Introduction to Energy Efficiency, Approach and Working Steps

1. Introduction to Energy Efficiency, Approach and Working Steps Training on “Reducing Carbon Foot Print in Textile Industries” Windsor Hotel, Bangkok 27 October 2010 Dr. Balasankari B.E., M.Engg., Ph.D Arul Joe Mathias B.E., M.Engg., MBA

2. Introduction to Energy Efficiency

3. ENERGY EFFICIENCY - DEFINITION • Refers to how effectively energy is being used for a given purpose • Represents how efficiently energy is converted from one form to another • Method of using less energy to perform the same function

4. WHY ENERGY EFFICIENCY? • Due to limited availability of fossil fuels • To avoid wastage of resources, electricity, thermal energy • To reduce climatic change impact • To reduce environmental issues

5. BENEFITS • Reduces energy consumption • Reduce water and material consumption • Improves productivity with given energy • Increases profits

6. BENEFITS • Reduces dependence on conventional resources • Environmentally beneficial • Reduces air pollution • Reduces global warming

7. Energy Efficiency Approaches & Working Steps

8. APPROACHES Energy Efficiency involves : • Energy audit & report • Setting up energy management program

9. ENERGY AUDIT • First step to improve energy efficiency • Tool for energy efficiency improvement

10. ENERGY AUDIT - TYPES • Walk through audit • Utility cost analysis • Standard energy audit • Detailed energy audit

11. WALK THROUGH AUDIT • Short site visit of the facility • Identification of areas of simple and inexpensive actions possible • Goal: Immediate energy and/or operating cost savings

12. UTILITY COST ANALYSIS • Evaluation of metered energy uses, operating costs and utility data for several years • Identification of energy use, peak demand, weather effects, and potential for energy savings

13. STANDARD ENERGY AUDIT • Comprehensive energy analysis • Development of baseline for the energy use of the facility • Identification of energy conservation measures • Evaluation of energy savings and cost effectiveness

14. DETAILED ENERGY AUDIT • Similar to standard energy analysis, but time consuming • Use of instruments to measure energy use • Analysis of measured data • Identification of energy efficiency measures and potential for energy savings

15. ENERGY AUDIT REPORTS • Designed to encourage implementation • Recommendations to achieve energy efficiency and energy cost saving

16. CONTENTS OF AUDIT REPORT • Energy management plan • Energy action plan • Energy financing options • Maintenance recommendations • Standard calculation and assumptions • Audit recommendations

17. ENERGY MANAGEMENT PROGRAM

18. ENERGY MANAGEMENT PROGRAM • Most successful and cost effective way • It begins with strong organizational commitment to continuous improvement of Energy Efficiency • It involves: • Assigning management duties to energy director • Establishing energy policy • Creating cross functional energy team

19. ENERGY MANAGEMENT PROGRAM • Steps to assess performance through: • Regular review of energy data • Technical assessment and • Bench marking • From this, develop: • Baseline energy use • Goals for improvement (implementation of action plan)

20. MAKE COMMITMENT • Commitment by management to energy management program • Assignment of energy management coordinator • Creation of energy management committee of major plant and department representatives

21. ASSESS PERFORMANCE • Review of historical patterns of fuel and energy use • Facility walk-through survey • Preliminary analyses, review of drawings, data sheets, equipment specifications • Development of energy audit plans • Conduct of facility energy audit for processes, facilities and equipment

22. ASSESS PERFORMANCE • Calculation of annual energy use based on audit results • Comparison with historical records • Analysis and simulation to evaluate energy management options • Economic analysis for energy management options (life cycle costs, rate of return, cost benefit ratio)

23. SET GOALS • Establish energy effectiveness goals for the organization and individual plants • Determine capital investment requirements and priorities • Establish measurement and reporting procedures • Install monitoring and recording instruments

24. CREATE ACTION PLAN • Define technical steps and targets • Crete performance target for each facility, operation etc. • Set timelines for action • Establish monitoring system • Determine roles and resources • Internal roles (personnel in the plant) • External roles (consultant, service providers, vendors etc.) • Determine resources (in terns of human resource and cost)

25. IMPLEMENT THE ACTION PLAN • To implement actions plan: • Create a communication plan with workers • Raise awareness to them • Build capacity • Motivate working personnel • Tract and monitor

26. EVALUATE PROGRESS • Evaluate the progress in plants through: • Energy data • Review of activities as a part of action plan • Compare them to established goals • Revise the action plan based on results

27. Introduction to Textile Industry

28. TEXTILE INDUSTRY • Textile industry – one of the major energy consuming industry • Energy plays important role in manufacturing process • Cost of energy is a major factor, next to chemical cost

29. SECTORS IN TEXTILE INDUSTRY • Spinning (blending, carding, combing, drawing, simplex and spinning) • Weaving/Knitting • Wet processing (desizing, scouring, bleaching, mercerizing, printing, dyeing and finishing) • Garment manufacturing

30. TEXTILE INDUSTRY • Spinning and Weaving/knitting – large scale • Spinning and Weaving/knitting combine together known as composite unit • Wet processing – small scale • Garment Manufacture – medium scale

31. RAW MATERIALS Man-made & synthetic fibres: • Polyester (PES) • Polyacrylonitrile (PAC) • Polyacrylonitrile (PAC) • Polypropylene (PP) • Elastane (EL) Natural fibers : • Cotton • Wool • Silk • Flax • Jute

32. PRODUCTION PROCESSES • All processes do not occur in a single facility • Processes and technologies differ across factories • Numerous technologies • Depends on type of raw material and expected product output

33. PRODUCTION PROCESSES • Different methods available (for spinning, weaving, dyeing, printing etc.) • Uses large quantity of electricity and fuel • Electricity or fuel depends on type of industry • Spun yarn spinning – electricity use is more • Wet processing – fuel use is more

34. Thank You