Energy Efficiency at Vale

Energy Efficiency at Vale

ITEMS

Goal

Energy Management: Energy Efficiency

Plant Assessments

Energy Saving Needs in Brazilian Industry

Conclusion

GOAL

Present the form of action from Vale regarding energy efficiency, share experiences in plant assessment, as well as provide an insight into potential energy savings in industry

ENERGY MANAGEMENT AT VALE

ENERGY MANAGEMENT

Value Criation Optimization

of Supply Costs

Supply Secutiry

Social-Environmental Responsibility Energy

Efficiency

* There is no hierarchy among the pillars

WHAT IS CONSIDERED ENERGY EFFICIENCY?

Energy Efficiency

Reduction of unitary

prices

Contractual Arrangements

Energy quality

Optimization of industrial

assets

Consumption Reduction

Productivity increase

Change in energy

transport alternative

Energy – any sort, and

not only electricity

Energy Efficiency -

Optimization of energy

expenses

Energy Efficiency Projects - Projects or

activities that lead to

reductions in energy

spending, which are

crucial for the economic

viability of investments

ENERGY MANAGEMENT – ENERGY EFFICIENCY

PERFORMANCE

Expenses

Energy End-use

Unitary price

• Energy service (heat,

driving force)• Energy evaluation and

selection (demand,

availability, unitary price)• Supply choice (self

production, market)

• Contracts• Tariffs• Taxes• Transport

• Corrections and improvements• Process changes• Energy recovery• Technology development

Operations

Energy

End- Use

Unitary Price

Projects

Plant Assessments Contractual Renegotiations and RevisionsImprovements, Replacements and Corrections

Project Validation (FEL)New Energy ContractsProject Revisions and Adjustments

ENERGY MANAGEMENT – ENERGY EFFICIENCY

Standards

TGEE

Energy Management

Operations

Current Projects

Capital Projects

Energy Policy / Technical Standards for projects and equipments

Local and Global Energy Committees / Evaluation of results and sharing of best practices

Monitoring of specific consumption and costs of operations

Plant Assessments, measurement and verification of results

Exploration, engineering and project implementation

Analysis of energy efficiency through the steps of FEL

ENERGY MANAGEMENT – ENERGY EFFICIENCY

PLANT ASSESSMENTS

Falhas de equipamentos apontadas no OEE

Energy Management (Specific Consumption)

Problemas PotenciaisTGEE – Technical

Groups

Gestão da Mudança Innovates Vale

(Stock ideas)

Mapeamento da Cadeia de Valor (Assessment)Plant Management

(Strategy)

Emissão de SEPsCurrent Projects

Estudos KaizenSES – System of

Engineering Standards

Estudos de Confiabilidade

APS – Action Plan Sustainability

ENTRADAINPUT PROCESSOPROCESS

Outras alternativasDepartment of Energy /

Alternatives

TCIEnergy DepartmentFase 1 - Avaliação do impacto

econômico ou risco associado a cada um das preocupações

identificadas

Technical and economic analysis Decides on performing

broad or specific assessment

Geração de lista de estudos priorizada pelo impacto/risco,

dificuldade de execução e estimativa de investimento

Gerência IndustrialPlantsFase 2 - Priorização dos estudos

a serem conduzidosProvide the infrastructure and validate stages of assessment

TCIDep. of Energy / PlantsFase 3 – Endereçamento dos

estudos e formação das equipes de trabalho

Addresses the improvements /Incorporate the

opportunities in the budget

SAÍDAOUTPUT

ROM/RNC - Estudos de Engenharia

Lean Six Sigma Department

Performs contracting company service provider and makes management of contracted

PLANT ASSESSMENTS PIMS

Energy Management System – Brucutu Plant

Superior PerformanceNormal PerformanceAverage PerformanceBad Performance

MotorsSystem

Ventilation andExhaust

Lighting

Compressed Air

Thermal Systems /

Cogeneration

Instrumentation and Control

Conveyor Belts

Pumps

SYSTEMS

PLANT ASSESSMENTS

SCOPE

Analysis and measurements of electrical and mechanical systems

Analysis of systems the utilities area

Analysis of processes that interact on the plants

Energy Management

Incorporation of technology

Creation of control parameters

Performance evaluation

PLANT ASSESSMENTS

SYSTEMS AND EQUIPMENTS ANALYZED

PLANT ASSESSMENTS

Couplings Solar heating Pumps Boilers Chillers Cogeneration Compressors Variable speed drive Capacitors Conveyors Effluent treatment plant Exhaust Filters Energy management Lighting Thermal insulation

Hot water lines Power transmission lines Steam lines Measurement of electric

and magnetic fields Mills Motors Industrial water system Compressed air system Ventilation system Chilled water system Transformers Pneumatic conveyors Heat exchangers Turbines

SYSTEMS AND EQUIPMENTS ANALYZED

PLANT ASSESSMENTS

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL CASE

Total Electric Energy

% Savings per system

Plant AssessmentPumping

Compressed air

Motors

Lighting

Variable speed drive

VENTILATION AND EXHAUST Elimination of head losses Reduction of power exhaust fans Use of variable speed drive in motors Use of thermal energy from exhaust gases

COMPRESSED AIR Elimination of leakage and drainage of condensate Reduced pressure losses Classification and division of compressed air lines Sizing of compressors in accordance with the appropriate application Suitable arrangement of the house of compressors Optimization of the air intake system in order to reduce the temperature Automation of the operation of the compressor (load / idle)

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL ACTIONS

MOTORS SYSTEMS Sizing of motors Use of energy efficient motors Use of variable speed drive Automation control systems to reduce no-load operation

PUMPING (Water, pulp ou vacuum) Elimination of leaks Use of variable speed drive for variable flow demands Reduction of the Head by dividing reservoirs Proper selection of the pump to the point of maximum efficiency Elimination or reduction of pumping due to the route optimization Reduction of friction in the pump shaft seals Control of temperature and water flow sealing vacuum pumps

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL ACTIONS

LIGHTING, AIR CONDITIONING AND HEATING WATER Proper specification and distribution of equipment in environments Integration of natural resources to the solution of thermal comfort and light Promotion of adequate and regular maintenance of equipment Automation and suitable actuation of system Using solar energy to heat the water used for washing parts, restaurants and

clothing room

ELECTRIC POWER SYSTEM Evaluation of the load transformers Evaluation of power factor and installation of capacitors and filters Monitoring of power quality

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL ACTIONS

TRANSPORT Implementation of measurement system Relocation of supply points Automatic calibration of tires Training of operations focused on efficient driving Reduction of MDT (Middle Distance Transport) Maintenance plans focused on energy efficiency Auxiliary systems to operate the equipment (on-board computers connected to the

dispatch system) Maintenance of roads running Replacement trucks for pumping pulp or conveyor belts, where applicable

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL ACTIONS

THERMAL SYSTEMS Preheating of the combustion gases Improved insulation and reducing losses of hot gases Evaluation of the steam distribution system Analysis of the refrigeration system (cooling towers and others) Use of additives to improve fuel combustion in motors Evaluation of cogeneration systems

NEW TECHNOLOGIES Trolley Trucks Studying application of electrical energy for supply of locomotives to replace

diesel Truckless system for mines

ENERGY SAVING NEEDS IN INDUSTRY

TYPICAL ACTIONS

CONCLUSION

SWOT ANALYSIS – ENERGY EFFICIENCY

STRENGTHS

Electricity from low carbon sources

Wide range of energy (electricity, gas, fuels, biomass and others)

Energy matrix is converted to energy from renewable sources  

CONCLUSION

SWOT ANALYSIS – ENERGY EFFICIENCY

WEAKNESSES

Imposition of non-energy costs on the tariff Lack of technical courses for industrial energy

efficiency (technical and superior levels) Lack of tax and credit incentives for thermal systems Low investment in instrumentation and control Lack of knowledge on energy laws

CONCLUSION

SWOT ANALYSIS – ENERGY EFFICIENCY

OPORTUNITTIES

PNE (National Energy Efficiency Plan) ISO 50001 (Energy Management Standard) Expansion of investment in instrumentation Certification in Measurement & Verification

processes Strong performance in thermal systems Effective fiscal and credit incentives Increase the importance of PROCEL and CONPET

programs

CONCLUSION

SWOT ANALYSIS – ENERGY EFFICIENCY

THREATS

Importing solutions not suitable to the Brazilian reality

Dissociation of efficiency incentives for different energy sources

CONCLUSION

EVOLUTIONARY VISION – ENERGY EFFICIENCY

Management Maturity

Impa

ct o

f act

ions

Continuous monitoring (power + indicators)

Contractual tariff adjustment

Adjustment of consumption profile (awareness)

Review of the production process (automation)

Technology upgrades (retrofit)

Cogeneration and Renewable

Fábio A. ChavesDINE (Energy Department)General Management of Trading and Market Solutions+55 (13) [email protected]