Detroit June 23rd, 2009

Transcription

1 Energy Efficiency in German Chemical Industry Detroit June 23rd, 2009 Beuth Hochschule für Technik Berlin University of Applied Sciences Bastian Bohm effizienzwerk, Berlin 1

2 1) Motivation The biggest source of oil can be located within Germany: It is energy efficiency Die größte Ölquelle liegt unter Deutschland: Es ist die Energieeffizienz Jürgen Hambrecht, CEO BASF 2

3 1) Motivation The biggest source of oil can be located within Germany: every country itself: It is energy efficiency 3

4 1) Motivation and Outline 1) Motivation and Outline 2) Energy Efficiency: Why? 3) Energy Efficiency: How? 4) Energy Efficiency: Why else? 5) Summary 4

5 2) Energy Efficiency: Why? 1) Motivation and Outline 2) Energy Efficiency: Why? 3) Energy Efficiency: How? 4) Energy Efficiency: Why else? 5) Summary 5

6 2) Energy Efficiency: Why? Energy consumption by industries in Michigan [Trillion Btu]: Chemical Industry is one of the key industries (Source: Energy Information Administration, 2002) Energy consumption of Chemical Industry above EU average One of the biggest Chemical Industries in the World High Potential for Optimization 6

7 3) Energy Efficiency: How? 1) Motivation and Outline 2) Energy Efficiency: Why? 3) Energy Efficiency: How? 4) Energy Efficiency: Why else? 5) Summary 7

8 3) Energy Efficiency: How? Methods for finding efficiency optimization potentials Project definition Study Detailed Analysis Specification Implementation Targets Conceptual Require- Scope Potentials design ments Interfaces Evaluation 8

9 3) Energy Efficiency: How? Fields for Optimization Process - Heat integration - Thermal & Mechanical process engineering - Reaction engineering Process Intensification - combine process steps Component Efficiency (classification acc. to EN ISO 10628) - Facilities for Heating and Cooling - Heat Exchangers - Dryers - Mills - Agitators, Kneaders - Pumps - Compressors, vacuum pumps - Lifting, conveying and transport - Motors and Drives - Lifecycle costs / total cost of ownership Usage of energy sources - cogeneration - steam (pressure levels) - condensate return and reuse - water (river, city, cooled) - pressurized air with levels e.g.: 10bar (100%), 6bar (71%), 3.2bar (41%)) - natural gas Production buildings - Insulation - HVAC (heating, ventilation & air conditioning) - lighting Process control and operation - Automation - Production planning - Information management - Energy management Management - Energy contracting - New methods for project financing 9

10 3) Energy Efficiency: How? Fields for Optimization Process - Heat integration - Thermal & Mechanical process engineering - Reaction engineering Process Intensification - combine process steps Component Efficiency (classification acc. to EN ISO 10628) - Facilities for Heating and Cooling - Heat Exchangers - Dryers - Mills - Agitators, Kneaders - Pumps - Compressors, vacuum pumps - Lifting, conveying and transport - Motors and Drives - Lifecycle costs / total cost of ownership Usage of energy sources - cogeneration - steam (pressure levels) - condensate return and reuse - water (river, city, cooled) - pressurized air with levels e.g.: 10bar (100%), 6bar (71%), 3.2bar (41%)) - natural gas Production buildings - Insulation - HVAC (heating, ventilation & air conditioning) - lighting Process control and operation - Automation - Production planning - Information management - Energy management Management - Energy contracting - New methods for project financing 10

11 3) Energy Efficiency: How? Example 1: Component efficiency 11

12 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive Power = pressure drop * flowrate / efficiency G M FC 1) Plant 2) Flow 3) Control 4) Drive System 12

13 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive 1) Plant Pipe systems e.g. cooling water, HVAC Very often: flow rate for single consumers too high G M FC Reduce flow rate of plant or parts of plant! Apply only pressure level really needed 13

14 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive 2) Flow (centrifugal pump) If size too big: efficiency i drops dramatically Very often: do something good by overdesign G M FC DO NOT OVERDESIGN PUMP! Change rotor to smaller size Trimming of rotor acc. to characteristic pump curve Exchange pump for smaller one 14

15 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive 3) Control Bypassing and throttling ttli are destroying energy G M FC If flow control is needed: SPEED CONTROL! 100% bypass Power throttle Speed control Flowrate 15

16 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive 4) Drive System G M FC Gear: high h efficiency i available but often expensive Motor: 2005/32/EG (Eco Design) and IEC rule efficiency class of motors IE1, IE2, IE3: standard, high, premium efficiency From 2011 only > IE2 for new investments! Life cycle: investment often only 5% of overall costs! For new investments: check IE2, IE3 For existing gplants: consider exchange of drive! 16

17 3) Energy Efficiency: How?Component efficiency: pumps P 1 = pv & η η η η Flow Control Gear Drive Power = pressure drop * flowrate / efficiency G M FC 1) Plant 2) Flow 3) Control 4) Drive System Increase efficiency by up to 30-50% 17

18 3) Energy Efficiency: How? Example 2: Production Planning 18

19 3) Energy Efficiency: How?Use of utilities in batch plant Nat Gas Cooling water steam Compr. air Use of utilities/ energies How much? -natural gas When? - cooling water Base load? - steam Peak load? - compressed air Efficient use of equipment? 19

20 3) Energy Efficiency: How?Use of utilities in batch plant 1) Measure/ Record! Nat Gas Cooling water steam Compr. air [t/h] Steam consumption Time [h] Measurement gives: high peak load Equipment is too big! Equipment utilization and specific costs high! Equipment design is inefficient! Peak-load price is very expensive e 20

21 3) Energy Efficiency: How?Use of utilities in batch plant 1) Measure/ Record! 2) Analyze Nat Gas Cooling water steam Compr. air R1 D1 V1 R2 D2 V2 M1 M2 Perform capacity analysis (i.e. batch mass balance): Detailed view of process possible Equipment utilization Basis for optimization 21

22 3) Energy Efficiency: How?Use of utilities in batch plant Nat Gas Cooling water steam Compr. air [t/h] Steam consumption 1) Measure/ Record! 2) Analyze 3) Optimize Time [h] Optimized process: Better equipment utilization Better energy efficiency of pumps and heat exchangers No more peak load: reduced energy price 22

23 3) Energy Efficiency: How? Example 3: Information Management, Energy Management 23

24 3) Energy Efficiency: How? ERP Production scheduling Warehouse management Quality data management Process data management Enterprise Resource Planning g( (ERP) e.g. SAP Manufacturing Execution Systems (MES) Instrumentation Automation/ DCS Controls Automation and Controls Manufacturing Execution Systems (MES) = Information Management 24

25 3) Energy Efficiency: How? Manufacturing Execution Systems (MES) = Information Management/ Energy Management Speed up business processes/ decisions Supply data source for - Optimization of plant availabilty -Optimization of processes - Improvement of quality - Improvement of maintenance Advanced process control (APC) Visualization 25

26 3) Energy Efficiency: How? Manufacturing Execution Systems (MES): Example Key Performance Indicators (KPI) Process monitoring e.g. selectivity, yield, conversion Heat Exchanger Fouling Technical condition monitoring e.g. fouling, heat transfer coefficient e.g. pressure drop e.g. expected mechanical life Plant utilization and economical efficiency Production plan operation performance energy efficiency Benchmarking [t/h] Peak load violation Time Time [h] 120 kw 26

27 3) Energy Efficiency: How? No. 1 2 E-Efficiency Field Current status Measure Potential Tasks for detailed analysis Install new drive Component efficiency Process operation Pumps are with FC, Reduce energy Conceptual operated in automate, consumption by bypass mode change piping 30% Parallel operation Change Increase of dryers causes production equipment Perform Capacity peak load and planning, efficiency by 10%, analysis inefficiency of implement reduce peak load equipment visualization costs Estimate ed time for impleme entation [months ] Estimate ed benefit [ ] Estimate ed Costs [ ] design and cost estimation 6 4,250 5, ,000 19,200 Systematic analysis gives potentials and priorities at an early stage for low cost 27

28 3) Energy Efficiency: Why else? 1) Motivation and Outline 2) Energy Efficiency: Why? 3) Energy Efficiency: How? 4) Energy Efficiency: Why else? 5) Summary 28

29 3) Energy Efficiency: Why else? EU Countries: commitment for reduction EU Kyoto protocol Grant Emission i Currently: Allowance Unit EAU Grant & Sell EAU Other industries Pulp and Paper refinery, cracker Power Chemical Industry Cement, glass steel Households Industry Agriculture Reduce emission/ invest Trade EAU European Energy Exchange EEX Buy EAU Transport 29

30 3) Energy Efficiency: Why else? Third phase of emission trading from 2013: Other industries Pulp and Paper refinery, cracker Power Chemical Industry Cement, glass steel Households From 2013: Emissions cost money/ have a market value Essentially all industries included in system Agriculture Transport 30

31 4) How much? 31

32 3) Energy Efficiency: Why else? Emission Factors, prices, costs Energy direct emissions indirect emissions Emission Factor Price energy/ fuel price emission right (value of EAU) price emission right (value of EAU) [tco 2 /MWh] [ / MWh]* [ / MWh]** [% of fuel cost] electricity included included 1,3-1,4*** 32 ~ 5-15 ~ mineral coal included d not included d 04 0,4 6,5 5,2 95 crude oil included ~ +20% 0, ,4 20 natural gas included ~ +15% 0, ,9 22 direct indirect Energy emissions emissions Emission Factor Price Value of EAU Value of EAU [tco 2 / t] [ / t] [ / t fuel]** [% of fuel cost] mineral coal included not included 3, crude oil included ~ +20% 3, natural gas included ~ +15% 2, * EEX spotmarket ** EAU = Emission Allow ance Unit *** depends on fuel type, process, grid efficiency Basis (EEX, Frankfurt or ICE, London as of ) electricity 32/MWh - - mineral coal $/t 50 / t 8 kwh/kg natural gas 11/kWh 160 / t 12,5 kwh/m3 crude oil $ 50/Bbl; 40/ 200/t 12 kwh/kg Carbix EAU 13 / t 13 / t - 32

33 5) Summary There still is a huge Potential for Energy Efficiency in Chemical Industry Typical Optimization Fields were given Potentials and Priorities can be evaluated by systematic Analysis Energy Efficiency can be achieved by Engineering Technology Automation In the Future EU/ Kyoto Legislation will further increase Pressure and Motivation for Energy-efficient i Production 33

34 Efficient Energy Use! effizienzwerk Gustav-Meyer-Allee 25 D Berlin Bastian Bohm M.B.A. Dipl.-Ing. Environmental Technologies Managing Director T: F: M: E: ien erk 34