School of Aerospace, Mechanical and

Manufacturing Engineering

Climate Change Seminar: Australian Industry Group, 15 Nov 2007

RMIT-NORTHLink Greenhouse RMIT-NORTHLink Greenhouse Challenge Support ProgramChallenge Support Program

Dr John AndrewsDr John Andrews

Deep cuts (at least 60% compared Deep cuts (at least 60% compared to 1990) in greenhouse gas to 1990) in greenhouse gas

emissions by 2050 are now seen as emissions by 2050 are now seen as essential to avoid catastrophic essential to avoid catastrophic

climate changeclimate change

globallygloballynationallynationally

by by each company/organisationeach company/organisationindividuallyindividually

A Commonwealth Government A Commonwealth Government cooperative program with industry to cooperative program with industry to

encourage greenhouse gas encourage greenhouse gas abatementabatement

The Australian Greenhouse The Australian Greenhouse Office has provided funding over Office has provided funding over the past four years for RMIT and the past four years for RMIT and the northern region’s business the northern region’s business network, NORTHLink, to help network, NORTHLink, to help

firms in Melbourne’s north reduce firms in Melbourne’s north reduce their greenhouse gas emissionstheir greenhouse gas emissions

RMIT-NORTHLink Greenhouse RMIT-NORTHLink Greenhouse Challenge Support programChallenge Support program

Opportunity for fourth-year Bachelor of Opportunity for fourth-year Bachelor of Mechanical Engineering students, and Mechanical Engineering students, and Master of Engineering (Sustainable Master of Engineering (Sustainable Energy) students, to conduct research Energy) students, to conduct research projects with companies in Melbourne’s projects with companies in Melbourne’s north on cutting energy use and north on cutting energy use and greenhouse gas emissionsgreenhouse gas emissions

Companies involved in 2007Companies involved in 2007

CaterpillarCaterpillar City of DarebinCity of Darebin Foster’s Brewing Foster’s Brewing

GroupGroup HondaHonda OricaOrica RiotintoRiotinto

South Pacific TyresSouth Pacific Tyres Yarra TramsYarra Trams Edlyn FoodsEdlyn Foods Hotel SofitelHotel Sofitel Moreland Energy Moreland Energy

Research FoundationResearch Foundation RMIT Property RMIT Property

ServicesServices

Companies involved in 2006Companies involved in 2006::

P&O PortsP&O Ports RMIT Property RMIT Property

ServicesServices The Age Print The Age Print

CentreCentre Wentworth Wentworth

FurnitureFurniture Yarra TramsYarra Trams

Armstrong World Armstrong World IndustriesIndustries

BostikBostik GWA Intl/CaromaGWA Intl/Caroma City of HumeCity of Hume Greer IndustriesGreer Industries Hilton Melbourne Hilton Melbourne

AirportAirport

Companies involved in 2004 and Companies involved in 2004 and 20052005

2004: 2004: Air International, Armstrong World Industries, Air International, Armstrong World Industries,

Autoliv, ED Oates, Greer Industries, Kangan Autoliv, ED Oates, Greer Industries, Kangan Batman TAFE, Northern Hospital, Noteprinting Batman TAFE, Northern Hospital, Noteprinting Australia, Original Juice Co., Sutton Tools, Australia, Original Juice Co., Sutton Tools, Venture Industries, Yarra Valley WaterVenture Industries, Yarra Valley Water

2005: 2005: Autoliv, City of Whittlesea, Marsden and McGain, Autoliv, City of Whittlesea, Marsden and McGain,

RMIT (Property Services), Schiavello Commercial RMIT (Property Services), Schiavello Commercial Interiors, Sealed Air Cryovac, Yarra Trams, Yarra Interiors, Sealed Air Cryovac, Yarra Trams, Yarra Valley WaterValley Water

2006 Program was a huge 2006 Program was a huge success!success!

The participating firms will:The participating firms will: save up to $3 million/yearsave up to $3 million/year cut their emissions of carbon dioxide by cut their emissions of carbon dioxide by

more 14 000 tonnes/yearmore 14 000 tonnes/year

if they implement the recommendations made if they implement the recommendations made by the 11 B Mech Eng and 6 M Eng by the 11 B Mech Eng and 6 M Eng Sustainable Energy students involved in the Sustainable Energy students involved in the program.program.

The Northern HospitalThe Northern HospitalEpping, VictoriaEpping, Victoria

Student: Tom Doherty and Low Eng Wah Student: Tom Doherty and Low Eng Wah

Project Aim:Project Aim:

To reduce energy used for water and To reduce energy used for water and space heatingspace heating

Solar water heatingSolar water heating

Economisers for boilersEconomisers for boilers

The Northern Hospital: Outcomes 1The Northern Hospital: Outcomes 1

Flow control valves could cut hot water Flow control valves could cut hot water consumptions by 35%, and greenhouse emissions consumptions by 35%, and greenhouse emissions by 70 Tonnes COby 70 Tonnes CO22-e/year-e/year

Solar water heating plus demand management Solar water heating plus demand management would save an additional 58 tonnes/year would save an additional 58 tonnes/year

Total emission reduction ~1% of hospital’s totalTotal emission reduction ~1% of hospital’s total Total investment: $210 000Total investment: $210 000 Payback period: Flow control valves - 2 years; Payback period: Flow control valves - 2 years;

solar water heating – just over 10 yearssolar water heating – just over 10 years

The Northern Hospital: Outcomes 2The Northern Hospital: Outcomes 2

Installation of an Installation of an economizer on the economizer on the main boiler supplying main boiler supplying hot water for both hot water for both space and domestic space and domestic water heating would water heating would reduce total reduce total emissions by up to emissions by up to 60 Tonnes/year60 Tonnes/year

Capital cost $25 000Capital cost $25 000 PPayback period ~5 ayback period ~5

yearsyears

Note Printing Australia LtdNote Printing Australia Ltd(Cragieburn, Victoria)(Cragieburn, Victoria)

A global producer of A global producer of currency and security currency and security products supplying Australia products supplying Australia with polymer currency and with polymer currency and passports.passports.

Alex Kim project:Alex Kim project:– Reduce emissions by Reduce emissions by

cutting spoilage ratecutting spoilage rate– Rationalise boilersRationalise boilers

Note Printing Australia Ltd: OutcomesNote Printing Australia Ltd: Outcomes

Reduce spoilage rate from 15% to 5%Reduce spoilage rate from 15% to 5% Cut greenhouse gas emissions by ~ 70 Cut greenhouse gas emissions by ~ 70

Tonnes CO2-e /year, plus additional Tonnes CO2-e /year, plus additional reductions due to lower usage of inks and reductions due to lower usage of inks and polymer substratepolymer substrate

Capital cost $1.3 m, annual savings ~$3 mCapital cost $1.3 m, annual savings ~$3 m Payback: less than 6 months Payback: less than 6 months

Sealed Air - Cryovac - InternationalSealed Air - Cryovac - International World leader in global World leader in global

manufacturing of food manufacturing of food packaging plastics.packaging plastics.

Operate in 51 countries Operate in 51 countries over 100 manufacturing over 100 manufacturing plants, approximately plants, approximately 17,600 employees.17,600 employees.

Inventors of Bubble WrapInventors of Bubble Wrap®®

Students: Stuart Sisley Students: Stuart Sisley and Brett Gillespieand Brett Gillespie

Barrier Bag ManufactureBarrier Bag ManufactureBlowing /Racking ProcessBlowing /Racking Process

18 blowing / racking machines

Staples used for joining

Sealed Air Cryovac: OutcomesSealed Air Cryovac: Outcomes

New heat sealing method reduces annual New heat sealing method reduces annual greenhouse gas emissions by 1900 tonnes greenhouse gas emissions by 1900 tonnes (~2% of plant total)(~2% of plant total)

Capital cost: $90 000Capital cost: $90 000 Annual savings from reduced energy Annual savings from reduced energy

consumption and waste - $1.04 millionconsumption and waste - $1.04 million Simple payback period - 1 monthSimple payback period - 1 month

Student: Tasman Student: Tasman HigginsHiggins Reducing diesel Reducing diesel fuel consumption fuel consumption and greenhouse gas and greenhouse gas emissions of straddle emissions of straddle carrierscarriers

P&O Ports: West Swanson TerminalP&O Ports: West Swanson Terminal

P&O Ports: Outcomes P&O Ports: Outcomes

Limiting the over-lifting of containers Limiting the over-lifting of containers reduces greenhouse gas emissions by reduces greenhouse gas emissions by approximately 150 tonnes annuallyapproximately 150 tonnes annually

Installing limit switches to each machine: Installing limit switches to each machine: $7,500$7,500

Annual fuel saving $80,000 Annual fuel saving $80,000 Payback period: just over one monthPayback period: just over one month

ORICA LAVERTON PLANTORICA LAVERTON PLANT

Produces chlorine through electrolysisProduces chlorine through electrolysis– High electricity consumption High electricity consumption – Emissions well over 100 000 tonnes/yEmissions well over 100 000 tonnes/y– produces hydrogen gas as a by-productproduces hydrogen gas as a by-product

Student: Andrew O’DeaStudent: Andrew O’Dea Using vented hydrogen for electricity Using vented hydrogen for electricity

prodcution and heat prodcution and heat

Greenhouse gas reduction Greenhouse gas reduction optionsoptions

Utilise wasted hydrogen to offset electricity Utilise wasted hydrogen to offset electricity and gas consumption by:and gas consumption by:

– producing electricity through:producing electricity through: a fuel cell, ora fuel cell, or a gas turbine generatora gas turbine generator

– reducing natural gas usage by fuelling the reducing natural gas usage by fuelling the boiler with hydrogenboiler with hydrogen

PEM hydrogen fuel cellPEM hydrogen fuel cell Electrochemical device Electrochemical device

(no burning)(no burning)

Latest technology Latest technology

No CONo CO22 emissions emissions

Produces electricity Produces electricity and hot waterand hot water

Hydrogen-fuelled gas turbine Hydrogen-fuelled gas turbine generatorgenerator

Turbo shaft engine Turbo shaft engine driven AC generatordriven AC generator

2000 kg/h steam 2000 kg/h steam generationgeneration

Electricity generationElectricity generation No CONo CO22 emissions emissions

Potential savingsPotential savings

Annual Annual COCO22

reductionreduction

Payback periodPayback period

Fuel cellFuel cell ~20 000 ~20 000 tonnestonnes

~ 5 years~ 5 years

Gas turbineGas turbine ~12 000 ~12 000 tonnestonnes

~ 3 years~ 3 years

Solar Lighting at Tram Stops for Solar Lighting at Tram Stops for Yarra Trams:Yarra Trams:

Student: Andrew DeveneStudent: Andrew Devene

Yarra Trams: Yarra Trams: Outcomes Outcomes

EnvironmentEnvironmentPotential Greenhouse Gas Emission Potential Greenhouse Gas Emission

savings: savings: 328 kg CO328 kg CO22-e/yr/light-e/yr/light

335 tonnes CO335 tonnes CO22-e/yr -e/yr (60% of Network)(60% of Network)

Financial Financial Estimated Annual energy bill savings Estimated Annual energy bill savings

($0.08/kWh):($0.08/kWh): $60/year/light$60/year/light $60,373/year $60,373/year (60% of network)(60% of network)

Social Social Increased community awareness of Increased community awareness of

Sustainable Energy OptionsSustainable Energy OptionsIncreased security & safetyIncreased security & safety

Yarra Trams

To participate in the RMIT-To participate in the RMIT-NORTHLink Greenhouse Challenge NORTHLink Greenhouse Challenge

Support program next yearSupport program next year Must be a Greenhouse Challenge Plus memberMust be a Greenhouse Challenge Plus member Contacts:Contacts:

Dr John AndrewsDr John Andrews, SAMME, SAMME

RMIT UniversityRMIT University

Ph: 03 9925 6085 Ph: 03 9925 6085 andrews.john@rmit.edu.auandrews.john@rmit.edu.au John WyettJohn Wyett, Australian Greenhouse Office: , Australian Greenhouse Office:

02 6274 1752; 02 6274 1752; www.greenhouse.gov.auwww.greenhouse.gov.au Mick ButeraMick Butera, NORTHLink, 03 9479 3337; , NORTHLink, 03 9479 3337;

m.butera@latrobe.edu.aum.butera@latrobe.edu.au