In today’s dynamic world Energy has high demand and its nature is changing along with new technology and systems. New hybrid systems were implemented to try out for higher efficiency and to meet the sustainable development goals defined in ISO50001. Industries introducing new parameters to define energy consumption. To achieve sustainability goals, Energy saving and reliable use of energy are setting out new trends in the energy market. In this paper, I want to discuss some of the practical barriers and solutions to them. Recently I completed my Internship at Tata Motors where I get to work on Energy Management Principles and certainly, we caught some issues and barriers to implementing the solutions. Energy can be saved in a structured manner depending upon cost, amount of energy saving, and Risk of the project
Generally, these types of ideas are low cost and low energy saving with almost no risk. It consists of sharing the load, idle time reduction, demand matching, rewinding of old aged machines, and manual off. In industries, some machines are present in the factory who have the same job work with the same accuracy but different machine ratings. We can share more load on lower machine ratings than higher machine ratings. If we have enough data on machines in the factory, we can analyze such conclusions for energy saving at different feasibility levels. In idle time reductions some machines on conveyor line various machines are working and in each takt time conveyor move a step and such steps complete one cycle and time required to complete one cycle is called cycle time. In an industry, such cycle time is calculated by taking all machining works on each step. the most critical function which requires the highest time on the conveyor line is condolence by 17% and cycle time is decided. It's obvious now that the machines other than critical times on the same conveyor line working idle for some time. So, we have to find what we can do here in some cases for saving energy. In demand matching, energy can be saved by efficient energy consumption by driving the load to its highest efficiency. Rewinding machines is also an alternate solution for replacing old machines with new ones. These ideas are now developing a mindset about how can we start thinking about energy saving from scratch.
In control systems, ideas for energy saving are generally HVAC, use of VFD, and Capacitor Banks. Those ideas require some fund allocation with some risk and with increased energy saving than housekeeping ideas. Variable drives control speed and capacitor banks improve PF by reactive power compensation. Here we have to implement the learned concepts into realities and enjoy the benefit of saving Energy.
System Thinking idea usually consists of a balcony view of the floor and energy flows within the factory can be analyzed. Such analysis can also provide some conclusions about energy saving for example using waste heat of one process can be utilized for another process input as useful heat (CHP). System Thinking Idea implementation requires more cost, project risks are high while energy saving is also high. Here we have to develop our analytical skills and ability to derive conclusions from it.
Process Design Ideas are accepting new technologies, innovation in existing processes, and plant expansion decision-making. Here the cost and risk involved are high and energy savings are also high. Renewable Energy Generation, Automation in the plant are examples of process design. Here is the main focus on project financials. If the Cost-benefit analysis is positive and satisfactory decisions are taken. We were able to categorize the ideas and what we have to focus on in each category.
“Generation of Ideas is important but the actual implementation is the Game”
During practical implementation in the real world, we have to consider many more things than actual. Here we are discussing some barriers at various levels and some solutions so that you get tricked to think about barriers.
1. How to spread awareness and create an environment on ground level for energy saving?
2. How to analyze data and how frequently audits of such energy flows and data can be done?
Awareness programs, Training, and Energy Saving Rewards for competency among the operators.
1. How to generate funds for new projects?
2. How to minimize the Risk of Projects?
3. How to Improvement in ROI?
Investing the savings from housekeeping ideas into the control system and savings from the control system must be invested into further categories of projects, Renting the projects to suppliers.
1. How to implement the competence model?
2. How to Nudge for desired aims?
Create Energy saving concepts into the parameters which can be easily understood by the operator on machines, Nudge the organization for adaptive changes in behavior.
These are barriers and possible solutions. Your suggestions are also appreciable and now we can develop a structured design thinking to tackle problems in Energy saving.
Now start thinking and Set targets for Achieving such common goals. We are near to our Sustainability Development Goal.
Active Analytical Thinker, Currently working on Financial Literacy.
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