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Energy Efficiency in Industrial Areas: Examples,

Chances and Challenges

Dr.-Ing. Alexander Schlüter

Introduction

0

250

500

750

1000

1250

1500

1750

2000

0

1000

2000

3000

4000

5000

6000

7000

8000

Prim

ary

en

erg

y/

MW

h/a

Gre

enhouse

gas

em

issio

ns

/t

CO

2e

/a

Present state Step a Step b Step c Step d Step e

Source: Schlüter et al. (2011)

Introduction

General information about energy efficiency measures

Single measures

Holistic approach

Conclusion

Content of the presentation

Energy efficiency fields

Increasingenergy efficiency

HouseholdsIndustry,

manufacturing trade

Services, energy supply

Transport, mobility

• Monitoring

• Development of controls

• Systems, machines and plants

• Organisation

• Sectoral addressing and implementation

• Monitoring (smart metering)

• Basic structure of buildings (financing programmes)

• Heat supply

• Pattern of use

• Intelligent decentralised hybrid structures

• Minimise conversion losses

• Usage of waste heat

• Minimise transport losses

• Lightweight construction

• Drive concepts

Source: Hesselbach (2012), p.3

space heating8%

hot water1%

other process heat66%

process cooling and air

conditioning1%

mechanical energy

21%

ICT (electricity)1%

lighting2%

conversionin thermal energy

(heat)75 %

Source: German Federal Ministry of Economics and Technology (2014)

Final Energy Consumption in German Industry

Example: Way to decrease energy costs

Trend of costs when applying short

time energy management

Activities for saving energy only

occasionally, without continuous control

und improvement

Trend of costs when applying continuous enms-processes (constant improvements, training and motivation)

Successful and longterm reduction of energy costs

Decision to implement an EnMS according toISO 50001

InvestmentOngoingInvestment

Risingdemandof energy

Simple measures ofenergy savingsdropping costs

moremeasures

Saving energybecomes part ofthe company`sculture

Source: Austrian Energy Agency (2007), p. 6

Before optimization: know your energy flows!

Measures on the basis of energetic comparison

Energy monitoring

Live monitoring

Analysis ofhistoric data

Key values andbenchmarking

kWh/part, kWh/kg

Volume compressed air per day

coefficient of performanceSource: Limón GmbH

Main primary energy demand in a plastic processing factory

Source: Schlüter, Rosano (2016)

HVAC: heating, ventilation and airconditioning

Energy efficiency by increasing productivity

Optimization of robots

Usage of coolers instead of compression chillers

Lighting

Adaption of the cooling water temperature

Auto industry: Quick wins I

6

8

10

12

1,0

1,5

2,0

2,5

3,0

3,5

4,0

2529

3337

4145

49

1,0-1,5 1,5-2,0 2,0-2,5

2,5-3,0 3,0-3,5 3,5-4,0

Sources: Ostfalia (2014); Schlüter (2013)

Optimization of pneumatic system

Insulation of hot processes

Heating, ventilation, air conditioning (HVAC)

Auto industry: Quick wins 2

geschlossener

Strömungs-

kanal

Produkt

Luftein- und

auslass

Source: Müller et al. (2009), Gloor (2000); J. Wagner (2014)

Energetical overview concerning air-conditioning systems

Deluting Air

Conventionalmixed-

ventilation

0 %

Customisedmethod

-24 to -37 %

Air volumeadaptation

Standby-switching

Layering

Layer ventilation

-41 to -53 %

Housing

Connection ofrelevant

productionareas

geschlossener

Strömungs-

kanal

Produkt

Luftein- und

auslass

-63 % to -87 %

Spot cooling

Cooling only theproduct

-95 to -99 %

Punktkühlung

Produkt (18 °C)

Luftein-

und auslass

Punktkühlung:

Nur Produkt

auf 18 °C

23 °C

23.02.2016

11Source: J. Wagner (2014)

Temperaturesensors

Air volumesensors

Optimization of pneumatic system

Insulation of hot processes

Heating, ventilation and air conditioning (HVAC)

Utilization of waste heat

Heat recovery

Switch off belts/machines when possible

Auto industry: Quick wins 2

geschlossener

Strömungs-

kanal

Produkt

Luftein- und

auslass

Source: Müller et al. (2009), Gloor (2000); J. Wagner (2014)

Changing a whole plastics factory –

Impact of a holistic approach

Holistic approach clearly betterSource: Schlüter, Rosano (2016)

23.02.2016 Dr.-Ing. Alexander Schlüter 13

Σ = 26 %

Σ = 41 %

• 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!

Conclusion

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basINGa Engineering office B. A. Schlüter

Percevalstr. 27

D-23564 Lübeck, Germany

Contact

Dr.-Ing. Alexander Schlüter

Tel.: + 49 (0) 176 – 222 89 532

b.a.schlueter@outlook.de

Thank you very much for your attention!

• 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.limon-

gmbh.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 I

• 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

List of references 2

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Backup

Final energy consumption in the EU

Source: EU, Eurostat, (2012)

Services 16%

Industry24%

Transport33%

Households 27%

Degree of efficiency is very low: about 10 %

Example: Compressed air system

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

1 Measure

1

2

3

4

5

Mod. int. rate ofinterest in %

10

12

20

24

15

Time ofamortization in a

4.5

4

2

1.5

3.5

• Contracting bycompany b

• Crowd funding

Benefits:• Energy savings in

company a• Good rate of interest

company a

2

3

4

5

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

Steam

Power

Natural gas

Dry air

Power

Losses

Filtrating-facilities, Engines, Refrigareting machines…

Evaporizer,Pasteurizer,Cleaning …

Dry tower

Source: Schumm, G.; Philipp, M. (2015)

End energy

Partly cogeneration-suitable

Dr.-Ing. Alexander Schlüter

Example: Usage of a CHP in a dairy

Steam

Dryer

Power

Losses

CHP

Warm water

Dry air

Losses

Evaporizer

Cleaning,Pasteurizer

• 23 % CO2-saving• 20 % primary energy-saving• 22 % energy costs-saving

Very cogeneration-suitable

Dr.-Ing. Alexander Schlüter

Filtrating-facilities, Engines, Refrigareting machines…

Source: Schumm, G.; Philipp, M. (2015)