A Fiamewoik foi Achieving Sustainable Eneigy

Reuuction

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Lnerav ConsulLanL uepuLv Lo ulrecLor for llnance and Puman 8esources

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ln Lhls alobal economv buslnesses are conLlnuouslv sLrlvlna Lo reduce Lhelr cosL base lncrease value
creaLlon for lLs cusLomers and meeL Louah healLh safeLv and envlronmenLal reaulaLlons ln order Lo
compeLe ln buslness As such manv buslnesses are aolna leaner bv lmplemenLlna lean pracLlces
complex quallLv conLrol 3S kalsen 6 slama 1M enerav efflclencv wasLe reducLlon resource
efflclencv eLc

ln Lheorv lmplemenLaLlon of anv Lechnlques chosen would represenL a fanLasLlc opporLunlLv for Lhe
buslness Lo reduce cosL and compeLe ln Lhe markeL 1he reallLv ls LhaL manaaers and enalneers
lnvarlablv have mulLlple [ob funcLlons and responslblllLles each requlrlna a dlfferenL sklll seLs and
demands for aLLenLlon

1o manv Lhls wlll sLreLch Lhe capablllLles and knowhow of each lndlvldual manaaer and enalneer
manv fold 1he ablllLv for manaaers and enalneers Lo lmplemenL enerav savlna proarammes wlll be
llmlLed Lo avallable Llme resources Lo lmplemenL enerav reducLlon proarammes lnLeresL and
capablllLv Lo arasp Lechnlcal aspecLs of savlna enerav

Lnerav savlnas ls noL a new concepL lL has been ln exlsLence slnce World War 1wo under manv
names enerav conservaLlon enerav manaaemenL alobal warmlna cllmaLe chanae carbon
fooLprlnL low carbon eLc PlsLorlcallv Lhev are a resulL of enerav prlce lncreases and/or uncerLalnLv
ln supplv and demand of enerav

8eaardless of Lhe Lermlnoloav used Lhe underlvlna concepL ls enerav efflclencv Lnerav savlnas ls a
hoL Loplc 1he enerav consumed ls laraelv dependenL on Lhe companv culLure and lLs asseL base lL ls
made up of a flxed and varlable enerav componenL undersLandlna where and how enerav ls used
wlLhln Lhe buslness wlll lead Lo Lhe successful reducLlon ln lLs cosL 1he buslness beneflLs of lower
enerav consumpLlon are clear lower enerav cosLs lmmedlaLe savlnas Lo Lhe boLLom llne and
lmproved compeLlLlveness varlous lndusLrv benchmarks and naLlonal enerav savlna proaramme
have shown LhaL savlnas of up Lo 10 and more have been reporLed

W nd to Rduc Enrgy Us

As wlLh all buslness processes Lhe prlmarv purpose ls Lo lncrease neL proflLs whlle slmulLaneouslv
lncreaslna reLurn on lnvesLmenL and cash flow ln a manufacLurlna buslness Lhls ls accompllshed bv
converLlna raw maLerlal lnLo saleable producLs and servlces AlmosL all of Lhese processes wlll
lnvolve Lhe use of some lf noL all of Lhe avallable enerav forms elecLrlclLv fuel sLeam compressed
alr coollna waLer oxvaen nlLroaen and waLer AlLhouah Lhls arLlcle ls focused on manufacLurlna
processes lL ls equallv appllcable Lo commerclal and domesLlc enerav and uLlllLv svsLems

An efflclenLlv manaaed and effecLlve planL would ldeallv produce producLs wlLh Lhe leasL amounL of
enerav consumed ln a compeLlLlve buslness envlronmenL mosL manufacLurlna planLs are far from
runnlna opLlmallv whlch ls easv Lo lanore when Lhev're worklna adequaLelv 1hev mav be worklna
adequaLelv lf kepL unchecked wlll cosL a loL more Lhan Lhev should and wlll reduce Lhe buslness
proflL maralns

As an example for a buslness operaLlon wlLh a 10 proflL maraln everv 1 saved on enerav cosLs
Lhe buslness would have Lo sell an equlvalenL of 10 Lo make Lhe same 1 of proflL WasLlna 1000
a vear would Lhus need 10000 worLh of sales Lo make achleve Lhe same proflL

lrom a buslness perspecLlve Lhe real reasons behlnd manaalna enerav consumpLlon and lLs
efflclencv conslsL of a flve ma[or elemenLs llsLed below ln order of prlorlLv lnLearaLed lnLo Lhe enLlre
buslness value chaln All flve componenLs are lnLerrelaLed and none can hlLchhlke from each oLher
1 Macro Lconomlcs
2 8uslness urlvers
3 CperaLlons ManaaemenL
4 LnvlronmenLal roLecLlon
3 CompeLlLlve AdvanLaae

When Lhe sub[ecL of enerav efflclencv and envlronmenL proLecLlon ls brouahL up chances are LhaL
people foraeL LhaL Lhe prlnclpal exlsLence of a buslness enLlLv ls Lo make monev 1hus Marco
Lconomlcs 8uslness urlvers and CperaLlonal ManaaemenL were llsLed before LnvlronmenLal
roLecLlon

lrom a buslness perspecLlve enerav savlnas musL flrsL and foremosL be consldered for buslness
survlval and buslness lonaevlLv lL does noL mean LhaL a corporaLlon cannoL lnvesL ln envlronmenLal
proLecLlon LnvlronmenLal lnvesLmenL has Lo be made ln a consclous and lnformed manner

A buslness musL flrsL have a aood and fundamenLallv sound buslness plan and buslness vehlcle lL
musL Lhen be able Lo successfullv operaLe Lhls process operaLe lL safeLv operaLe lL economlcallv
and Lo aeneraLe a proflL lf Lhls cannoL be achleved Lhe buslness ls noL healLhv and wlll be ln Lhe rlsk
of closure ln a shorL perlod of Llme

ow Do Enrgy Efficincis Aris?

As a rule of Lhumb onlv abouL 40 of Lhe lnefflclencv and poor use of enerav are Lhe dlrecL resulL of
poor deslan lrom a poor deslan enerav ls used lnefflclenLlv resulLlna ln lL belna operaLed poorlv
and devlaLed from orlalnal lnLenL

1hls ln Lurn aeneraLes poor overall buslness resulLs from hlah cosL of operaLlons and poor
envlronmenLal performance oor operaLlons mav cause Lhe planL equlpmenL Lo fall premaLurelv
and ln hlaher frequencv 1he overall resulL ls a hlah level of apaLhv and reslanaLlon from Lhe
oraanlsaLlon and furLher consequenLlal cosLs assoclaLed wlLh repalrlna Lhe planL machlnerv When
Lhls ls noL recLlfled Lhe performance splrals ln clrcles aeneraLlna more apaLhv and hlaher cosL 1hls
ls shown ln llaure 1


I|gure 1 1he sp|ra| of poor energy eff|c|ency

ln order Lo break free from Lhe splral of poor enerav efflclencv lL ls lmporLanL Lo recoanlse and Lake
effecLlve acLlons Lo lmprove efflclencv and cosL savlnas

lanL ManaaemenL needs Lo have hlah expecLaLlons from Lhe planL machlnerv Cood enalneerlna
sLandards and learnlna from pasL experlence needs Lo be lncorporaLed Lo lmprove exlsLlna and/or
new planL deslans 1hls wlll lmprove Lhe uLlllsaLlon of Lhe machlnerv Cood Lralnlna and educaLlon
realme musL be provlded and reaularlv audlLed Lo ensure LhaL Lhe machlnerv ls LreaLed and
operaLed properlv and Lo deslan AdequaLe and approprlaLe quallLv manaaemenL svsLems such as
SLaLlsLlcal rocess ConLrol (SC) lmplemenLed onslLe shall Lrack and conLlnuouslv LlahLen Lhe
conLrol varlable Lo lmprove efflclencv

1hls mav be done for lmprovemenLs ln Lhe deslan operaLlons and operaLlna procedure
malnLenance pracLlces modlflcaLlons and/or from lnsLallaLlon and commlsslonlna pracLlces Manv
Lools and Lechnlques are avallable ln Lhe markeL place Lo asslsL and supporL lmplemenLaLlon of
enerav manaaemenL and efflclencv lmprovemenL proarammes use of new Lechnoloales new
approaches and new conLrol meLhods are consLanLlv markeLed bv varlous companles All of Lhese
Lechnlques and Lechnoloales have a novel lnLenL and form a vlslon of Lhe end resulLs

When lmplemenLlna enerav efflclencv aL work manaaers are faced wlLh onaolna operaLlonal
problems fallures and Lhelr resoluLlon 8econclllna Lhese lssues and sLlll lmplemenLlna enerav
efflclencv proarammes mav be a challenae

When maklna plans Lo manaae enerav consumpLlon and lmprove efflclencv
O Pow shall Lhe manaaemenL approach and achleve Lhe vlslon?
O ls lL Lhe rlahL vlslon for Lhe planL? ls lL flnanclallv vlable?
O uoes Lhe enerav consumpLlon have enouah leveraae Lo slanlflcanLlv lmpacL mv boLLom llne?
O WhaL ls Lhe value of enerav efflclencv vs Lhe rlsk Lo producLlon and proflL losL?
O WhaL wlll be Lhe consequences lf lL's noL lmplemenLed?
O WhaL order and sequence should Lhese proarammes be lmplemenLed?
O Wlll advanced meLhods prevenL fuLure fallures?
O Wlll fuLure buslness requlremenL resLrlcL Lhe cholces and opLlons for enerav efflclenL
Lechnlques? uoes Lhe chosen Lechnlque llmlL or hedaes fuLure buslness and cllmaLe chanaes?

All Lhese are valld concerns for Lhe planL and needs Lo be addressed slmulLaneouslv wlLh an enerav
manaaemenL and efflclencv lmprovemenL proaramme As a aenLle remlnder a vlslon wlLhouL a plan
ls a wlsh A plan wlLhouL a LlmeLable ls a wlsh llsL

owards An Enrgy Efficint Upration

Armed wlLh Lhe need for enerav savlnas and how lnefflclencles arlse we now focus on a sLraLealc
lssue how do we lmplemenL enerav savlnas or where do we sLarL or whaL sLraLeav do we use?

rofessor 8osenzwela ln hls book 1he Palo LffecL and Lhe 8 CLher 8uslness ueluslons 1haL
uecelve Manaaers" sLraLeav ls abouL performlna dlfferenL acLlvlLles or performlna Lhe same acLlvlLv
dlfferenLlv ln some lmporLanL wavs from Lhose of Lhe rlval companles A sLraLeav alwavs lnvolves rlsk
because we do noL know for deflnlLe how Lhev wlll Lurn ouL 1hls ls due Lo uncerLaln cusLomer
demand unpredlcLable compeLlLlon and chanalna Lechnoloav

8efore embarklna on an enerav savlna lnlLlaLlve Lhe manaaer needs Lo deflne and adhere Lo Lhe
ob[ecLlves of Lhe lnlLlaLlve and lLs performance measures 1hls can be ln Lhe form of healLh and
safeLv rellablllLv efflclencv cosL per unlL producL and speed of chanae

Manaaers mav be asked how healLh and safeLv and planL lnLearlLv lnLearaLe wlLh enerav savlnas
CperaLlna a manufacLurlna planL has manv processes LhaL are lnLerllnked A hollsLlc vlew and
approach ls essenLlal Lo avold Lhe 3 common plLfalls ln enerav savlnas
1 WasLlna Llme and efforL opLlmlslna or schedullna Lhe wrona processes or parL of Lhe process
2 CpLlmlslna a unlL operaLlon or process Lo produce savlnas whlch are of no economlc value
3 lmplemenLlna one savlnas pro[ecL LhaL has a knockon effecL elsewhere whlch has noL been
assessed

An ldeal vlslon for a hollsLlc approach would mean zero safeLv lncldenLs or near mlsses aood
occupaLlonal healLh manaaemenL aood and susLalnable envlronmenLal sLewardshlp rellable asseLs
wlLh hlah avallablllLv and flrsL Llme rlahL LhrouahpuL A superlor performlna asseL descrlbed wlll
provlde a plaLform Lo bulld up opporLunlLles for raw maLerlal savlnas enerav savlnas and buslness
llfe cvcle cosL savlnas

Cnce Lhe sLraLeav and LaraeL are aareed Lhe manaaers musL ldenLlfv Lhe obvlous and hldden
opporLunlLles for lmprovemenL SubsequenLlv and mosL lmporLanLlv lmplemenLaLlon of Lhe savlna
pro[ecLs 1he ma[orlLv of Lhe lmprovemenLs wlll be found where anv 2 or more parLs of a process
meeL

tp Improvmnt Plans

WlLh a aood sLraLeav ln place lL needs Lo be lmplemenLed Lo reduce enerav consumed bv Lhe
manufacLurlna process 1here are manv cholces for Lools Lechnlques and Lechnoloav avallable ln Lhe
markeL Lo reduce enerav use

ln Lhe medla manaaers would be able Lo flnd new and evolvlna Lechnlques belna markeLed bv
varlous consulLanLs and suppllers Lach Lechnlque has been developed based on lLs own seL of
assumpLlons Lach has lLs own advanLaaes sLrenaLhs and a falr share of fallures Pow do we choose?
Whlch Lechnlques wlll auaranLee success?

1o borrow anoLher phrase from rofessor 8osenzwela's book execuLlon of a plan ls abouL
carrvlna ouL sLraLealc cholces made bv Lhe manaaemenL racLlces LhaL work well ln one companv
mav and mav also noL have Lhe same effecL ln anoLher companv"

1he nexL sLep would be Lo ldenLlfv Lhe hldden opporLunlLles and Lhe pace of chanae requlred Manv
opporLunlLles can be found ln a manufacLurlna planL Lquallv manv opLlons for lmprovemenL are
avallable for each of Lhe ldenLlfled lmprovemenL measures

Lnerav savlnas can be from all planL machlnerv wlLhln a buslness lL ls noL llmlLed Lo anv speclflc
equlpmenL ln Lhe markeL Lhere are manv consulLanLs and suppllers LhaL speclallse ln speclflc areas
of enerav savlnas ln uLlllLv svsLems sLeam compressed alr coollna waLer chllled waLer moLors and
drlves and power quallLv 1hls ls purelv due Lo uLlllLles belna Lhe mosL common denomlnaLor ln
manv process planLs 1he besL pracLlces Lo each of Lhese svsLems would be slmllar from one lndusLrv
Lo anoLher 1here ls a loL of llLeraLure and besL pracLlces publlshed ln Lhe markeL and lnLerneL

1here are also some consulLanLs and suppllers who speclallse ln less common areas such as
rellablllLv furnaces dlsLlllaLlon and separaLlon svsLems whllsL oLhers speclallse ln pushlna Lhe
envelope of modern Lechnoloav advance process conLrol dvnamlc slmulaLlon compuLaLlonal
dvnamlcs 1here are also some consulLanLs and suppllers who are process and/or machlne speclflc
1hev are malnlv llcensed processes or proprleLarv machlnerv

1o lmplemenL a successful enerav savlnas lnlLlaLlve manaaers and enalneers musL recoanlse Lhe facL
LhaL each consulLanL and suppller has Lhelr sLrenaLhs and llmlLaLlons 1he kev ls Lo have one parLv
manaae recommended besL pracLlces bv Lhe varlous consulLanLs whlle noL loslna slahL of Lhe overall
ob[ecLlve and Lhe effecL each lmprovemenL has on Lhe oLher planL machlnerv

lmprovlna enerav efflclencv and reduclna enerav cosL ls also noL [usL abouL lmplemenLlna besL
pracLlces lmplemenLlna besL pracLlces requlres a cerLaln mlndseL lnvolvlna shared companv aoals
companv culLure and proven besL pracLlces Lack of besL pracLlces ls ofLen noL Lhe onlv reason for
lnsufflclenL planL performance

CommlLmenL from Lhe lanL ManaaemenL Lo allocaLe resources and Lo Lake acLlon Loward lmprovlna
efflclencv ls requlred A Leam can be formed Lo asslsL and supporL Lhe lanL ManaaemenL bv
undersLandlna Lhe quanLlLv of enerav used ln Lhe planL Lhe sLrenaLh and weaknesses of
lmplemenLlna and susLalnlna an enerav manaaemenL proaramme Lhe needs of Lhe buslness and
anLlclpaLlna anv llkelv barrlers Lo lmplemenLaLlon

When Lhls ls compleLe Lhe lanL ManaaemenL can work wlLh and vla Lhe Leam Lo develop an enerav
manaaemenL pollcv sLaLemenL seL ob[ecLlves and LaraeLs and prepare deLalled acLlon plans for lLs
lmplemenLaLlon 8oles and responslblllLles wlll be Lo be allocaLed Lo prlorlLlse lmprovemenL acLlons
and lnvesLmenL requlremenLs 8arrlers Lo lmplemenLaLlon need Lo be resolved

Cnce lmprovemenL proarammes are lmplemenLed Lhev need Lo be monlLored and conLrolled A
proaress revlew needs Lo be puL ln place for conLlnuous feedback and conLlnuouslv lmproved
lrequenLlv all of Lhe lmprovemenL measures wlll noL be lmplemenLed as a oneoff lnvesLmenL
and/or achleve full savlnas ln onesLep 1he Leam wlll need Lo reassess Lhe enerav requlremenLs and
repeaL Lhe conLlnuous lmprovemenL cvcle as lllusLraLed ln llaure 2


I|gure 2 |anDoCheckAct cyc|e

A well deslaned enerav manaaemenL and efflclencv lmprovemenL proaramme can save slanlflcanL
amounL of caplLal expendlLure 1he Leams' challenae would be Lo selecL a paLhwav forward for
maxlmum effecLlveness and efflclencv 1hls wlll lnvolve selecLlna Lhe rlahL Lask and performlna Lhe
Lask well 1he easlesL and mosL obvlous would be Lo prlorlLlse whlch ls Lhe mosL presslna planL
machlnerv sLarL wlLh Lhe cheapesL and mosL cosL effecLlve measure le Lhe Low Panalna lrulL"

Commitment
Understand
Implement
Plan
Carry Out the Audit Process
Review Progress
Distribute Audit Findings
Seek Continuous Improvement
Develop Draft Action Plan
Quantify Energy Usage
Define Objective and Targets
Define Responsibilities
Identify Management Strength and Weaknesses
Analyse Stakeholder Needs
Anticipate Barriers to Implementation
Develop a Policy Statement
Set Objectives and Targets
Prepare Detailed Action Plans
Allocate Roles and Responsibilities
Review Improvements
Apply Corrective Actions
Apply Sustaining Actions
Engage Whole Organisation
Manage Resistance for Change
Allocate Appropriate Resources
Management Reporting
easure
Document
Initiate Priority Actions and Investments
Carry Out Training and Raise Awareness
Integrate Energy into Business Processes
Overcome Barriers to Implementation
Measure Improvements
Compliance with Legislation Requirements, Climate
Change Agreements, Energy Management Standards

I|gure 3 Lnergy sav|ng measures and |ts cost of |mp|ementat|on

lor manv planLs and facLorles aood housekeeplna ls a sLarLlna polnL Lo brlna Lhe larae enerav
varlaLlon lnLo conLrol 1he enerav savlna pro[ecLs should be almed for ldenLlfvlna and reduclna Lhe
observed enerav varlaLlon

Measures classlfled as housekeeplna lnclude Lhe reducLlon ln wasLaae leaks machlnerv ldle Llme
producLlon raLe losses unLended Laps and hoses lL also applles Lo uslna slmple and readllv avallable
besL pracLlces such as lmplemenLlna beLLer cleanlna meLhods uslna spravs ln place of flll and draln
and hose Lrlaaers lnvesLmenL ln emplovee educaLlon and Lralnlna Lo lncrease awareness and Lhe
need for enerav efflclencv should be complemenLed bv an adopLlon of a zero Lolerance pollcv for
lnefflclencles and lneffecLlve use of uLlllLles

1he rewards for aood housekeeplna ln a planL ls wldelv recoanlsed buL rarelv pracLlced 1he
advanLaaes lnclude besL reLurn on expendlLure low (or on some cases no) caplLal lnvesLmenL and
less apparenL enerav wasLaae 1here ls no LhreaL Lo operaLlons or processes as Lhe rlsks lnvolved are
mlnlmal Powever lL requlres a consLanL efforL Lo malnLaln hlah sLandards ln pracLlce monev
savlna housekeeplna has a hablL of dlsappearlna over Llme A aood basellne for manaaemenL conLrol
ls essenLlal and should be based on conslsLenL and Lhe smallesL enerav varlaLlon ln enerav daLa
1here ls llLLle polnL looklna for oLher enerav savlnas unless housekeeplna ls under conLrol

1he nexL caLeaorv of enerav savlna measures ls classlfled as conLrol svsLems Lnerav savlna pro[ecLs
ln Lhls caLeaorv furLher reduces Lhe enerav varlaLlons seen durlna Lhe housekeeplna phase bv
lnLroduclna beLLer operaLlna condlLlons of exlsLlna enerav users and uLlllLles A Lhorouah
examlnaLlon of enerav and uLlllLles efflclencv svsLem halfllfe eLc ls lnLroduced aL Lhls sLaae

1he alm wlll be Lo LlahLen Lhe conLrols of exlsLlna process and uLlllLles requlrlna Lhem Lo operaLe
closer Lo Lhe conLrol llmlLs 1hls wlll maxlmlse Lhe efflclencv reduce excess usaae lncrease cvcles of
concenLraLlon reduce blow down eLc 8eLLer conLrol and measuremenL svsLems mav be
commlssloned aL Lhls sLaae Lo faclllLaLe accuraLe readlnas and Lrack lmprovemenLs Plah efflclencv
moLors and varlable speed drlves are also lncluded aL Lhls phase

1here wlll be a hlaher lnvesLmenL requlred aL Lhls phase 1he correspondlna rewards for LlahLer
operaLlna conLrol svsLems are reduced enerav and uLlllLles usaae and hlaher process efflclencv
ENERGY
SAVING
HOUSEKEEPING
CONTROL SYSTEMS
PROCESS MODIFICATION
PROCESS INTEGRATION
ALTERNATIVE PROCESS
COST OF IMPLEMENTATION
Machine LeveI
PIant LeveI
Site LeveI
Machine, PIant, or Site LeveI
Powever as Lhe enerav savlna measures now lnvolve process and manufacLurlna operaLlons lL mav
cause oLher problems LhaL affecL producL quallLv lor a well deslaned and lmplemenLed enerav
efflclencv proaramme Lhe lmpacL of Lhese problems ls small ldenLlfled earlv ln lLs lmplemenLaLlon
and can be recLlfled lL requlres more supervlslon and manaaemenL of Lhese measures and Lhe
assoclaLed measuremenL and monlLorlna svsLem Lhan Lhe housekeeplna phase

Cood housekeeplna and conLrol svsLems are Lvplcallv lmplemenLed aL a unlL operaLlons level le
bollers compressor Lralns dlsLlllaLlon Lralns eLc

When Lhe planL ls successful ln lnsLllllna aood housekeeplna and lmplemenLs conLrol svsLems Lhe
lanL ManaaemenL wlll be readv Lo explolL hlaher enerav savlnas from performlna slmple process
modlflcaLlon Lo Lhe exlsLlna faclllLv 1hls wlll lnclude Lhe reuse and recvcle of Lhermal enerav ldeallv
local dlrecL use wlLhouL need for Lanks plpe work and pumps Some of Lhe poLenLlals lnclude wasLe
heaL recoverv bollers preheaLers and economlsers redeslan Lo use less enerav ea close Lhe open
condensaLe svsLems use of new packlnas ln separaLlon columns eLc

1hese enerav savlna meLhods can brlna abouL furLher reducLlon enerav consumpLlon producL and
raw maLerlal recoverv WlLh Lhe modlflcaLlons and recvcllna of enerav Lhere mav be a hlah chance
Lo Lransfers Lhe rlsk of conLamlnaLlon from Lhe produclna process Lo Lhe recelvlna process resulLlna
ln poorer producL quallLv conLamlnaLlon wlLh Lrace maLerlals scallna foullna corroslon
mlcrobloloalcal arowLh ln Lhe svsLem 1here wlll be a need for beLLer conLrol and monlLorlna for all
Lhe same problems as ldenLlfled alreadv ln prevlous phase buL areaLlv enhanced and much more
apparenL

ConLrol svsLems and process modlflcaLlon are Lvplcallv and more commonlv lmplemenLed aL Lhe
planL level

lurLher lnLearaLlon of processes and uLlllLles aL a slLe level ls Lhe nexL naLural proaresslon for hlaher
enerav savlnas oLenLlals for process lnLearaLlon lnclude Lhermal plnch analvsls process
lnLenslflcaLlon opLlmlsaLlon and enhancemenL and planL deboLLlenecklna and upraLlna

1he advanLaae on a successful process lnLearaLlon exerclse can be measured ln Lhe value of enerav
recovered and also ln producL and raw maLerlal savlnas WlLh less enerav belna consumed less
enerav wlll be wasLed resulLlna ln CC
2
reducLlon

Lnerav savlna pro[ecLs ln Lhls phase would lnevlLablv cosL more Lhan Lhe oLher phases descrlbed
above more equlpmenL mav ao wrona and lL would be more compllcaLed Lo LroubleshooL lL would
Lherefore requlre a aood level of manaaemenL supervlslon Lo deslan a successful enerav
manaaemenL proaramme aL Lhls phase and Lo avold over lnLearaLlon of Lhe process

1he hlahesL avallable form of enerav efflclencv would be from a sLep chanae perspecLlve bv
commlsslonlna an alLernaLlve and more modern process 1hls could ranae from lnsLalllna and
operaLlna a comblned heaL and power planL reflLLlna an exlsLlna sLeam reformer wlLh Lhe laLesL
deslans and lmprovemenLs Lo applvlna dvnamlc slmulaLlon and predlcLlve conLrols and a compleLe
chanae Lhe process Lechnoloav Lo a hlah efflclencv process

8efore applvlna new Lechnoloav for sLep chanae ln performance lL ls essenLlal Lo undersLand where
enerav should and where lL should noL be used CosL pracLlcallLv manaaemenL and rlsk need Lo be
carefullv welahed before sancLlonlna such an opLlon 1he speclflc alLernaLlve process mav noL be off
Lhe shelf" and would requlre vlslon lnvesLlaaLlon research and manv monLhs of planL Lrlals

1he rewards for uslna an alLernaLlve process are numerous Whlle Lhe flnanclal reward mav be
neaaLlve ln Lhe shorL and medlum Lerm lL mav alve rlse Lo lmproved operablllLv reduced healLh and
safeLv rlsk less wasLe waLer smaller and slmpler wasLe waLer LreaLmenL planLs and mav even have
a slmpler measuremenL and conLrols requlremenL

1he rlsks assoclaLed wlLh an alLernaLlve process are LhaL lL mav evenLuallv chanae one area of
problem for anoLher ln Lhe process oorlv consldered and planned alLernaLlves mav also be less
efflclenL and/or envlronmenLallv poor As such Lhls phase mav be besL sulLed for new planLs and
areen developmenLs raLher Lhan ln old planLs where caplLal has alreadv been lnvesLed

Several enerav savlna measures from Lhe same caLeaorles can and are normallv ldenLlfled
lndusLrlallv publlshed flaures are Lhe up Lo 10 savlnas can be achleved from applvlna aood
housekeeplna Lechnlques 20 savlnas ln Lhe conLrol svsLems caLeaorv wlLh [usLlfled caplLal
expendlLure 30 or more have been reporLed ln Lhe process modlflcaLlon and process lnLearaLlon
caLeaorles

1he exacL flaure wlLh each planL and faclllLv wlll depend heavllv on where Lhev are ln Lhe enerav
efflclencv maLurlLv model and where Lhev wanL Lo be operaLlna aL


1
1hls frame has been adapLed lnLo enerav and uLlllLv conLexL and furLher developed from Lhe orlalnal skeLches
bv a former colleaaue menLor and frlend ur 8ob ! 1errell A88 Clobal ConsulLlna A88 LLd