IDC/KfWShowcase on

Industrial Energy Efficiency

ENOVEEREngineering Innovation

Thank You

Honey Mamabolo

Vuyo Nomvalo

Dirk Oosthuizen

Lena Chirwa

Wessel Smith

et al.

Lindelani Nyathikazi

Steffi Jose

Cor de Jager

et al.

Andre Botha

Victor Martins

Arvin Lankesar

Linda Mbongwa

et al.

Overview

o Company Profileo Enoveer Offero Implementation Processo Case Study

Variable Speed Drives

o Challengeso Success Factors

Company Profile

o Enoveer Engineering Innovation - 2010o Partners

• Deon Arndt (PhD Eng) • Werner Bouwer (PhD Eng) (Pr Eng)

o Services Energy Optimisation (Energy Management) Thermo-hydraulic design, simulation and analysis

o Industries Nuclear Mining Industrial Commercial

o Total Partner Experience of 30 yearso Quality vs. Quantity

Enoveer Offer

o Enoveer primarily focuses on establishing energy savings partnerships, through energy efficiency interventions with medium to large industrial energy consumers.

o Enoveer offers energy savings partnership financially incentivised by the ESKOM Integrated Demand Management (IDM) Standard Offer Programme (SOP).

Enoveer Offer

o Enoveer conducts the investigations, develops savings strategies, acts as ESKOM IDM project developer, designs the systems, appoints the contractors, manages the installation and manages the energy savings for three years.

o Enoveer funds up to 100% of the total project capital (partner in energy savings).

o Enoveer takes all the ESKOM IDM rebates and all the energy cost savings until a 100% return on investment is realised.

o The savings are calculated against a pre-determined baseline by an independent Measurement and Verification (M&V) group.

o Exit point for client if the investigation outcome not feasible, no cost for client , IP of investigation stays with Enoveer.

Implementation Process

1. The client signs the letter of intent/contract to initiate the project.

2. Enoveer conducts the energy savings investigation.

3. Enoveer presents the findings to the client for approval (exit point, no cost).

4. The client and Enoveer sign an Energy Services Agreement.

5. Enoveer submits a formal proposal to ESKOM IDM for approval.

6. Independent Measurement and Verification (M&V) measures and proposes energy baselines.

7. Enoveer manages the tender process.

8. The client and Enoveer sign the Project Scope Agreement.

9. ESKOM IDM and Enoveer sign the Standard Offer Contract.

10.Enoveer appoints the installation contractors.

11.Enoveer manages the installation of the energy savings strategies.

12.Enoveer manages energy savings over the three year period.

Case Study

o Enoveer was contracted by Xstrata Alloys to assist with energy savings investigations of the excess gas fans of the Premus plant located at the Lydenburg site.

o The investigation was conducted under the ESKOM IDM Standard Offer Program where Enoveer acts as the project developer.

Xstrata Alloys – Excess Gas Fans

Case Study

Xstrata Alloys – Excess Gas Fans

Case Study

Xstrata Alloys – Excess Gas Fans

Case Study

Xstrata Alloys – Excess Gas Fans

o The excess gas fans are responsible for drawing hot gas through Kiln A and Kiln B of the Premus plant.

o The gas moves through two cyclones for dust removal before entering the fans. The gas finally exhausts to the atmosphere through a bag filter plant.

o Inlet fan dampers are controlled to maintain the required gas mass flow rate through the kilns. Fan electrical motor power is used as control feedback signal.

Case Study

Xstrata Alloys – Excess Gas Fans

From Kiln A

93 kg/s

-5.56 kPa

115 °C

To Start UP FCE

To Filter Plant

-3.63 kPa 45% 1.00 kPa1453 kW

Cyclones

Control

50%

41%63%

Case Study

Excess Gas Fan Kiln A

o Actual measurements from the plant was taken to ensure high fidelity for accurate energy saving predictions.

o Simulation models for Kiln A and Kiln B were configured in Enoveer’s own developed Transient Computational Fluid Dynamics Code Enoflux to calculate the potential for energy savings.

Case Study

Investigation Measurement

Case Study

Investigation Simulation

o The fan inlet air dampers of Kiln A and Kiln B are currently on average 45% and 31% open respectively.

o These dampers induce an additional pressure drop over the system of 1.9 kPa and 4.9 kPa respectively.

o Opening these dampers completely and reducing the fan speeds to achieve the required gas mass flow rate will result in fan energy consumption savings.

Case Study

Investigation Results

Case Study

Total Excess Gas Fans Proposal

o Install Variable Speed Drives (VSDs) on the two excess gas fans of Kiln A and Kiln B.

o Ensure that one of the two dampers is always completely open.

o Control the speed of the fans to maintain an average mass flow rate of 85 kg/s using fan motor power as control feedback.

Case Study

Investigation Proposal

From Kiln A

85 kg/s

--2.79 kPa

115 °C

To Start UP FCE

To Filter Plant

-2.69 kPa 100% 0.81 kPa788 kW

Cyclones

50%

100%

Open dampers

Open damper

VSD

Install VSD and reduce speed

Case Study

Excess Gas Fan Kiln A Proposal

Case Study

Variable Speed Drives

o No loss of existing installed capacity.o Generally can be installed within existing infrastructure.o Commissioning times are generally shorter.o Wide range of make and models available.o Cost of installed VSDs in the order of R 2000 – R 2500 per kW.o For Medium Voltage (MV) VSD drives lead times are generally

24 weeks.

Case Study

Variable Speed Drives

Item Description Parameter

1 General

1.1 Make and Model Allan Bradley PowerFlex 7000. 1 500 kW, 6.6 kV

1.2 Manufacturing and Testing Standards

ISO 9001:2008, IEC 61800-3, IEC 61800-4, IEC

61800-5-1, EMC Directive 89/336/EEC and

92/31/EEC, General Product Safety

Directive (GPSD), 92/59/EEC, UL 508C,

UL 347, UL 347A, IEC 61800-5-1, NEMA

61800-4, IEC 61800-3,

1.3 Drive Topology Current Source PWM Topology

1.4 Total VSD Weight (kg) Estimate of 9006 kg

1.5 Availability (%) The VSD system shall be designed for a

minimum availability of 99%.

1.6 Mean Time Between Failures (hours)

Greater than 100,000 hours

1.7 Designed Life Expectancy (years)

Minimum life expectancy of 20 years

Case Study

Environmental Analysis

o Enoveer funds 100% of the total project capital (partner in energy savings).

Case Study

Financial Analysis

*Project Cost excludes engineering consulting fees.

Investment(R)

Energy Savings(kWh)Return

(R)

Energy Savings(kWh)

Return(R)

Rebates(R/kWh)

Investment(R)

Case Study

Role PlayersSupplier(s)

Capital(R)

Equipment(R)

o Initiation Meeting(s)

o Application Proposal

o Basic Assessment Questions & Answer(s)

o Due Diligence Detail business model assessment Termsheet

o Approval Letter

o Legal Agreement(s)

o Execution

Case Study

IDC GEEF Funding

(2) Investigation Report(9)Tender Evaluation Report

(1) Letter of Intent/Contract(3) Service Agreement

(12) Project Scope Agreement

(4) Proposal(6) Baseline Report

(10) Proposal

(5) Letter of Approval(7) SOP Contract

(11) Loan Agreement

Challenges

Time & IntegrationSupplier(s)

(8) RFQ(13) Order Agreement

M&V

(14) Installation

Success Factors

Quality & Systems

Thank You

Enoveer Engineering Innovation

Contact Person: Werner BouwerCell: 082 497 5716Email: werner.bouwer@enoveer.co.za

Contact Person: Deon ArndtCell: 082 2560 907Email: deon.arndt@enoveer.co.za

For more information please visit

www.enoveer.co.za