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Karsten Visby-Kjærgaard Dept. Man. - Project Management Energy responsible

Karsten Visby-Kjærgaard Dept. Man. - Project Management Energy responsible. Aalborg Portland 2004. Net turnover 1,716,000,000 DKK Profit for the year 201,000,000 DKK Production capacity 2,900,000 tons Domestic 53% Exports 47%.

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Karsten Visby-Kjærgaard Dept. Man. - Project Management Energy responsible

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  1. Karsten Visby-Kjærgaard Dept. Man. - Project Management Energy responsible

  2. Aalborg Portland 2004 • Net turnover 1,716,000,000 DKK • Profit for the year 201,000,000 DKK • Production capacity 2,900,000 tons • Domestic 53% • Exports 47%

  3. Aalborg Portland 2004 • Plant area 75 ha/185 acres • Chalk Pit area 400 ha/1120 acres • Total area 1420 ha/3500 acres • Employees 602

  4. Drum washer Chalk slurry Chalk Quarry Raw mill Kaolin/Alu-silicate Sand Quarry Kiln slurry Sand mills Fuel Precipitator Wet Kiln Heat Recovery Gypsum Cement silos Clinker storage Roller-press Cement mills

  5. Aalborg Portland 2004 • Energy consumptions: • Electricity 361,000 Mwh • Coal 408,000 tons • Oil 22,000 tons • CEM fuel 101,000 tons • (Water 3,548,000 m3)

  6. Production Costs 2004

  7. ”Energy history” • 2 energy inspections (1992 and 1996) • 3-year agreements with the Danish Energy Agency since 1992 • Latest agreement:- Period: 2003 - 2005- Updating of energy mapping- Annual report to the Danish Energy Agency- Establishment and verification of an energy management system according to DS2403.

  8. Certifications • ISO 9002: Quality • ISO 14001: Environment, energy and working environment- Energy management verified by “Dansk Standard” (DS 2403) • EMAS: Environment, energy and working environment • OHSAS 18001: Working environment

  9. Energy Management General headlines • Mapping and updating of mapping • Energy policy, goal-setting and goals • Operational control • Maintenance of energy consuming plants • Energy conscious engineering and procurement • Information and training • Assessment

  10. Energy Management Mapping and updating of mapping • Basic mapping (energy inspection) • Annual updating of the mapping (block diagrams) • Screening of potential energy savings • Special investigations • Environmental registration teams

  11. Energy Management Example of a block diagram

  12. Energy Management Typical Special investigations: • Heat recovery from the surface of a cement kiln. • Draining of water from sand slurry • Plant for dry or moistened iron additive • Production of new cement types with less heat consumption

  13. Energy policy, goal-setting and goals Management tools : Environment and Energy Group: Group management and environmental manager Publication in Environmental Report About 10 annual follow-up meetings Energy Management

  14. Energy Management Energy management • Key personsPersons with influence on the energy consumption • Key figuresMonthly reports to the energy responsible person • Follow-up meetings (quarterly) Review of reports Corrective actions? Development of key figures?

  15. Energy Management Maintenance of energy consuming plants • Approved list of preferred components • PC-based maintenance system • Procurement and stocking of energy-saving motors

  16. Procurement Uses standard text in relation to energy conscious procurement when inviting offers. Assists project managers and draws up commercial conditions / negotiates prices. Project manager Makes the real energy assessment. Contacts suppliers. Drawn up the technical basis of the purchase. Energy ManagementEnergy conscious engineering and procurement

  17. Energy ManagementEnergy conscious engineering and procurement Overall energy assessment: • Statement of energy demands • Possible alternative process arrangements • Possibility of recovery of e.g. waste heat from/to other plants

  18. Energy ManagementEnergy conscious engineering and procurement Basic registration of data:Plant no.Machine typePurpose of machineCapacityWorking timePower consumptionMotor sizeAnnual energy consumption

  19. Energy ManagementEnergy conscious engineering and procurement Energy study – at energy costs more than 20,000 £/year • Description of the result of the energy study • Statement of annual energy savings achieved

  20. Energy ManagementEnergy conscious engineering and procurement Further assessment - conclusionIs the energy-saving alternative a cheaper investment:”Natural choice”.Is the alternative more expensive:- At pay-back time < 4 years it must be chosen.- At pay-back time > 4 years assessment is made in every single case.

  21. Energy Management Information and training • Information about energy-saving projects • Information about the co-operation with the Danish Energy Agency • At the annual personnel appraisal: Discussion of potential courses in a.o. energy savings

  22. Energy Management Assessment • Internal audits • Annual audit by “Dansk Standard” • The management’s assessmentOnce annually:Performance during the year Setting up goals for the coming year

  23. Energy Management Final observations • The organisation being more focused on energy issues. • Employee attitude: More work, but will eventually become routine tasks. • It is a good idea having a standardised method for reduction of the energy consumption.

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