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July 2014
Watts in Your Business
Program
Goulburn Valley Region
Energy Efficiency Information Grant
Watts In Your Business Program
• Purpose
� Empower SMEs to make informed decisions
about energy efficiency.
� Enable SMEs to achieve reductions in their
operational energy costs.
• Process
� Department of Industry to provide funding to
industry associations to develop and deliver
practical, tailored energy efficiency information
to SMEs.
Watts In Your Business Program
1. Market Survey and Analysis
• Identify “Temperate fruit sector representative” sites
2. Energy Audits
• Identify energy efficiency opportunities
3. Learning Tools - Fact Sheets and Case Stories
• Detailed ways to reduce energy for the largest energy
uses and examples of implementation
4. Shed Walks / Seminars
• Deliver the learning tools to the sector in a practical
and relevant manner – ‘hands on and on site’
Watts In Your Business Program
• Audited 30 sites across 10 regions
� 3 regions in VIC
� 3 regions in NSW
� 1 region in QLD, SA, WA, TAS
• Results provided relate to the Watts in Your Business
Program outcomes and averages
Energy Source Usage Costs
Electricity (kWh) 20,257,165 $3,700,501
LPG (Litres) 1,506,331 $541,521
Fuel (Litres) 1,015,653 $1,435,805
Total $5,677,827
Energy Usage and Costs
47%
14%
39%
Energy Usage
Electricity
LPG
Vehicle Fuel 65%10%
25%
Costs
Electricity
LPG
Vehicle Fuel
Electricity Usage Breakdown
64%
18%
8%
6%
3% 1%
Electricity Usage
Refrigeration
Irrigation Pumps
Grading Equipment
Controlled Atmosphere
Lighting
Other
Refrigeration Electricity
Breakdown
48%
27%
14%
9%2%
Refrigeration Usage
Compressors
Evporative Fans
Pumps
Condensors
Other
Program Electricity Outcomes
Aspect Program Total Average TotalCost Effective
Program Average
Electricity Savings
(kWh) 5,576,010 185,867 94,999
Cost Savings $965,763 $32,192 $16,281
Capital Investment $10,513,759 $350,459 $60,960
Simple Payback 10.9 10.9 3.7
% reduction of
electricity use27.5% 32.4% 14%
LPG Usage Breakdown
43%
31%
15%
11%
LPG Usage
Dryers
Hot Water
Controlled Atmosphere
Fork Lifts
Tariff Charges
65%
32%
3%
Sites with a Demand Charge
Usage
Demand
Fix97%
3%
Sites without a Demand Charge
Usage
Fix
Tariff Cold Store Irrigation GV Cold Store GV Irrigation
Usage- Peak (per kWh) $0.27 $0.31 $0.18 $0.27
Usage- Off-Peak (per kWh) $0.13 $0.15 $0.09 $0.11
Usage- Average Total (per kWh) $0.20 $0.22 $0.14 $0.15
Demand (per kVA or kW) $13.53 - $9.10 -
Fix (per annum) $1,791 $866.50 $1,682 $928
Interval Data
0
50
100
150
200
250
30000:1
5
01:3
0
02:4
5
04:0
0
05:1
5
06:3
0
07:4
5
09:0
0
10:1
5
11:3
0
12:4
5
14:0
0
15:1
5
16:3
0
17:4
5
19:0
0
20:1
5
21:3
0
22:4
5
00:0
0
Consumption (kW)
Time
Mon
Tue
Wed
Thu
Fri
Sat
Sun
Interval Data
0
50
100
150
200
250
300
35000:1
5
01:3
0
02:4
5
04:0
0
05:1
5
06:3
0
07:4
5
09:0
0
10:1
5
11:3
0
12:4
5
14:0
0
15:1
5
16:3
0
17:4
5
19:0
0
20:1
5
21:3
0
22:4
5
00:0
0
Consumption (kW)
Time
Summer
Autumn
Winter
Spring
Key Performance Indicators
(KPI)
Crop TypeElectricity
(kWh/tonne)
LPG
(ltr/tonne)
Fuel
(ltr/tonne)
Costs
($/tonne)
Apple & Pear 129 7 12 $52
Mix 224 11 14 $81
Stonefruit 323 12 28 $151
Goulburn Valley 179 13 13 $48
Program Total 193 9 17 $78
• A set of quantifiable measures that a company or
industry uses to gauge or compare performance.
• Program KPI’s is crop type per tonne of fruit
produced.
Key Performance Indicators
(KPI)
Orchard SizeElectricity
(kWh/tonne)
LPG
(ltr/tonne)
Fuel
(ltr/tonne)
Costs
($/tonne)
Small 271 13 27 $128
Medium 171 9 12 $63
Large 137 7 10 $44
• Alternative KPI’s separated by orchard size
based on tonne of fruit produced.
Top Ten Program Opportunities
Reference OpportunityAverage
payback
Reduction in site
electricity use
1 Off-Peak Irrigation (17%) 1.0 -
2 Variable Head Pressure (73%) 3.4 2%
3 Air Compressor Leak Maintenance (17%) 3.5 >1%
4 Automatic Cold Storage Doors (90%) 4.6 3%
5 VSDs on Irrigation Pumps (57%) 5.6 3%
6 Voltage Power Optimisation (37%) 5.6 8%
7 Lighting Upgrades (100%) 5.6 1%
8 VSD on Evaporative Motors (63%) 6.2 4%
9 Solar (93%) 6.2 8%
10 High Efficiency Motors for Irrigation (63%) 6.9 1%
11 Replacement of HCFC Refrigeration Systems 39.5* 7%
* Payback is only based on electricity savings and does not include maintenance
and refrigerant cost savings.
Top 5 Regional Opportunities
(Goulburn Valley)
1. Air Compressor Leak Maintenance
2. Automatic Cold Storage Doors
3. Lighting Upgrades
4. VSDs on Irrigation Pump Motors
5. Variable Head Pressure Control
Air Compressor Leak
Maintenance
• Consistent maintenance issue
• Educate staff to identify leaks
(through hissing sound)
• Create maintenance program
• Install shut off valves
Parameter Program Range Program Average GV Average
Electricity Savings (kWh) 111 – 2,076 825 1,234
Annual Cost Savings $17 - $228 $109 $159
Capital Costs $150 - $750 $380 $508
Simple payback (years) 2.5 – 10.0 3.5 3.4
Automatic Cold Storage Doors
ParameterProgram Average
(Electronic)
Program Average
(Rapid Lift)
GV Average
(Electronic)
Electricity Savings (kWh) 8,337 9,018 10,899
Annual Cost Savings $1,624 $1,743 $1,927
Capital Costs $7,435 $20,292 $8,464
Simple payback (years) 4.6 11.6 5.6
Lighting- Tubes
ParameterProgram
Average (T5)
Program
Average (LED)
GV
Average (T5)
Electricity Savings (kWh) 1,030 1,207 1,267
Annual Cost Savings $219 $285 $230
Capital Costs $1,022 $1,777 $1,152
Simple payback (years) 4.7 6.2 5.1
• T8 or T12 to T5
• T8 to LED
Lighting - High Bays
• High Bays to LEDs
Parameter Program RangeProgram
Average
GV
Average
Electricity Savings (kWh) 268 – 22,542 7,766 10,961
Annual Cost Savings $72 - $4,200 $1,533 $2,003
Capital Costs $800 - $44,800 $10,478 $15,596
Simple payback (years) 1.7 – 30.1 6.8 8.3
Variable Speed Drives on
Irrigation Pumps
• Variable Speed Drive (VSD)- regulate the frequency
of the electrical power supplied and match the
volume or pressure requirements of the refrigeration
system
0%10%20%30%40%50%60%70%80%90%
100%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Energy Savings
Reduction in Fan Speed
VDSs on Irrigation Pump Motors
Parameter Program RangeProgram
Average
GV
Average
Electricity Savings (kWh) 925 – 285,000 40,557 31,733
Annual Cost Savings $167 - $40,755 $6,024 $5,213
Capital Costs $4,000 - $200,000 $37,090 $26,087
Simple payback (years) 4.8 – 45.5 6.2 5.4
Head Pressure Basics
• The head pressure (discharge pressure)
or condensing temperature of a
refrigeration system has a direct impact on
compressor power consumption
• At cooler ambient temperatures it is easier
to liquefy the compressed refrigerant due
to the temperature differential
Head Pressure Reduction
• Optimise the relationship
between the compressor
and condenser
• On average optimising the
head pressure of a system
can achieve a 3-12%
reduction in power
consumption
• Recommended to speak to
your refrigeration contractor
on how/when to implement
Variable Head Pressure Control
and Head Pressure Reduction
Parameter Program RangeProgram
Average
GV
Average
Electricity Savings (kWh) 540 – 110,000 13,393 37,875
Annual Cost Savings $195 - $15,730 $2,113 $4,899
Capital Costs $1,500 - $65,000 $8,813 $23,275
Simple payback (years) 1.1 – 13.3 5.2 6.1
Audit FAQs
• What is my demand charge? How can I reduce it?
� Demand is the largest amount of electricity being consumed at
any one point in time
� Load Shifting, Contract Negations, VPO, Power Factor Correction.
See Tariff Fact Sheet.
• Which refrigerant is the “best”?
� HCFC- (R22, R123,R401/2/3/8/9) Phase out
� R427A- R22 replacement initial estimates have 7% efficiency loss
� HFCs- (R143a, R404a, R407a, R410a)
� Ammonia- High capital cost/corrosive
� Natural Hydrocarbons- (propane mixtures) flammable
� CO2- No industry examples
Funding
• Federal Funding
– With the repeal of carbon tax there is some
uncertainty in this area
• State Funding
– VEET/VEEC
– Sustainability Victoria
• Private Funding
– Financing (e.g. CBA)
Acknowledgements