EDITORIAL

Since the previous edition of our Bulletin “Optimizing Energy” we have noticed a growing interest from companies, institutions and home users to obtain greater efficiency in the electric energy used daily.

Therefore, this 2003-1 Bulletin is aimed to contribute in disseminating new techniques to allow a greater and better knowledge of the scope of this important issue.

We believe that the best learning takes place when it is supported with practical and successful cases from Peru and the Andean Region, making it possible for industries to optimize their energy consumption throughout time.  Likewise, we provide some details of PROCOBRE PERU’s work on the domestic and international levels.

We would like to express our gratitude to three institutions involved in promoting the energetic efficiency for having shared with us important information for the preparation of this Bulletin: the Energy and Environment Conservation Center [Centro de Conservación de Energía y del Medio Ambiente – CENERGIA] from Lima, Peru, the Andean Community’s network of the Organizations for the Promotion of Energetic Technologies [OPET Network], and the Trusteeship for Electric Energy Saving [Fideicomiso para el Ahorro de Energía Eléctrica – FIDE] from Mexico FD.

We hope our Bulletin meets your expectations.

• Successful cases abroad

• A view of other countries

• Solving cases

• Important information

• Learning

• Successful cases in Peru

• Workshop Courses sponsored by PROCOBRE

•  International Seminar

• New publications

• Links of interest

• Suggestions box

SUCCESSFUL CASES ABROAD

¡Colombian industries save 3,500 GWh/year by using their electric energy in a rational manner!

Several Colombian industries were surveyed with the support of the Colombian Ministry of Energy and Mines, the Pontifical Bolivarian University of Medellin and other institutions in order to identify the optimization potentials for electric energy.

Companies:

Cementos Argos
Papelsa
Colombiana Kimberly
Loceria Colombiana
Química Amtex
Pigmentos S.A.
Compañía de Empaques
Incametal
Cerámica Italia
Cervunión
Compañía Nacional de Chocolates
Electroporcelana Gamma
Entre otras.

Description of the action:

Implement an energetic resources management and administration program by collecting and processing data on real and historic time.

Corrective measures:

• Control the main energetic variables for the consumption so as to maintain the levels required for a specific production.

• Clean and calibrate the measurement equipment.

• Eliminate long plant downtimes.

• Replace inefficient energetics and technologies with efficient ones (use of high-efficiency engines).

• Replace insulations and continue with new processes to ensure efficiency.

• Use new materials to optimize the energy used.

Benefits: These corrective measures allowed a saving of 10,1%, i.e. 3,500 GWh/year –the annual generation of a 400 MW power station-- from said company’s current total consumption of electric energy.

Source: Andean Community OPET Network – CENERGIA.

¡Towards energy optimization in Ecuador!

The Ministry of Energy and Mines is currently implementing a long-term electric energy savings program in order to improve the efficiency of the country’s electric system, create a new culture on the rational use of energy among the Ecuadorian population, increase the country’s competitiveness, preserve the natural resources and protect the environment.

Addressed to:

Users of the residential, industrial, service and public sectors.

 

 

Corrective measures:

• Reduce high losses of electric energy.

• Encourage the use of efficient equipment (i.e. high-efficiency engines) so the user would not consider only the equipment’s initial investment cost but also the operation and maintenance costs during lifetime.

• Prepare Energy Efficiency Regulations for the residential sector.

• Encourage the use of alternative energy sources such as energy saver light bulbs, solar heaters, etc.

Benefits:

The index benefit/cost obtained from applying these measures shows their application is profitable for users.

Source: Andean Community OPET Network - CENERGIA

A VIEW OF OTHER COUNTRIES

 

FIDE MEXICO is a non-profit association organized in Mexico FD in 1990 with the purpose of encouraging measures to promote the saving and rational use of electric energy.  And, one of the goals of the organization is the use of high-efficiency engines.

In compliance with the institutional mission and goals, FIDE offers a wide range of projects to offer support to industrial, commercial and domestic users by providing training, information, advisory, technical asisstance, etc.

 

 

Andean Community OPET is the Andean partner of the Network OPET (Organization for the Promotion of Energy Technologies), which purpose is to disseminate, use, share and publish information on new and better energy technologies among the countries of the Andean Community.

 

 

 

 

SOLVING CASES

 

Dear Sirs,

I have a 200 HP standard engine working permanently, at full charge, for about 8,000 h/year in my industrial plant.  I would like to know what economic benefits I can obtain if I replace said engine with a high-efficiency engine.

 

Answer:
The standard engine currently has a 92,4% efficiency, generating a 149,1 KW output from a 164,4 KW input, which represents energy losses of 12,3 KW.

If you replace the standard engine with a high-efficiency engine (96,2%), the same output will require an input of 155,0 KW.  Therefore, energy losses would be 5,9 kW (i.e., 6,5 kW lower than that for the standard engine).

Considering that the difference in the cost of the engines is US$ 2,608 and that they are used 8,000 hours per year, the investment will be recovered in 8 months for an energy cost of US$ 0,074 per kW/h.  And, from the 8th month to an average lifetime of 10 years, it will represent a permanent benefit throughout time for your industry.

Let’s consider the most profitable solution!

Fig.  High-efficiency engine & standard engine

IMPORTANT INFORMATION

Electrical conductors used at home...

The replacement of conductors in a 90m2 department will have a costo of S/.510 for the installation of 14 TW (2,08 mm²) instead of 16 TW (1,31 mm²).

 

This replacement will reduce losses of electric energy with an annual saving of S/. 740.  Therefore, the initial cost will be recovered in 8,3 months and the energy saving will be present during the 20-year lifetime of the installation.

 

Source: PROCOBRE PERU

 

 

Fluorescent lights...

 

When we turn the lights off, and replace common and fluorescent lights with energy saver light bulbs we are using the energy rationally and efficiently.

 

In addition, it is necessary to make a previous overall evaluation of the investment before buying an electrical appliance in order to analyze not only the initial cost but also the operation costs.

These measures will allow us to improve our quality of life and achieve a “true economy”.

 

Source: PROCOBRE PERU

 

 

 

LEARNING

Characteristics of High-efficiency Engines

High-efficiency engines reduce energy losses caused by using copper conductors with a greater length --between 35 and 40%-- than those used with older standard efficiency engines since it reduces resistance and satisfies the power output requirements.

A lower operation temperature is obtained and thus, the electric energy consumption reduced.  This explains how the efficiency index of engines and the payment for electric energy are important factors to recover the investment made.

SUCCESSFUL CASES IN PERU

Cementos Pacasmayo saves US$32,394 per year!

Cementos Pacasmayo enforced corrective measures following the recommendations made by CENERGIA that carried out an evaluation as part of the institutional program to promote Energetic Efficiency. Company: Cementos Pacasmayo S.A.A.

 

Background:

Cement producer industry.

 

Description of the savings potential:

Reduction in the consumption of electric energy by reducing losses and improving the electric system in general.

 

Corrective measures:

• Eliminate leakages and inadequate use of compressed air. 

• Shift the charge with the coal mill to transfer the peak hour consumption into non-peak hours.

• Replace mixed light lamps of 250 W with fluorescent lights of 2 x 36 W.

• Control the operation of lamps in the industrial plant’s area.

Benefits: The application of these corrective measures allowed the company to save nearly 1,095 MWh/year, i.e., US$ 32,394 per year, almost 1,20 % of the current total consumption of electric energy.  An initial investment of US$1,575 was required to implement said measures, which means that the investment was recovered in 0,6 months.

 

Aditionally:

CENERGIA recommended other measures which have been gradually carried out by Cementos Pacasmayo, such as replacing conventional engines with high-efficiency engines as well as maneuvering and protective systems with modern thermal-magnetic switches, reducing losses in the control panels of engines, monitoring permanently the energy quality levels from the main supply of the distribution company, among others.  Altogether, these corrective measures would allow a saving of nearly US$ 141,000 per year.

 

Source: “Project Management of Energetics in the Industrial Sector, Case Cementos Pacasmayo S.A.A." [Proyecto Administración de los Energéticos en la Industria Caso Cementos Pacasmayo S.A.A.] - CENERGIA

 

 

 

 

¡Industrial Papelera Atlas saves US$ 13,736 per year!

 

Industrial Papelera Atlas was also evaluated by CENERGIA in order to recommend measures to reduce the consumption of electric energy.

Company:
Industrial Papelera Atlas

Background:
Paper and by-products producer industry.

Description of the savings potential:
Reduction in the consumption of electric energy by replacing equipment and optimizing the operation of other elements of the system.

Corrective measures:

Replace a 100 HP pump with a 50 HP pump according to the plant needs.

• Install an automatic compressed air pressure control valve to maintain a constant pressure for the plant’s principal processes.

Benefits:

These corrective measures allowed the company to save nearly 422,640 kWh/year, almost 2.85% of the current total consumption of electric energy.  This means an annual saving of US$ 13,736, with an initial investment of US$ 8,600, i.e., the recovery time for the investment was 7.5 months.

Additionally:
Industrial Papelera Atlas is gradually implementing other recommendations issued by CENERGIA, such as replacing the low-efficiency lamps with other lamps with higher efficiency, improving the ignition control to reduce the consumption, replacing the conventional engines with high-efficiency engines, and monitoring permanently the use factor of the most important engines so they operate within the highest efficiency range, among others.  .  Altogether, these corrective measures would allow an annual saving of nearly US$ 120,000.

Source: “Project Management of Energetics in the industrial Sector, Case Papelera Atlas” ["Proyecto Administración de los Energéticos en la Industria Caso Industrial Papelera Atlas"] - CENERGIA

WORKSHOP COURSES SPONSORED BY PROCOBRE

Workshop Course for the Industrial Sector

 

The workshop course “Energy saving for the Industrial Sector”, organized by the Catholic University of Peru (Mechanical Engineering Department) took place from June 5 to 11.  102 persons mainly engineers from the industrial sector attended the course.

Energetic Efficiency Seminar

The seminar “Energetic Efficiency: Policies, Successful Experiences and Technology" organized by the College of Engineers of Peru took place on August 7 and 8.  320 engineers from different areas of expertise attended the event.

 

Workshop Course for the Commercial Sector

 

The workshop course “Energy Saving for the Commercial and Service Sector” organized by the Catholic University of Peru (Mechanical Engineering Department) took place on September 11 and 16.  60 persons attended the course.

INTERNATIONAL SEMINAR ON ENERGETIC EFFICIENCY IN COLOMBIA

The seminar “Efficient Use and Quality of Electric Energy” [Uso Eficiente y Calidad de la Energía Eléctrica] organized by the Western Autonomous University Corporation, Cali, Colombia, took place on June 27 and 28 at the institutional venue.  80 Engineers attended the seminar.

NEW PUBLICATIONS

New brochure on Energy Quality

 

PROCOBRE PERU has published the brochure “How to prevent problems caused by harmonics”.

Have you ever witnessed a harmonic distortion, cuts in the electricity supply, fluctuations in the energy and temporary phenomena? These are some signs of the poor quality of the electric energy received, which troubles users, reduces the equipment’s lifetime and increases the industrial production costs.

 

 

Technical Bulletin of CENERGIA

CENERGIA has published the Bulletin “Management of Energetics in the Industry” from May 2002, presenting the results of the company project.

The purpose of the project was to increase the energetic efficiency and reduce the industry’s emissions related to CO2 by introducing the system “Management of Energetics”.

LINKS OF INTEREST

We recommend the following web pages:

CENERGIA
http://www.cenergia.org.pe
PAE - Perú
http://www.mem.gob.pe/PAE
FIDE Mexico
http://www.fide.gob.mx
Eficiencia Energética - Asociación Internacional del Cobre
http://energy.copper.org

 

SUGGESTIONS BOX

Please send your comments, suggestions and cases of interest to the following e-mail addresses:

Colombia     :          colombia@copper.org
Venezuela    :          venezuela@copper.org
Ecuador       :          ecuador@copper.org
Bolivia         :          bolivia@copper.org
Perú            :          peru@copper.org

 

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