Abstract
Energy management refers to the efficient and effective use of energy to minimize costs and enhance productivity, with a resultant benefit of cost optimization. The global industrial sector consumes more than 54% of the world’s energy. This is the highest energy demand in comparison to any other end-use sector. The South African outlook is not materially different from the global outlook, with the industrial sector demanding 52% of the country’s total energy; furthermore, South Africa’s energy demand is ranked the highest in the African continent. Although the sector can be categorized according to energy intense and non-energy intense subsectors, the manufacturing sub-sector, within which food and tobacco manufacturing is classified, is considered energy intensive. For many complex plants, energy management and distribution affects a collective of complex systems such as steam generation, large electrical motors, compressed air systems, processing systems and many more. These complex systems involve significant energy efficiency opportunities that require thorough analysis and understanding to determine and implement appropriate energy saving measures. Energy consumption is one of the key contributors to production costs, and the effective and economic use thereof is critical for the manufacturing plant’s success. This study seeks to evaluate the implementation of an integrated energy management system in a complex process plant. The study is centered around two case studies, developed through application of the Pareto principle, more commonly known as the 80/20 rule. This rule informed prioritization and selection of two high impact SOI’s within the complex plant. A clear PDCA methodology was followed, which sought to formulate and test propositions pertinent to observed phenomena within the selected SOI’s. Based on the outcomes of the tests formulated to assess these propositions, conclusions were deduced on whether the propositions were supported or refuted. A total of 8 propositions were developed within the boundaries of the two case studies, and the outcomes of the case studies demonstrated, to a considerable extent, the immense benefits of proactive energy management. Future opportunities have also been identified through this study, and these too represent highly beneficial platforms for continued value creation.
M.Phil. (Engineering Management)