Improving Resource Efficiency in the Manufacturing Industries

Transcription

1 Improving Resource Efficiency in the Manufacturing Industries Sustainable Resources Management (1) Identifying priority natural resources Brussels, Andreas Kunsleben Effizienz-Agentur NRW (EFA), Duisburg / Germany 1

2 Overview State of North Rhine Westphalia (NRW) Effizienz-Agentur NRW ( Efficiency Agency NRW ) EFA-Toolbox consulting services for sustainable growth Some examples and figures Remarks 2

3 Facts about North-Rhine Westphalia Population: 18 m Area: 34,084 km² GDP: 462 Euro bn Rank 14 in the world Foreign Trade: Imports: 122 Euro bn Exports: 119 Euro bn 3

4 Approach of NRW s government: Effizienz-Agentur NRW EFA NRW: - founded as a centre of excellence for Cleaner Production - now with 18 employees in Duisburg and 4 regional offices Objective: - Improve Competitiveness of Small and Medium sized Enterprises (SMEs) by supporting a strategy of sustainable growth Approach: - Introduce Innovative Technologies and (Business-) Processes to SMEs that improve resource efficiency, avoid waste & hazardous emissions and deliver instant results Note: - The economic benefits should be the driving factor behind the implementation of measures and not environmental legislation 4 Aachen Münster Duisburg Siegen Bielefeld

5 Product Life Cycle Non- renewable Resources Energy-Consumption Raw Material Extraction Raw Material Processing Recycled Content Product- Manufacturing Product Usage Waste Treatment Renewable Resources Recyclability 5

6 A Study by EFA: What do Manufacturers think? In which area do you see future efficiency potentials? Percentage of companies questioned Processes Workforce Materials Energy low med high 6 Source: Prof. Matthias Schmieder(FH Köln)/ Michael Ferger, 2006

7 Working with Manufacturing Companies Basic Approach: Offer: Resource consumption as a cost factor and Reduction of resource consumption as a competitive advantage Competent and independent support with the first steps towards resource efficiency 7

8 EFA-Toolbox: Consulting services for sustainable growth EFA provides proven tools to support sustainable growth Production Implementing Cleaner Production Material Solutions Flow Analysis Costs Transparency regarding costs and Resource business Cost processes Accounting Product Creating Greener Products faster Eco-Design Funding PIUS-Financing & Funding 8

9 Conventional Manufactoring Process High Precision Parts Hazardous Waste Landfill Recycling Metal Chips Grinding Sludge Steel Industry Sawing (Turning, Drilling) Hardening Grinding/ Polishing Coolant Coolant Coolant 9

10 Improved Recycling: Grinding Sludge Pellets for the Steel Industry Recycling De-oiling / Pelletizing Recycling Metal Chips Grinding Sludge Steel Industry Sawing (Turning, Drilling) Hardening Grinding/ Polishing Coolant Coolant Coolant 10

11 Shortening the Process Chain Recycling Metal Chips Steel Industry Sawing Hardening Hard & Dry Precision Coolant 11

12 Reviewing Production Parameters Dirostahl Karl Diedrichs KG, Remscheid Industry : Steel, forge and rolling mill Employees : 470 Products: Focus: - open-die forgings from 10 kg up to kg - seamless rolled rings up to mm OD - forged bars up to 850 mm OD/square and up to 15 m in length in alloyed and unalloyed steel grades. Reduction of allowance regarding Material Input 12 Picture: Dirostahl Karl Diedrichs KG

13 Software Solution for more accurate production orders Problem: Solution: Cost: Savings: 13 Material Input in the production process was planned on the basis of the final dimensions of the product (height and width) Self programmed software for planning accuracy regarding the Material Input. Now additional parameters are taken into account: Steel quality, tinder losses, offcuts, variances in the chipless forming processes ½ man-year internal work 3% of the Material Input regarding the product range seamless rolled rings t/a of Steel EURO per year

14 Electricity Consumption in German Households 13 % Hot Water Circulating Pumps 14

15 High efficiency pumps for heating systems: Wilo GmbH, Dortmund - conventional circulating pumps for heating systems are responsible for 13 % of the annual electricity bill - Wilo developed a pump that can save up 80 % of electricity - this was achieved through clear goal setting in the development process for an energy efficient product - the higher initial cost for the pump pays off to the customer in 2 years 15

16 Scope About 87 Million Heat Water Circulating Pumps with less than 250 W Power in European Buildings Energy consumption : 41 TWh/a 1) This is approximately the Energy Production of 5 big Powerstations (1 GW) Saving 80% means: 16 1) Source: Wilo GmbH

17 Current results of PIUS-Checks PIUS-Checks (since 2000) Implemented projects Investment amounts to Annual savings in the production processes Annual savings of the resource water/waste water Annual savings of the resource energy % total 27.6 m 8.7 m m m³ 50.5 GWh per SME* 155,000 50,000 6,000 m³ 300 MWh Annual savings of CO 2 20,000 t 113 t 17 * Average value March / 2008

18 Remarks Resource efficiency in the manufacturing industries, a key to sustainable growth! 1. Transparency, visibility of costs regarding resource consumption and accountability of costs are crucial 2. Greening of Products Creating more value with less impact 3. How much resources did you use? Do you know your figures? 18

19 Effizienz-Agentur NRW Center of Excellence for Sustainable Production Thank you very much for your attention! Further information under: or get in touch under: Tel.: ++49/203/ Fax: ++49/203/