- The Environmental Managers -

Energy Efficiency Programs in Industrial Companies

Energy Efficiency in IPPC Installations

Energy Efficiency in IPPC Installations Andreas Kollegger 2

- The Environmental Managers -

DI Andreas Kollegger

ALLPLAN GmbHSchwindgasse 10, A-1040 Wien

fon: +43 1 505 37 07 53fax: +43 1 505 37 07 27

andreas.kollegger@allplan.athttp://www.allplan.at

Energy Efficiency in IPPC Installations Andreas Kollegger 3

- The Environmental Managers -

Method

Some Crucial Points

Experience

Clients

Results

Agenda

Energy Efficiency in IPPC Installations Andreas Kollegger 4

- The Environmental Managers -

Analysis

Calculations

Saving potential

Cost assessment of energy saving

measures

Calculation of savings

Data gathering Existing data

Measurements

Optimum technical and economic

solution

Method

Energy Efficiency in IPPC Installations Andreas Kollegger 5

- The Environmental Managers -

Some Crucial Points

Comprehensive analysis

Starting with an overview

Identifying large energy flows and consumers

Focusing on relevant areas

Main production processes very often well optimised

Concentrating on auxiliary processes

“To boldly to go, where no man has gone before”(© Star Trek)

Energy Efficiency in IPPC Installations Andreas Kollegger 6

- The Environmental Managers -

Example: Sankey Diagram

Data Basis: Own measurements Company data Client´s measurements Own calculations

Energy Efficiency in IPPC Installations Andreas Kollegger 7

- The Environmental Managers -

Example: Optimisation of Boilers Use of Waste Heat from Boilers

Energy Efficiency in IPPC Installations Andreas Kollegger 8

- The Environmental Managers -

Comprehensive boiler analysis

Optimisation of burners

Reduction of radiation losses

Reduction of CO content

Decrease of fluegas temperature

Flue gas condensation

Optimisation

75%

85%

95%

105%

115%

0 100 200 300 400flue gas temperature [°C]

effi

cien

cy

75%

85%

95%

105%

115%

0 100 200 300 400flue gas temperature [°C]

effi

cien

cy

Energy Efficiency in IPPC Installations Andreas Kollegger 9

- The Environmental Managers -

Example: Use of Waste Heat from a Production Process

Scheme

electrostatic filter

transportation air

water

Variant 190°C70°C

bypassM

bricks

brick cooling system

electrostatic filter

transportation air

waterwater

Variant 190°C70°C

Variant 190°C70°C

bypassMM

bricks

brick cooling system

Energy Efficiency in IPPC Installations Andreas Kollegger 10

- The Environmental Managers -

Example: Change in Control Systems

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%Relative Flow

Rel

ativ

e P

ow

er

Flow Control via Throttle

Flow Control via FC

Energy Efficiency in IPPC Installations Andreas Kollegger 11

- The Environmental Managers -

Optimisation – Control Systems

Highly sophisticated control systems installed

Settings do not fit actual demand(due to adaptations / extensions of plants)

Adjustment of control system to actual demand

Continuous control of correct settings

Retrofit of simple overhead control units

No general rules possible due to many different types of control systems

Trial and error procedures

Energy Efficiency in IPPC Installations Andreas Kollegger 12

- The Environmental Managers -

Example: Optimisation of Compressed Air

no-load operation

full operation

no operationno-load operation

full operation

no operation

Energy Efficiency in IPPC Installations Andreas Kollegger 13

- The Environmental Managers -

Optimisation of Compressed Air

Adaptation of control unitspressure levels load to idle run ratio

idle run time

Upgrade or change of control units

Compressors with frequency converters

Exploitation of the inevitable waste heat

Refurbishment of the distribution system

Optimisation of pipe diameters

Energy Efficiency in IPPC Installations Andreas Kollegger 14

- The Environmental Managers -

Example: “Free Cooling” of Tanks

Energy Efficiency in IPPC Installations Andreas Kollegger 15

- The Environmental Managers -

Advantages of “Free Cooling”

Requires only a small share of the electricity needed for common chillers

Provision of additional annual cooling load

Common chillers can fully be switched off under certain conditions

Additional safety due to redundancy

Energy Efficiency in IPPC Installations Andreas Kollegger 16

- The Environmental Managers -

Countries Austria

Czech Republic

Germany

Hungary

Netherlands

Romania

Slovakia

Slovenia

Economic Fields Pulp Production

Paper Production

Cardboard Production

Ferrous Metal Production / Processing

Non-Ferrous Metal Production / Processing

Mineral Industry

Food Industry

Utilities

more than 50 AEEP´s

Our Clients - Examples

Energy Efficiency in IPPC Installations Andreas Kollegger 17

- The Environmental Managers -

The Results – Heat & Electricity

0

1

2

3

4

5

6

7

8

9

10

Maximum Potential Average Weighted Average

Sa

vin

g P

ote

nti

al [%

]

HeatElectricity

>20%

Energy Efficiency in IPPC Installations Andreas Kollegger 18

- The Environmental Managers -

The Results – Overall Financial Savings

0

1

2

3

4

5

6

7

8

9

10

Maximum Potential Average Weighted Average

Sav

ing

Po

ten

tial

[%

]

>15%

Energy Efficiency in IPPC Installations Andreas Kollegger 19

- The Environmental Managers -

The Results – CO2 Reduction

0

1

2

3

4

5

6

7

8

9

10

Maximum Potential Average Weighted Average

Sa

vin

g P

ote

nti

al [%

]

>30% (due to a Fuel Switch)

Energy Efficiency in IPPC Installations Andreas Kollegger 20

- The Environmental Managers -

Results of 28 AEEP´s(carried out in various Austrian industry companies)

Saved Electricity: > 6.000.000 MWh/a

Saved Heat Energy: > 25.000.000 MWh/a

Saved Energy Costs: > 7.000.000 €/a

Saved CO2 Emissions: > 50.000 tCO2/a

Energy Efficiency in IPPC Installations Andreas Kollegger 21

- The Environmental Managers -

DI Andreas Kollegger

ALLPLAN GmbHSchwindgasse 10, A-1040 Wien

fon: +43 1 505 37 07 53fax: +43 1 505 37 07 27

andreas.kollegger@allplan.athttp://www.allplan.at

Thank you for your attention