The lean energy and the reduction of energy cost and GHG emissions: a proven approach

摘要

The processes of lean energy (i.e. tools for continuous improvement) expand the boundaries of energy efficiency. Inspired by the “Toyota method”, this proven approach allows companies to optimize systems already installed, before considering new investments. Systems already installed in cement plants that can lend themselves to energy optimization include crushing, milling, pyroprocessing and pneumatic transport. Non-production systems can include HVAC, lighting and cooling water. Various industries that have adopted this model report savings of 8% - 25%, which is proven by our team's related projects. This presentation will cover the ABCs of lean energy and its two main components: 1. Identifying opportunities to save energy and optimizing existing systems through a Kaïzen approach, which is particularly effective in eliminating losses, regardless if it is in or out of the production line. 2. The development and implementation of an Energy Management System (EMS) that is inspired by best management practices (ISO 50 001) and makes it possible to audit and maintain assets, while pursuing continuous improvement of energy performance. A cement plant having implemented such a system have reported initial energy savings of $1.6 M in the first year, followed by an annual 2% cost improvement plan. Plants are powered by people before any energy input. That is why shared responsibility and employee understanding of how their decisions impact the bottom line are critical. The presentation will also move through the stages involved in implementation of the approach, discuss the obstacles, educate on the concrete benefits and reveal why numerous companies, in all sectors of activity, are engaging more in this approach.