Why and how does Germany s industry invest in energy efficiency?

Transcription

1 Why and how does Germany s industry invest in energy efficiency? Hannover, 15th April, 2015 Prof. Dr.-Ing. Dipl.-Kfm. Alexander Sauer Director of the Institute for Energy Efficiency in the Production University of Stuttgart Director Development Group Efficiency Systems Fraunhofer-Institut for Manufacturing Engineering and Automation IPA

2 Research Environment in Stuttgart Industrial Research Fraunhofer Institutes in Stuttgart: IPA, IAO, IGB, IBP Engineering Design, Production & Automotive Engineering Energy, Process & Bio- Engineering German Aerospace Center Max Planck Institutes Solid State Research Intelligent Systems Hahn-Schickard-Gesellschaft e.v. Institute for Microsystems Technology 2

3 EEP - Driving Global Action Energy Efficiency Index of the Industry informing legislators on instruments advising companies informing financial institutions International partnership for Energy Efficiency Cooperation Indicators and Data International Best Practice (Industry) EE in Industry and EE Finance Energy Efficiency Financial Institutions Group Drivers for Investment into Energy Efficiency in Buildings and Industry G20 Energy Efficiency Action Plan (through ipeec) Industrial Energy Management Finance Electricity Generation Sustainable Energy for All Accelerator for Energy Efficiency in Industry 3

4 Agenda/Outline Energy efficiency in Germany The perspective of companies Examples And what s the future? 4

5 The Energiewende is in danger to halt! D 2050 Target of the German Federal Government GDP per capita (EUR 2008) D 2050 Trend D 2013 D 2012 Strategic lines: Expanding the use of renewable energy sources Decentralization of energy production (Smart Grids) Serious improvements in energy efficiency primary energy consumption per capita (GJ/a) Picture source: BMWi (2013), appended by EEP 5

6 Future Energy Supply will not follow the demand-side Flexibility of energy demand and storages are required Electricity demand and generation from renewable sources in 2022 GW Beginning of February (week no. 6) GW Beginning of April (week no. 14) Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Electricity demand Photovoltaic Fossil Power Plants Water Wind Onshore/Offshore Biomass Source: Agora Energiewende (2012) 6

7 Energy efficiency benefits the electricity grid Cost savings per saved MWh electricity in the overall system of 114 Euro 2012 /MWh (2035) up to 140 Euro 2012 /MWh (2050) Billion 2012 BAU efficiency energy WWF plus concept Source: Agora Energiewende (2014) BAU efficiency energy WWF plus concept Electricity savings vs. business as usual Efficiency plus: 19% Energy concept: 28% WWF: 42% 7

8 Realisitic scenarios are behind the German goal Innovations as key to energy-saving goals Final energy savings in PJ By 2020 By Verkehr Transport Industrie Industry GHD Commerce, trade, services Haushalte Households 0 Goal Ziel Realistic Potential Goal Ziel Realistic Potential Saving goals, actuel development and economically viable potential [cf. Schlesinger et al. 2010; Pehnt et al. 2011] Low-hanging Fruits are often already reaped Savings in existing systems are subjects to technical limits (-30% possible) Only transport and households could achieve energy goals in 2030 General saving targets neglect sectoral restrictions 8

9 Industrial energy efficiency measures with high impact Current efforts are not sufficient to achieve energy efficiency goals of the German government Billion Euro By 2020 By Haushalte Households GHD Commerce, trade, services Industrie Industry 50 0 Investition Einsparung Savings Investition Einsparung Savings Verkehr Transport Investments vs. savings of potential by 2020 and by 2030 [cf. Pehnt et al. 2011] High profitability of efficiency measures in the industrial sector broadly remains unused Long payback periods of households as a result of small monetary savings Additional 20 to 30% final energy savings are possible by optimizing material efficiency Main potentials consist of cross-section applications in the field of electricity and fuel applications in energy-intensive industries 9

10 Agenda/Outline Energy efficiency in Germany The perspective of companies Examples And what s the future? 10

11 The importance of energy efficiency decreases with the size of the company. 60% 53,1% How do you currently assess the importance of energy efficiency for your company in general? 50% 40% 30% 26,9% 35,6% 32,2% 32,2% 27,8% 30,6% 41,7% 37,5% 45,0% 20% 20,0% 17,5% 10% 0% Micro enterprises (up to 9 employees) Small businesses (10 49 employees) Medium sized enterprises ( employees) Large enterprises (over 250 employees) relatively low synonymous with other factors relatively large Source: EEP, Energy Efficiency Index, winter survey

12 The share of investments in energy efficiency also decreases with the company size. The share of energy efficiency related investments among your total investments was... 45% 40% 35% 35% 32% 39% 30% 25% 20% 15% 10% 5% 10% 6% 28% 28% 28% 24% 24% 23% 18% 15% 24% 21% 10% 18% 17% 21% 14% 0% > 0% and < 5% 5% to 10% 10% to 20% > 20% Micro enterprises (up to 9 employees) Small businesses (10 49 employees) Medium sized enterprises ( employees) Large enterprises (over 250 employees) Total Source: EEP, Energy Efficiency Index, winter survey

13 There is a big range of exploiting energy efficiency potentials. 25% Which measures are significant drivers for energy efficiency improvements in your company? 23% 20% 19% 16% 17% 15% 13% 12% 10% 5% 0% Organizational efficiency measures Change in capacity of the production Reduction of rework and scrap Process integrated efficiency measures Cross process efficiency measures New technologies Source: EEP, Energy Efficiency Index, winter survey

14 The way to exploit energy efficiency potentials differs between company sizes Which measures are significant drivers for energy efficiency improvements in your company? aus dem Einsatz New neuer technologies Technologien aus prozessübergreifenden Cross-process efficiency Effizienzmaßnahmen measures 8,1% 17,2% 18,2% 19,7% 15,2% 11,7% 24,5% 26,0% Kleinstunternehmen Micro enterprises (bis (up 9 to Beschäftigte) 9 employees) aus Process prozessintegrierten integrated efficiency Effizienzmaßnahmen measures 16,0% 13,4% 22,1% 20,2% Kleine Small Unternehmen businesses (10-49 Beschäftigte) employees) aus der Reduzierung Reduction von Nacharbeit of rework und and Ausschuss scrap aus der Änderung Change der in Auslastung capacity of in the der production Produktion 10,7% 13,1% 13,3% 13,4% 13,9% 16,2% 17,6% 16,7% Mittlere Medium-sized Unternehmen ( enterprises Beschäftigte) ( employees) aus organisatorischen Organizational efficiency Effizienzmaßnahmen measures 16,4% 17,2% 17,0% 22,4% Großunternehmen Large enterprises (über (over Beschäftigte) employees) 0% 5% 10% 15% 20% 25% 30% Source: EEP, Energy Efficiency Index, winter survey

15 Agenda/Outline Energy efficiency in Germany The perspective of companies Examples And what s the future? 15

16 Use of new technologies Example: narrow strip-forming-laser welding (SUL) Approach: High amount of cutting waste in the production of seals New manufacturing process: Forming and welding instead of punching Coating of the activ-components Benefits: No more environmentally harmful lubricants High productivity and flexibility Savings: Material reduction up to 85% Cost reduction for steel of 1,62 Mio /year Reduction of CO 2 emissions by 2700 t/year Picture source:

17 Process-integrated measures Example: Green Carbody Energy efficient paint dryer Plant and process engineering measures to consistent exploitation of energy saving potentials in the operation of paint dryers (Green Carbody - Consortium: Audi, Daimler, Eisenmann, IPA) Greenfield and brownfield measures according to the energy on demand strategy, including: Energy-efficient exhaust air cleaning Skidless bodyshell transport Controlled bodyshell heating Thermal optimization of plants Energy-saving potential Bodyshell heating Exhaust air cleaning Plant optimization Skidless transport Effort of implementation Source: Fraunhofer IPA 17

18 Organizational measures SCA Hygiene Products Implementation of various energy efficiency measures in an energy intensive sector. Implementation of an enterprise-wide energy management system Process optimization, e.g. by driving without pretreatment level Introduction of the Leak-Seek-Day, a routine to identify leaks in plants regularly Improved isolation of steam pipes Source: dena Percentage of energy saving 6 % Reduction of energy consumption 216 GWh/year Reduction of energy costs 8 Mio. /year Investment 35 Mio. Return on Investment 23 % 18

19 Agenda/Outline Energy efficiency in Germany The perspective of companies Selected examples And what s the future? 19

20 And what s the future? Industrial Smart Grids Efficiency and flexibility Integration of energy generation, distribution, usage and storage Planning and controlling of production and the internal energy demand in real time Internal management for smoothing the peak loads Adaptability of fluctuating prices and energy availability of the overall system 20

21 Thank you for your attention! Prof. Dr.-Ing. Dipl.-Kfm. Alexander Sauer