Bradken Presentation 2013 - Energy Efficiency Opportunities

Report
Energy Efficiency Program
July 2013
By Greg Chaplin
Bradken Overview
•
Bradken® is a leading global manufacturer and supplier of differentiated
consumable and capital products to the mining and construction, rail and
transit, energy and general industrial markets
•
As a leading heavy engineering company, Bradken can manufacture fully
machined cast iron and steel products from a mass of 0.5kg to over 25
tonnes
•
Bradken is a publicly listed Company on the Australian Stock Exchange
(BKN)
•
Founded in 1922 in Alexandria, Sydney (AUS) – Leslie Bradford & Jim
Kendall won money on a horse “Jack Findlay” and used the winnings to
establish Alloy Steel Syndicate to build the foundry.
•
Global Corporate Centre located in Newcastle, NSW (AUS)
©2011BRADKEN®
Bradken – Environmental Basics
•
All Bradken’s major facilities in Australia & UK are independently certified to
ISO14001, other sites at implementation stage.
•
Bradken’s steel foundries account for 90% of the Company’s total energy usage
•
Electricity ~ 60% and Natural Gas ~ 40%
•
Australian energy use ~ 1.15 Peta Joule & 139,300 t CO2e
•
Australian energy costs ~ 5-8% of costs
•
Approximately 92% of all cast products are produced from scrap steel
•
Product Stewardship – Buy Back Scheme
•
Foundry sand used up to 10 times
•
Used foundry sand often used by other industries (beneficial reuse)
©2011BRADKEN®
Foundry Processes
Bradken foundries use a range of
modern technologies including:
•
•
•
•
•
•
•
•
©2011BRADKEN®
CAD/CAM
3D Modelling
Discrete Element Modelling
Dynamic Simulation
Analysis
Finite Element Analysis
Virtual Prototyping
Casting simulation
Robotic Manufacturing
EEO First Round
•
Bradken identified it used more than 0.5 PJ, registered and submitted the
assessment plan
•
Bradken used four separate energy consultants to audit seven of its
foundries with the intention of ending up with four different sets of
recommendations. Overall, the ideas were very similar:
•
Savings in GJ and tons CO2e identified were very similar between auditors
•
Upgrade cost estimates varied significantly (up to a factor of five)
•
Savings of 10-17% in GJ and costs were identified
©2011BRADKEN®
Factors affecting first round
•
Age of equipment
•
Retrofitting costs & difficulty
•
Training & awareness
•
Accuracy of estimates
•
Sub metering
•
GFC
•
Company growth
•
International competition & Value of the Australian dollar
•
Productivity, quality and safety improvements
•
Environmental demands - NIMBY
©2011BRADKEN®
Bradken Growth - 2006 to 2013
Bradken has experienced significant growth through:
•
The acquisition of existing foundries in the Australia, UK, USA,
Canada, Malaya and New Zealand
•
New fabrication facilities in China
•
Commissioning new foundry in China
Production
Employees
Revenue
Foundries - Australia
Foundries - International
©2011BRADKEN®
2006
2012
56,000 t
147,600 t
2500
6250
$548 M
$1,451 M
7
9
1
10
Energy Performance overall GJ/t - Australia
•
©2011BRADKEN®
Changes in overall energy use per tonne of product
EEO Round 2 - Key Element 1 & 2 – Leadership & People
For the second round of EEO audits Bradken has:
•
Updated Environmental Policy in 2011
•
Added Energy & GHG Policy in 2011
•
Updated Corporate Environmental Goals to include specific goal to reduce
energy use per ton of product by 2% per year.
– Consistent with UK Climate Change Agreement
– US sites set goal at 2.5% - US DoE “Better Buildings, Better Plants
Program”
•
Utilised internal and external resources to develop internal knowledge,
awareness and skills.
©2011BRADKEN®
EEO Round 2 – Key Elements 3 & 4 - Assessment &
Identification
•
Internal audits where practical – combine energy, raw material & waste
audits
•
Developed own checklists & utilise US DoE tools
•
Purchased thermal image cameras, flue gas analysers, compressed air
leak detection equipment for internal use
•
Update previous audits with better monitoring
•
Utilise extensive publicly available information from
– US DoE & AFS - various
– UK Carbon Trust & DEFRA & CTI - various
– Environment Canada - various
– European Commission “Best Available Techniques in the Smitheries and Foundries
Industry”
•
Bring in external specialist consultants eg. arc furnace specialists (July
2012) where needed
•
Benchmarking across Bradken’s 19 foundries
©2011BRADKEN®
EEO Round 2 – Key Elements 3 & 4 – DATA
INTERNATIONAL COSTS
©2011BRADKEN®
EEO Round 2 – Key Elements 3 & 4 – DATA
BENCHMARKING
©2011BRADKEN®
EEO Round 2 – Key Elements 3 & 4 – DATA - GAS
•
Gas use ~40 % of total GJ - 80 to 93% in heat treatment
•
Heat Treatment has specific quality requirements – heat castings to
specific temperatures for specific amounts of time.
•
Thermal imagery used to identify hot spots.
•
New ovens 30% more efficient with recuperative burners & pulse firing
than same sized oven with conventional burners & controls
©2011BRADKEN®
EEO Round 2 – Key Elements 3 & 4 – DATA - GAS
•
Ladle Heaters use 7 to 20% of site gas
•
Heated to as hot as practical to carry molten metal from furnace to moulds
and pour metal into moulds.
•
“State of the art” – oxy fuel burners – up to 50% gas savings (ref
FOUNDRYBENCH – Europe) – one installed OS that demonstrates these
savings.
©2011BRADKEN®
EEO Round 2 –– DATA - Electricity
•
Equipment Electricity use
©2011BRADKEN®
EEO Round 2 – DATA - Furnaces
•
Melting Furnace Efficiency Factors
–
–
–
–
©2011BRADKEN®
Operators, Tap to tap times
Furnace size, Alloys, Scrap Quality
Age of furnaces - 1930s to 1990s
“Furnace Whisperer”
EEO Round 2 – Key Elements 3 & 4 – DATA Furnaces
•
•
•
Different steel alloys have different melting efficiencies
Product design affects Yield
Starting from cold - 20% extra
©2011BRADKEN®
EEO Round 2 – DATA – Compressed Air
•
Compressed electricity use while compressed air leaks are fixed.
©2011BRADKEN®
Factors Affecting Decisions
•
New foundry in China
•
Sub metering
•
International Competition
•
Clean Technology Food & Foundry Program – 33%
– Sub metering & power factor
•
US Funding – Tacoma Compressed Air Project
– Cost $765k – Incentive $536k => 70%
– Annual Saving $130k and 3,148,285 KWh
•
Energy Costs and Carbon Tax
©2011BRADKEN®
Carbon Tax
•
UK Carbon Tax
– Tax on electricity offset by Climate Change Agreement (reduce energy use
per ton by 2% per year)
– Low CO2e t/KWhr factor
– Low impact – (site managers) – changes may come
•
New Zealand Carbon Tax
– Increase in LPG costs
– Not detectable in electricity - low CO2e t/KWhr factor
•
Australian Carbon tax (plus transmission charges)
– Estimated $3.5 million
– To date price rises for electricity 8 to 34%
– LRECs, SRECs also a carbon tax
– July 2014 ???
©2011BRADKEN®
EEO Round 2 – KE 6 - Communicating Outcomes
Bradken Eco-Efficiency Games - 2012
•
Bradken benchmarked all 18 steel foundries KPIs against each other and
ranked performances
•
KPIs were:
– Energy => GJ/t, $/t, GHG/t
– Key resources => t/t (scrap metal, alloys, sands, water, manhours/t)
– Waste => t/t, $/t product, $/t waste
•
Gave overall performance levels and winners were:
• GOLD MEDAL => Adelaide, SA
• SILVER MEDAL => Mont Joli – Quebec, Canada
• BRONZE MEDAL => Henderson, WA
USE LESS, WASTE LESS, COST LESS
©2011BRADKEN®
USE LESS, WASTE LESS, COST LESS
•
THOSE WHO DO NOT LEARN FROM HISTORY ARE DOOMED TO REPEAT
IT (??)
•
DO NOT RE-INVENT THE WHEEL
•
BENCHMARKING
•
TRAINING & AWARENESS
©2011BRADKEN®

similar documents