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Zam energy efficiency workshop lusaka rev1
The document summarizes the key findings from energy audits conducted at several manufacturing companies in Zambia. The audits found inefficient energy usage, including lack of energy management systems, unnecessary equipment running, and use of non-energy efficient lighting. Recommendations included establishing energy audit teams, training and awareness programs, installing efficient lighting and automated controls, improving maintenance to reduce leaks, and investing in power factor correction and quality equipment. Follow up audits and workshops were proposed to encourage energy efficiency improvements.
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Zam energy efficiency workshop lusaka rev1
- 1. ZAM ENERGY WORKSHOP: ENERGYAUDIT FINDINGS PRESENTED BY READLAY MAKALIKI Date: 03 June 2015
- 2. PRESENTATION OUTLINE Introduction Definitions Why Energy Efficiency Companies Audited Audit Findings Recommendations Way Forward 06/03/2015 2
- 3. INTRODUCTION Zambia’s economygrowing very favorably (6.5% :2011) Industrial & Commercial sector consumes about 20% of the total electricity in Zambia (49% Mining) Electricity demand strongly correlated to economic growth Electricity is a key driver of economic growth as it is a major input in all major social and economic sectors; domestic, agriculture, mining, manufacturing, and tourism Manufacturing as a potential economic activity for the country heavily depends on electricity Recently generation challenges due to low water levels 06/03/2015 3
- 4. INTRODUCTION The ZambiaAssociation of Manufacturers (ZAM) is keen to implement measures that will help the Zambian local industry to conserve and utilize energy more efficiently. Supported by the Embassy of Finland in Zambia through the Funds for Local Cooperation (FLC), the Project aims to a) Promote the conservation and efficient utilization of energy for production in the manufacturing sector thereby contributing to cost saving and environmental sustainability. b) Assess energy utilisation and management practices & determine the level of energy efficiency, wastage and implications on competitiveness 06/03/2015 4
- 5. INTRODUCTION c) To assessthe current energy technologies being used and recommend better (efficient, environmentally friendly) technologies d) Build ZAM secretariat’s capacity to survey and provide energy management consultancy e) Provide actionable recommendations for replication in other sectors f) Assist firms comply with the newly set power factor target (0.92) Under this programme ZESCO carried out energy audits for some Copperbelt based ZAM affiliate companies This presentation reports on the findings of these audits. 06/03/2015 5
- 6. DEFINITIONS Energy Efficiency Ratioor other quantitative relationship between an output of performance, service, goods or energy and an input of energy Energy Audit Verification, monitoring and analysis of use of energy including submission of technical report with recommendations for improving energy efficiency with cost benefit analysis Energy Management System Set of interrelated or interacting elements to establish an energy policy and energy objectives, and processes and procedures to achieve those objectives 06/03/2015 6
- 7. Dwindling energy resourcesespecially fossil fuels Concerns about environment and climate change IEA has coined Energy Efficiency as the “Hidden Fuel” Article 5.9, Energy Management, in the Energy Policy of 2008 seeks to promote efficient use of energy resources in all sectors of the economy Government incentives through SIs that waive duty on energy efficient products and equipment Legislation – Zambian Grid Code Hence need to manage energy WHY ENERGY EFFICIENCY 06/03/2015 7
- 8. COMPANIES AUDITED 23Companies available for audit but the following have been done between February & March on the Copperbelt NAME LOCATION PRODUCT TYPE ANNUAL ENERGY CONSUMPTION (GWh) ANNUAL ENERGY COST (ZMW) SCAW KITWE STEEL BALLS & CASTINGS 23.98 8,847,320.27 ZAMEFA LUANSHYA COPPER & ALLUMINIUM CABLES 21.5 5,176,584.55 NONFERROUS NDOLA STEEL CASTINGS 0.416 217,121.56 MATALLOY LUANSHYA FERROSILICON 17.8 4,593,027.63 SKF KITWE STEEL FABRICATION 0.144 44, 794 ART NDOLA STEEL WIRES 0.198 74,173 06/03/2015 8
- 9. No formalenergy management system exists No awareness of energy management among employees Poor maintenance regimes-multiple system leakages in water and air Office lighting and air conditioners observed on even when occupants not present Use of non energy saving lights and no automatic switching mechanism for external lights Power factor okay during normal operations (0.98) when running capacitive loads but low during maintenance (0.4) from Friday to Sunday during offloading and loading AUDIT FINDINGS - X 06/03/2015 9
- 10. High harmonics(9.4%) observed above the 8 % international threshold Furnaces, consuming 80% of total energy are run open without hoods. This reduces efficiency as most energy is lost in form of heat Non essential units like pumps continue to run even during non productive hours e.g maintenance There is no process flow studies to ascertain energy inputs/production outputs. Thus opportunities to de-rate equipment or eliminate extra capacity units are missed. AUDIT FINDINGS - X 06/03/2015 10
- 11. Use oftransparent roofing of factory observed to allow natural lighting All 15 tonnes cranes have VSDs incorporated, thus ensuring optimal use of energy. There is willingness from top management to support the system AUDIT FINDINGS - X 06/03/2015 11
- 12. Transparent roofingobserved on the entire factory Power factor of 0.94, power factor correction equipment with filters installed Apparent power observed to be almost equal to the actual power, thus this system is efficiently run Automated switches for external lights are functional thus eliminating manual intervention There is willingness from top management to support the system Observed installed non-energy efficient lighting AUDIT FINDINGS - Y 06/03/2015 12
- 13. ART, SKF andNon-Ferrous Metals Power factor too low 0.3 Actual consumption too low compared to declared demand No energy efficient lighting No automated switches for external lights There is lack of appreciation of the energy costs by top management Inadequate diagnostic equipment for artisans AUDIT FINDINGS - OTHERS 06/03/2015 13
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- 16. PIPE & PUMPLEAKAGES 1606/03/2015
- 17. SECURITY LIGHT -DAYTIME 1706/03/2015
- 18. CHALLANGES During the exercise,the following challenges were enountered: Time of audit was too short and could not provide data representative enough to make recommendations 90% of clients audited could not complete questionnaires and looked reluctant to provide some company data on grounds of mistrusts Power quality tools were not enough as hey had to be rotated between the various clients Companies lack updated equipment inventory Low tariff affects pay back period 1806/03/2015
- 19. RECOMMENDATIONS The following aresome of the recommendations that should set a basis for review in the future audits to be conducted All companies audited need to form functional energy audit teams with clear goals embedded in the company policy Training of personnel thus providing awareness on energy management initiatives and providing of incentives to deserving employees Phase out non energy efficient lights by replacing them with CFLs , LEDs Installation of automated switching devices such as sensors in offices and photocells for external lights Invest in power factor correction equipment with filters 1906/03/2015
- 20. RECOMMENDATIONS All furnacesmust be run with the hoods on top to reduce loss of heat by convection During non productive hours, non essential equipment must be switched off There is need ensure thorough maintenance by eliminating all leaks on pumps, pipes etc. for both water and compressed air Invest in power quality equipment and training Use of transparent roofing sheets in factories and warehouses, so as to avoid using electric lights during day time. (Industrial, Commercial) Review systems to ascertain areas of opportunity for savings Sensitize employees on costs particularly energy costs. 2006/03/2015
- 21. WAY FORWARD Follow upaudits on copperbelt firms Persuade industries to invest in energy efficiency Intensify planned annual or half yearly audits to review implementation Hold Energy Efficiency sensitization workshops with stakeholders and ZAM Sensitization on low power factor surcharge 21 06/03/2015
- 22. END - THANKYOU 06/03/2015 22