How do you prioritize energy-saving initiatives when faced with budget constraints in your plant?

Most of the rotary equipment including drives for pumps, agitators, blowers require electrical power to operate. First step is to identify the unit processes where rotary equipment viz agitators are avoidable. For example a Flash Mixer could be replaced by Weir mixer. Energy efficient pumps with VFD should replace fixed speed pumps. Installation of solar panels in the area available can directly or indirectly reduce the energy bill. All rotary equipment should undergo energy audit periodically. And final not only capital cost but 25 years Life Cycle cost should be evaluated.

Na minha experiência como engenheiro ambiental, eu penso em priorizar iniciativas de economia de energia: Começando em otimizar o consumo de energia, melhorando o isolamento térmico, como iluminação natural, LED, ajustar e climatização e monitorar o uso de eletricidade. Uso de fontes de energia renovável, como painéis solares e eólicas. Investir em geração de energia limpa é fundamental. Eduque as pessoas e incentive práticas sustentáveis, como desligar aparelhos não utilizados e reduzir o consumo de água quente.

Como ingeniero ambiental, al enfrentar restricciones presupuestarias en una planta, priorizaría las iniciativas de ahorro de energía siguiendo un enfoque sistemático y estratégico. La clave está en abordar primero las iniciativas que ofrecen los mayores ahorros con la menor inversión, y luego ir avanzando hacia proyectos más ambiciosos conforme se disponen de más recursos.

Following steps could be considered : 1. Start with small actions : This actions can be with no cost or very little cost like, - fixing leakages - Setting up moderate temperatures - Optimise schedule. - Identify Power wastage. 2. Analyze energy usages : Highlight areas with highs energy consumption & potential savings like, - Fully automated heavy Machine operations. - Conduct energy audit with existing team, if possible. 3. Implement in phases: Start with high priority projects maximizing energy savings with budget constraints. 4. Monitor and adjust : Keep tracking and adjust strategies

Considero más útil realizar un Balance de Energía por procesos, junto con los Balances de materia. Lo anterior, requiere de instrumentación en línea y calibrada para calcular las pérdidas de calor. Se podrá determinar aquellas energías imposibles de recuperar para producir trabajo, por ley de termodinámica. Además, de medir eficiencias de procesos y contar con KPI para su control. Los balances energéticos se complementan con los balances de materia y al mapear los resultados, se podrá contar con un mapa de calor para un proceso o planta determinada, identificando aquellos equipos con mayores gastos energéticos. Finalmente, se podrá cuantificar en US$, dichas pérdidas, para justificar proyectos de remediación y/o optimización de la energía.

Além de trazer ganhos diretamente no custo de operação, também temos as economias de custo embutidas e escalonadas, matéria-prima, processo e produto final com custos mais baixos, proporcionam uma margem de negociação melhor, preços mais atrativos para apresentar ao cliente e mais lucratividade para empresa sobre a venda.

Calculate the payback period for each initiative. For example, if the installation of high-efficiency motors has a payback period of three years and a VFD has a payback period of one year, the VFD should be should be prioritized first. Integration with Existing Systems: Consider how new technologies will integrate with existing systems. Proper integration can enhance overall system efficiency and performance. An electrical engineering approach focuses on channelising both immediate and long-term energy savings through selection, design, and implementation of technologies, guided by detailed financial and efficiency analyses.

If I ask to most of the persons that what you or your organization do for the Energy saving, sustainable future, ESG ?, they give answer that Yes, we have installed Solar panels, we are planning to install Solar panels. This is good initiative but it is not the only solution. We should not think about the cost to install Eco-friendly system, Energy Saving system, we should consider as Investment for future not as a cost of expense. We can get a Log-term ROIs from the investment too. #SaveEnvironment #GoGreen #SaveElectricity

Quick wins are great, but think big for lasting impact. Invest in high-efficiency motors or solar panels. These projects might cost more upfront, but they pay off big time. Prioritize those with the best ROI and shortest payback periods to free up funds for even more energy-saving initiatives. It's about smart, sustainable growth.

Always for important manners such as Long Term Plan under energy consumption and saving, should have a plan similar to Risk Management Plan that covers all aspects of the displines especially when we talk about the most consumed part of any building or activity. This plan is more similar to Emergency preparedness and response Plan which assess and guide as OBR Owner Building Requirements for his building.

In long run, energy saving will supersede the high cost of investment, and should always be encouraged. Energy saving shall be implemented right from conceptual and planning phase to operations phase.

Sometimes we think that Energy saving is the call of Top Management only. But energy saving ideas & efforts can come from the bottom or lower workforce also. We just need to motivate them, give guidance, education on Energy Savings, benefits only. The most important thing is the appreciation for their Ideas & recognition among other employees too. This can lead to Sustainable future of plant/organization. #SaveEnergy #SavePower #SaveEarth #SaveNaturalResources

Sem uma equipe igualmente focada e engajada no processo, é claramente evidente que haverá pontos de fuga e perda onde não só prejudica o processo com a desestabilidade de resultados, mas a equipe já que a mesma não vê resultados tangíveis e tendem a desmotivar, por isso, é importante saber engajar corretamente todos os membros da equipe de modo a aproveitar corretamente todas as habilidades diversas a favor do processo e resultado.

If you will not adopt the technologies and not go with the trend, you'll become NOKIA. Technology adaptation can increase the efficiency and higher the productivity too. There are many technologies available which can make our Environment Sustainable and preserve for our future generation. #SaveEnvironment #SustainableFuture

Human also get diseases if we will not take care of ourselves, then machines/equipment can also have some problems. We have to take of machines/equipment too for their better life and waste of energy/waste of plant. 'Preventive Maintenance' is the commonly used word and habit in industries which shows the focus of organization's on Maintenance. It can lead to lower the break-down of the machinery or the waste of energy too. #SaveEnergy #PreventiveMaintenance

There are a lot of energy-saving moves that do not require much budget to implement. Like the simple turning off of lights and machines that will be not be in used say during break time. Of course this has to be evaluated because there are machines that consume more energy on start-up. Water conservation must also be looked on to because large plants use water pumps to bring water to the whole plant. And we know pumps consume lots of energy. Regarding the equipment used in the plant, there must be an evaluation stating the energy consumption of each equipment or each process step. If the company can afford to replace those high energy consuming equipment with less energy consuming equipment better do it.

Na indústria temos uma demanda energética enorme. Afinal, a produção é contínua e o maquinário utilizado consome bastante e quanto mais complexos são os processos produtivos e maior a necessidade de equipamentos, mais alto é o consumo de energia. Fazer manutenção periódica das instalações elétricas em empresas, indústrias ou residências não significa apenas evitar acidentes, é mais do que garantir a segurança dos usuários de um edifício. É também evitar desperdícios que encarecem a conta de luz. Quando há sobrecarga em um sistema, ocorre o sobreaquecimento dos cabos e componentes. Isso gera uma perda de energia que já é estatisticamente contabilizada. A manutenção identifica esses pontos de fuga e o desperdício de energia é sanado.

O consumo de energia vai além da questão orçamentária. É lógico que deve haver uma priorização na redução do consumo, no entanto, não devemos considerar apenas o custo, mas, também, a sustentabilidade de toda a cadeia, desde a geração, transmissão, distribuição, até o consumo final. Atualmente, existe uma infinidade de empresas especializadas em energia renovável. Isso deve ser considerado no programa de consumo de energia das empresas. Adicionalmente ao fato de poder adquirir ou produzir a energia renovável, há, também, fornecedores que desenvolvem ações de ESG em seus processos, como neutralização de carbono, por exemplo. Em um programa de consumo de energia, esse é um aspecto que merece adicionalidade.

Los cambios radicales en materia presupuestaria han sido, son y serán un examen de temple para las organizaciones de toda índole. La experiencia y la formación en campo me enseñaron : 1. Una comunicación eficaz en todos los niveles en condición necesaria para mitigar los impactos. 2. Priorizar los diagnósticos con información confiable. 3. Es usual destacar que lo que no se mide no se mejora. En mi experiencia, tampoco se sostiene en períodos de reducción presupuestaria. 4. La eficiencia energética impacta en costos directa e indirectamente. Toda acción debe contemplar ambos casos priorizando los procesos claves sin obviar indicadores que muestren resultados.

Assess "Energy loss". I never found any system which is 100% efficient. Every system has certain losses...either due to restricted work utilization or due to changing environmental patterns. If budget is really constrain...then you must approach in 2 ways: 1. Identify energy loss and try to recover/ store back for processing OR 2. Utilize energy more efficiently to yield maximum/ increased productivity. In first option, you can reserve your expenses, whereas in second option, you can increase your profitability. Key note: Assessment of any system is not easy task. You may need diversified competencies to address fundamentals. In short, team work is essential.

Present energy savings in terms of money. Don't forget to include all the fully developed costs and benefits. Management understands money. Then they can rank, and add the energy project to other competing projects.