POTTERS INDUSTRIES EEO
DATA ANALYSIS PROGRAM
Who are Potters Industries
• Potters Industries is part of the
internationally owned PQ Corporation
• The PQ Corporation is the world’s largest silicate manufacturer and a major player
in the engineered glass bead market
• PQ Corp. spans over 50 countries employing more than 3000 people
• The 3 local (Australian) manufacturing facilities are split into two business units ,
“Industrial Chemicals” and “Engineered Glass Materials”
• EGM
Glass Beads
Sunshine
Hollow Microspheres Dandenong
• Industrial Chemicals
Alkali Silicates
Dandenong
Sydney
• The Dandenong facility operates in 24/7 while the Sunshine and Sydney facilities
are 5 day operations.
• Combined, the sites employ approx. 65 personnel
Energy History & Data Systems
History
• Energy is a major operational cost and accordingly energy reduction
programmes have been a focus for the business for >10years
• As a result, some energy monitoring and analysis systems were in place
prior to the EEO program and many projects had already been completed
Systems
• Existing
• Monthly data capture (Essentially Total Energy Use Only)
• Live process data but NOT energy capture
• Data Analysis - such as measuring production efficiencies vs. costs
Our Approach
The EEO program guidelines provided the outline of our approach by
ensuring the following actions:1.
Gaining “Commitment” from Senior Management
2.
Establishing an “Energy Team”
3.
Developing a Program Plan covering the “Key Elements” of the
Program
4.
Establishing “Program Structure”
5.
Setting “Timelines” for actions
Energy Management Groups
For each Business sector we established Steering Management Groups which
included an Energy Management Champion to ensure the overall program did
not stall. Each Team had responsibilities and accountabilities assigned.
Example:
Project Phases
We utilised an existing model for the project. This model similar to the EEO
Model
Collect
Data
Review &
Report
Analyse
Data
Each of these project parts
have tools associated with
them (Not Discussed Here)
Implement
Project
Identify
Projects
Prioritize
Projects
Planning & Support Systems
To ensure the program was controlled we established a Project Plan and had
existing support systems to assist manage any information developed such as:


Policies
Procedures & Instructions
Records or Data Information
Without these systems we may not have been able to complete the program in
the timeframe we did
Data Collection
Due to an internal personal change Potters joined the EEO program late and
we’re behind schedule in data collection.
Establishing the Baseline
To enable analysis of usage patterns and identify the operational areas of
greatest opportunity Potters embarked on a rigorous 3 month data collection
program.
• A log of all equipment which utilized electricity was generated.
• This log encompassed both operations and support and included
every item from major cooling fans down to the coffee machine.
• The energy rating (kwh) was recorded against each item and for
those with VSD operational trends were analysed.
• Data collection templates were generated for each part of the
operation (Sales, Laboratory, Logistics, Furnace, Dissolvers, etc.).
• Every staff member on site was responsible logging equipment use in
their area on an hourly basis. It should be noted however that most
staff updated once daily based on best recollection.
Data Collection Model
Data Collection
VR6
BC7
CR8
EL9
VR11
DR12
BU14
EL15
BL242
VR174
VR175
EL176
SR25
CR23
SC28
EL29
SPL35
SR44
SR30
SR31
SR32
SC177
SC231
MAG267
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CULLET
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
CRUSHING
Feeder
Belt Conveyor
Mighty Bite
12 Foot Elevator
Barrel Dryer Feeder
Barrel Dryer
Barrel Dryer Burner
90 Tonne Elevator
Cullet Baghouse
Sprinkler system
Area lighting x 6
Area Lighting x 35
Feeder tube
Feeder tube
Scalper Elevator
Scalper
Primary Crusher
Screw
Bucket Elevator
Top Splitter
Rotex 0
Rotex 1
Rotex 2
Rotex 3
Primary O/R Screw
Fines Screw
Fines Magnet
Establishing the Baseline (continued)
After 3months of data collection we had gathered nearly 1.2million data points.
4:00 PM 0 0 0 0 0 0 0 0
5:00 PM 0 0 0 0 0 0 0 0
6:00 PM 0 0 0 0 0 0 0 0
7:00 PM 1 1 1 1 1 1 1 1
8:00 PM 0 0 0 0 0 0 0 0
9:00 PM 0 0 0 0 0 0 0 0
10:00 PM 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
11:00 PM 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
12:00 AM 1 1 1 1 1 1 1 1
1:00 AM 1 1 1 1 1 1 1 1
2:00 AM 1 1 1 1 1 1 1 1
3:00 AM 1 1 1 1 1 1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
0
1
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
0
0
1
1
1
1
1
1
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0
0
1
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1
1
1
1
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1
0
0
1
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1
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1
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1
1
1
0
0
Scada Code / Power Rating
Month
Week
Date
2011
2011
2011
2011
2011
2011
2011
2011
2011
2011
2011
2011
5
5
5
5
5
5
5
5
5
5
5
5
19
19
19
19
19
19
19
19
19
19
19
19
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
5/05/2011
Time
Year
Plant Area
Data Collection
Establishing the Baseline (continued)
The data was compiled and the total energy use for both electricity and gas was
compared against the supplier invoiced quantities.
Despite inaccuracies involved in manual collection the relative usages
aligned very closely for both natural gas and electricity.
Site
Electricity
kWh
Site Energy
Gas GJ
Sunshine
98%
102%
98%
Dandenong
Sydney
99%
104%
100%
NA
NA
POTTERS Total
99%
* Sydney was not included due to the relative size and energy use.
Due to the good alignment it was agreed this data could be considered a valid
representation of energy use patterns.
Data Analysis - Trending
• Establishing the Baseline (continued)
• Trend data was used to isolate events that may skew data, for
example, maintenance shutdowns, breakdowns, etc.
Data Analysis - Trending
• Operational efficiency for each product type was also conducted using
trends. This information allowed costs to be assigned to products
which in turn could be used to develop sales and marketing strategies
• Trending also showed the benefits of timer controlled heating in
administrational areas.
• Clarified the relationship no link between shift and efficiency.
ENERGY USE by PRODUCT TYPE
70
60
50
40
30
20
2/08/2011
29/07/2011
27/07/2011
25/07/2011
21/07/2011
19/07/2011
15/07/2011
Visimax
13/07/2011
11/07/2011
8/07/2011
6/07/2011
4/07/2011
30/06/2011
Medium
28/06/2011
24/06/2011
22/06/2011
20/06/2011
16/06/2011
14/06/2011
Econo
9/06/2011
7/06/2011
3/06/2011
1/06/2011
30/05/2011
26/05/2011
24/05/2011
20/05/2011
18/05/2011
16/05/2011
12/05/2011
10/05/2011
6/05/2011
4/05/2011
0
2/05/2011
10
Data Analysis - Pareto
• Establishing the Baseline (continued)
• Once the data was cleaned we used Pareto Analysis to confirm the
areas which consumed the most energy.
• Unsurprisingly the furnace operation accounted for 59% of the
energy with the Hollows operation accounting for 35%.
Sum of kWH Usage
Rotary dryer Motor
New Baghouse Blower fan
Spray Drier Stack Fan
Screener Baghouse Transfer Fan
Pit Pump
Quality/Manufacturing Admin Heating
Finance Admin Aircon/Heating
Sales / CS Offices - Heating/Cooling
Cumulative %
Blower Fan
Cooling Fan A
Chiller recirculator pump
Cooling Fan B
MCC AirCon
Main Baghouse Fan Motor
Scrubber fan
Atomiser
Push fan
Kaeser Compressor #1
Atlas Compressor
Hot Water
Suction fan
Boiler Burner
Zone 2-5 Burners
Flash Popper Burner
Spray Drier Burner
Burners
Usage
80
100%
70
90%
60
80%
50
70%
60%
40
50%
30
40%
20
30%
10
20%
10%
0
0%
Cumulative % Energy Use
Data Analysis - Pareto
• Pareto charts were used to rank the energy use of specific parts of each
operation and help focus energy saving efforts.
• The operation burners accounted for 92% of all energy use
Data Analysis - Correlations
• We used correlations to examine possible links and preconceived
ideas about energy use such as perceived links between ambient
temperature and operational efficiency. Is there value in running
more during the day?
Burner1 SP
Burner2 SP
Ambient
Burner1 SP Burner2 SP Ambient
100%
10%
100%
20%
-33%
100%
• Correlations between operational conditions and energy input were
also explored. One example was the link between Tower pressure
and burner set points. Managing Pressure better allows lower set
points and less energy input
Pressure
Burner 1 SP
Burner 2 SP
Pressure Burner 1 SP Burner 2 SP
100%
5%
100%
82%
-45%
100%
Projects
• The Pareto clearly showed that the most value could be obtained by reducing
gas use in the burners with a secondary focus on major motors and
compressors
• Projects identified for further investigations as a result of the program were as
follows:
• Waste heat boiler
• Furnace Heat Recovery
• Hollows Heat Recovery
• Push Fan Replacement
Complete
• Office Heating/Cooling
• Hollows Burner Replacement
• Boiler Burner Control Upgrade
• Suction Fan
Proposed for 2013
• Furnace Burner Design
Ongoing
Questions ??