Industrial Energy Efficiency

Esa VakkilainenLappeenranta University of Technology

Industry

Industrial sector uses about 37% of the world’s total deliveredenergy.Industry energy demand is predicted to grow rapidly, at 1.4% peryear (IEA WEO 2010)Most of the growth is in China and IndiaDisparity of CO2 reduction costs means extra 5 –15 % efficiencygains for industry in OECD to be able to compete with China andIndia

Change in industry energy use2008-2030

EkV IEA WEO 2010

OECD and non-OECD industrial sectorenergy consumption from 2006 to 2030

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U.S Energy Information AdministrationInternational Energy Outlook 2009

Primary energy use in industry byindustrial sub-sector in 1997

EkV Worrell, 2001

Energy management

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Energy management

Energy management is the strategy of meeting energy demandwhen and where it is needed.This can be achieved by adjusting and optimizing energy usingsystems and procedures so as to reduce energy requirements perunit of output while holding constant or reducing total costs ofproducing the output from these systems.In any industry, the three top operating expenses are energy (bothelectrical and thermal), labor and materials.

To minimize energy costs/waste without affecting production andquality and to minimize environmental effects

EkV Abdelaziz et al., 2011

Energy management

1. Analysis of historical data;2. Energy audit and accounting;3. Engineering analysis and investments proposals based on

feasibility studies;4. Personnel training and information.

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Analysis of historical data

Collect energy use per unit manufacturedCompare it to best practice data

EkV LLNL, 2008

Energy management actions

1. Energy audit2. Energy efficiency courses and training program3. Housekeeping

EkV Abdelaziz et al., 2011

Energy audit

Energy audit is an inspection, survey and analysis ofenergy flowsfor energy conservation to reduce the amount ofenergy input intothe systemwithout negatively affecting the output.Theenergy auditis the key for decision-making in the area of energymanagement.Energy audit is thus a reliable and systematicapproach in theindustrial sector. It helps any organization to analyzeits energy useand discover areas where energy use can bereduced and waste canoccur, plan and practice feasible energyconservation methods thatwill enhance their energy efficiency, serve to identifyall the energystreams in a facility, quantify energy usage, in anattempt to balancethe total energy input with its use

EkV Saidur, 2010

Benefits of an energy audit

Reduction in specific energy consumption and environmentalpollution.Reduction in operating costs (approximately 20–30%) by systematicanalysis.Improves the overall performance of the total system and theprofitability and productivity.Slower depletion of natural resources and narrowing demand supplygap.Averts equipment failure.

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Targets for energy audit

Ensure top management commitment.Establish energy consumption in the organization.Estimate the scope for saving.Identify the most likely (and the easiest areas for attention).Identify immediate (especially no-/low-cost) improvements/savings.Identify areas for more detailed study/measurement.Preliminary energy audit uses existing, or easily obtained data.

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Operational energy efficiency indicators

Operational energy efficiency indicators should assist in the followingIndicate performance and progress,Identify the need to take corrective or preventive actions,Enable benchmarking to assess competitiveness, andIdentify opportunities for performance improvement

EkVSivill, Manninen, Ahtila, 2009

Improvement of energy efficiency

EkVSivill, Manninen, Ahtila, 2009

Ten step energy audit

The detailed audit expands on thegeneral energy use figures byproviding a dynamic model ofenergy-use characteristics of boththe existing facility and all energyExtensive attention is given tounderstanding not only theoperating characteristics of allenergy-consuming systems, butalso situations that cause loadprofile variations on short andlonger term bases (e.g. daily,weekly, monthly, annual).Existing data is supplemented withmetering of major energy-consuming systems and monitoringof system operating characteristics

EkV Bureau of Energy Efficiency, 2010

Energy efficiency courses and training

Energy efficiency courses and training programs are very importantto increase the awareness of people who are involved in theindustrial sector.Generally, there are two ways to get an industrial energymanagement course.

The first one is relevant to engineers working in industryThe second is based on the energy management course at theuniversity level.

Both should involve a report which covers a case study, which is anactual on site study or analysis performed for an industry.These courses, in general, focus on legal, technological,environmental, social and economical dimensions of energyefficiency

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Housekeeping

In industry, efficient production and a good working environmentare complementary.The elimination of inefficiencies and accident hazards caused byunfavorable conditions in the workplace is essential in getting thejob done efficiently and safely.The attention to these important details is widely referred to as‘‘good housekeeping’’.Housekeeping involves every phase of industrial operations.It is more than mere cleanliness.It requires orderly conditions, the avoidance of congestion, andattention to such details as an orderly layout of the wholeworkplace, the marking of aisles, adequate storage arrangements,and suitable provision for cleaning and maintenance.

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Housekeeping

1. LightingMaintain the light fittingsMaintain adequate levels

2. Waste removalDispose of scrapPrevent spillage

3. Regular maintenance4. Prepare a check

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Energy saving - Variable speed drive

Load is controlled by motorspeedIn many applications stillconstant speed

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Speeddecrease

Powersaved

10 22 %

20 44 %

30 61 %

40 73 %

50 83 %

Energy saving –high efficiencymotors

improved steel properties,thinner laminations,increase conductor volume,modified slot design,narrowing air gap,improved rotor insulation,more efficient fan design.

Now new EU MEPS standards out –ABB has very efficient modelout thanks to LUT

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Energy savings –air compressors

Air leaks are the single greatest source of energy loss inmanufacturing facilities with compressed air systems.Leaks can waste 20–50% of a compressor’s output.Stopping leaks can be as simple as tightening a connection or ascomplex as replacing faulty equipment such as couplings, fittings,pipe sections, hoses, joints, drains, and traps.Leaks occur most often at the joints, connections, elbows, reducingbushes, sudden expansions, valve systems, hoses, tubes, filters,hoses, check valves, relief valves, extensions, and the equipmentconnected to the compressed-air lines.Utilizing big enough air storage and optimizing compressor usagecan lead to 30 –60 % energy savings.

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Energy efficiency

Country Industrial policy

Canada Industry Program for Energy Conservation (CIPEC)

Denmark Agreements on Industrial Energy Efficiency

Germany Declaration of German Industry on Global Warming Prevention(DGWP)

Finland Agreements on Industrial Energy Conservation Measures

U.K Energy Efficiency Best Practice Program, Energy-Intensive IndustrySector Efficiency Targets

Australia Energy Smart Business Program; Greenhouse Challenge

France Voluntary Agreements on CO2 Reductions

Sweden ECO-Energy

Norway Norwegian Industrial Energy Efficiency Network

Netherlands Long-Term Agreements on Energy Efficiency (LTAs)

China China’s National Climate Change Programme, 11th Five-Year Plan(FYP), Energy Conservation Law

Energy efficiency in ChinaState projectsArea of focus Title of project

Technology Energy-Efficient Motors and Boilers Technology Cooperation

Efficient Industrial Boilers

Motor Test Laboratory and Test Procedure Project

Training China Motor System Energy Conservation Program

Standards and labeling China Energy Efficiency Program: Labeling and Certification Programfor High Efficiency Motors

Information dissemination anddemonstration

Energy Conservation Information Dissemination Center

Policy development Chinese Energy and Carbon Scenarios Project

Industrial Sector Energy Efficiency

Developing Chinese Regulatory Infrastructure Project

Exergy analysis

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Exergy and heat

One can divided energy into two partsexergy as the electricity contentEnergy –exergy as the heat content

Exergy analyses are done to show where potential for electricitygeneration is lost

A detailed exergy analysis, in which the exergy destruction is splitinto the previously mentioned parts, is called advanced exergyanalysis. Such analysis facilitates the improvement of an exergyconversion system from the viewpoints of thermodynamics,economics and environmental impact.

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Heat network –pinch point

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Typical industrial process

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How to dimension heat transferfrom hot streams to cold streamsMinimize added energy toheatingMinimize heat transfer surfacecost

Typical problem to be solved

EkV Aaltola, 2003The problem contained 2684 single equations, 1376 single variables and 103 binaryvariables.

Composite curve summer

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Typical problem to be solved

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Solution to example problem

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Target to save money not energy

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Studies on Finnish mills

EkV Siitonen et al., 2010

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