Energy efficiency potential in Thailand's iron foundries

Transcription

1 Exportinitiative Energieeffizienz Energy efficiency potential in Thailand's iron foundries Report on the experiences from the project Capacity Development for Increasing of Energy-Efficiency in Medium Sized Enterprises Focus: Energy Efficiency and Best Available Techniques Konrad Mair, Dipl.-Ing. Government of Upper Bavaria, Munich Head of Department Environmental Protection, Public Health and Consumer Protection The Programme The International Climate Initiative of the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU) In 2008/09 the German-Thai Climate Initiative has started GIZ implemented 3 projects 1. Development and Implementation of Climate Protection Policy in Thailand; Partner: Ministry of Natural Resources an Environment (MoNRE), Office of Natural Resources and Environmental Policy and Planning (ONEP) 2. Capacity Development for Increasing of Energy-Efficiency in Medium-Sized Enterprises; Partner: Ministry of Industry (MoI), Department of Industrial Works (DIW) 3. Dissemination of Experiences in the Implementation of Climate Protection Policy in the Nature-Oriented Tourism; Partner: Designated Areas for Sustainable Tourism Administration (DASTA). 2 1

2 Goal of the project Reduction of climate affecting emission through the improvement of energy efficiency in medium-sized enterprises. (Industrial enterprises in production and manufacturing) Target groups Thai Administrative Offices Thai Industrial Associations Unit operators of Medium-Sized Enterprises Consulting firms in the energy and environment sector Education and training institutes and universities 3 Project s Objectives and Services Elaboration of a Guideline on Best Available Techniques for 5 industrial sectors Ferrous Metal Casting Industry Glass Manufacturing Industry Textile Industry: Dyeing and Finishing Secondary Aluminium Industry Canned Food Industry Ad hoc advice and recommendations during On-Site Visits Pilot installation Consultations with stakeholders on the side of the operators and administrations on Best Available Techniques for Environment and Energy Efficiency Curriculum for Trainers Train the Trainers; Train the SMEs 4 2

3 Expected Results/Effects New forms of organisation and sponsor structures of the facility (Centre of Energy and Environment for Thai Industry) Improvement of the consultation service for the medium-sized enterprises Improvement of economic relation between Thai and German Reduction of greenhouse gas emission through the implementation of energy efficient measures and Best Available Techniques (BAT) in medium-sized enterprises Recommendations for improvement of administrative processes and procedures (permitting, monitoring, inspection) 5 Guideline Ferrous Metal Casting Industry Table of Contents Main Chapters 1. Introduction 2. Basic Processes Ferrous Metal Casting 3. Resources 4. Energy Efficiency 5. Environmental Impacts and Measures 6. Safety 7. Annexes 6 3

4 Training: Ferrous Metal Casting Industry 1. Introduction 2. Basic Processes Ferrous Metal Casting 3. Resources 4. Energy efficiency 4.1 Energy Management 4.2 Process specific measures 4.3 General measures cross-sectional technologies 5. Environmental Impacts and Measures 6. Safety 7. Annexes 7 Energy consumption in German ferrous metal foundries - kwh/to good casting - others compressed air process heating Energy consumption total kwh/to good casting 8 4

5 General Impression Production procedures in Thai foundries are similar to German foundries Great interest and understanding of the operators as well as of the civil servants and consultants to modern technology Energy efficiency is becoming increasingly important great interest in forward-looking technology Main interest is currently focused to casting quality and competitive costs Automation is not yet in focus Environmental performance depends on the company's philosophy 9 Potential Energy Efficiency Energy Audit o No results of audits were reported Energy Management System (EnMS) o Hardly respectively not implemented (EN 16001, ISO 50001) Energy consumption o Generally no separate department gathering Good chance for Consultants implementation of the results regularly brings of cost saving and benefits for environment protection 10 5

6 Potential Energy Efficiency production units 1 Main consumer: Melting Process (50 60 %) Predominantly use of induction furnaces Production of GG and GGG Energy consumption o Theoretically: o High performance induction furnace: o Examples: 390 kwh/t casting 600 kwh/t casting 780, , kwh/t Great potential for improvement 11 Potential Energy Efficiency production units 2 Induction furnaces o Great chance for modern medium frequency technology combined with process control technology connected with o BAT technology: cover extraction (or swing aside hood) plus fabric filter Ladle management (10 15 % energy consumption) o Till now hardly focused 12 6

7 Potential Energy Efficiency cross sectional technology Compressed air systems Electric motors and motor systems Illumination Air conditioning Air ventilation systems Potential for improvement: Electric motors 13 Summary The Ferrous Metal Casting Industry produces in a wide range Knowledge on production procedures is very high To be in compliance with national emission limit values is of course Basics how to improve energy efficiency should be known Improvement of energy efficiency and environmental performance always is hand in hand The demand for consulting and investment to improve the energy efficiency and to keep BAT in the Ferrous Metal Casting Industry is estimated to be high Even if the industry was invited to all of our project workshops, the guideline should be presented once more to the Ferrous Metal Casting Industry 14 7