Process energy analysis and saving opportunities in small and medium size enterprises for cleaner industrial production.

Small and medium industries (SMEs) savings analysis can help to reduce energy consumptions and greenhouse gas emissions (GHG) and support the individual company to make a better decision to improve facility energy performance. The main idea was to get enough data to recreate simple Excel-based tool so that SMEs could conduct quick energy and GHG emission benchmarking and to come up with potential savings by using their utility bills and plant specifications. Having such knowledge will help these industries to promote energy efficiency, sustainability, and competitiveness in their operation. Energy consumption data of eleven companies have been collected and analyzed. The methodology involves energy benchmarking, separation of process and seasonal energy consumptions, heating degree days estimation, normalized annual energy consumption, and normalized process and seasonal energy consumptions. The leading performance indicator was identified energy intensity of oven. It was estimated, the energy intensity of bake ovens varies from 24 m3/ft3 to 30 m3/ft3, while the energy intensities of ovens with finishing process varies from 8 m3/ft3 to 36 m3/ft3. Potential savings can be realized from retrofits such as the addition of a VFD controller (exhaust loss), insulation (shell loss). Depending on the investment and the type of estimated retrofits, the return on investment can be realized in less than a year or up to ten years. It was also noted that by optimizing production scheduling; 8%–69% of energy consumption could be saved by proper shut-down and scheduling the non-production hours. Flow diagram of research program to investigate energy-saving opportunities of SMEs in the GTA. Image 1092 • Small and Medium Enterprises energy analysis, performance indicators, and savings potential. • Methodology involves heating degree days, normalized annual process and energy consumptions. • The observed energy intensity of ovens varies from 24 m3/ft3 to 30 m3/ft3 (and 8 m3/ft3 to 36 m3/ft3). • Savings can be realized from retrofits of a VFD controller (exhaust loss), insulation (shell loss). • Natural gas savings from the facilities processing varies from 19% to 53%. [ABSTRACT FROM AUTHOR]