energy committee mx - supplierspartnership.org enegy_comittee_ava ne… · 2012 obj. 2013 (m usd)...
TRANSCRIPT
Energy Committee MX
2nd Quarter 2013
May 30th , 2013
Agenda
2
Introduction
Committee Objectives and Structure
Energy Base Line
Energy Measurement System Assessment
Energy Goals
Energy Projects
Committee Objectives and Structure
3
Energy Committee NMK MTY
All BU will have a member in the Energy Committee
4
Energy Committee:
Project Mgmt. & Measuring System
Leader P3 &P4
Leader P5 & P6
Leader Plant
Service
Leader Melting center
Leader P1 & P2
Leader MVA
Leader SAL
Energy Committee Objectives
Energy Project ManagementIdeas for Energy ProjectsProjects related to the main energy consumers both EE & GNFeasibility Analysis of Energy ProjectsSupport on Energy Project Implementation
Energy Measurement System ManagementEnergy Measuring System AssessmentEnergy Measuring System Expansion (P3.5 + P6 + P2+ MVA? + SAL?)Energy Measuring System Operation
Energy Project & Best Practice DatabaseKnowledge Sharing on Energy Best PracticeEnergy Project Archive
Energy Committee ApproachMTYMVASAL
5
Energy Base Line
6
Energy Base Line (Nemak MX)
All MX sites have high energy intensityBOB MX Head MTY on EE & NG
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Ideal Target Zone
Projects in development
8
Vital Project YTD2012
Obj. 2013 (M USD)
Impact2013
IQ 13
IIQ 13
IIIQ 13
IQ 14 Notes:
30 min HT cyclereduction
Start Apr 13 10P + 1E Capex +
EBITDABK P2 P3
• S: within variation process• W: Block HF / A356 %E• O: Energy saving / Shutdown furnace / Sustain.• T: Equipment configuration & controls
SRU + Fluidizer bed shut down
Start Apr13 1.1E EBITDA
BK
• S: unrelated to HT process• W: sand reclamation capacity• O: Energy savings / Sustain.• T: Sand reclamation capacity
Heat recovery from holding furnace to HTF 3, 4 & 5
Start Apr 13 1.2 E EBITDA
BK
• S: Wasted heat available• W: Investment• O: Energy Saving + Sustainability approach• T: Temperature control @ HTF
HT Hibernation state during starve +settings conditions
Start Apr 13 0.53 E EBITDA
BK
• S: Parameter change / Starve @ HTF• W: Temperature issues @ Equip.• O: Energy Saving + Sustainability approach• T: Automation cost + maintenance
Optimized HT cycle Pentastar @ HTF6
Start Jan 12
5.4P + 0.38E
Capex + EBITDA
BK
• S: No issues on MP @ Pnst with less time• W: Sand issues @ Equipment• O: Energy Saving + Sustainability approach• T: Sand Issues @ Equipment / HT of BF5.0L
Rev. – Abril 2013Especialista : Tratamiento Térmico
On Schedule Completed In Progress Delay
The scheduled dates are a function of current resources department and assuming the support of all department involved.
Project implemented
10
Alternatives of solution
11
Project: Optimize compressed air in the cleaning of filters in the dust collector of Block
Alternative 1: Perform filter cleaning through PLC (Logic)
Alternative 2: Perform the filter cleaning through a Sequencer (Pressure difference)
A1: Perform filter cleaning through PLC (Logic)
12
Perform filter cleaning through PLC programming sequence.
Conditions Actual cleaning(continuous)
Cleaning through PLC (sequence)
Valve Size 1 Ø 1 Ø
Pulse time 0.25 sec. 0.25 sec.
Pulse interval 10 sec. 10 sec.
Air consumption (scfm) 1.05 1.05
Operation time 24 Hrs. 12 Hrs.
Scfm Conversion to kW 0.193 0.096
Consumption in kW200 installed valves. 38.6 19.3
Annual kwh consumption200 installed valves. 278,452 139,226
Annual Cost(0.69$/kWh) $192,000 $96,000
Savings --- $96,000
A1: Justification energy basics
13
Measurement of consumption for compressed air was made in one complete cleaning cycle, obtaining the following consumptions:
Calculations:
Analysis for a 1 diameter valveCompressed air consumption according to the table:1516 scfm - 60 sec.1.05 scfm - 0.25 sec.
Annual consumption in 7,200 hrs = 454.800 scfm
Energy consumption per table:1516 scfm - 279.1 kW1.05 scfm - 0.193 kW
There are 200 valves installed with an annualconsumption of 278.452 kW.
With the installation of PLC would reduce theconsumption of 139,220 kW = $ 96,000 annual
Avoid generating 91Ton CO2/year
A2: Perform the filter cleaning through a Sequencer (Pressure difference)
14
Perform filter cleaning through pressure difference caused by the fines and dust embedded in the filter element (Bag or cartridge).
Conditions Actual cleaning(continuous)
Cleaning through a Sequencer
Valve Size 1 Ø 1 Ø
Pulse time 0.25 sec. 0.25 sec.
Pulse interval 10 sec. 10 sec.
Air consumption (scfm) 1.05 1.05
Operation time 24 Hrs. 8 Hrs.
Scfm Conversion to kW 0.193 0.096
Consumption in kW200 installed valves. 38.6 11.5
Annual kwh consumption200 installed valves. 278,452 82,958
Annual Cost(0.69$/kWh) $192,000 $57,200
Savings --- $134,800
A2: Justification energy basics
15
Measurement of consumption for compressed air was made in one complete cleaning cycle, obtaining the following consumptions:
Calculations:
Analysis for a 1 diameter valveCompressed air consumption according to thetable:1516 scfm - 60 sec.1.05 scfm - 0.25 sec.
Annual consumption in 7,200 hrs = 454.800 scfm
Energy consumption per table:1516 scfm - 279.1 kW1.05 scfm - 0.193 kW
There are 200 valves installed with an annualconsumption of 278.452 kW.
With the installation of PLC would reduce the consumption of 195,4942 kW = $ 134,000 annual
Avoid generating 128 Ton CO2/year
A2: Justification energy basics
16
Attached Sequencer equipment calibration parameters.Brand: Mecair Model: MCS.
Consultation of suppliers
17
In the last months, we had the visit of various specialist on dust collectors:
With GE company, we had a course in our installations.David Currence was hired by Nemak for advising in problems in differents Sites, with him we had an inspection in the equipment last February
GE Power & Water – Ing. Michael Johnson e-mail: [email protected] Power & Water - Cesar Jimenez, e-mail: [email protected] Power & Water - Arturo Romero e-mail [email protected] – Ing. David Currence e-mail: [email protected]
Financial analyzes of the project
18
Savings $96,000 Mx- Investment $ 104,000 MxThe investment is fullyrecovered in 13 months.
SequencerPLC
Savings $134,000 Mx- Investment $ 139,000 MxThe investment is fullyrecovered in 13 months.Less production of kWh
Cartridge filters
19
1,200 KMx since 2012 to now.700 Filters changed VS 464 installed.
180 KMx since 2012 to now.141 Filters changed VS 80 installed.
Total of 1,380 KMx since 2012 to now.
Possible damages:• Mechanic damage.• Humidity in compressed air• Cleaning Fatigue.• Standard of change in bags.
