AMAP Colloquium Aachen, February 19 th Dipl.-Phys. Christoph Kausch
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1 Energy Efficiency by Analysis & Management AMAP Colloquium Aachen, February 19 th 2015 Dipl.-Phys. Christoph Kausch perpendo Energie- und Verfahrenstechnik GmbH Am Viadukt Aachen Tel. 0241/ Fax 0241/ c.kausch@perpendo.de
2 perpendo Energie- und Verfahrenstechnik GmbH perpendere (lat.) to investigate, to examine, to consider carefully perpendo I investigate, I examine Who we are: the energy specialists for analysis & optimisation of complex issues highly qualified engineers from various different disciplines experience of more than 500 projects in commerce and industry What we do: Energy Design For new developments or extensions Energy Efficiency Analysis For existing sites and processes Energy Management Design, controlling and benchmarking Sustainability Carbon footprinting and emissions reduction perpendo Energie- und Verfahrenstechnik GmbH, Aachen 2
3 Energy Design For new developments or extensions Knowing at an early stage if an idea will work simulation is the way to be sure Typical aims of using simulation tools: minimising energy costs ensuring thermal comfort avoiding unwanted operating conditions Benefits of using simulation tools: optimisation of material usage and the need for technical equipment (sizing) minimising investment costs high planning reliability by using detailled analyses evaluation of life cycle costs perpendo Energie- und Verfahrenstechnik GmbH, Aachen 3
4 Energy Efficiency Analyses Methods for Optimisation Data-based analysis logging, handling and evaluation of existing energy data increasing transparency of status-quo Model-based analysis quantification of quantities not-measured forecast of modifications or measures ( what if ) perpendo Energie- und Verfahrenstechnik GmbH, Aachen 4
5 Energy Efficiency Analyses Spectralanalysis of Electricity Demand Based on electricity supplier load data. perpendo Energie- und Verfahrenstechnik GmbH, Aachen 5
6 Energy Efficiency Analyses Weekly Electricity Load Curves Based on electricity supplier load data. perpendo Energie- und Verfahrenstechnik GmbH, Aachen 6
7 Energy Efficiency Analyses Measurements Full Load Min Load Single Compressor rated at 136 kw on load. Min Load Variable Speed 30 % perpendo Energie- und Verfahrenstechnik GmbH, Aachen 7
8 Energy Efficiency Analyses BMS Display of a HVAC System These values are physically not possible if the cooling register is closed. perpendo Energie- und Verfahrenstechnik GmbH, Aachen 8
9 Energy Efficiency Analyses Simulation Based Analysis Site Data (Weather) Geometry (Building Plan) HVAC Systems Hourly energy balances for one year Usage (Process) Breakdown of the energy demand to single consumer groups Interaction between the energy consumers Identification of unusual or unwanted operational conditions Quantification of the benefit of saving measures Forecast of the energy demand under changed operating conditions Design basis for the development of an energy controlling system ( Benchmarks) perpendo Energie- und Verfahrenstechnik GmbH, Aachen 9
10 Energy Efficiency Analyses Evaluation of the Current State: Heat Consumption Building Geb MWh Building 4 Geb. 1,9 % 781 MWh 5,5 % Building Geb MWh 25,6 % Building Geb MWh 0,5 % Tents Zelte 181 MWh 1,3 % Warmwasser Hot Water 332 MWh 2,3 % where? Electrolyte Bäder 555 Baths MWh 3,9 % Lackierung Paint Shop 1 / 1KTL MWh 7,6 % Building Geb MWh 45,0 % Lackierung Paint Shop MWh 6,4 % stat. Static Heizung Heating 696 MWh 4,9 % Process Ventilation PLT inkl. and Evaporation Abdunstzonen Zones MWh 13,9 % what is it used for? Electrolyte Bäder Baths 555 MWh 3,9 % Warmwasser Hot Water 332 MWh 2,3 % 103 Produktion 101a Lager 101 Produktion RLT Esta5 (FCM) MWh/a MWh/a MWh/a MWh/a HVAC-Systems RLT MWh 74,9 % PLT Esta4 (Eisenmann) 952 MWh/a 103 Büro innen 104 Extruder 102 Besprechung 102 Speisesaal 56 MWh/a 35 MWh/a 25 MWh/a 14 MWh/a or specifically by which unit? Jahresheizwärmebedarf annual heat demand [MWh/a] [MWh/a] perpendo Energie- und Verfahrenstechnik GmbH, Aachen 10
11 Fluid c 1 2 M h c h c h c in out strip h c c h Pww5 Prw_HYDR Prw_BK Prw_BW h h h c c c _Controller controller Energy Efficiency Analyses Further Simulation Instruments Example: optimising operations of freezing plants Elektrische Electrical Leistung power [kw] Pumpen / Ventilatoren [kw] Carrier 30HXC / 3 [kw] Carrier 30HXC / 2 [kw] Carrier 30HXC / 1 [kw] Trane CVGF [kw] Trane RTHD [kw] 0 0:00 6:00 12:00 18:00 0:00 6:00 12:00 18:00 Zeit time Temperatur [ C] Speisew. Kessel Rauchgas ECO Rauchgas WT Nachspeisewasser Mangelabluft WWW (41,4 C) Abwasser FW WWW (32 C) WWW (22,2 C) Übertragene Wärme [kw] Hydraulikkühlung Abwasser BW Anwaschwasser P50/18 Abw. FW (41 C) Abwasser BK KWW Speicher Erdtank >> KWW Abw asserp5018 Abw asserfw WT_Mangel Speicher_GFK_WWW_50 Brunnen_2_2 Brunnen_2_1 Brunnen_1 WT_1 Speicher_RGW WT_2 Erdtank WT 3.1 (neu) Example: improvement of thermal integration Prw 3 WT 4 (neu) Speicher_GFK_KWW_100 Ionentauscher WT 3.2 (neu) WT_Hydraulik Speicher_KHW WT_BK WT_BW WWW_P5013 WWW_P5018 Bedarf_WWW Bedarf_RGW P5018_AWWasser P5018_Tank_B Bedarf_KWW Bedarf_SPW RLHydraulik VLHydraulik Kanal_BK Abw asser_bk Kanal_BW Abw asser_bw Kanal_FW Bedarf_KHW perpendo Energie- und Verfahrenstechnik GmbH, Aachen 11
![[kw] Trane RTHD [kw] 0 0:00 6:00 12:00 18:00 0:00 6:00 12:00 18:00 Zeit time Temperatur [ C] 220 210 200 190 180 170 160 150 140 130 120 110 Speisew.](/docs-images/43/8559322/images/page_11.jpg "Kessel 100 90 80 70 60 50 40 30 20 10 0 Rauchgas ECO Rauchgas WT 1 + 2 Nachspeisewasser Mangelabluft WWW (41,4 C) Abwasser FW WWW (32 C) WWW (22,2 C) 0 100 200 300 400 500 600 Übertragene Wärme [kw]")
12 Energy Efficiency Analyses Fields of Application for Simulations Buildings dynamic building and plant simulation (heating, ventilation and air conditioning) light simulation for determination of daylight proportion building element simulation for optimisation of individual constructions computational fluid dynamics (CFD) Processes and facilities optimisation of facility plants (heat / cooling energy, vapor, compressed air,...) operation strategies sequential switching dynamic load adjustement cogeneration and trigeneration, heat pumps thermal integration waste heat utilization and heat recovery perpendo Energie- und Verfahrenstechnik GmbH, Aachen 12
13 Optimisation of a Chilling System The setting: 5 cold water chillers (KKM) 3 of identical type 2 independent cooling tower systems Group of 3 cooling towers Central cooling water supply central Zentrale Kühlwasserversorgung cooling water 36 / 26 C supply Central cold water distribution network KKM 1-3 KKM 5 KKM 6 Key data: Required cooling: kw Annual demand: 9,7 GWh/a perpendo Energie- und Verfahrenstechnik GmbH, Aachen 13
14 Chilling System Optimisation: Control Strategy Commitment control of the chillers based on the actual chilling power delivered: Switch-on condition for the next chiller: Switch-off condition for the last chiller: 95 % capacity of the chillers in operation exceeded for 10 min 85 % of the available capacity undercut for 15 min Switching sequence Carrier 30HXC / 1 Carrier 30HXC / 2 Carrier 30HXC / 3 Trane RTHD Trane CVGF Summer Winter => Question: Is this switching sequence the optimal choice? perpendo Energie- und Verfahrenstechnik GmbH, Aachen 14
15 Chilling System Optimisation: Part Load Efficiency of the Chiller Types COP Carrier 30HXC 3.5 Trane RTHD Trane CVGF Part Load Q0/Q0N 0 / Q 0,N Cold water: 6 / 12 C, Cooling water: 26 / 32 C perpendo Energie- und Verfahrenstechnik GmbH, Aachen 15
16 Chilling System Optimisation: Dependency of the COP on the Fluid Temperatures 9,0 8,5 8,0 7,5 7,0 COP 6,5 6,0 5,5 5,0 4,5 4, Cooling Kühlwasservorlauftemperatur water flow inlet temperature [ C] [ C] Cold water 6/12 C, COP at 6/12 C 28/32 C = 5, ξ = const. perpendo Energie- und Verfahrenstechnik GmbH, Aachen 16
![Kühlwasservorlauftemperatur water flow inlet temperature [ C] [ C] Cold water 6/12](/docs-images/43/8559322/images/page_16.jpg "C, COP at 6/12 C 28/32 C = 5, ξ = const.")
17 Chilling System Optimisation: Switch on / off conditions Switching Schaltreihenfolge sequence for Sommer summer time cooling Kälteleistung capacity in [kw] Trane Turbo Trane Screw Carrier 33 Carrier 22 Carrier 1 Trane Schraube Carrier kw 1700 kw 2200 kw 2760 kw perpendo Energie- und Verfahrenstechnik GmbH, Aachen 17
18 Chilling System Optimisation: Results Measures: Changing to optimised switching sequences Swap condenser side pumps for evaporator side pumps Adapt the cooling water temperature set point Costs: Low implementation costs (programming of the existing metering system and installation work for the pumps) Effect: Reduction of power consumption by 730 MWh/a (36 %) Savings of /a perpendo Energie- und Verfahrenstechnik GmbH, Aachen 18
19 Energy Efficiency Analyses Techno-Economic Measures perpendo Energie- und Verfahrenstechnik GmbH, Aachen 19
20 Energy Management Interacting Systems perpendo Energie- und Verfahrenstechnik GmbH, Aachen 20
21 Energy Management ISO Framework Source: perpendo Energie- und Verfahrenstechnik GmbH, Aachen 21
22 Energy Management Continuous Cycle Proven Approaches on a regular basis Energy Reports Status-quo is evaluated Feedback is given Make recognition possible do Energy use check & monitor Energy Forum Workshop discussions Department-head meeting Jour-Fix Internal audit Important Aspects plan act Less documents more content Less EnPI s more interpretation Less instructions more conversations perpendo Energie- und Verfahrenstechnik GmbH, Aachen 22
23 Energy Management Design and Implementation An efficient energy management has diverse requirements which are different for each company - meter structure - sensor technology - central control technology - - energy flow diagram - energy aspects - energy goals - savings listing - technical requirements organisational requirements knowledge about energy data-based requirements - strategy - responsibilities - operating cycle (workflow) - data access software - interfaces - data management - reporting - Adapted to individual needs perpendo Energie- und Verfahrenstechnik GmbH, Aachen 23
24 Energy Controlling Different Approaches to Increase Energy Efficieny energy consumption classical energy controlling effective energy controlling increasing energy knowledge time Advantage of a detailed analysis: gain in time lower installations costs for the EIS perpendo Energie- und Verfahrenstechnik GmbH, Aachen 24
25 Energy Controlling Provide Coordinated Information Key Indicators: Cost development Target achievment Management Controlling Okt. Nov Dez Jan Feb Mrz Apr Mai KS Kostenstelle qm qm qm qm qm qm qm qm 56 Sozialräume 131,0 132,0 144,0 147,0 127,0 137,0 111,0 100,0 02 Allgem. Werkdienst 06 Schlosserei 536,0 432,0 443,0 304,0 337,0 348,0 373,0 409,0 07 Elektrowerkstatt 39,0 58,0 192,0 224,0 165,0 97,0 27,0 45,0 10 Fuhrpark Planwagen 64,0 43,0 46,0 52,0 51,0 46,0 47,0 57,0 13 Fuhrpark Silorfahrz. 15 Produktionsleitung 3,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 16 Labor 4,0 2,5 3,0 3,0 3,0 3,0 2,0 2,0 17 Versuchsbäckerei 2,0 1,5 1,0 1,0 1,0 1,0 1,0 1,0 14 Techn. Einkauf 2,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 24 Getreide-Silo/-Lager 41 Reinig.1 u. Mühle 536,0 432,0 443,0 304,0 337,0 348,0 373,0 409,0 Staff Consumption Data: Billing data Product energy costs Historic Data: Data for analysis Consumption Information: Current values Alarms Data Preparation Data Acquisition Field Level Energy Manager perpendo Energie- und Verfahrenstechnik GmbH, Aachen 25
26 Energy Controlling Example of Reporting accumulated natural gas consumption [MWh Hs ] (initial state) 2008 (analysis by perpendo) 2009 (measures implementing) 2010 (energy controlling) benchmark (simulation) measured comsumption (weather corrected) target values (by simulation) Month perpendo Energie- und Verfahrenstechnik GmbH, Aachen 26
27 Energy Controlling Specification of Benchmarks & EnPI A. Historical characteristics: Consumption figures from previous years Difficulty: Modifications and new construction are not considered. Potential savings are not revealed. B. Comparative characteristics: Consumption figures of comparable sites Difficulty: Site-specific features are not considered. Comparable real estate often does not exist. Consumption figures per production unit Difficulty: Characteristics only exist for some sectors and specific production methods. C. Calculated characteristics: Determination of theoretical ideal values Difficulty: Theoretical boundaries are sometimes only known for parts. Model development is time-consuming. perpendo Energie- und Verfahrenstechnik GmbH, Aachen 27
28 Sustainability Carbon Footprint and Emissions Reduction Avoiding emissions begins with knowing the sources Target balancing of greenhouse gas emissions according to GHG-protocol product carbon footprint company carbon footprint Procedure determine of appropriate allocations consider the supply chain elaborate reduction potentials advanced experience with food processing meat processing works, balance Cradle to Gate, without emissions resulting from meat generation perpendo Energie- und Verfahrenstechnik GmbH, Aachen 28
29 Thank you for your attention! Your Contact: Dip.-Phys. Christoph Kausch perpendo Energie- und Verfahrenstechnik GmbH Am Viadukt Aachen Tel. 0241/ Fax 0241/ c.kausch@perpendo.de
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