Energy Efficiency in Industrial Areas: Examples, Chances and Challenges Dr.-Ing. Alexander Schlüter www.renewables-made-in-germany.com
Primary energy / MWh/a Greenhouse gas emissions / t CO2e/a Introduction 8000 2000 7000 1750 6000 1500 5000 1250 4000 1000 3000 750 2000 500 1000 250 0 Present state Step a Step b Step c Step d Step e 0 Source: Schlüter et al. (2011)
Content of the presentation Introduction General information about energy efficiency measures Single measures Holistic approach Conclusion
Energy efficiency fields Increasing energy efficiency Industry, manufacturing trade Services, energy supply Households Transport, mobility Monitoring Development of controls Systems, machines and plants Organisation Sectoral addressing and implementation Intelligent decentralised hybrid structures Minimise conversion losses Usage of waste heat Minimise transport losses Monitoring (smart metering) Basic structure of buildings (financing programmes) Heat supply Pattern of use Lightweight construction Drive concepts Source: Hesselbach (2012), p.3
Final Energy Consumption in German Industry conversion in thermal energy (heat) 75 % other process heat 66% process cooling and air conditioning 1% mechanical energy 21% ICT (electricity) 1% lighting 2% space heating 8% hot water 1% Source: German Federal Ministry of Economics and Technology (2014)
Example: Way to decrease energy costs Trend of costs when applying short time energy management Trend of costs when applying continuous enms-processes (constant improvements, training and motivation) Decision to implement an EnMS according to ISO 50001 Investment Ongoing Investment Rising demand of energy Simple measures of energy savings dropping costs more measures Saving energy becomes part of the company`s culture Activities for saving energy only occasionally, without continuous control und improvement Successful and longterm reduction of energy costs Source: Austrian Energy Agency (2007), p. 6
Energy monitoring Live monitoring Before optimization: know your energy flows! Measures on the basis of energetic comparison Analysis of historic data Key values and benchmarking kwh/part, kwh/kg Volume compressed air per day coefficient of performance Source: Limón GmbH
Main primary energy demand in a plastic processing factory HVAC: heating, ventilation and air conditioning Source: Schlüter, Rosano (2016)
Auto industry: Quick wins I Energy efficiency by increasing productivity Optimization of robots Usage of coolers instead of compression chillers Lighting 4,0 3,5 Adaption of the cooling water temperature 3,0 2,5 2,0 12 1,5 1,0-1,5 1,5-2,0 2,0-2,5 10 2,5-3,0 3,0-3,5 3,5-4,0 1,0 25 29 33 37 41 45 49 6 8 Sources: Ostfalia (2014); Schlüter (2013)
Auto industry: Quick wins 2 Optimization of pneumatic system Insulation of hot processes Luftein- und auslass Heating, ventilation, air conditioning (HVAC) geschlossener Strömungskanal Produkt Source: Müller et al. (2009), Gloor (2000); J. Wagner (2014)
Energetical overview concerning air-conditioning systems Deluting Air Customised method Layering Housing Spot cooling Conventional mixedventilation Air volume adaptation Luftein- und auslass Punktkühlung 0 % Produkt Punktkühlung: Standbyswitching geschlossener Strömungskanal Lufteinund auslass 23 C Nur Produkt auf 18 C -24 to -37 % Air volume sensors Layer ventilation -41 to -53 % Temperature sensors Connection of relevant production areas -63 % to -87 % Produkt (18 C) -95 to -99 % Cooling only the product 23.02.2016 Source: J. Wagner (2014) 11
Auto industry: Quick wins 2 Optimization of pneumatic system Insulation of hot processes Luftein- und auslass Heating, ventilation and air conditioning (HVAC) geschlossener Strömungskanal Produkt Utilization of waste heat Heat recovery Switch off belts/machines when possible Source: Müller et al. (2009), Gloor (2000); J. Wagner (2014)
Changing a whole plastics factory Impact of a holistic approach Σ = 26 % Σ = 41 % Holistic approach clearly better Source: Schlüter, Rosano (2016) 23.02.2016 Dr.-Ing. Alexander Schlüter 13
Conclusion There are several opportunities to increase your energy efficiency! Conduct energy management system according to ISO 50001! Train your staff they might bring in ideas. Start with quick wins but try to think and conduct holistically!
Contact Dr.-Ing. Alexander Schlüter basinga Engineering office B. A. Schlüter Tel.: + 49 (0) 176 222 89 532 b.a.schlueter@outlook.de Percevalstr. 27 D-23564 Lübeck, Germany www.renewables-made-in-germany.com
Thank you very much for your attention!
List of references I Hesselbach, J.: Energie- und klimaeffiziente Produktion: Grundlagen, Leitlinien und Praxisbeispiele, Vieweg+Teubner, 2012 Austrian Energy Agency. Guide Step by step direction for im-plementation of an energy management system, Vienna, Austria, 2007 German Federal Ministry of Economics and Technology, 2014 Limón GmbH, product for energy monitoring e.visor, www.limongmbh.de/ Schlüter, B.A.; Rosano, M.B.: A holistic approach to energy efficiency assessment in plastic processing. J. of Cleaner Production, 2016 Ostfalia Hochschule für angewandte Wissenschaften; talk of Geckler, D., Roboterkinetik: Energieeinsparungen bei Robotern, Munich, Germany, 2014 Müller, E. et al: Energieeffiziente Fabriken planen und betreiben, Springer, Berlin, Heidelberg, 2009
List of references 2 Gloor, R.: Energieeinsparung bei Druckluftanlagen in der Schweiz, Sufers, 2000 Schlüter, A.: Beitrag zur thermischen Energieversorgung in der Kunststoffverarbeitung Systemische Lösungen und Potenziale, Dissertation, Kassel Univ. Press, 2013 Unpublished figures and results of J. Wagner, Univ. of Kassel, Germany, 2014 EU, Eurostat, http://epp.eurostat.ec.europa.eu/, 2012 VDI 6025; VDI-Guideline. Betriebswirtschaftliche Berechnungen für Investitionsgüter und Anlagen, 2012 Schumm, G.; Philipp, M.; Energieeffizienz in der milchverarbeitenden Industrie, talk, Kassel, Germany, 02/20/2015
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Final energy consumption in the EU Households 27% Services 16% Industry 24% Transport 33% Source: EU, Eurostat, (2012)
Example: Compressed air system Degree of efficiency is very low: about 10 % Compressor manufacturers: enlarge usage of waste heat Problem: demand at 65-90 C Heating demand for building only in cold days Increase of overall degree of efficency from 10 to ca. 25 % Source: Müller et al. (2009), Gloor (2000)
Financing of energy efficiency measures company a 1 Measure 2 1 3 2 4 3 5 4 Time of amortization in a 4.5 4 2 1.5 Mod. int. rate of interest in % 10 12 20 24 5 3.5 15 Contracting by company b Crowd funding Benefits: Energy savings in company a Good rate of interest
Modified internal rate of return im: mod. internal rate of interest E: earnings A: expenses A0: initial invest n: number of periods N: complete number of periods i: market interest rate source: VDI-Richtlinie 6025, 2012
Example: Consumption footprint of a dairy End energy Filtrating-facilities, Engines, Refrigareting machines Power Natural gas Power Steam Dry air Evaporizer, Pasteurizer, Cleaning Losses Dry tower Partly cogenerationsuitable Dr.-Ing. Alexander Schlüter Source: Schumm, G.; Philipp, M. (2015)
Example: Usage of a CHP in a dairy CHP Losses Filtrating-facilities, Engines, Refrigareting machines Power Steam Warm water Dry air Evaporizer Cleaning, Pasteurizer Very cogenerationsuitable 23 % CO2-saving 20 % primary energy-saving 22 % energy costs-saving Dryer Losses Dr.-Ing. Alexander Schlüter Source: Schumm, G.; Philipp, M. (2015)