: High savings, Easy to implement x

Phase : 3: Prioritized x

Net GJ savings : 3.572 GJNet CO2 savings : 593.595 kgNet savings/year : $27.491Total impl. costs : $37.000

Lead time : 6 weeksInternal FTE time : 4 days

Savings : Estimate x

Idea date : 13-apr-2012 10:50

Last update : 16-apr-2012 21:35 1,3 Payback years (Total impl. costs / net savings)

Approval date :Responsible : Tim Evans x

Remarks : 5% savings on energy use 2011 is normally assumed.

Idea category

-60.000

-40.000

-20.000

0

20.000

40.000

60.000

80.000

100.000

120.000Savings after implementation

1 year 2 years 3 years 4 years 5 years

GJ

Giga Joule Footprint

Page 25: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

25Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 26: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Measure Card used in theprogram

26Sustainable Energy Management

1. Ready for using in theAppropriation Request

2. Standard excel sheet forthe visualization ofenergy savings

3. Automatic calculation ofGJ and CO2 footprint

Page 27: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

27Sustainable Energy Management

Measure CardDetails

Page 28: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementIdeation Process

28Sustainable Energy Management

• Ideas– Cleaned up– Prioritized

• Opportunities– Measure Card Candidate– Measure Card Ready– Measure Card Approved

• Measures– Measure defined– Measure approved– Measure implemented

Page 29: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementIdea Prioritizing

29Sustainable Energy Management

100%

0% 100%

0:Sa

ving

s,V

ery

easy

toim

plem

ent

1: High savings,Easy to implement

2: High savings,Not easy to implement

3: No high savings,Easy to implement

4: No high savings,Not easy to implement

5:N

otfe

asib

le

Implementation effort

Savi

ngs

Page 30: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management22 Opportunities (-28% carbon footprint)

Sustainable Energy Management 30

12.442 548.248 € 121.867 € 148.278 GJsavings

CO2 (kg) savings

Netsavings

Impl.costs

Page 31: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

31Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 32: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management

32Sustainable Energy Management

WhyWhy

WhatWhat

HowHow

1. Introduction

2. Program approach

3. Program execution Technical

4. Technical examples

5. Program execution Mindset & Behavior

Page 33: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Building / Piping insulationCommon opportunities

33Sustainable Energy Management

•Conditioned air (hot and cold) is lost through roofs, open doors, windowsetc. Can be prevented with roof insulation, strip doors, tinted, reflective orcoated glass

•Insulating could save over 40% of the energy required for heating orcooling.

Source: www.gruenecodesign.com

Page 34: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

HVACCommon opportunities

34Sustainable Energy Management

•Reduced set points for heating and increase setpoint for cooling. Reducing a temperature setpoint with one degree can save up to 7% of theheating energy consumed by that room.

•During nights and/or non-production hours setpoints of heating and/or cooling should bereduced/increased or shut down.

Page 35: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

MaintenanceCommon opportunities

35Sustainable Energy Management

The difference between clean and dirty heat exchangers can go up to35% of the energy efficiency of the equipment.

Page 36: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

TimersCommon opportunities

36Sustainable Energy Management

Switching off the equipments that are not continuouslyin use. Opportunity in mixers, compressed air system,A/C (to reduce running time).

Page 37: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Heat RecoveryCommon opportunities

37Sustainable Energy Management

• Recovery of heat from the furnace exhaust gas/flue gases, fromcondensate or from compressors.

• Within forced draft air systems several systems are available torecover energy with the following energy savings*:

• Recirculation of air: 100%• Heat wheel with absorption: 70% + humidity• Heat wheel: 70%• Cross flow heat exchanger: 60%• Twin coil: 50%*Efficiencies are approximate values

Page 38: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Adiabatic (top-)coolingCommon opportunities

38Sustainable Energy Management

COP Chiller : about 4 (COP = Coefficient of Performance)COP Cooling tower: about 14

Page 39: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

BoilersCommon opportunities

39Sustainable Energy Management

•Insulate boiler•Minimize excess air•Heat recovery (economizer)•Repair steam leaks•Use high efficiency boiler

•Shut down boiler when not in use•Reduce temperature of the boiler•Replace high emission fuels (oil) with less polluting fuels (natural gas)•Avoid over dimensional pumps for heating water circuit•Ensure that circulation pumps are switched off in summer

Page 40: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Compressed air systemCommon opportunities

40Sustainable Energy Management

•Reduce pressure of the network•Reduce inlet temperature•Replace air- by electrical equipment (20x more efficient)•Install variable speed drive on the motor.•Differentiate day and night settings.•Maintain equipment•Remove improper compressed air users•Conduct periodic leak surveys and repair•Use the residual heat of the compressor

Page 41: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Electric motorsOpportunities

41Sustainable Energy Management

•Life Cycle Analysis for the electric motor•High efficiency motors, consider buying a more efficient motor:

• For all new installations• When purchasing equipment such as compressors, HVAC systems

and pumps• When major modifications are made to facilities or processes• Instead of rewinding older, standard efficiency units• When replacing oversized or under loaded motors• As part of preventive maintenance or energy conservation programs

Page 42: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Variable frequency for electrical motorsCommon opportunities

42Sustainable Energy Management

Page 43: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Innovative opportunitiesEnergy Efficiency Program

43Sustainable Energy Management

•Replace the conventional boilers with Combined Heat and Power unit(CHP)•Preserve energy during down-time =>Utilities like (hot)water can bestored during down-time instead of discard to sewer.

•Heat / cold storage

•Solar energy

•Wind energy

•Biomass

Page 44: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Heat / cold storageInnovative opportunities

44Sustainable Energy Management

Installed installation in Sassenheim by Wout Versluis

Page 45: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Solar heat, Solar collectors on the roof ofthe cafeteria building at Planta Colón

45Sustainable Energy Management

•15 Heat Pipe Solar Collectors heat the water in the cafeteria (200 employees)and locker rooms

• Execution Period: Nov 2008 – Jan 2009• Investment: US$ 20.000• Installed Power Capacity: 34.968 Kwh/year

In 15 years, the solar collectors will cut anestimated 120 tons of CO2 emissions

Page 46: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Solar & wind energySun and wind light streets of Lang Fangplant, China

46Sustainable Energy Management

•Deco China decided to replace 18 electrical street lights with solar ones. Acombination of solar and wind energy was used to power these five lights, most ofthe power being wind generated in winter and sunlight at other times of the year.

•With an annual electricity consumption of 21024 kWh, the system will generate acost saving of 2.359 EUR with a payback time of 52 months.

Page 47: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Solar energySolar cells on rooftop in Castelletto,

47Sustainable Energy Management

•Cristiano Taverna, Supply Chain & HSE Manager in Italy, took this opportunity toput solar cells on the site’s roof. With a total energy consumption of 1.3 mega Wattper year 15% comes from the solar cells, thereby reducing Castelletto’s externalenergy consumption and energy bill.

•After 6.5 years we will have a positive cash flow and we don’t have to buy asignificant part of the energy from external parties any longer,

Page 48: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy RoofInnovative opportunities

48Sustainable Energy Management

Page 49: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy RoofInnovative opportunities

49Sustainable Energy Management

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Energy opportunity typesSEM Results

50Sustainable Energy Management

1. Maintenance

2. Awareness

3. Control/Timers/Tuning

4. On/Off, Setpoints

5. Insulation

6. Efficient equipment

7. Heat recovery

a) Rework / off spec

b) Over-dimension

c) Over-production

d) Planning

e) Transport

f) Renewables

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Energy opportunity typesSEM Results Process control related

51Sustainable Energy Management

1. Maintenance

2. Awareness

3. Control/Timers/Tuning

4. On/Off, Setpoints

5. Insulation

6. Efficient equipment

7. Heat recovery

a) Rework / off spec

b) Over-dimension

c) Over-production

d) Planning

e) Transport

f) Renewables

Page 52: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy Management

52Sustainable Energy Management

WhyWhy

WhatWhat

HowHow

1. Introduction

2. Program approach

3. Program execution Technical

4. Technical examples

5. Program execution Mindset & Behavior

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Behavioral effects of performanceimprovements

53Sustainable Energy Management

Perfo

rman

ce

TimeBefore Step change Sustainability

Behavioraleffect

Deterioration

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Sustainable Energy ManagementDeliverables

54Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 55: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy survey questions aboutDIRECTION (I know what to do)

• Vision, Policy

• KPI’s

• Targets

• Responsibility

• Improvements

55Sustainable Energy Management

Page 56: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy survey questions aboutCAPABILITIES (I am able to do it)

• Training

• Knowledge

• Conferences

• Renewable sources

• Purchasing

• Budget

56Sustainable Energy Management

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Energy survey questions aboutFEEDBACK (I know how well I am doing)

• Measurements

• Feedback

• Idea box

• Communication

• Reports

57Sustainable Energy Management

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Energy survey questions aboutMOTIVATION (I have a reason for doing so)

• Attention

• Implementations

• Recognition

• Rewards

• Role models

• Continuous improvement

58Sustainable Energy Management

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Energy Survey results presentationPerformance Management axis

59Sustainable Energy Management

Direction

Feedback

I know what to doVision, Leadership,

CoordinationKPI, Targets, Plans

I know how well I amdoing

Dialogs, Dashboards,Metering, (Automatic)

tracking

Page 60: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy Survey results presentationMindset and behaviour axis

60Sustainable Energy Management

CapabilitiesMotivation

I am able to do itEducation, Budget

External orientation,Innovation, Decisions

I have a reason fordoing so

Culture, Accountability,Actions, Values,

Engagement, Rewards

Page 61: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Energy Survey results presentationPMMB axes

61Sustainable Energy Management

CapabilitiesMotivation

Direction

Feedback

I know what to doVision, Leadership,

CoordinationKPI, Targets, Plans

I am able to do itEducation, Budget

External orientation,Innovation, Decisions

I know how well I amdoing

Dialogs, Dashboards,Metering, (Automatic)

tracking

I have a reason fordoing so

Culture, Accountability,Actions, Values,

Engagement, Rewards

Page 62: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

SEM Program DeliverablesEnergy Awareness Survey

62Sustainable Energy Management

0,0

10,0Direction

Capabilities

Feedback

Motivation

Current PracticeQuestionaire Max. score

I know what to doVision, Direction

Leadership, CoordinationKPI, Targets, Plans

I am able to do itEducation, Budget

External orientation,Innovation, Decisions

I know how well I am doingDialogs, Feedback

Dashboards, Metering(Automatic) tracking

I have a reason for doing soMotivation, Accountability

Culture , Values, Engagement,Actions, Rewards

Example graph

Page 63: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementProgramDeliverables

63Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 64: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

SEM programDashboard

64Sustainable Energy Management

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Energy consumption overview Wing A

65Sustainable Energy Management

15001600170018001900200021002200230024002500

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

Ener

gyco

nsum

ptio

n(k

Wh)

Week number

Actual weekly energy consumption (kWh) Energy usage running average (kWh)

Annual Electricity ConsumptionActual versus Target

Actual Consumption

Target Consumption

£ 1,163,573

£ 1,045,000

Year to date

Energy consumption overview Wing A

Page 66: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

SEM programCompressed Air Leakage dashboard

40 4530

4030 32

4070

50 55

0

100

35 36 37 38 39 40 41 42 43 44Week no.

Compressed air leaks TargetkW/hr

48

Week no. Remarks Performance43 Leak survey and repair ready Current loss € 4.23839 Leak survey requested Target loss € 4.66038 Broken hose detected Deviation € 422

Sustainable Energy Management 66

Page 67: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

VisionSet direction and context Set KPI’s

& targets

Budget& plans

Tracking

Dialogues

Actionsrewards 5

Performance Management modelCreate Dialogues

67Sustainable Energy Management

Daily Weekly Monthly

BU manager

Plantmanager

Productionmanager

Supervisor

OperatorBest score: $ 350

Current score: $ 380

C o n t r o l v a lve p o s it io n

0

2 0

4 0

6 0

8 0

10 0

0 2 4 6 8 1 0 1 2

t im e

%op

en

432

ETHOMEEN® C/12 BULK

$ (30)

LBS 45.295

12-12-06

21:44

13-12-06

08:36

Natural Gas/lb produced

0.00000

0.00050

0.00100

0.00150

0.00200

0.00250

0.00300

Jan-

09Fe

b-09

Mar

-09

Apr-0

9M

ay-0

9Ju

n-09

Jul-0

9Au

g-09

Sep-

09O

ct-09

Nov-0

9De

c-09

Jan-

10Fe

b-10

Mar

-10

Natural Gas/lb produced

Natural Gas/lb produced

0.00000

0.00050

0.00100

0.00150

0.00200

0.00250

0.00300

Jan-

09Fe

b-09

Mar

-09

Apr-0

9M

ay-0

9Ju

n-09

Jul-0

9Au

g-09

Sep-

09O

ct-09

Nov-0

9De

c-09

Jan-

10Fe

b-10

Mar

-10

Natural Gas/lb produced

Page 68: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementDeliverables

68Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior

Page 69: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Change WorkshopI will change my behavior if……

69Sustainable Energy Management

CapabilitiesMotivation

Direction

Feedback

I know what to doVision, Direction

Leadership, CoordinationKPI, Targets, Plans

I am able to do itEducation, Budget

External orientation,Innovation, Decisions

I know how well I am doingDialogs, Feedback

Dashboards, Metering(Automatic) tracking

I have a reason for doing soMotivation, Culture,

Accountability, Actions,Values, Engagement, Rewards

Page 70: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Continuous ImprovementPerformance management model

70Sustainable Energy Management

VisionSet direction and context Set KPI’s

& targets

Budget& plans

TrackingDialogues

Actionsrewards

CapabilitiesMotivation

Direction

Feedback

Page 71: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Continuous Improvement SEMPerformance management model

71Sustainable Energy Management

VisionSet direction and context Set KPI’s

& targets

Budget& plans

TrackingDialogues

Actionsrewards

last ID number 129

ID no. : 100 Filter

Site : Pontiac x

Utility : All x

Subject : Other x

Source : Tim Evans x

Install metering for visualization and awareness

1: High savings, Easy to implement x

Phase : 3: Prioritized x

Net GJ savings : 3.572 GJNet CO2 savings : 593.595 kgNet savings/year : $27.491Total impl. costs : $37.000

Lead time : 6 weeksInternal FTE time : 4 days

Savings : Estimate x

Idea date : 13-apr-2012 10:50

Last update : 16-apr-2012 21:35 1,3 Payback years (Total impl. costs / net savings)

Approval date :Responsible : Tim Evans x

Remarks : 5% savings on energy use 2011 is normally assumed.

Idea category

-60.000

-40.000

-20.000

0

20.000

40.000

60.000

80.000

100.000

120.000Savings after implementation

1 year 2 years 3 years 4 years 5 years

GJ

Giga Joule Footprint

PRODUCEDPURCHASED UTILITIES

UTILITY 100% eff 9,2 m3/kWh 82% eff 82% eff eff

0 kWh 0 Nm3 kwh 0 kWh 0 kWh 0 m3100%

3.409.476 Euro 354.151 Euro 39.142 Euro 13.047 Euro 62.627 Euro 573.333 Euro 2.265.025 Euro11 17 26 29 32 35

51.861.000 kWh 1.918.857 kWh 1.918.857 kWh 777.915 kWh 259.305 kWh 1.244.664 kWh 726.054 kWh 45.015.348 kWh76,5% 10

2.609.476 Euro 96.551 Euro 96.551 Euro 39.142 Euro 13.047 Euro 62.627 Euro 36.533 Euro 2.265.025 Euro

28.118.563 kWh 196.830 kWh 9.054.177 kWh 0 kWh 0 kWh 0 kWh 18.867.556 kWh 0 kWh23,5% 14

800.000 Euro 5.600 Euro 257.600 Euro 0 Euro 0 Euro 0 Euro 536.800 Euro 0 Euro

51.643 kWh 51.643 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh0,0% 30

0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro

kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh 0 kWh0,0% 34

Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro 0 Euro

Gas cooling

1,5%

Helium 100,0%

0,0%32,2% 0,0%

10,4% 1,1%

0,5%

Compressed air

0,7%Natural Gas

Electricity

Hot water

Diesel 0,0%

3,7%

Total Energy Cost Direct

3,7%

0,0%100,0% 0,0%

0,0%0,0% 0,0%

2,4% 1,4% 86,8%

0,0% 67,1% 0,0%

VSDS cooling GRU heating Compressors

0,0% 0,0% 0,0%

0,0% 0,0% 0,0%

Page 72: Sustainable Energy Management (SEM) - KIVI SEM.pdfEnergy KPI Breakdown Overview Sustainable Energy Management 17 PRODUCED PURCHASED UTILITIES UTILITY 100% eff 9,2 m3/kWh 82% eff 82%

Sustainable Energy ManagementQuestions?

72Sustainable Energy Management

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

KPI breakdown

Monitoring system

Idea list

Measure cards (AR-ready)

SurveyKPI cockpit

Dashboards

Continuous improvement

SurveyKPI cockpit

Dashboards

Continuous improvement

Technicalsystem

PerformanceManagement

Mindsets andbehavior