Energy Efficiency in Egyptian IndustriesTechnical & Financial Support

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Presented by: Eng. Wafaa Ismail

Energy Sector Head ECO SD

Environmental Compliance Office

Federation of Egyptian Industries

Energy Efficiency Actions in Egypt

Energy Efficiency Actions in Egypt engage in five main areas. These area are:▪ Institutional Development ▪ Legislations and polices

❖ In July 2014, Egypt introduced long-awaited Energy Subsidy Cut gradually for five years .

❖ Feed in Tariff as a policy mechanism designed to accelerate investment in renewable energy technologies. (in Oct 2014 )

❖ Egyptian Electricity Law, issued by law no. 87 for year 2015 last July along with its executive regulation which issued in May 2016.

▪ Training and awareness ▪ Energy information systems (case studies, etc)▪ Technical programs and Implementation projects

Friday, January 25, 2019 2ECO/FEI

History of Energy Efficiency Activities in Egypt

Establishment of OEP (Organization of Energy Planning) in 1980

Funded Projects:

▪ USAID: ECEP – Energy Conservation & Efficiency Project

• Cairo University

• Tabbine Institute for Metallurgical Studies TIMS

• Federation of Egyptian Industries FEI

▪ DANIDA : ESP - Environmental Sector Program

• Environmental Compliance Office in Federation of Egyptian Industries

ECO-FEI

▪ UNIDO : IEE - Industrial Energy Efficiency

• Egyptian Environmental Affairs Agency EEAA

• Environmental compliance office ECO- FEI

• Industrial Modernization Centre IMC

• Industrial Development Authority IDA

• Egyptian organization for standardization EOS

Currently, wider scale implementation needed to supplement funded

Energy End Use in Egypt

5% 3%

37%

15%

8%

26%

4% 2%

Agriculture Roads and Construction Industry

Transport Petroleum Sector Commercial and residential

public utilities Government

Environmental Compliance Office

Federation of Egyptian Industries ECO-FEI

Established in 2001 within the Federation of Egyptian Industries (FEI) with the aim of presenting services to the industrial SME concerning Sustainable Development.

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Main Services

Technical & Financial assistance for implementing Cleaner Production ,Energy Efficiency &Renewable Energy technologies in industrial sector.

CFP measurement provides Egyptian companies with opportunity to present their products to international markets.

Main Activities

Egyptian Solid Waste Management Council (ESWMC)

Responsible Care in Chemical sector

REEF- Resource Efficiency in the Food Industry .

The private Public Sector Industry (PPSI) Project

Integrated Electronic Waste Management System

Industrial ECO Parks (Green Industrial City)

Corporate Social Responsibility S&M Enterprise

Financial SupportSoft Loans

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Financing new industrial equipment for implementing Energy Efficiency ,Renewable Energy and Cleaner Production technologies in industrial sector .Loans up to EGP 7 million per enterprise.Repaid over 5 years including one year grace period.With an 3.5% interest rate per year; can be through the National Bank of Egypt or other

Funding Procedures:

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Partners

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Services Submitted byEnergy Sector in ECO

Technical & Financial assistance for implementing energy efficiency technologies in industrial sector .

Realizing energy management systems in companies and business review to improve the performance of energy use and high efficiency .

Training for managerial personnel for Certified Auditors to reduce energy costs in their facilities (Certified Energy Auditors)

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1- Energy Audit

Objective of Energy Audit

Control energy consumption cost.

Identifying technical tool to reduce consumption to a minimum.

Classifying the where about of wasteful consumption, and techniques necessary to implement a set of actions and projects that ultimately lead to reduce consumption of energy as a specific energy consumption .

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2- Production of Energy from Alternative Fuel

Encourage orientation of the projects for the production of energy from biomass, solid waste and agriculture as an alternative fuel in industry .

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3- Energy Management System EnMS in Industrial Companies

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▪ Prepare organization for Energy Management

Systems EnMS in accordance with standard

ISO 50001, upon which the entity can develop

and implement an energy policy and establish

objectives, targets & action plan.

4- Thermal and Electrical Measurements

Adjust thermal function of boilers and furnaces to improve combustion efficiency , save energy use and conformity to environmental laws through controlling air/fuel ratio by using mobile gas analyzer.

4- Thermal and Electrical Measurements

Carry out all measurements related to the application of EE technologies in cooperation with certified measurement agencies.

power Factor Improvement .

5- Implementing technologies for Improving Energy Efficiency

Technical studies for implementation energy efficiency technologies and financing of best available techniques through revolving fund .

Initial reviews and detailed assessment to power various industrial sectors.

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Energy Efficiency Implemented projects by ECO SD

Energy Efficiency Technologies

Friday, January 25, 2019Energy Efficiency - Mohamed Salah

Elsobki (jr.)

Improving Combustion Efficiency (ICE)Steam System Optimization (SSO)Waste Heat recovery (WHR )

Power Factor Improvement (PFI)High Efficiency Lighting (HEL)High Efficiency Motors (HEM)Variable speed drive for Compressors (VSD)Cooling System Improvement (CSI )Co-Generation (Co-Gen )

Environmental and Economic Benefits of implemented Projects

Low consumption of energy leads to increased cost savings and higher profitability .

Addressing the increased energy prices .

quick profits and Conformity to environmental laws

Reduce GHG emission and global warming .

Wise use of water and chemicals represented in the recovery of condensation through steam system optimization .

EE Saving Potentials in Major Industries

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10

20

30

40

50

60

70

80

90

100

% Max. Achievable Savings

Min. Achievable Savings

EE Project Potential Energy Reduction

Application

Waste Heat recovery A) 30 % Boiler installations and furnacesAll sectors

Combustion efficiency improvement A) 5 ~ 10 % All sectors

Steam system improvement B) 10 ~ 20 % Food, chemical, textile sectors

Cogeneration A) 50 % Food, chemical, textile sector companies with low-pressure steam demand

Absorption chillers A) (N/A, economic savings only)

Cooling demand above 5-10 ºC (mostly for AC) Improving cooling system especially in food sector

Compressed air generation/ distribution improvement B)

10 ~ 15 % All sectors with pneumatic systems

Cooling system improvement B) 10 ~20 % Food sector

Boiler tune-up B) 10 % Food , chemical, textile sectors

Fuel switching B) 5 ~ 10 % All sectors

High efficiency lighting B) 30 % All sectors, commercial buildings

High efficiency motors, pumps and fans B) 10 ~15 % All sectors

Energy Efficiency Projects in small and Mediums Enterprise's

Combustion ControlSteam System ImprovementCogeneration High Efficiency Lighting Power Factor Improvement

Improving combustion Efficiency

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• Adjust the thermal performance of boilers and furnaces, and improvement of combustion efficiency by controlling the ratio of air to fuel using mobile gas analysis devices to reduce fuel consumption between 1-7%, which helps to reduce pollutants and their conformity with environmental law

Waste Heat Recovery

Providing sodium Silicate melting furnaces with recuperator for heating combustion air resulted in lower consumption of fuel (96000 L.E annually) and reduction of CO2 emissions by 1240 tons annually.

Replacement of operating burners in the treatment furnace by automatic heat recovery one resulted in savings of 510,000 L.E of energy used and reduction of CO2 by 1470 tons/year.

Steam System Optimization

❖ Installation of Condensate Return and went to retrieve water blow down heat content and repair leaks and insulation inspection in addition to maintenance steam traps for condensate.

✓ Annual savings = 480,500 L.E/year.

✓ Investment cost = 600000L.E . ✓ The Pay back period = 15 months

Fuel switching

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Erecting unit for melting lead and antimon alloy sealed and working by LPG rather than the open oven to reduce electricity consumption and reduce pollutants lead oxides of refractory Crucible cover which posed a threat to the health of workers and the high consumption of electrical energy

✓ Implementation costs = 648625 L.E ✓ Annual savings = 200170 L.E / year✓ Pay pack period = 38 Month

Cogeneration

❖ Cogeneration is the simultaneous production of electricity and thermal energy from the same fuel source.

❖ Fuel switching is to use:

❖ Natural gas

❖ Biofuel.

❖ Agro waste

Power factor Improvement

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❑Reduction of loss in distribution network and increase internal network capacity for electricity.

❑Increase the share of productive uses in generating capacity.

❑Contractual capacity reduction and the use of different scale for calculating the cost of KWh consumption.

❑reducing emissions from reduced the decrease in the internal network which represent 5% of annual consumption of electrical energy.

Power factor Improvement

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Installation of capacitors to improve PF from 0.85-0.91.❑ annual saving = 100 000 L.E/year as a result of the provision

for the estimated annual reduction due to low power factor. And reduce energy demand payments.

❑ Investment cost = 150,000 L.E. ❑ Pay pack period = 18 months

Replacement of light sources with high efficiency lamp

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Replace fluorescent longitudinal 60 cm (4*20 watt ) headlamp by led lamp

provided 32 watt

كشاف ليد

60cm*60cmالخاصية

4* 8W الكشاف المكافئ الذى سيتم تغيره بكشاف لد

<40W القدرة

80% وفر الطاقة عند إاإلستبدال

SMD نوع اللد

70 lm/w الفاعلية

(85-265 v)AC جهد المدخل

2600-2800lm الفيض الضوئى

72 عدد وحدات اللد

50000hr عمر التشغيل

Replacement of light sources with high Efficiency lamp

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❑The total investment required to replace bulbs = 853660 L.E ❑Savings resulting from the reduction in the

rate of consumption of lighting = 286608 L.E/year period of investment recovery = 36 months

Controlling Separate AC Units download

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❖Use efficient AC and less consuming and more environmentally friendly in accordance with the energy efficiency code card upon consumption of the model if replace current devices or when you buy new hardware.

Biomass Energy

Used in highly efficient and convenient automatic pellets boilers

Compact and easy to store.

1kg Rice Straw pellet replaces 0.35 kg of light fuel oiL

Reduce air pollution (Black Cloud) & GHG.

Gives a significant contribution to use biomass as renewable energy

Rice Straw Pellets

WHAT OUR EXPERIENCE SHOWS

Barriers to EE Projects in Egypt

Incentives and Pressure for EE Projects

Barriers to EE Projects in Egypt

On the National Level

Institutional limitations

On Enterprise LevelManagement and staff behavior and awarenessManagement view: “EE = less productivity”Lack of or insufficient communication between management and staffLack of energy cost-awarenessNon-existence or marginalization of the Energy Engineer PositionLack of monitoring equipment and metersLack of systematic monitoring and evaluation routines

VISION FOR ENERGY SECTOR

TEM and Monitoring Systems Implementation

Introduction of Energy-Conscious Design

Generation of EE Guidelines for each Sector

Consultancy and Implementation of EE Technologies

TEM and Monitoring Systems Implementation

Implementation of Total Energy Management systems through:

1. awareness-raising concerning management and staff behavior

2. outlining energy management systems in companies in all sectors

3. installing hardware/meters for monitoring systems

Introduction of Energy-Conscious Design

Highlight importance of energy efficiency versus cost efficiency when purchasing new equipment

Obtain and examine energy-conscious designs

Raise awareness for EE labeled equipment

ECO SD Competitive Advantages

Good contact with FEI members and industrial chambers.

Acting like intermediate between industrial sector and researches centers.

Availability of financial mechanism for implementing EE&RE projects.

Accessibility to different types of industries

Group of consultant and consulting firm.

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Conclusions

High potential for EE project implementation in Egypt

Implementation must be supplemented by proposed consultancy, dissemination, and awareness-raising activities for effectiveness and sustainability

Energy subsidy cut is Being a driving force for EE investment

EE projects and activities inline with national environmental and development goals

Thanks for Considering our Resources & Environment