Transcript
UNEP 2006 1
Energy Efficiency
Methodology
Energizing Cleaner Production
Management Course
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Training Agenda: Company Energy
Efficiency methodology
Introduction to the methodology
Methodology step by step
Purpose, outputs and tasks
Company examples
Worksheets
Energy focus
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Introduction
The Company Energy Efficiency Methodology (Methodology) has been developed for Asian industrial companies
to help them improve energy efficiency
through Cleaner Production.
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Benefits from Energy Efficiency
Cost reductions through efficient use of energy Reduced exposure to fluctuating energy supply
and prices and blackouts
Increase in productivity and product quality Improved reputation with customers and society
through environmental protection
Improved employee motivation, health and safety
Compliance with legislation and ISO 14001 targets
Increased profits and shareholder
value
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The Methodology
Is tailored to energy-intensive industrial
companies in developing Asian countries
Focuses on energy, which is less visible than
waste, water and raw materials
Explains
what should be done in theory how it is done in practice in different companies
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The Cleaner Production (CP) strategy:
Prevention of waste Systematic approach Integrated into business processes Aimed at continuous improvement
Existing CP and energy audit methodologies
Real practice experience from energy assessments carried out as part of the GERIAP
project in more than 40 Asian industrial
companies
The Methodology is based on:
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task 1a: Meeting with top management task 1b: Form a Team and inform staff task 1c: Pre-assessment to collect general information task 1d: Select focus areas task 1e: Prepare assessment proposal for top management approval
Step 1: Planning and Organization
task 2a: Staff meeting and training task 2b: Prepare focus area flow charts task 2c: Walkthrough of focus areas task 2d: Quantify inputs and outputs and costs to establish a baseline task 2e: Quantify losses through a material and energy balance
Step 2: Assessment
task 3a: Determine causes of losses task 3b: Identify possible options task 3c: Screen options for feasibility analysis
Step 3: Identification of Options
task 4a: Technical, economic and environmental evaluation of options task 4b: Rank feasible options for implementation task 4c: Prepare implementation and monitoring proposal for top
management approval
task 5a: Implement options and monitor results task 5b: Evaluation meeting with top management
Step 5: Implementation and Monitoring of Options
task 6a: Prepare proposal to continue with energy efficiency for top management approval
Step 6: Continuous Improvement
Step 4: Feasibility Analysis of Options
task 1a: Meeting with top management task 1b: Form a Team and inform staff task 1c: Pre-assessment to collect general information task 1d: Select focus areas task 1e: Prepare assessment proposal for top management approval
Step 1: Planning and Organization
task 2a: Staff meeting and training task 2b: Prepare focus area flow charts task 2c: Walkthrough of focus areas task 2d: Quantify inputs and outputs and costs to establish a baseline task 2e: Quantify losses through a material and energy balance
Step 2: Assessment
task 3a: Determine causes of losses task 3b: Identify possible options task 3c: Screen options for feasibility analysis
Step 3: Identification of Options
task 4a: Technical, economic and environmental evaluation of options task 4b: Rank feasible options for implementation task 4c: Prepare implementation and monitoring proposal for top
management approval
task 5a: Implement options and monitor results task 5b: Evaluation meeting with top management
Step 5: Implementation and Monitoring of Options
task 6a: Prepare proposal to continue with energy efficiency for top management approval
Step 6: Continuous Improvement
Step 4: Feasibility Analysis of Options
6-Step
Cleaner
Production
Approach
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Information under each Step
Several tasks: what a company should do as a
minimum
Company examples: how the task was applied at
different companies and lessons learnt
Worksheets: to assist completing the task
Remember: apply the methodology flexibly as long as energy efficiency is improved because each company is different.
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Step 1: Planning and Organization
Purpose:
Obtain top management commitment
Plan and organize an energy assessment
Output:
Written proposal with selected steps and tasks to improve the companys energy efficiency
Approved by top management.
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Step 1: Continued
Time: 3 6 days
Tasks include: Task 1a: Meeting with top management (1-2 hours) Task 1b: Form a Team and inform staff (0.5-1 day) Task 1c: Pre-assessment to collect general information
(1-3 days)
Task 1d: Select focus areas (0.5-1 day) Task 1e: Prepare assessment proposal for top
management approval (2-3 days)
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Task 1a: Meeting with Top
Management (1 2 hours)
Purpose of first meeting:
Top management: Get commitment of company middle managers, staff
and/or external facilitators to carry out a pre-
assessment
Write a proposal for a detailed energy assessment
Company middle manager or external
facilitator:
Get top managements approval for a pre-assessment
Write a proposal for a detailed energy assessment
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Task 1a: Meeting with Top
Management (continued)
Discuss at this 1-2 hour first meeting:
If/Why top management is interested in energy efficiency
Energy areas of interest or concern Where the company is now Other factors of influence on the assessment Time needed for pre-assessment and writing
proposal for feasible options
Team composition and management representative
How staff will be informed to ensure cooperation
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Worksheet 1: Reasons for Energy
Efficiency
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Worksheet 2: Energy Management
Matrix
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Worksheet 3: Factors influencing
the energy assessment approach
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Task 1b: Form a Team and inform
staff (0.5 1 day)
The Team should consist of:
Someone who knows the main energy uses and environmental impacts, e.g. the
Environment Manager or Energy Manager
Someone who knows the production process, e.g. the Head of Production
Someone with access to general company information and energy cost data, e.g. the
companys Accountant or Finance Manager
A communications or training person
A top management representative
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Task 1b: Form a Team and inform
staff (cont.)
Team should have
Knowledge of energy equipment
Energy intensive production processes
Access to energy data
Typical positions
Utilities Manager
Energy Manager
Maintenance Engineer
Energy
Focus
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Worksheet 4: Team Members and
Roles
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Task 1c: Pre-assessment to collect
general information (1 3 days)
Information collected should include:
General company details
Organization chart
General production flow chart
Production data for the past 3 years
Energy, resource consumption data and costs for the past 3 years
Inventory of major equipment
Overview of information collected for each process step / department
Company greenhouse gas (GHGs) emissions
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Task 1c: Pre-assessment to collect
general information (cont.)
Include auxiliary sections in the
general production flow chart
Water treatment
Boiler and steam systems
Compressed air systems
Air conditioning / refrigeration
Ventilation
Energy
Focus
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Task 1c: Pre-assessment to collect
general information (cont.)
Production and resource data should
also include
Fuel consumption rates and costs
Electricity consumption and costs
Fuel mix
Electricity bills from utility
Energy
Focus
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Task 1c: Pre-assessment to collect
general information (cont.)
Inventory of major equipment
Name of equipment: motor
Numbers: 50
Capacity: 1 with 100 HP, 39 with >25 HP, 10 with
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Worksheet 6: General Production
Flow Chart
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Worksheet 7: Production and
Resource Data
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Worksheet 8: Inventory of Major
Equipment
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Task 1d: Select focus areas (0.5 1 day)
A focus area can be:
Entire plant A department, production line, or process
step
Specific (energy) equipment or resources
The process for selecting focus areas:
Identify possible focus areas Determine selection criteria Rate each focus areas High, Medium, Low for
each criteria
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Different focus areas can be selected
when energy is considered
An auxiliary system instead of a production step
- Steam system
- Compressed air
Specific major energy equipment
- Boiler house (not just the boiler!)
Energy
FocusTask 1d: Select focus areas (cont.)
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Worksheet 10: Selection of Focus
Areas
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Task 1e: Prepare assessment
proposal for top management
approval (2 3 days)
It is important to obtain top management
commitment
The assessment proposal should include: Objective, scope (i.e. focus areas) Outputs Approach (step 2, 3 and 4 of the Methodology) Team Time & budget
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Step 2: Assessment
Purpose: assess where energy is lost/wasted for the focus area(s)
Output: overview of how much energy is lost and how much money this costs for the focus
area(s)
Then it becomes easier to identify options to
improve energy efficiency in step 3!
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Step 2: Assessment
Time: minimum 3 days
Tasks include:
Task 2a: Staff meeting and training (>0.5 day for staff meeting only)
Task 2b: Prepare focus area flow charts (>2 hours per focus area)
Task 2c: Walkthrough of focus areas (> 0.5 day per focus area)
Task 2d: Quantify inputs and outputs and costs to establish a baseline (time required depends on data
available)
Task 2e: Quantify losses through a material and energy balance (0.5 1 day per focus area)
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Task 2a: Staff meeting and training
Staff meeting (0.5 day)
Inform staff about assessment and their roles
Get their support
Staff training
Importance of energy efficiency
How to carry out an assessment
Energy equipment & monitoring instruments
Financing, GHG Indicator, other
Information:
Posters, newsletters, meetings
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Task 2b: Prepare focus area flow
charts (>2 hours per focus area)
Flow chart for each focus area
Different steps of the focus area
Most important inputs (resources) for each step
Most important outputs for each step
Intermediate and final products between the steps
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Task 2b: Prepare focus area flow
charts (cont.)
Different types of focus areas require
different types of charts:
Production step: process flow diagram
Auxiliary systems: layout chart for steam or
compressed air distribution system
Specific major equipment: major equipment and
all auxiliary equipment
Energy
Focus
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Task 2c: Walkthrough of focus
areas (>0.5 day per focus area)
Purpose of the walkthrough(s)
Better understand the focus area
Get feedback from production staff about problems
Write down visible losses of energy and materials
Obtain information about quantities and costs
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Worksheet 14: Walkthrough
observations
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Task 2d: Quantify inputs and outputs
and costs to establish a baseline
Time required depends on information available
Why a baseline? Measure improvements after implementing
options
Management only convinced to continue if you can show savings
Collect the following information: Quantities (e.g. tons of coal per day) Costs (e.g. $ per ton of coal) Other characteristics (e.g. temperature of
water going in and out of the boiler, pressure)
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Worksheet 13: Process flow chart,
inputs/output, energy balance
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Task 2d: Quantify inputs and outputs
and costs to establish a baseline (cont)
Examples of material-related
parameters for the boiler house
Fuel and electricity
Water
Blow down
Ash
Steam produced
Condensate recovered
Energy
Focus
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Task 2d: Quantify inputs and outputs
and costs to establish a baseline (cont)
Examples of energy-related parameters
for the boiler house
Pressure
Temperature
Flue gas composition
Draft
Radiation
Note: specific monitoring equipment may be
needed
Energy
Focus
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coal yard
manual
screening
and crushing
ID fan Standard
parameters:
##
Head developed
## PROCESS STEP REFERENCE process
step steam generation
process
paramete
r
Standard
equipme
nt boiler
pressure
rating
Operatin
g
steam separation
FD fan
standard parameters:
##
##
BFW pump
Standard
parameters:
##
Hidden loses:
H2 & moisture:
##
Radiation:
##
Moisture in air:
## air:
## (actual)
## (standard)
##
(actual)
wate
r
electricity
conditionin
g chemical
dry steam (##)
##(actual)
## (actual) wet stream
unburnt in ash: ##
blow down loss: ##
electricit
y
## (actual) coal (lignite) ## (actual)
coal
(lignite)
coal
(lignite)
water spray Coal fines( carpet loss)
fugitive emissions
Hot condensate (#)
## (actual)
electricity
##(actual)
Energy
Focus
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Task 2e: Quantify losses through a
material and energy balance (0.5 1 day per focus area)
Try to balance inputs and outputs (what goes into a process must come
out!)
Identify losses: energy, products, materials
Calculate costs of losses
Be practical: this is the most difficult task!
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Task 2e: Quantify losses through a
material and energy balance
electricity
9 kW(actual)
Flue gases
loss: 13.2%
(actual)
2.25 Mk/hr
(actual)
coal yard
manual
screening
and crushing
ID fan Standard
parameters:
250 mmWC
Head developed
200o C & 20kW PROCESS STEP REFERENCE
process
step steam generation
process
paramete
r
Standard
12 kg/cm2
6 t/hr
equipme
nt boiler
pressure
rating
Operatin
g
10
kg/cm2
4 t/hr
steam separation
FD fan
standard parameters:
100 mmWC;
30o C & 15 kW at
BFW pump
Standard
parameters:
8 t/hr at 13 kg/cm2
Hidden loses:
H2 & moisture:
2.5 Mk/hour (actual) 14.4%
Radiation:
0.17 Mk/hr (actual) 1%
Moisture in air:
0.03 Mk/hr (actual) 0.15% air:
12.61 t/hr (actual)
14.34 t/hr
(standard)
0.5
Mk/hr
(actual)
wate
r
electricity
conditionin
g chemical
dry steam (97%)
11.3 Mk/hr
(actual)
11.40 Mk/ht
(actual)
wet stream
unburnt in ash: 4.85%
0.83 Mk/hr (actual)
blow down loss:
1.4%
0.24 Mk/hr (actual)
electricit
y
17.0 Mk/hr (actual) coal (lignite) 1.1 t/hr
(actual)
coal
(lignite)
coal
(lignite)
water spray Coal fines( carpet loss)
fugitive emissions
Hot condensate (3%)
0.09 Mk/hr (actual)
Energy
Focus
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Step 3: Identification of Options
Purpose: identify opportunities to improve energy efficiency for the selected focus areas
Output: list of options that will be investigated on their feasibility in step 4
Tasks and minimum time:
Task 3a: Determine causes of losses (0.5 day per focus area)
Task 3b: Identify possible options (0.5 day per focus area)
Task 3c: Screen options for feasibility analysis (0.5 day)
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Task 3a: Determine causes of
losses (0.5 day per focus area)
Brainstorm session with staff and others
Ask the question: Why are these losses
occurring?
Keep asking until you found the root cause
Look for different causes: Man Method Machine Material
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Task 3a: Determine causes of
losses (cont.)
Fishbone diagram
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Task 3a: Determine causes of
losses (cont.)
Material losses with an energy-related
cause
Low dye exhaustion caused by low temperatures
Scale losses caused by cold air infiltration in rolling mills
Energy losses with an energy-related
cause
High electricity use in rollers caused by overheating of bars in rolling mills
High transmission and distribution losses caused by low power factor
Energy
Focus
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Task 3a: Determine causes of
losses (cont.)
Energy losses with a material-related
cause
Inefficient combustion caused by improper sizing of coal
High steam consumption in dyeing process caused by too high liquor-to-cloth ratio
Poor product quality with an energy-
related cause
Thin zinc layer caused by high temperature of
zinc bath in galvanizing
Uneven strength of forged products caused by
low/non-uniform temperature in furnace
Energy
Focus
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Task 3a: Determine causes of
losses (cont.)
Other examples
Low boiler efficiency caused by operating at
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Task 3b: Identify possible options (0.5 day per focus area)
Brainstorm session with staff and others
Ask the question: What can we do to
reduce energy losses?
Options can fall in the following categories: Good housekeeping Improved process management Production process / equipment modification New technology / equipment Input material substitution On-site reuse / recovery Production of useful by-product Product modification
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Task 3b: Identify possible options (cont.)
A combination of options is likely
Poor bleaching can be solved by:
Reducing the liquor-to-cloth ratio
thereby increasing the bleaching bath temperature
Energy
Focus
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Task 3c: Screen options for
feasibility analysis (0.5 day)
Put identified options in three groups:
Options that can be implemented directly
Options that require further analysis
Options that can be considered at a later stage
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Worksheet 15: Causes, identify
options and screening
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Step 4: Feasibility Analysis of
Options
Purpose: Determine which options are technically,
financially and environmentally feasible
In what order feasible options should be implemented
Output: proposal that is approved by top management with:
Recommended options for implementation How to do this List of options that require further investigation
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Step 4: Feasibility Analysis of
Options
Tasks:
Task 4a: Technical, economic and environmental evaluation of options
Task 4b: Rank feasible options for implementation (0.5-1 day)
Task 4c: Prepare implementation and monitoring proposal for top management
approval (2-3 days)
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Task 4a: Technical, economic and
environmental evaluation of options
The Team should (time depends on options):
Investigate which options are technically, economically and environmentally feasible
Identify other possible reasons for implementing the option
Think of possible barriers to implementing the option
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Worksheet 16: Option analysis and
implementation (part for feasibility analysis)
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Task 4a: Technical, economic and
environmental evaluation of options
Technical
Location of power, steam, compressed air lines
Handling capacity of existing system for new equipment
Environmental
Fluorescent tube lights use less electricity than incandescent lamps but contain toxic materials
Bag filter reduces dust but uses electricity
Energy
Focus
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Task 4b: Rank feasible options for
Implementation
Team meeting to give each option a
Rank (0.5 1 day):
1. Implementation in short term (e.g.
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Task 4b: Rank feasible options for
Implementation (cont.)
For options to be implemented (rank = 1)
(time depends on options):
Implementation and monitoring tasks Who is responsible Completion dates How much staff time required Comments
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Worksheet 16: Option analysis and
implementation (part for implementation)
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Worksheet 17: Ranking of options
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Task 4c: Prepare implementation and
monitoring proposal for top
management approval
Prepare Implementation and Monitoring
Plan Introduction Number of options identified, options
investigated for feasibility, feasible options,
options requiring further investigation, and
unfeasible options
Options recommended for implementation in the short term
Worksheets for each option
Obtain management approval
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Step 5: Implementation and
Monitoring of Options
Purpose Implement feasible options in order of priority Monitor results Discuss findings with top management
Output Improved energy efficiency, reduced costs and reduced GHG
emissions
Agreement with top management about the next steps
Tasks
Task 5a: Implement options and monitor results (time depends on options)
Task 5b: Evaluation meeting with top management (0.5 day)
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Task 5a: Implement options and
monitor results
Carry out the Implementation and
Monitoring Plan
Record results for each option: Economic results Environmental results Other results: e.g. any other benefits from the
option and barriers encountered
Communicate results to staff
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Worksheet 16: Option analysis and
implementation (part for feasibility analysis)
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Task 5b: Evaluation meeting with
top management (2-4 hours)
Purpose: Close the first round of energy efficiency projects Gain management commitment to continue with energy
efficiency
Discuss the following: Results How to communicate results internally and externally How to continue
Additional options for implementation / investigation New focus areas to carry out more assessments How to integrate energy management throughout the
companys systems
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Step 6: Continuous Improvement
Purpose: ensure that the company continuesimproving energy efficiency in a systematic
way that is integrated in company processes (these are the key components of Cleaner Production!!)
Output: Continuation of implementing energy efficiency
options
Integration of energy management into company processes
Task 6a: Prepare proposal to continue with energy efficiency (2-3 days)
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Task 6a: Prepare a proposal to continue
with energy efficiency for top
management approval
Write a proposal
Based on what was agreed with top management at the evaluation meeting
Considering new focus areas and options identified for later implementation / investigation
Include how to integrate energy management into company processes!!
Seek top management approval
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In Summary:
The Company Energy Efficiency
Methodology helps companies to:
Save energy
Reduce costs
Protect the environment
Now and in the future!
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Training Session on the Company
Energy Efficiency methodology
How to become
Energy Efficient
THANK YOU
FOR YOUR ATTENTION
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This training session was prepared as part of the
development and delivery of the course Energizing
Cleaner Production funded by InWent, Internationale
Weiterbildung und Entwicklung (Capacity Building
International, Germany) and carried out by the United
Nations Environment Programme (UNEP)
The session is based on materials from the Energy
Efficiency Guide for Industry in Asia developed as
part of the GERIAP project that was funded by the
Swedish International Development Cooperation
Agency (Sida)
The textbook chapter is available on
www.energyefficiencyasia.org
Disclaimer and References
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