Topic #2: Energy usage of existing equipment 

Drive down costs by maximising the operation and energy efficiency of your key equipment items, from process heating systems to motors, pumps and fans. Apply the same principles to improve your building’s performance and reduce running costs.

Start by watching this video about Replas, an Australian plastics SME that has significantly improved energy efficiency and reduced costs by only running certain equipment components when required, and using “daylighting” and sensors to reduce the energy consumed by lighting. You could do the same in your business using PACIA energy+!

Overview

All equipment commonly used in the chemicals and plastics industries uses energy. Items such as compressors, boilers, extruders, motors, pumps and fans need electricity, gas or other fuels to function. Your buildings also play a role in the amount of energy consumed – or saved – in your business. As Mark Jacobsen, Replas Director, says in the video above, “Energy efficiency and growing your business go hand in hand.”

Ensure that your equipment and buildings are operating as effectively as possible, and are not causing energy to be wasted. This will reduce your total energy consumption and may even improve your overall productivity.

In this section, you will find the tools you need to understand and maximise the energy performance of: 

☑ Process heating, hot water and steam systems
☑  Compressed air systems
☑  Motors, pumps and fans
☑  Evaporation, drying, cooling and chilled water
☑  Industrial buildings

Start by working through the Tutorial below, to identify priorities and opportunities specific to your business. Use the tools and resources provided on this page to take action, and remember to regularly refer back to your energy plan to ensure you stay on track.

Tutorial

Maintaining and operating your plant and equipment can offer significant energy efficiency improvements and cost savings. Use the following tutorial questions to ensure you have considered key equipment items and areas, and gain plenty of ideas to take action within your business.

Question one:
Do you use compressed air systems? If yes, energy may be wasted through incorrect sizing and system leaks - see PACIA energy+ 5 Minute Guide #3 for ideas to save energy and costs.

Question two:
Do you use process heating, steam or hot water? If yes, PACIA energy+ 5 Minute Guide #2 provides advice and ideas on actions such as correct temperature setting, pre-heating, insulation and leaks to help you stay energy efficient.
Do you use motors, pumps and fans? If yes, PACIA energy+5 Minute Guide #4 will help ensure correct sizing, speed, maintenance and control systems for optimal energy use outcomes.

Question three:
Do you use evaporation and drying processes, cooling or chilled water at your facility? If yes, PACIA energy+ 5 Minute Guide #5 breaks down process operations and provides advice on energy saving actions at every stage.

Question four:
Have you reviewed your building’s energy use and opportunities for efficiency or improvements? If yes, well done – and remember to schedule a regular review. If not, PACIA energy+ 5 Minute Guide #6 provides insights and ideas on heating, cooling, insulation and lighting to reduce energy used in running and maintaining your building.

Question five: 
Have you considered other areas of your operations where energy savings might be achievable? View the above video to hear a real life example from a plastics manufacturing company that has cut costs just by assessing its existing equipment.

 

Relevant PACIA energy+ 5 Minute Guides

Download the 5 Minute Guides under this topic, which provide you with detailed information and suggested actions for specific areas of your plant and buildings. Use these Guides to help you identify prioritised targets and actions to improve the energy usage of existing equipment in your business. This will assist you to develop and act on your energy plan.

PACIA energy+ 5 Minute Guide 2.1 PACIA energy+ 5 Minute Guide 2.2 PACIA energy+ 5 Minute Guide 2.3
5 Minute Guide 2.1
Process heating, hot
water and steam systems
[2.8MB]		 5 Minute Guide 2.2
Compressed air systems
[1.5MB]		 5 Minute Guide 2.3
Motors, pumps and fans
[1.5MB]
PACIA energy+ 5 Minute Guide 2.4 PACIA energy+ 5 Minute Guide 2.5
5 Minute Guide 2.4
Process operations
and equipment
[2.4MB] 		 5 Minute Guide 2.5
How to make existing industrial buildings more energy efficient
[4.7MB]

 

Additional resources

The following external resources relate specifically to this topic, and supplement the information provided in the PACIA energy+ 5 Minute Guides above.

  • Heating systems: 
    • Sustainability Victoria has an Energy Efficiency Best Practice Guide for Steam, Hot Water and Process Heating Systems
    • The Australian Government’s Energy Efficiency Exchange website provides further information on improving process heat, boilers and steam systems
  • Compressed air systems:
    • Sustainability Victoria has an Energy Efficiency Best Practice Guide for Compressed Air Systems
    • Compressed Air Australasia provides information on how to calculate losses and size your compressed air system
  • Motors, pumps and fans:
    • The Australian Government’s Department of Resources, Energy and Tourism provides a Motor Solutions Online package including checklists, detailed information on electric motors, pumps and fans, and case studies
    • The Australian Government’s Energy Efficiency Exchange website provides further information on improving motors and motor systems and pumps and fans
    • Sustainability Victoria has a detailed Energy Efficiency Best Practice Guide to Pumping Systems
  • Cool roofs: Melbourne City Council’s 2011 Research Report provides further information

  • Daylighting strategies: The National Institute of Building Sciences in U.S.A. has a guide to the implementation of ‘daylighting’ strategies

  • Lighting upgrade options: For a full breakdown of the comparable costs savings for different upgrade options and improvement opportunities, refer to:
    • The Commonwealth Government’s Energy Efficiency Exchange website
    • The Carbon Trust UK’s website
    • The Carbon Trust UK’s overview guide
  • All equipment: The European Care+ program provides a comprehensive energy efficiency best practice handbook for SMEs in the chemicals and plastics industries. It includes information and techniques to improve the energy efficiency of various equipment items

Did you know?

Save money by fixing leaks

Leaks waste energy and money. Check for leaks and ensure they are repaired quickly. Fixing a 1.6mm hole in a compressed air pipe would save you over $200 per annum.

Improved pumping systems save Murray Goulburn Co-operative $6,000/yr

By increasing the energy efficiency of pumping systems in one process area, Murray Goulburn Co-operative reduced that processes pump system costs by 42% and saved more than $6,000 a year in energy costs. Many chemicals and plastics SMEs use similar pumping equipment and could achieve significant energy savings in this area. Read more about this case study.

Significant cost savings through better control of chemicals manufacturing

Queensland agricultural chemical manufacturing company Accensi combined staff education with controls on compressors and air conditioning to save energy and money. Accensi identified and implemented energy, water and waste improvements delivering total annual costs savings of more than $142,000 per year. Read more about this case study.