Redução de Custos de Energia e Eficiência Energética. Case 3M

Redução de Custos de Energia e Eficiência Energética.
Case 3M
DJÉBEL A. NOGUEIRA
Plant Engineering Manager - 3M do Brasil
1902 - 2011
MINESOTTA MINING MANUFACTURING
►
Hundreds of new products every year
►
7,000 scientists in the world
►
6% of sales invested in R & D
Strategic brands
Global Net Sales (US$ billion)
$
Brazil Results (R$ Million)
3.000
2.464
2.500
2.000
2.034
1.982
1.631
1.775
1.515
1.500
1.000
500
71
86
104
117
72
73
2005
2006
2007
Série1 Série2
Investments
2008
Sales
2009
2010
International Focus
►
Plants & Laboratories in over 60 countries
►
52% of employees outside the U.S.
Expanding
Globally
Global Operations
República
Dominicana

Porto Rico

Polônia

Noruega

República
Tcheca Suécia


Alemanha

Canada
Estados 
Unidos

Suiça
East
Finlândia 


Austria

Hungria

Ucrânia

Dinamarca

Holanda

Bélgica

Jamaica

México

Koréia

Japão

Reino
Unido

China

 More than 80,000 employees globally
Guatemala

El Salvador

Costa Rica

Panamá

Colômbia

Venezuela

Equador

Trinidad
& Tobago
Peru


Portugal


 63% of sales occur
outside the United States
Espanha
França

Marrocos

Paquistão

UAE

Israel

Egito

Itália

Grécia

Brasil Chile
 
Uruguai

Argentina

Kenya

Turquia

África do Sul

Romênia

Russia

Zimbabue

Indonésia

Malásia

Sri
Lanka

India

Austrália

 Sales and Marketing
 Manufacturing
 R&D
Hong Kong

Taiwan

Vietnã

Philippines

Thailândia

Singapura

Nova Zelândia

Brazil Operations
 Since 1956 on Brazil
 Employees 4.100
Manaus
Organization
 Sumaré-SP (Built Area): 104.648 m²
 Ribeirão
Brasília - DF
Preto-SP (Built Area): 28.254 m²
 Itapetininga-SP (Built Area): 30.845 m²
Ribeirão Preto
Itapetininga
 Mairinque-SP (Built Area): 10.231 m²
Belo Horizonte
S. José Rio Preto
Sumaré
Mairinque (Cuno Latina)
Curitiba
 Manaus-AM (Built Area): 3.004 m²
 S.
J. do Rio Preto-SP (Built Area): 11.088 m²
 Bom
8
Principio-RS (Built Area): 88.330m²
Incavas
Manufacturing
Sales
SUMARÉ - SP
RIBEIRÃO PRETO - SP
ITAPETININGA - SP
S. J. DO RIO PRETO - SP
MAIRINQUE - SP
BOM PRINCIPIO - RS
MANAUS - AM
Energy Efficiency
&
3M
Energy efficiency Goals
 Global Goal:
• 20% of reduction in energy consumption/Kg (product)
Period of 5 years (2006 – 2010) & (2011 – 2015)
 Brazil Goal
• 10% of reduction on manufacturing since 2008 !!!
 Support of High Administration
• Global Energy Efficiency Policy
• Corporate Energy Management Programs
• Results presentations to the Supply Chain Director
• CEO and Executive Members receive quarterly the numbers and progress of
energy efficiency programs
Work Methodology
Opportunities
Dashboard:
Hopper &
Projects
Natural Gas (m³) / Product (m²)
Steam(ton) / Product (m²)
Electrical Energy (Kwh) / Product (m²)
Ideation
Process
Challenge/Activities - Energy Efficiency Commitee
Energy Efficiency Comittee
Increasing energy efficiency (MMBTU/KG) => Target
10 %
- Measurements and monitoring
- Replication and benchmark successful projects
- Opportunities to implement new technologies and modernization of equipments
- Evaluation of different heating inputs (direct combustion vs steam)
Discipline
- Production planning to reduce losses
- Prevention plans in distribution systems (lines, traps, valves, etc ...)
- Contracts with energy providers (class, risk, values, etc ...)
- Matrix input cost of steam generation and direct combustion
- Alternative energy inputs (fusel, wood, LPG)
- Analysis of data management
- Working groups with staff located in manufacturing
(Plant Engineering, Project Engineering, Process Specialists, External Specialists)
Considerations
 Definition of objectives = Challenges and Possible








Energy multifunction team = Efficiency focus
Evaluation of available inputs x equipments
Evaluation of equipments performance…
Evaluation of contracts, costs, auction, market, others…
Resources, investments e returns
Medium and long term alternatives
Recognition and motivation
Walk throught in the manufacturing field
Energy
Management
Plant Engineering
Steam Production
Facilities / Utilities
Thermal Oxidizer
Manufacturing 10%
Kitchen
Clothes Treatment
Maker Abrasives
LPG
Maker Scotch-Brite
Propane Station
Coater #7 - Tapes
Cylinder Dryers
Mixers
Ovens
NG
Heat Changers
Radiators
Boiler Aalborg
Ovens
Oil
Boiler Babcock
Shells
Valves and lines
Boiler ABB
Electrical Energy
H.V. Substations
Biodiesel
Generators
Manufacture
Measurement Method
Natural
Gas
Vapor
Steam
Finished
Goods
(unid.)
Finished
Goods
(m²)
Raw
Material
Finished
Goods
(Kg)
* Not 3M equipment
Electrical
Energy
Propane
How We Measure?
Thermal Energy / Compressed Air
Electrical Energy
22 Steam meaters
09 NG meaters
06 Compressed Air meaters
52 Meaters
Sumaré
Energy Quality
Example – Abrasives Manufacturing
Good Practices / Benchmark
Maker #1 / #2 Back Rack and Mainline
Balancing
g
EWR - Energy Management System
!
OK
10%
10%steam
steam
consumption
consumption
reduction
reduction
Air Flow - BEFORE
oin
g
On
• Energy supplied by the equipment and required
by cure process comparison
Approved
• Data monitoring through Proficy
Approved
• Drum oven and Mk#1 pilot project
Air Flow - AFTER
• Air flow and temperature consistency
• Quality consistency during the cure process
• New balancing each 03 months
Change Over Wheel
K!
O
Maker #1
• Weekly program according to the ovens T°C
• From the cooler to the hotter product
!
OK
Only
Onlyone
oneheating
heating
process
process
BCT / Maker #2
• Optimized production sequence according to
ovens temperature and formulation
Maker #1 Engineering Projects
Mainline Wall Insulation
• Heating time from 12 to 3 hours
• Boiler on Sundays - eliminated need
Silent Day
Heating
Heatingtime
timefrom
from
12
12to
to33hours
hours
Dumpers Automation
• 24% steam consumption reduction/lm
• Consistency of temperature and cure quality
!
OK
• Action to identify air and steam leaks
• All equipments turned off
• Operators commitment
• Maintenance Plan

Example – Scotch-Brite Manufacturing
Good Practices / Benchmark
Plant Engineering
Ovens - Thermal Analyses
New Technology Compressed Air Central
Old Central
3.590 cfm/MWh
New System
5.409 cfm/MWh
Electrical Energy Consumes reduction
US$ 114,800/year
Maintenance Cost reduction
US$ 18,300/year
20% optimized
And more ! Significant improvement
about compressed air quality
Quality and Energy Efficiency
Steam Production
Aalborg Boiler project
Actions:
• VFD instalation on air supply system;
• New Control System (PLC/IHM);
• Burn Control Optimization
Results:
• New minimal capacity (9 ton/h → 4 ton/h):
• Precision burn control;
• Reduction of NG consumption;
• Automation of Bi-Fuel operation;
Plant Engineering
Sumare
Plant Engineering
Steam Production
Steam Production
(Aalborg Project)
 New Burning Control System at Boiler House.
NG
2,49
Supervision
MMBTU/Ton
Project Result
PLC
NG
Energy
2,07
17 %
MMBTU/Ton
MMBTU/ton
Instruments
Conscious of Manfacturing Employees
•
Presentations to Employees
– Presents the Energy Efficiency Plan to Develop Commitment
– Theoretical explanations about Energy Use on Equipments
– Ideas and suggestions Gathering
–
Manufatura de Scotch-Brite
Face a Face: Energia Elétrica e Térmica
• Teoria:
Março de 2009
– Energia Elé
Elétrica:
trica energia utilizada:
• Motores e Resistências das má
máquinas.
• Lâmpadas.
• Ar Condicionado.
• Computadores, ...
Energia
– Energia Té
Térmica = Vapor, Gá
Gás, Ar comprimido:
comprimido energia utilizada:
• Estufas.
• Cilindros pneumá
pneumáticos, ...
Elétrica e Térmica
© 3M 2007. All Rights Reserved.
© 3M 2007. All Rights Reserved.
Face a Face: Energia Elétrica e Térmica
• Para 2009:
- Objetivo para Todas as Manufaturas:
• Reduzir em 10% o $ gasto com energia (elétrica e
térmica) da nossa Manufatura.
• Área de S. Brite:
– Conversão de Industrial:
• Principal energia utilizada: ELÉTRICA (Todas as Máquinas).
– Maker de Nomad:
• Principais energias utilizadas: ELÉTRICA (Extrusora) e
TÉRMICA (Estufa).
– Makers 1 e 2:
• Principais energias utilizadas: ELÉTRICA (Grande nº de
motores) e TÉRMICA (Estufas).
© 3M 2007. All Rights Reserved.
Face a Face: Energia Elétrica e Térmica
Manufatura de Scotch-Brite
• SUGESTÕES EM 26/03. 2T
Março de 2009
•
•
•
•
•
•
•
•
Lâmpadas banheiro acessas qdo não utilização (Ricardo).
Aproveitamento cxs de ESC e RDRF (Rufino).
Ventiladores das Mqs ligados no café e refeições (Rufino).
Desligar “geral” iluminação e EE das Mqs hor ref (J Vitor).
Desligar Mqs nos setup de produtos (Ricardo).
Ter acionamentos lâmpadas separados no Maker 2 int. (Bidutti)
Reduzir T estufas Maker 2 qdo menor velocidade de Mq (Ademicio).
Garantir utilização dos 2 lados da placa de pp (Ricardo).
© 3M 2007. All Rights Reserved.
© 3M 2007. All Rights Reserved.
Face a Face: Energia Elétrica e Térmica
Obrigado
Confiamos em vocês!
© 3M 2007. All Rights Reserved.
Special Features
Facilities
 Steam Production Alternatives
Boiler
Aalborg
Oil OC1A / Fusel
Boiler
Babcock
Steam
Electrical Energy
Boiler
ABB
MMBTU
X
$$$$$
Leading
Direct Burn – Natural Gas
Manufacturing
Natural Gas/ GLP
Oil Boiler
Boiler Cobrasma
(Babcock & Wilcox)
Type: Watertube
Year: 1973
Pressure: 16Kgf/cm2
Capacity: 20 ton/h
Imput: Oil OC1A
Electrical Boiler
Boiler Sulzer
Type: Electrical
Year: 1984
Pressure: 16Kgf/cm2
Capacity: 17,48 ton/h
Imput: Electrical Energy
Power: 12MW
Natural Gas Boiler
Caldeira AALBORG
Type: Mixed
(Flametube & Watertube)
Year: 1998
Pressure: 16Kgf/cm2
Capacity: 30 ton/h
Imput: NG
LPG Station
Capacity 60.000 Kg
Electrical Energy Generators
Electrical Energy Generators
Results !?
Plant Engineering
3M Energy Dashboard Sumaré - 2009
Steam
2009
Results
Natural Gas
Electrical Energy
Summary Results
-8,1%
-29,9%
-13,9%
-20,7%
Plant Engineering
3M Energy Dashboard Sumaré - 2010
Steam
2010
Results
Natural Gas
-7,4%
-8,0%
Electrical Energy
-8,6%
Summary Result
-7,9%
Steam Production
Plant Engineering
Energy Corporate Dashboard
ET10 => 20 % 2005 – 2010 (BTU/Pound) = AVG 4% year
Energy Committee
Steam
Production
Corporative Dashboard
-23,37
97%
9,9%
Result ET 10
2010
Historical Consumes & Cost ??
Consumption x Cost
(2003 - 2011)
KWh
R$
4.000.000
900.000
3.500.000
800.000
700.000
3.000.000
600.000
2.500.000
500.000
2.000.000
400.000
1.500.000
300.000
1.000.000
200.000
500.000
MWh
100.000
R$
0
jan/03
0
jan/04
jan/05
jan/06
jan/07
jan/08
jan/09
jan/10
jan/11
Plant Engineering
Energy Matrix - MMBTU
50.000
40.000
30.000
20.000
LPG
Fuel Oil
Biodiesel (Generators)
Electricity (Boiler)
Electricity
Natural Gas
10.000
jan/06
7%
jan/07
jan/08
jan/09
25%
6% 2%
44%
2008
jan/11
3%
23%
62%
jan/10
0,5% 0,9%
25%
29,0%
8%
69,7%
70%
23%
2009
2010
2011
Plant Engineering
Total Energy Usage MMBTU / Pound - Sumaré
7
6
5
4
3
Energy cost under control
2
Operational efficiency improved
1
0
jan-04
jan-05
jan-06
jan-07
jan-08
jan-09
jan-10
jan-11
Plant Engineering
Energy Management
Corporate Award
Platinum 2011
2010
BRAZIL ENERGY ISSUES
 Energy cost under control
 Improve operational efficiency
 Reduction of Environmental Impacts
3M CEO – Award
Mr. George Buckley
 Avaliation of energy imputs and their
Oportunities
Electrical Energy and Steam from
High Efficiency Gas-Turbine
Energia Térmica “COMBIO”
Steam
Generation With Biomass
Pellets / 4.600Kcal/kg
Briquete / 4.800Kcal/kg
Bagaço / 2.275 Kcal/kg
Cavaco / 4.300Kcal/kg
NG Electrical Energy Production
Electrical Energy PCH
Djébel A. Nogueira
19 3838 7421
[email protected]
www.3m.com.br