Grey Green recently completed a comprehensive energy audit at one of the largest tyre manufacturers in Africa. Our team investigated all energy and material flows. Excellent savings opportunities were found on:
- Air compressors, plus compressed air distribution and use
- Boiler, steam distribution and use
- Materials handling
- Solid waste
- Water heating
The sixteen best savings opportunities gave payback periods between immediate (no Capex required, just improved control or maintenance) to ~3.9 years, with the average at less than 2 years. These were also quantified in terms of reduced carbon dioxide emissions and decreased carbon tax liability.
Annual financial savings were several millions of Rands.
The tyre company management shall also be able to use our Scenario Planning Tool to:
- Graphically compare the savings produced by each savings opportunity
- Decide when each opportunity should be implemented
Grey Green also conducted pre-feasibility studies on various sources of renewable energy:
- Earth – Biogas, from anaerobic digestion of locally sourced organic matter and biomass as a boiler fuel
- Wind – Wind turbines opportunities in the region
- Fire – Solar PV (i.e. photovoltaic) and solar water heating
- Water – Hydro-electric options available.
As expected, the renewable energy opportunities have longer payback periods than energy efficiency opportunities, but once factory efficiency has been maximised, the only way of reducing energy costs further is by producing one’s own energy from renewable sources.