MBEYA UNIVERSITY OF SCIENCE AND
TECHNOLOGY
LECTURE NUMBER ONE
INDUSTRIAL ENERGY MANAGEMENT
CODE: MEB 3116
Number of credits: 6
Facilitator: Mr. Emmanuel Mwangomo
Mech Staff 05
LEARNING CONTEXT
• The module will conducted through lectures and
Tutorials. Special projects will be given.
• Introduction to energy management data
recording and processing
• Plant survey
• electrical metering and tarifs,
• electrical fundamentals
• Potential industrial energy saving regimes.
• Financial analysis and environmental impact of
industrial processes.
LEARNING MATERIALS
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Chalkboard,
Overhead Projector,
Flipcharts and
Audio Visual.
REFERENCES
• Murphy, W.R. and G. Mckay: Energy
management , Butter worth publishers Ltd.
• Handbook of Industrial Energy analysis, Ellis
Howood publishers.
• Turner, W.C. Energy Handbook, John Wiley
and sons, New York.
INTERGRATED METHODS ASSESSMENT
• Contionous Assessment Components 40%
• End of Semester Examination 60%
INTRODUCTION TO ENERGY MANAGEMENT
• Energy management is not an event but a
process that involves energy auditing as well
as number of key elements these are:
• - overal assessment of the manufacturing operation
or building to identify areas of energy wastage and
ineffiency
• -Daily recording of electricity , fuels and water use
• -A listing of appropriate energy conservation
measures based on the assessment
INTRODUCTION TO ENERGY MANAGEMENT…….
• - Carefully planned implementation
• - Regular review of actual enegy and cost
saving
• Once initiated energy management is ongoing
process that is intergrated with routine plant
operation or building maintenance and with
any subsequent changes to product
manufacturing or building envelope,
occupancy or mechanical equipment.
Energy management program
Energy management program
Other definitions
• The judicious and effective use of energy to
maximize profits (minimize costs) and
enhance competitive positions
• The strategy of adjusting and optimizing
energy, using systems and procedures so as to
reduce energy requirements per unit of
output while holding constant or reducing
total costs of producing the output from these
systems
OBJECTIVE OF ENERGY MANAGEMENT
• The objective of Energy Management is to
achieve and maintain optimum energy
procurement and utilisation, throughout the
organization and:
• • To minimise energy costs / waste without
affecting production & quality
• • To minimise environmental effects.
ADVANTAGES OF ENERGY MANAGEMENT
• The best and most cost effective measures for
a particular process or facility are selected and
implemented in proper order.
• Monitoring energy conservation results
provides feedback for improving the energy
consumption and check on project progress.
• The useful service life of the facility and
operating systems is extended.
• Longterm result and total operating cost.
ENERGY MANAGEMENT STEPS
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Step 1: Energy data analysis
Step 2: Energy Audit
Spep 3: Implementation
Step 4: Monitoring
ENERGY MANAGEMENT STEPS
• Energy Data Analysis
• The enegy data analysis involves reviewing
energy bills on a monthly and annual basis
and comparing them to previous reference.
• In addition Energy use indices(EUI) can be
calculated from the collected data such as
energy intensity per unit
production(GJ/tonne) or energy intensity per
unit area (MJ/m2)
ENERGY MANAGEMENT STEPS
• Energy Audit
• Energy audit is a complete assessment of the
manufacturing facility or of the building and
its energy use patterns.The physical
characteristics of the facility and various
electrical and mechanical systems such as
ligthing,motors, compressed air, heating and
cooling etc are inspected.
ENERGY MANAGEMENT STEPS
• Implementation
• The following practical concerns are used in development of
implentation plan
• - the existing maintenance programmes for envelope and
mechanical and electrical systems
• -projected plans for changes in manufacturing processes or
use of the buildings
• -projected plans for major repairs or renovations
• -available funds and
• - available staff resources for implementation and programme
management
ENERGY MANAGEMENT STEPS
• Monitoring
• -Monitoring techniques involves daily review of
energy use data against the production output to
spot any sudden deviation from the normal
consumption patterns and to take corrective
action where necessary.
• Review of enegy bills on monthly and annual
basis and comparing them to a prevoius
reference year provides a historical picture of the
energy use patterns.
Need for Energy Audit
• In any industry, the three top operating
expenses are often found to be energy (both
electrical and thermal), labour and materials
• Energy Audit will help to understand more
about the ways energy and fuel are used in
any industry, and help in identifying the areas
where waste can occur and where scope for
improvement exists.
Type of Energy Audit
• The type of Energy Audit to be performed
depends on:
- Function and type of industry
- Depth to which final audit is needed, and
- Potential and magnitude of cost reduction
desired
• Thus Energy Audit can be classified into the
following two types.
i) Preliminary Audit
ii) Detailed Audit
Preliminary Energy Audit Methodology
• Preliminary energy audit is a relatively quick
exercise to:
• Establish energy consumption in the
organization
• Estimate the scope for saving
• Identify the most likely (and the easiest
areas for attention
Preliminary Energy Audit Methodology
• Identify immediate (especially no-/low-cost)
improvements/ savings
• Set a 'reference point'
• Identify areas for more detailed
study/measurement
• Preliminary energy audit uses existing, or
easily obtained data
Detailed Energy Audit Methodology
• A comprehensive audit provides a detailed
energy project implementation plan for a
facility, since it evaluates all major energy
using systems.
• This type of audit offers the most accurate
estimate of energy savings and cost. It
considers the interactive effects of all projects,
accounts for the energy use of all major
equipment, and includes detailed energy cost
saving calculations and project cost.
Phases of Detail Energy Audit
• Detailed energy auditing is carried out in three
phases: Phase I, II and III.
Phase I - Pre Audit Phase
Phase II - Audit Phase
Phase III - Post Audit Phase
Ten Steps Methodology for Detailed Energy Audit
Ten Steps Methodology for Detailed Energy Audit
Ten Steps Methodology for Detailed Energy Audit
Ten Steps Methodology for Detailed Energy Audit
Phase I -Pre Audit Phase Activities
• A structured methodology to carry out an
energy audit is necessary for efficient working.
An initial study of the site should always be
carried out, as the planning of the procedures
necessary for an audit is most important
• An initial site visit may take one day and gives
the Energy Auditor/Engineer an opportunity
to meet the personnel concerned, to
familiarize him with the site and to assess the
procedures necessary to carry out the energy
audit.
Phase I -Pre Audit Phase Activities
• Activities of site visit
• Discuss with the site's senior management the aims
of the energy audit.
• Discuss economic guidelines associated with the
recommendations of the audit.
• Analyse the major energy consumption data with
the relevant personnel.
• Obtain site drawings where available -building
layout, steam distribution, compressed air
distribution, electricity distribution etc.
• Tour the site accompanied engineering/ production
Phase II- Audit Activities
• The information to be collected during the detailed audit
includes: • Energy consumption by type of energy, by department, by
major items of process equip
ment, by end-use
• Material balance data (raw materials, intermediate and final
products, recycled
• materials, use of scrap or waste products, production of byproducts for re-use in other industries, etc.)
• Energy cost and tariff data
• Process and material flow diagrams
• Generation and distribution of site services (eg.compressed
air, steam).
Phase II- Audit Activities
• Sources of energy supply (e.g. electricity from
the grid or self-generation)
• Potential for fuel substitution, process
modifications, and the use of co-generation
systems (combined heat and power
generation).
• Energy Management procedures and energy
awareness training programs within the
establishment.
Phase III- post Audit Activities
• The audit team should collect the following
baseline data:
• - Technology, processes used and equipment
details
• - Capacity utilisation
• - Amount & type of input materials used
• - Water consumption
• - Fuel Consumption
• - Electrical energy consumption
• - Steam consumption
• - Other inputs such as compressed air, cooling
water etc
• - Quantity & type of wastes generated
• - Percentage rejection / reprocessing
• - Efficiencies / yield
Process flow diagram
• An overview of unit operations, important
process steps, areas of material and energy
use and
• sources of waste generation should be
gathered and should be represented in a
flowchart as shown in the figure below.
Example: A flowchart of Penicillin-G manufacturing
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THANK YOU