November/1/2004
Energy Efficiency Increase
The concept of energy efficiency increase brings along an idea of performing a work or process using less energy than previously used. In every improvement process, there are some simple and low-cost measures that can bring, in some cases, very satisfactory and surprising results. As the implementation of these initial measures take place, and its gains are obtained, new improvements that provide interesting results become harder to find. In this matter, within the continuously improvement processes performed by the companies, better results are becoming harder to achieve.
Simple measures, such as the ones adopted in Brazil during the power rationing in 2001, reduced the residences consumption in about 20%, and electric power spending reduction was proved possible without exaggerated sacrifices. Many families incorporated the habits, witch provided that significant economy. Nevertheless, if consumers were to achieve the same 20% economy over the current consumption, things would get much more difficult. This is not different within industries.
Many Brazilian industrial sectors have gone through an energy efficiency increase, and significant results were achieved. New improvements are necessary, but significant gains are getting much more difficult to obtain. This way a more technical, deeper and critical approach is required. The current scenario shows companies mobilized in seeking better tools to improve energy efficiency, focusing in reducing electric power and fuel consumption, or using alternative (and cheaper) fuels.
Nowadays, two streams for energy efficiency works are mostly used: the model represented by ESCO companies, and those who perform Specialized Studies. Both seek to reduce spending caused by inefficiencies, whether they result from process, mechanical or electrical matters, but with different commercial approaches.
The energy service companies (ESCO) may or may not share the required investments with the client, and the earnings are shared in a previously agreed form, and formalized through a performance contract (energy savings performance contract – ESPC). A financial agent, partner of the ESCO, may participate in the process, being remunerated for the invested capital. This kind of contract generally is used by limited budget companies, or short in technical staff specialized in the energy area, and dependent in large scale on the ESCO to diagnose and to put in practical purpose the savings recommendations.
On the other hand, companies with available investment capital and a certain degree of technical qualification to implement the energy efficiency increase measures, have been willing to contract specialists that, for a fixed contract value, perform a number of thorough studies and diagnoses at the industrial plants, detecting improvements opportunities. In this case, the client company is entirely responsible for the investments, but the earnings resulting from the energy efficiency increase revert integrally to their industrial plants.
The time is long gone for installing thermal insulation, elimination of steam and compressed air leaks, replace mercury vapor for sodium vapor lamps, replace oversized electric motors with adequate capacity and high efficiency ones, and many other trivial measures. In the current situation, a thorough and deeper analysis is required.
The measures that can be implemented on industries range from equipment substitution to layout or process changes. If simple measures with high economic returns are detected and executed, case the company contracted an ESCO both companies will have done a good business. On the other hand, if such measures are the result of a Specialized Study, then the client has performed an excellent business.
It is up to the Directors, Industrial and Engineering Managers to define which ways are more convenient to their companies today, and to harvest the results in the future.
Energy Efficiency Increase
The concept of energy efficiency increase brings along an idea of performing a work or process using less energy than previously used. In every improvement process, there are some simple and low-cost measures that can bring, in some cases, very satisfactory and surprising results. As the implementation of these initial measures take place, and its gains are obtained, new improvements that provide interesting results become harder to find. In this matter, within the continuously improvement processes performed by the companies, better results are becoming harder to achieve.
Simple measures, such as the ones adopted in Brazil during the power rationing in 2001, reduced the residences consumption in about 20%, and electric power spending reduction was proved possible without exaggerated sacrifices. Many families incorporated the habits, witch provided that significant economy. Nevertheless, if consumers were to achieve the same 20% economy over the current consumption, things would get much more difficult. This is not different within industries.
Many Brazilian industrial sectors have gone through an energy efficiency increase, and significant results were achieved. New improvements are necessary, but significant gains are getting much more difficult to obtain. This way a more technical, deeper and critical approach is required. The current scenario shows companies mobilized in seeking better tools to improve energy efficiency, focusing in reducing electric power and fuel consumption, or using alternative (and cheaper) fuels.
Nowadays, two streams for energy efficiency works are mostly used: the model represented by ESCO companies, and those who perform Specialized Studies. Both seek to reduce spending caused by inefficiencies, whether they result from process, mechanical or electrical matters, but with different commercial approaches.
An obvious energy efficiency increase measure, that can look at first glance obvious but is frequently suggested, is the use of thermal insulation. For example, a metallic tank with a volume of 300 m3, that needs to be heated to maintain a liquid at 80°C, loses to the environment about 100 kW, if not insulated. If a proper thermal insulation is applied, the losses would be reduced to 25 kW. Depending on how the tank heating is made, the investment pay-back can be achieved between 4 to 8 months.
The energy service companies (ESCO) may or may not share the required investments with the client, and the earnings are shared in a previously agreed form, and formalized through a performance contract (energy savings performance contract – ESPC). A financial agent, partner of the ESCO, may participate in the process, being remunerated for the invested capital. This kind of contract generally is used by limited budget companies, or short in technical staff specialized in the energy area, and dependent in large scale on the ESCO to diagnose and to put in practical purpose the savings recommendations.
On the other hand, companies with available investment capital and a certain degree of technical qualification to implement the energy efficiency increase measures, have been willing to contract specialists that, for a fixed contract value, perform a number of thorough studies and diagnoses at the industrial plants, detecting improvements opportunities. In this case, the client company is entirely responsible for the investments, but the earnings resulting from the energy efficiency increase revert integrally to their industrial plants.
The time is long gone for installing thermal insulation, elimination of steam and compressed air leaks, replace mercury vapor for sodium vapor lamps, replace oversized electric motors with adequate capacity and high efficiency ones, and many other trivial measures. In the current situation, a thorough and deeper analysis is required.
A practical example: the pre-heating of the combustion air in ceramic gas kilns. In a tunnel type kiln, if there is pre-heating of the combustion air through “Heat Recovery” process, the gas economy can reach up to 20% of the total fuel bill. Frequently, energy efficiency increase projects using this resource have their pay-back in less than 2 years.
The measures that can be implemented on industries range from equipment substitution to layout or process changes. If simple measures with high economic returns are detected and executed, case the company contracted an ESCO both companies will have done a good business. On the other hand, if such measures are the result of a Specialized Study, then the client has performed an excellent business.
It is up to the Directors, Industrial and Engineering Managers to define which ways are more convenient to their companies today, and to harvest the results in the future.
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