1. Sustainable
Development
Polymer Processing ‐ Cost
Savings Potential in the
Process
Ciaran O'Reilly
Chartered Engineer
Process
Chartered Engineer
Technical Adviser
Sustainable DevelopmentSustainable Development

2. M i i iMaximising
Efficiencies
5 Programmers
Efficiencies
(1) Resource Efficiency Audit
(2) P j t M t F k(2) Project Management Framework
(3) Energy Efficiency Loan Scheme
(4) Capital Grants for SME’s of up to £40 000(4) Capital Grants for SME s of up to £40,000
(5) Industrial Symbiosis
Sustainable Development

3. M i i iMaximising
Efficiencies
Progress
Last 3 YearsEfficiencies Last 3 Years
850 Audits Completed
£60,000,000
of Identified Savings
Sustainable Development

4. CostCost
Savings Hidden Potentialdde o e a
Polymer Processing ‐ Cost Savings Potential in the Process
Areas of High Process Energy ConsumptionAreas of High Process Energy Consumption.
Actions that can be taken to reduce Consumption.
S t i bl D l t
Indicative Potential Investment Costs and Cost Savings
Sustainable Development

5. EnergyEnergy
Process Energy v Carbon
Manufacturing Factory Polymer Processing
80%
100%
120%
80%
100%
120%
Polymer Processing
40%
60% Heating
Electric
40%
60%
80%
Heating
Electric
S t i bl D l t
0%
20%
Carbon Energy
0%
20%
Carbon Energy
Sustainable Development

6. CostCost
Savings Energy used in an
t d b iextruder business
66% Processing
Manufacturing business 16% Processing
equipment
10%
5%
5% 2%1%
66% Processing
equipment
11% Chillers
10% Compressed Air
16%
5%
10%
5% Chillers
10% Compressed
Air
66%
11%
5% Water Pumps
5% Lighting
2% Factory & office
5%
10%
5%
34%
5% Water Pumps
20% Lighting
S t i bl D l t
y
heating
1% Offices20% 34% Factory &
office heating
10% Offices
Sustainable Development

7. CostCost
Savings
Extrusion Blow MouldingInjection Stretch Moulding
45%
16%
8%
45% Extruder
31% Hydrulics
3% 3%
94% Infra Red Lamps
31%
16% Heat
3% Ventilation
3% Motion
S t i bl D l t
8% Granulator
94%
Sustainable Development

8. CostCost
Savings
Process 325 KW
1 000 kg/h
Specific energy to raise the temperature of the plastic is typically
0 16 kWh/k f i t lli l ti (lik PE PP)
1,000 kg/h
• 0.16 kWh/kg for semi-crystalline plastics (like PE or PP)
• 0.10 kWh/kg for amorphous plastics (e.g., PVC, PS).
The actual specific energy consumption will be higher because of losses in the motor, gearbox,
thrust bearings cooling the feed housing and extruder barrelthrust bearings, cooling the feed housing and extruder barrel,
• 0.20 to 0.25 kWh/kg semi-crystalline plastics
• 0.15 to 0.20 kWh/kg for amorphous plastics
d i i t t li d i l ti t t k
S t i bl D l t
• a dryer, resin conveying system, water cooling and circulation system, take-up
0.20 to 0.25 kWh/kg
Sustainable Development

9. Energy 55 KW / HEnergy
Savings
55 KW / Hour
£7.70 / Hour
Process power
Extruder 125kw
/
Extruder 125kw
Heat per hour 160kw
Cooling 40kw
Total 325kwTotal 325kw
Heat recovery 25% 40kw
Product stored at 30C 16kw
S t i bl D l t
Product stored at 30C 16kw
Energy Savings 56kw
17%
Sustainable Development

10. What
No 1
Energy Efficiency
What
Works
Energy Efficiency
Plant Replacement
Insulation
Induction HeatingInduction Heating
Heat Recovery
M&TM&T

11. FinanceFinance
Available
No and Low
InterestInterest
Interest free Loans Invest-NI
Growth Loan Fund Invest-NI
E h d C i l AllEnhanced Capital Allowance
ROC’s & RHI for Renewables
Regulator Grants through the Utility providersRegulator Grants through the Utility providers
S t i bl D l tSustainable Development

12. Top 10 Investments
All SPB
Less 24 months
Sustainable Development

13. RenewablesRenewables
Economics Appraisal:
PV Array 50kWCAPITAL COST £65,000
PV Array 50kW
SPB 2 years
Supply and install 50kWp system
EXISTING ELECTRICITY COSTS
Existing electricity consumption 1,387,040kWh
Existing electricity consumption cost £194 186Existing electricity consumption cost £194,186
TOTAL COST SAVINGS
Estimated annual output of PV system 41,080kWh
INCOME
Electricty generated and used on site 90% 36,972kWh
(36,972 kWh X £0.14/p/kWh) £5,176
ROC's payment (41,080 kWh X £0.1696) £6,984
E t U it 10% (4 108 kWh X £0 0559) £246Export Units 10% (4,108 kWh X £0.0559) £246
TOTAL SAVINGS £12,406
Simple pay back 5.24 Years
Enhanced Capital Allowance £30,000
Sustainable DevelopmentIntrest Free Loan Invest‐NI (by CT) £13,063
CAPITAL OUTLAY SPB 2 Years £21,937

14. SustainableSustainable
Development
What Are We Doing
Next For YouNext For You
Implementation Audits
Polymer Sector Studyy y
Special Energy Task Group
ISO 50001 W k hISO 50001 Workshops
Sustainable Development

15. Sustainable MaximisingSustainable
Development
Maximising
Efficiencies
Next Events
Invest-NI Sustainex 9th &10th April La Mon Hotel
Bombardier June Joint Seminar
ISO 50001 Workshops
Sustainable Development