CR Plus

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Celsa Group ESOS

Energy Management

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Summary of Achievements
  • CR Plus historical involvement at the Celsa Cardiff plants since 2010 during which time successful projects were identified and implemented from EAF furnace control though to factory Lighting.
  • Appointed in 2015 to survey sites and be Group Lead Assessor for ESOS Compliance having previously surveyed the Cardiff Melt shop, Sections Mill and Rod & Bar Mill sites in the Group during 2010 to 2012 with positive feedback.
  • All work completed by November 2015 including submission to the Environment Agency.
  • Templates developed during this project to enable more efficient ESOS delivery for future clients.
  • Overall Savings identified
    • 4.4% of energy consumption
    • 3.7% of energy cost
    • 3.8% of carbon emissions associated with fossil fuel usage
    • Overall payback period of savings opportunities = 2.2 years
          Strategic Approach - Overview of Opportunities

          Based on our experience within the heavy industrial sector we presented opportunities in a way that fit the group’s current capital situation and therefore allowed more attractive or strategically important projects to get better buy in – the impact of this can be so positive that at one of the sites a Variable Speed Drive application project was actively progressed during the survey.

          The opportunities tended to fall into two groups:
          • CapEx projects of less than 2 year’s simple payback
          • CapEx projects of more than 2 year’s simple payback
          Sub 2 Year Payback - Examples
          • Variable speed drives to Dust extraction system – 3 large 1.7MWe fans with potential to link to steel melt cycle to achieve fan motor savings of £0.5M p.a.
          • Replace a re-heat furnace recuperator to make optimum use of exhaust gas and increase pre heated combustion air temperature.
          Above 2 year payback - Examples
          • Cooling system VSDs on pumps and fans – more appropriate application to cooling tower fans due to process risk and head pressure limitation on pumping
          • Progression of hot charging trials at the Sections Mill
          • Compressed air generation control improvements (VSD compressors, system control units)
          • Compressed air leak reduction
          • High bay lighting re lamping and controls (a small relative user but a savings opportunity with reduced associated process risk)
          The survey also then included the identification of ‘Car Park’ ideas to at least plant the seed for possible future projects that at this stage did not fit into the chosen payback groupings. A good example was to implement Waste Heat Recovery to furnace charge benches.

          WHAT CELSA SAY…

          Richard Lewis, Environmental Manager,
          Celsa Manufacturing (UK) Ltd

          “We appointed them due to their previous work with us taking opportunities they identified through to successful implementation with bottom line savings realised. We intend to continue using CR Plus with our next step being to involve them in our site energy management group”

          “In all situations we have found the company and all personnel within it to be friendly, professional, easy to work with and knowledgeable. They clearly understood our time pressures and therefore took real ownership of the work and only requested our involvement when absolutely necessary to deliver effective results”

          “CR Plus helped us look at ESOS from a business wide perspective, helping us mitigate risk and align ESOS compliance with our business strategy”

          “I would not hesitate to recommend CR Plus services to any business that is looking for a fresh perspective on improvement opportunities”
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