1 / 22

Energy Efficiency Program

Energy Efficiency Program. July 2013. By Greg Chaplin. Bradken Overview. Bradken ® is a leading global manufacturer and supplier of differentiated consumable and capital products to the mining and construction, rail and transit, energy and general industrial markets

adeola
Download Presentation

Energy Efficiency Program

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Energy Efficiency Program July 2013 By Greg Chaplin

  2. Bradken Overview • Bradken®is a leading global manufacturer and supplier of differentiated consumable and capital products to the mining and construction, rail and transit, energy and general industrial markets • As a leading heavy engineering company, Bradken can manufacture fully machined cast iron and steel products from a mass of 0.5kg to over 25 tonnes • Bradken is a publicly listed Company on the Australian Stock Exchange (BKN) • Founded in 1922 in Alexandria, Sydney (AUS) – Leslie Bradford & Jim Kendall won money on a horse “Jack Findlay” and used the winnings to establish Alloy Steel Syndicate to build the foundry. • Global Corporate Centre located in Newcastle, NSW (AUS)

  3. Bradken – Environmental Basics • All Bradken’s major facilities in Australia & UK are independently certified to ISO14001, other sites at implementation stage. • Bradken’s steel foundries account for 90% of the Company’s total energy usage • Electricity ~ 60% and Natural Gas ~ 40% • Australian energy use ~ 1.15 Peta Joule & 139,300 t CO2e • Australian energy costs ~ 5-8% of costs • Approximately 92% of all cast products are produced from scrap steel • Product Stewardship – Buy Back Scheme • Foundry sand used up to 10 times • Used foundry sand often used by other industries (beneficial reuse)

  4. Foundry Processes • Bradken foundries use a range of modern technologies including: • CAD/CAM • 3D Modelling • Discrete Element Modelling • Dynamic Simulation Analysis • Finite Element Analysis • Virtual Prototyping • Casting simulation • Robotic Manufacturing

  5. EEO First Round • Bradken identified it used more than 0.5 PJ, registered and submitted the assessment plan • Bradken used four separate energy consultants to audit seven of its foundries with the intention of ending up with four different sets of recommendations.Overall, the ideas were very similar: • Savings in GJ and tons CO2e identified were very similar between auditors • Upgrade cost estimates varied significantly (up to a factor of five) • Savings of 10-17% in GJ and costs were identified

  6. Factors affecting first round • Age of equipment • Retrofitting costs & difficulty • Training & awareness • Accuracy of estimates • Sub metering • GFC • Company growth • International competition & Value of the Australian dollar • Productivity, quality and safety improvements • Environmental demands - NIMBY

  7. Bradken Growth - 2006 to 2013 • Bradken has experienced significant growth through: • The acquisition of existing foundries in the Australia, UK, USA, Canada, Malaya and New Zealand • New fabrication facilities in China • Commissioning new foundry in China

  8. Energy Performance overall GJ/t - Australia • Changes in overall energy use per tonne of product

  9. EEO Round 2 - Key Element 1 & 2 – Leadership & People For the second round of EEO audits Bradken has: • Updated Environmental Policy in 2011 • Added Energy & GHG Policy in 2011 • Updated Corporate Environmental Goals to include specific goal to reduce energy use per ton of product by 2% per year. • Consistent with UK Climate Change Agreement • US sites set goal at 2.5% - US DoE “Better Buildings, Better Plants Program” • Utilised internal and external resources to develop internal knowledge, awareness and skills.

  10. EEO Round 2 – Key Elements 3 & 4 - Assessment & Identification • Internal audits where practical – combine energy, raw material & waste audits • Developed own checklists & utilise US DoE tools • Purchased thermal image cameras, flue gas analysers, compressed air leak detection equipment for internal use • Update previous audits with better monitoring • Utilise extensive publicly available information from • US DoE & AFS - various • UK Carbon Trust & DEFRA & CTI - various • Environment Canada - various • European Commission “Best Available Techniques in the Smitheries and Foundries Industry” • Bring in external specialist consultants eg. arc furnace specialists (July 2012) where needed • Benchmarking across Bradken’s 19 foundries

  11. EEO Round 2 – Key Elements 3 & 4 – DATAINTERNATIONAL COSTS

  12. EEO Round 2 – Key Elements 3 & 4 – DATABENCHMARKING

  13. EEO Round 2 – Key Elements 3 & 4 – DATA - GAS • Gas use ~40 % of total GJ - 80 to 93% in heat treatment • Heat Treatment has specific quality requirements – heat castings to specific temperatures for specific amounts of time. • Thermal imagery used to identify hot spots. • New ovens 30% more efficient with recuperative burners & pulse firing than same sized oven with conventional burners & controls

  14. EEO Round 2 – Key Elements 3 & 4 – DATA - GAS • Ladle Heaters use 7 to 20% of site gas • Heated to as hot as practical to carry molten metal from furnace to moulds and pour metal into moulds. • “State of the art” – oxy fuel burners – up to 50% gas savings (ref FOUNDRYBENCH – Europe) – one installed OS that demonstrates these savings.

  15. EEO Round 2 –– DATA - Electricity • Equipment Electricity use

  16. EEO Round 2 – DATA - Furnaces • Melting Furnace Efficiency Factors • Operators, Tap to tap times • Furnace size, Alloys, Scrap Quality • Age of furnaces - 1930s to 1990s • “Furnace Whisperer”

  17. EEO Round 2 – Key Elements 3 & 4 – DATA - Furnaces • Different steel alloys have different melting efficiencies • Product design affects Yield • Starting from cold - 20% extra

  18. EEO Round 2 – DATA – Compressed Air • Compressed electricity use while compressed air leaks are fixed.

  19. Factors Affecting Decisions • New foundry in China • Sub metering • International Competition • Clean Technology Food & Foundry Program – 33% • Sub metering & power factor • US Funding – Tacoma Compressed Air Project • Cost $765k – Incentive $536k => 70% • Annual Saving $130k and 3,148,285 KWh • Energy Costs and Carbon Tax

  20. Carbon Tax • UK Carbon Tax • Tax on electricity offset by Climate Change Agreement (reduce energy use per ton by 2% per year) • Low CO2e t/KWhr factor • Low impact – (site managers) – changes may come • New Zealand Carbon Tax • Increase in LPG costs • Not detectable in electricity - low CO2e t/KWhrfactor • Australian Carbon tax (plus transmission charges) • Estimated $3.5 million • To date price rises for electricity 8 to 34% • LRECs, SRECs also a carbon tax • July 2014 ???

  21. EEO Round 2 – KE 6 - Communicating OutcomesBradken Eco-Efficiency Games - 2012 • Bradken benchmarked all 18 steel foundries KPIs against each other and ranked performances • KPIs were: • Energy => GJ/t, $/t, GHG/t • Key resources => t/t (scrap metal, alloys, sands, water, manhours/t) • Waste => t/t, $/t product, $/t waste • Gave overall performance levels and winners were: • GOLD MEDAL => Adelaide, SA • SILVER MEDAL => Mont Joli – Quebec, Canada • BRONZE MEDAL => Henderson, WA USE LESS, WASTE LESS, COST LESS

  22. USE LESS, WASTE LESS, COST LESS • THOSE WHO DO NOT LEARN FROM HISTORY ARE DOOMED TO REPEAT IT (??) • DO NOT RE-INVENT THE WHEEL • BENCHMARKING • TRAINING & AWARENESS

More Related