Industrial Energy Efficiency

Esa Vakkilainen Lappeenranta University of Technology

Industry
Industrial sector uses about 37% of the world total delivered s energy. Industry energy demand is predicted to grow rapidly, at 1.4% per year (IEA WEO 2010) Most of the growth is in China and India Disparity of CO2 reduction costs means extra 5 15 % efficiency gains for industry in OECD to be able to compete with China and India

Change in industry energy use 2008-2030

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IEA WEO 2010

OECD and non-OECD industrial sector energy consumption from 2006 to 2030

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U.S Energy Information Administration International Energy Outlook 2009

Primary energy use in industry by industrial sub-sector in 1997

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Worrell, 2001

Energy management

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Energy management
Energy management is the strategy of meeting energy demand when and where it is needed. This can be achieved by adjusting and optimizing energy using systems and procedures so as to reduce energy requirements per unit of output while holding constant or reducing total costs of producing the output from these systems. In any industry, the three top operating expenses are energy (both electrical and thermal), labor and materials. To minimize energy costs/waste without affecting production and quality and to minimize environmental effects

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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 manufactured Compare it to best practice data

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LLNL, 2008

Energy management actions

1. Energy audit 2. Energy efficiency courses and training program 3. Housekeeping

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Abdelaziz et al., 2011

Energy audit
Energy audit is an inspection, survey and analysis of energy flows for energy conservation to reduce the amount of energy input into the systemwithout negatively affecting the output. Theenergy audit is the key for decision-making in the area of energy management. Energy audit is thus a reliable and systematic approach in the industrial sector. It helps any organization to analyze its energy use and discover areas where energy use can be reduced and waste can occur, plan and practice feasible energy conservation methods that will enhance their energy efficiency, serve to identify all the energy streams in a facility, quantify energy usage, in an attempt to balance the total energy input with its use

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Saidur, 2010

Benefits of an energy audit

Reduction in specific energy consumption and environmental pollution. Reduction in operating costs (approximately 2030%) by systematic analysis. Improves the overall performance of the total system and the profitability and productivity. Slower depletion of natural resources and narrowing demand supply gap. 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 following Indicate performance and progress, Identify the need to take corrective or preventive actions, Enable benchmarking to assess competitiveness, and Identify opportunities for performance improvement

Sivill, Manninen, Ahtila, 2009

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Improvement of energy efficiency

Sivill, Manninen, Ahtila, 2009

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Ten step energy audit

The detailed audit expands on the general energy use figures by providing a dynamic model of energy-use characteristics of both the existing facility and all energy Extensive attention is given to understanding not only the operating characteristics of all energy-consuming systems, but also situations that cause load profile variations on short and longer term bases (e.g. daily, weekly, monthly, annual). Existing data is supplemented with metering of major energyconsuming systems and monitoring of system operating characteristics

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Bureau of Energy Efficiency, 2010

Energy efficiency courses and training

Energy efficiency courses and training programs are very important to increase the awareness of people who are involved in the industrial sector. Generally, there are two ways to get an industrial energy management course. The first one is relevant to engineers working in industry The second is based on the energy management course at the university level. Both should involve a report which covers a case study, which is an actual on site study or analysis performed for an industry. These courses, in general, focus on legal, technological, environmental, social and economical dimensions of energy efficiency
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Housekeeping
In industry, efficient production and a good working environment are complementary. The elimination of inefficiencies and accident hazards caused by unfavorable conditions in the workplace is essential in getting the job 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, and attention to such details as an orderly layout of the whole workplace, the marking of aisles, adequate storage arrangements, and suitable provision for cleaning and maintenance.
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Housekeeping
1. Lighting Maintain the light fittings Maintain adequate levels 2. Waste removal Dispose of scrap Prevent spillage 3. Regular maintenance 4. Prepare a check

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Energy saving - Variable speed drive

Load is controlled by motor speed In many applications still constant speed

Speed decrease 10 20 30 40 50

Power saved 22 % 44 % 61 % 73 % 83 %
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Energy saving high efficiency motors

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 model out thanks to LUT

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Energy savings air compressors

Air leaks are the single greatest source of energy loss in manufacturing facilities with compressed air systems. Leaks can waste 2050% of a compressor output. s Stopping leaks can be as simple as tightening a connection or as complex as replacing faulty equipment such as couplings, fittings, pipe sections, hoses, joints, drains, and traps. Leaks occur most often at the joints, connections, elbows, reducing bushes, sudden expansions, valve systems, hoses, tubes, filters, hoses, check valves, relief valves, extensions, and the equipment connected to the compressed-air lines. Utilizing big enough air storage and optimizing compressor usage can lead to 30 60 % energy savings.

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Energy efficiency
Country Canada Denmark Germany Finland U.K Australia France Sweden Norway Netherlands China Industrial policy Industry Program for Energy Conservation (CIPEC) Agreements on Industrial Energy Efficiency Declaration of German Industry on Global Warming Prevention (DGWP) Agreements on Industrial Energy Conservation Measures Energy Efficiency Best Practice Program, Energy-Intensive Industry Sector Efficiency Targets Energy Smart Business Program; Greenhouse Challenge Voluntary Agreements on CO2 Reductions ECO-Energy Norwegian Industrial Energy Efficiency Network Long-Term Agreements on Energy Efficiency (LTAs) China National Climate Change Programme, 11th Five-Year Plan s (FYP), Energy Conservation Law

Energy efficiency in China State projects

Area of focus Technology Title of project Energy-Efficient Motors and Boilers Technology Cooperation Efficient Industrial Boilers Motor Test Laboratory and Test Procedure Project Training Standards and labeling Information dissemination and demonstration Policy development China Motor System Energy Conservation Program China Energy Efficiency Program: Labeling and Certification Program for High Efficiency Motors Energy Conservation Information Dissemination Center 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 parts exergy as the electricity content Energy exergy as the heat content Exergy analyses are done to show where potential for electricity generation is lost A detailed exergy analysis, in which the exergy destruction is split into the previously mentioned parts, is called advanced exergy analysis. Such analysis facilitates the improvement of an exergy conversion 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

How to dimension heat transfer from hot streams to cold streams Minimize added energy to heating Minimize heat transfer surface cost

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Typical problem to be solved

The problem contained 2684 single equations, 1376 single variables and 103 binary variables.

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Aaltola, 2003

Composite curve summer

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Aaltola, 2003

Typical problem to be solved

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Aaltola, 2003

Solution to example problem

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Aaltola, 2003

Target to save money not energy

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Studies on Finnish mills

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Siitonen et al., 2010

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