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Robert WilliamsRobert Williams
ChiefChief
Energy Efficiency and Climate Change Energy Efficiency and Climate Change UnitUnit
UNIDOUNIDO
Industrial System Energy Efficiency
An Overview
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Industrial Systems
For this discussion, the term “industrial system” refers to motor-driven or steam systems found in virtually all factories
Globally, motor-driven systems consume more than 70% of global manufacturing electricity (2564 billion kWh) annually1
Both markets and policymakers tend to focus on motor system components, which typically offer a 2-5% efficiency improvement potential
But the optimization of motor systems offer a 20-50% efficiency improvement potential Similar savings opportunities also exist for steam
systems
1 based on analysis conducted by Lawrence Berkeley National Laboratory, Alliance to Save Energy, and Energetics July 2004, updated by LBNL 2005
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Elements of System Optimization
Evaluating work requirements Matching system supply to these requirements Eliminating or reconfiguring inefficient uses
and practices (throttling, open blowing, etc) Applying sophisticated control strategies and
variable speed drives that allow greater flexibility to match supply with demand
Identifying and correcting maintenance problems
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Optimizing a Motor System
15 kW Motor Efficiency is ~ 91%
Measuredelectrical data
Nameplate data:
Information courtesy of Don Casada, Diagnostic Solutions, LLC
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Expanding the Box to include the pump
Pump head: 36 mFlow rate: 97.6 m3/h
=> hydraulic power: 9.6 kW
Combined pump andmotor efficiency = 59%
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Expanding the box still further – to include the discharge valve
There is > 28 m pressure drop across thethrottled valve
Useful hydraulic power = 2.1 kW
Actual System Efficiency is only 13%
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Energy Wasted in Pump System
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The Challenge of Energy Efficiency
If you don’t have a method to measure it and you can’t see it, how can you manage it?
Well-run plant responds to overheated motors caused by poorly controlled pump system
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Energy savings from Systems improvements.
System/facility
Total Cost$US
Energy savingskWh/y
Payback Period
Compressed air/forge plant
18,600 150,000 1.5 years
Compressed Air/machinery
32,400 310,800 1.3 years
Compressed air/tobacco
23,900 150,000 2 years
Pump system/ hospital
18,600 77,000 2 years
Pump system/pharmaceuticals
150,000 1.05M 1.8 years
Motor systems/ petrochemicals
393,000 14.1M 0.5 years
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Why aren’t industrial systems more energy efficient?
Industrial markets focus on components, not systems
Energy efficiency is not core mission for most industries
These are supporting systems- production practices can deeply affect their operation, but are outside of the facility engineer’s control
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Additional barriers to efficiency
Most industries have a budgetary disconnect between capital projects (equipment purchases) and operating expenses (energy and maintenance)
System optimization knowledge resides with the individual who has been trained- it is not institutionalized
Trained individuals leave or transfer and take this knowledge with them
Processes change over time and inefficiencies can re-occur
How can system energy-efficiency be maintained in this complex, changing environment?
