This document proposes a methodology for analyzing energy and resource use data to set rational consumption goals and identify savings opportunities. The methodology involves calculating specific consumption indicators, plotting them against production rates, and analyzing the data to establish "goal" and "alarm" lines. Applying this methodology to data from 21 Colombian companies found average potential electricity savings of 8.6% and natural gas savings of 13.5% were possible through operational practices alone. Generalizing the results using dimensionless variables allows predicting potential savings at other facilities.

1. RATIONAL ENERGY USE AND WASTE MINIMIZATION GOALS BASED ON THE USE OF PRODUCTION DATA ENRIQUE POSADA INDISA S.A. Medellín, Colombia www.indisa.com.co [email_address] R'07 World Congress Recovery of Materials and Energy for Resource Efficiency

8. How energy and resources use are typically reported in Colombia

10. How energy and resources use are typically reported in Colombia Example with a plot of energy data correlated with production

12. Methodology for rational use of specific energy consumption indicators Plot of the indicator vs. production rate.

13. Methodology for rational use of specific energy consumption indicators Specific consumption usually lowers as production rate increases. 7,26 % Extra cost at low production rates 6,13 % Savings at high production rates 3,61 3,16 3,37 US $/ton Cost of electricity 41,1 36,0 38,3 KWh/ton Specific consumption 1.422 1.825 1.680 tons Production At minimum production At maximum production At average production Condition

15. Methodology for rational use of specific energy consumption indicators Three data regions

17. Methodology for rational use of specific energy consumption indicators Analysis of data to establish goals 59.382 US $/year Possible yearly savings (300 days per year) 0,118 US $/ton Possible savings 0,088 US $/KWh Electricity cost 3,5 % Possible average savings 3,37 US $/ton Cost of electricity 38,34 KWh/ton Specific consumption at average production 1.680 tons Average production

23. Generalization of this methodology The dimensionless numbers are: Indicator of production rate = Rate / Average rate Indicator of specific consumption = Specific consumption / Average specific consumption.

24. Generalization of this methodology Examples with some of the 27 plots drawn with the dimensionless numbers

25. Generalization of this methodology General view of all the results obtained (electricity)

26. Generalization of this methodology General view of all the results obtained (natural gas)

27. Generalization of this methodology Potential savings (%) vs. production indicator for the studied sample

28. Generalization of this methodology Results of the correlations between indicators for the studied sample Electricity in 27 processes 0,52 0,96 0,007 Correlation factor R 2 of line 1,52 2,00 1,026 Intersection of line of correlation -0,520 -0,026 -0,998 Slope of linear correlation between indicators 129.165 898.357 2.335 Electric energy savings at average production, US $/year 8,62 26,40 1,58 Potential electric energy savings at average production, % 12,48 45,65 3,80 Standard deviation of specific consumption indicator, % 49,63 133,02 8,45 Range of specific consumption indicator, % 0,81 0,96 0,41 Lower value for the specific consumption indicator 1,31 1,93 1,05 Higher value for the specific consumption indicator 17,50 42,38 6,71 Standard deviation of production data, % 60,82 135,20 16,04 Range of production indicator, % 0,67 0,92 0,25 Lower value for the production indicator 1,28 1,66 1,02 Higher value for the production indicator Average Maximum Minimum Characteristic

29. Generalization of this methodology Results of the correlations between indicators for the studied sample Natural gas in 8 processes 0,60 0,90 0,16 Correlation factor R 2 2,08 2,94 1,50 Intersection of line of correlation -1,08 -0,50 -1,94 Slope of linear correlation between indicators 136.878 470.000 5.094 Natural gas savings at average production, US $/year 13,50 44,92 3,65 Potential natural gas savings at average production, % 20,86 53,05 8,80 Standard deviation of specific consumption indicator, % 69,83 154,81 29,54 Range of specific consumption indicator, % 0,72 0,90 0,28 Lower value for the specific consumption indicator 1,42 1,83 1,11 Higher value for the specific consumption indicator 15,45 42,38 6,98 Standard deviation of production data, % 48,90 117,31 16,04 Range of production indicator, % 0,73 0,92 0,34 Lower value for the production indicator 1,22 1,51 1,08 Higher value for the production indicator Average Maximum Minimum Characteristic

30. Generalization of this methodology Prediction of potential savings at average production

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