Energy cost reduction offering industrial manufacturing v2 170818

Energy Cost Reduction and Optimisation Specialising in large industrial plants with high natural gas, electricity and process heating demands

Contact: 1800 475 832 info@hrl.com.au

www.hrl.com.au

expertise in action

Energy Market: Rapidly Escalating Energy Costs • The prices of natural gas, electricity, coal and other fuels are rapidly escalating • Cost increases are impacting the commercial viability of many Australian manufacturing businesses • Action is needed to maintain sustainable margins and profitability • hrl: offers specialist engineering solutions to reduce energy costs

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Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Energy Cost Reduction Service Overview Our Offer

What makes hrl: different?

• Targets Australian industry with large natural gas, electricity, fuel and process heating demands

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Expert engineers with decades of experience in the energy industry delivering tangible results

• We identify, quantify and implement significant opportunities to improve your operations

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Practical outcomes not limited to changing light bulbs - partnering with hrl: delivers material commercial results

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A complete offering – from energy auditing, process modelling and design, through to turnkey implementation or ‘owners engineer’ support

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Commitment to sustainable on-going results

• We deliver cost reductions to your bottom line • Examples include 5 to 10% + energy cost savings with less than 2 year payback • Our customers have saved millions of dollars

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Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

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HRL has delivered successful energy cost savings with: •

Waste heat recovery

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Co-generation

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Equipment modification

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Process improvement

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Combustion optimisation

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Voltage optimisation and power factor correction

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Fuel switching

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Biomass and waste utilisation

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Asset reliability and integrity improvements

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Securing government incentives and rebates

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Typical results of Facility Energy Audits: 5-10%+ savings, <2 year payback Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

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Our Unique Approach Identify • Energy auditing to identify, quantify and prioritise opportunities Measure and Evaluate • Specialist plant performance testing to measure current and optimised plant performance • Process modelling to evaluate identified opportunities • Design of equipment improvements • Develop capital and operating cost estimates • Evaluate technical and economic feasibility of opportunities Deliver Solution • Develop business case • Assist in securing government funding and rebates • Project management – turn-key implementation or ‘owners engineer’ support Sustain Benefits • On-going partnership - increase savings over time • Maintain and improve asset reliability and integrity • Assistance with regulatory reporting, approvals and incentives Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Securing Rebates and Funding External funding and/or rebates are available for energy efficiency and energy/greenhouse gas reduction. hrl: assists with securing funding for clients under programs such as:

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Victorian Energy Upgrades

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South Australian Energy Productivity Program (SAEPP);

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NSW Energy Efficient Business Program (EEB);

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Emissions Reduction Fund (ERF);

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Renewable Energy Target (RET) and Renewable Energy Certificates (REC);

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NSW Energy Savings Scheme (ESS);

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NSW Major resource recovery infrastructure grants program

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Delivering Solutions hrl: delivers material commercial solutions: •

Detailed evaluation, costing and specification of process modifications and upgrades

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Turn-key project implementation

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Owners engineer support to project manage and implement solutions

Specific solution offerings include:

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Voltage Optimisation and Power Factor Correction: to significantly reduce electricity consumption

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Digital Monitoring: Development of digital on-line plant monitoring systems to enable plant performance optimisation and increase plant efficiency

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VSD’s: for fans, pumps and other motors to increase equipment energy efficiency

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Energy Audit and Waste Heat Recovery •

An energy audit of a major industrial facility including boilers, dryers, mills, distillation towers, etc.

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Identified energy savings opportunities equal to ~9% of the total fuel and electricity use with average payback of <2 years, including: • Boiler Optimisation: Insulation, Economiser repair, and O2 trimming • Waste Water Heat Recovery for Process Heating • Voltage Optimisation

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HRL were subsequently engaged to design the Waste Heat Recovery Plant: • Process modelling and integration with existing plant • Equipment specifications and cost estimates • Design verification • Installation scheduled by end of 2017

Value: Waste heat recovery Project >$3M/yr savings, $3M capital project, payback of less than one year 8

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Energy Audit and Waste Heat Recovery •

An energy audit of a brick production facility

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Identified savings opportunities amounting to 5% of the site total energy use with average paybacks of <3 years

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Waste heat recovery to reduce fuel use; o Process design, equipment specification and costing

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Power factor correction upgrade

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Variable Speed Drive (VSD) installation on large motors

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Air Compressor upgrade – replace multiple air compressors with a single VSD compressor

Value: $285k/yr savings identified, $300k capital projects, payback approximately one year 9

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Natural Gas Fuel Switching and Bioenergy •

A detailed technical and economic feasibility study of replacing large gas (>1.5 PJ Natural Gas p.a.) boilers with a technology utilising the client’s waste biomass, including: • Data collection and evaluation • Technology evaluation (e.g. solid-fuel boilers, co-firing biomass with natural gas, anaerobic digestion, etc.)

• Process modelling, technology selection and evaluation • Liaising with project stakeholders

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Review of technology options

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Develop equipment specifications

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Economic modelling and assessment

Value: Robust techno-economic basis for decision-making on future site energy strategy 10

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Boiler and Combustion Optimisation Operating steam generation and process heating systems is increasingly costly for industrial sites. hrl: draws on our deep experience with steam raising and power generation plant to assist clients to optimise their combustion processes. hrl: has delivered energy savings results through: •

Combustion tuning / oxygen trimming

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Economisers / feedwater heating

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Combustion air pre-heating / flue gas heat recovery

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Burner management and control systems

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Insulation / steam trap maintenance / leak repairs

Value: For one of our food industry clients, boiler combustion tuning provided immediate results and a 6.8% reduction in annual fuel bill 11

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Co-generation and Alternative Fuels •

Evaluation of technical and economic feasibility of cogeneration and fuel switching to aid our client with setting their future energy strategy

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Process modelling and design using Thermoflow (leading power and cogeneration thermal engineering software) to develop design specifications for the plant

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Feasibility studies from preliminary concept studies through to detailed Front End Engineering Design (FEED)

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Owner’s Engineering support to clients for major capital projects

Value: long-term energy strategy, finance plan and KPIs established 12

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

Case Study: Plant Reliability and Energy Improvements On-going technical support for Waste Heat Boiler (WHB) steam turbine â&#x20AC;˘

Tube erosion reduced efficiency and availability. Computational Fluid Dynamic (CFD) modelling designed baffles to reduce peak gas velocities. Installation of baffles eliminated the erosion problem improving availability and electrical (MWh) output.

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Further CFD modelling examined the effects of substantially increased plant throughput and resulting gas flow rates. Design modifications to the economiser were made which decreased erosion and increased electrical output by ~10%.

Velocity contours at tube bank entrance are high & unbalanced

Modified baffle design: velocity contours at tube bank entrance are lower and balanced

Value: < 2 week project payback, reduced maintenance costs, increased availability 13

Contact: 1800 475 832 info@hrl.com.au www.hrl.com.au

expertise in action

HRL Technology Group: Our Services Laboratory testing • • • •

Chemical testing Mechanical and metallurgical testing Niche thermal testing Laboratory outsourcing

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Asset integrity, reliability, and materials engineering

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Power and combustion performance engineering

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Process and energy efficiency engineering Specialist capital project implementation

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Innovation partnerships

Specialised engineering solutions • • ••

Feasibility, scale-up and commercialization R&D collaborations Global technology partnerships

Expert technical advisory Trusted, discrete and industry-renowned expert technical advice and witness to Legal, Insurance, and Banking firms for failure investigations, loss-adjusting, warranty claims, due-diligence etc

expertise in action

HRL Technology Group: Energy Efficiency Contacts Glenn Innes Senior Chemical Engineer, CPEng, RPEQ Telephone +61 3 9565 9932 Mobile +61 439 100 704 Email ginnes@hrl.com.au David Shoesmith Principal Chemical Engineer, CPEng, RPEQ Telephone +61 7 3243 4319 Mobile +61 417 004 683 Email dshoesmith@hrl.com.au

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Sam Clayton Senior Chemical Engineer Telephone +61 3 9565 9864 Mobile +61 407 015 763 Email sclayton@hrl.com.au