This paper is based on an implemented industrial energy efficiency optimisation project. The purpose of this project is to work with the Coleus Packaging Facility’s top Management in strategizing and exploring an approach towards elevating the already initiated steps to implementing an Energy Management System (EnMS) programme in order to Optimize Energy utilisation with an aim of optimising Energy utilization, creating an energy reserve, improve asset Reliability as well as reduce tCO2 footprint without compromising Product quality and Output. The result of which adds to better bottom line and making the world greener and more sustainable. Key activities in this exercise have been: Energy Audit and Analysis, Identify and communicate to Coleus Packaging senior Management on potential cost savings as a result of better energy management practices at the Facility, Provide expert advice on implementation methodology on all my recommendations that will have been approved.
Table of Contents
1. EXECUTIVE SUMMARY
1.1. Headlines of the project benefits at optimization of Energy Efficiency Technologies and improved systems management.
1.2. Tariffs
1.3. Summary of identified Key Energy Saving or Energy Reserve creation
1.4. Commentary and recommendation on Systems Energy Efficiency (SEE) optimization methodologies.
2. INTRODUCTION
2.1. Objective of the Survey:
2.2. Project Inception:
2.3. Scope of Energy Review
2.4. Systems Approach
3. Energy Consumption and Costs Analysis
3.1. Facility lay-out in simple diagram
3.2. Problem Area Details
3.3. Detailed analysis on types of Energy Demand, utilization and cost at both holistic and section component level including recorded, collected, captured and quantified data plus commentary on characteristics of energy utilization
3.3.1. Ekurhuleni Metropolitan Municipality (EMM):Electrical Energy Bills and Interpretation;
3.3.2. SASOL: Sasol GAS Bills and interpretation;
3.4. Ekurhuleni Metropolitan Municipality : Water Bills and Property rates commentary;
4. CHARACTERISTICS OF ENERGY USE AT COLEUS PACKAGING
4.1. QUANTIFICATION OF SEUs
4.2. ENERGY USE CHARACTERISTICS
4.2.1. Cost of Energy
4.2.2. Level of emission to the atmosphere of the by-products of using that energy
4.3. Analysis of Electrical Energy usage at Coleus Packaing and Impact on the Environment:
4.3.1. RECOMMENDATION ON PFC EQUIPMENT.
4.4. Analysis of GAS Energy usage at Coleus Packaing and Impact on the Environment:
5. KEY ENERGY SAVING OPPORTUNITIES
5.1. CONTEXT
5.2. Assessed Key Energy Saving Potential Opportunity areas:
5.2.1. Poor Power Factor at the Facility
5.2.2. Open Blowing of Compressed Air on In-feeds at Coater and Printer
5.2.3. Speed on Main Compressor
5.2.4. Each individual Line Chiller compressor except the newer Line 11 running R22
5.2.5. All factory shop lights are fluorescent tubes and all High Bays are high energy users
5.2.6. Yielding of Natural light during clear and Sunny days.
5.2.7. Insulation and ventilation of some portions of the factory shops
5.2.8. Motor management
5.2.9. Compressed Air system
6. Develop and Implement an Energy Policy for COLEUS PACKAGING.
6.1. Instigate a comprehensive staff awareness and motivation energy efficiency campaign:
7. NEXT STEPS:
7.1. Identified Opportunities Need Action.
8. Project Risks, Risk analysis and Risk mitigation
9. Close-out of the Energy Efficiency survey
10. Project(s) Execution
10.1. Summary of Projects deliverables
10.2. Factors taken into consideration before Projects execution.
10.3. Project Milestones
10.4. Work Breakdown Structure
10.5. Project Review and Monitoring
11. Inclusions and Exclusions statement
12. General Recommendation and Conclusion:
13. References
14. Annexures and Appendices
15. APPENDIX B
Project Goals and Thematic Focus
The primary objective of this report is to optimize energy utilization and create an energy reserve for Coleus Packaging (Pty) Ltd. By conducting a detailed energy audit and implementing a modern Energy Management System (EnMS), the study aims to reduce energy consumption, minimize carbon emissions, and lower operational costs without compromising product quality or production output.
- Energy audit and analysis of Significant Energy Users (SEUs).
- Identification of cost-saving opportunities through improved energy management.
- Implementation of energy efficiency technologies (e.g., Power Factor Correction, LED lighting, VSD retrofitting).
- Development of a formal Energy Policy and staff awareness campaigns.
- Strategic planning for energy reserve creation and load shedding mitigation.
Extract from the book
2.3. Project Inception:
The factors which instantly motivated this energy survey project’s approval by the owners of Coleus Packing comprise the following;
a) Fully externally funded project
The approach on meeting the costs for the consultant undertaking the energy survey and recommendation for implementation of energy optimization technologies to create an energy reserve and cut energy cost for the organization were streamlined from an already structured DFID-UK fully funded Programme and locally administered by the NBI-PSEE, which was at the time being rolled out to all subscribed Medium size private companies with a total spend on all forms of energy that does not exceed R45 million or £2.37 million approximately. The author of this report has been the consultant for the project.
b) Reality of high energy bills and ever-increasing tariffs
The fact that cost of energy within the past decade to date has cumulatively been increased by about 120% by the energy utility supply companies and that there no expectation of reduction in sight for the future makes every energy user, especially at corporate level, to start exploring means of making the best out of energy systems within their facilities.
c) Loss in production due to periodic and oftentimes unpredicted load shedding by the national power supply company
At Coleus Packaging, load-shedding has oftentimes resulted in loss of several tons of steel in scrapping off partially baked plates stuck in a 30-metre long by 3metre high LTG oven due to power cut (as a result of load-shedding) to the electrically driven conveying system. Intervention in ideas for cost-effective solution to the problem was therefore sought by the Managing Director, Mr Garth du Plessis at Coleus Packaging from the consultant for the project, Mr Gracious Banda.
Summary of Chapters
1. EXECUTIVE SUMMARY: Outlines the scope of the energy audit at Coleus Packaging, highlighting project benefits such as cost reduction, carbon footprint minimization, and energy reserve creation.
2. INTRODUCTION: Provides the background of the case study, defines the survey objectives, and explains the motivations behind the energy management initiative.
3. Energy Consumption and Costs Analysis: Details the analysis of electrical, gas, and water consumption data, including tariff evaluations and cost distribution patterns.
4. CHARACTERISTICS OF ENERGY USE AT COLEUS PACKAGING: Quantifies Significant Energy Users (SEUs) and analyzes the environmental and financial impact of the site's current energy usage.
5. KEY ENERGY SAVING OPPORTUNITIES: Identifies and prioritizes specific areas for improvement, such as power factor correction, compressed air efficiency, and lighting upgrades.
6. Develop and Implement an Energy Policy for COLEUS PACKAGING.: Discusses the importance of top-down management and workforce engagement in maintaining a sustainable energy policy.
7. NEXT STEPS:: Outlines the immediate actions and recommended courses for implementing the proposed energy efficiency solutions.
8. Project Risks, Risk analysis and Risk mitigation: Addresses the necessity of performing risk assessments for energy saving projects to ensure successful implementation.
9. Close-out of the Energy Efficiency survey: Summarizes the initial presentation of results to senior management and the transition into project execution.
10. Project(s) Execution: Describes the management process, deliverables, and milestones achieved during the implementation of the energy efficiency projects.
Keywords
Energy Management System, EnMS, Coleus Packaging, Energy Audit, Significant Energy Users, SEUs, Power Factor Correction, Energy Efficiency, Carbon Footprint, Load Shedding, Tariff Optimization, Compressed Air System, Renewable Energy, Industrial Sustainability, Energy Reserve.
Frequently Asked Questions
What is the core purpose of this work?
The work aims to optimize energy usage and operational costs at Coleus Packaging through an energy audit and the subsequent implementation of energy efficiency technologies.
What are the primary areas of focus in this report?
The report centers on significant energy users (SEUs) such as compressor systems, lighting, oven insulation, and power factor correction equipment.
What is the main goal or research question?
The primary goal is to create an energy reserve and reduce the site's carbon footprint and energy expenditure without sacrificing production quality.
Which scientific or analytical methods were utilized?
The study employed systematic energy auditing, data logging with energy analyzers, tariff analysis, and quantitative comparisons of energy consumption against utility bills.
What topics are covered in the main section?
The main sections cover current energy consumption patterns, detailed audits of production machinery, tariff migration, and proposed technical upgrades to improve efficiency.
Which keywords best characterize the project?
Key terms include Energy Management, Energy Efficiency, Power Factor Correction, Industrial Auditing, and Sustainable Manufacturing.
How does the author propose to mitigate the issue of load shedding?
The author suggests specific technological interventions and energy reserves that allow the facility to maintain critical production processes despite power interruptions.
What is the significance of the "Power Factor" discussed in the audit?
The audit revealed a poor power factor, which was causing unnecessary financial losses; correcting this leads to significant savings and reduces the strain on the electrical system.
How is the "Energy Policy" supposed to be implemented?
The policy requires strong management leadership, active employee participation, and the use of tools like CMMS for reporting and progress monitoring.
- Citation du texte
- MSc, IEng Gracious Banda (Auteur), 2015, Optimization of Systems Energy Efficiency and Creation of Energy Reserve for Manufacturing and Process activities at Coleus Packaging (Pty) Ltd using Modern Energy Management Technologies, Munich, GRIN Verlag, https://www.grin.com/document/412011
