Compressed Air Systems in the European Union

Transcription

1 Peter Radgen Edgar Blaustein (Eds.) Compressed Air Systems Energy, Emissions, Savings Potential and Policy Actions

2 ISBN Das Werk einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung ist ohne Zustimmung des Verlags unzulässig. Das gilt insbesondere für Vervielfältigungen, Übersetzungen, Mikroverfilmungen und die Einspeicherung und Verarbeitung in elektronischen Systemen. Copyright 2001 LOG_X Verlag GmbH, Stuttgart. Projektmanagement: Dr.-Ing. Peter Radgen, Fraunhofer ISI Umschlaggestaltung: Jürgen G. Rothfuß, Neckarwestheim Druck: Rondo Druck, Ebersbach-Roßwälden Bindung: Waidner GmbH, Fellbach Printed in Germany

3 Preface According to the Kyoto Protocol from 1997, the EU has to reduce greenhouse gas emissions by 8 % below their 1990 levels until the period of To achieve these reduction targets substantial efforts will be required by all sectors. Two main strategies have been identified, which allow significant emission reductions without harming economic growth. The first is the wider adoption of energy efficient technologies. Energy efficiency has been a key element in the energy policy of the European Union since it reduces the emissions related to energy consumption and, at the same time, saves energy costs and contributes to extending the remaining lifetime of our natural resources. Among the cross cutting energy savings technologies, electric motor systems are by far the most important type of electric load. They are used in all sectors in a wide range of applications, such as fans, compressors, pumps, or conveyors. Since electricity consumption in electric motor systems account for abut 70 % of all electricity use in the industry sector and since energy costs make up more than 70 % of the life cycle costs of a motor system, even small improvements in the energy efficiency of motor systems will produce large energy savings across the EU. Therefore, the EU has supported a number of studies, analysing the market for energy efficient electric motor applications. This book summarises the findings of the study on compressed air systems in the EU, while other studies such as a study on the use of pumps have recently been completed and studies on fans and on air conditioning systems are in preparation. As energy savings measures in compressed air systems are highly profitable, we hope that our propositions on how to stimulate further applications of energy savings techniques in compressed air systems will be adopted by the European Com-mission and the national Government of each Member State. Karlsruhe, February, 5th, Peter Radgen Edgar Blaustein

4 Compressed Air Systems Energy, Emissions, Savings Potential and Policy Actions Final Report, October 2000 The project was carried out with support from the European Commission, under the SAVE Programme, project XVII/4.1031/Z/ Project Officer: Paolo Bertoldi, Study team participants ADEME, Project co-ordinator Agence de l'environnement et de la Maîtrise de l'energie 27 rue Louis Vicat Paris, France Bruno Chrétien, Edgar Blaustein, Anne Rialhe, Fraunhofer ISI Fraunhofer Institute Systems and Innovation Research Breslauer Strasse Karlsruhe, Germany Peter Radgen, Christiane Schmid, DoE Department of Energetics University of L'Aquila Località Monteluco di Roio L'Aquila, Italy Roberto Cipollone, Roberto Carapellucci, ECE ECE International VOF De Spinhoek PX Hardenberg, Netherlands Gerard Hurink, <ece_international_vof@hetnet.nl> Industry representatives The study team would like to thank Pneurop (the European association of manufacturers and distributors of compressed air equipment) for their participation in the study. While the many members of the association who participated are too numerous to list, we would like to make particular mention of the participation of Henri Ysewijn (President of Pneurop), Guy Van Doorslaer (SG of Pneurop), Harry Craig and Desmond Wall.

5 I Compressed Air Systems Table of Contents Executive Summary... 1 Zusammenfassung... 5 Résumée Rapporto Conclusivo Samenvatting Introduction Characterisation of Compressed Air Systems in the EU Data Collection Methods Numeric Data Qualitative Data on CAS Decision Processes CAS Users Compressed Air Service Providers Model Energy Consumption and Growth Aim of Model Development Description of the Model The Simplified Model, the Data Used, and the Results Technical and Economic Energy Savings Potential Improvement of Drives Optimal Choice of the Type of Compressor Improvement of Compressor Technology Use of Sophisticated Control Systems Recuperating Waste Heat Improved Air Treatment Overall System Design Optimising End Use Devices... 48

6 Compressed Air Systems II 3.9 Reducing Frictional Pressure Losses in Networks Reducing Air Leaks Measuring and Tracking System Performance Synthesis of Technical Measures Organisational Aspects of Energy Savings Organisational Barriers to Improving CAS Energy Efficiency Outsourcing of the Compressed Air Function Analytical Accounting Methods Analysis of Impacts CAS Final Users Manufacturers of Compressors and CAS Equipment Electric Utilities Engineering Consultants and Compressed Air Suppliers Environmental Impact Actions to Promote Energy Efficient Compressed Air Systems Actions Advertising Campaign Technology Demonstration Measuring Campaign Contests and Awards Dissemination of Information, Training, and Education Life Cycle Costing Labelling and Certification Voluntary Agreements Development of Guidelines for Outsourcing Economic and Regulatory Actions Other Possible Actions Classification of Actions and Development of a Concerted Programme Proposition to the Commission on How to Act...108

7 III Compressed Air Systems 7. Evaluation of the Impact of Measures The Energy Scenarios Future Energy Consumption of CAS Bibliography APPENDIX 1: Market Characterisation: Qualitative Data APPENDIX 2: Market Characterisation: Numeric Data APPENDIX 3: ADEME Data Collection Guide for Compressed Air Outsourcing APPENDIX 4: Data Collection Guide for Compressed Air Users APPENDIX 5: Qualitative Data Collection Guide for Equipment Manufacturers

8 Compressed Air Systems IV List of Figures Figure 1: CAS electricity consumption...29 Figure 2: Number of air compressors by power range...30 Figure 3: Number of new and upgraded CAS until Figure 4: Process chain for CAS...43 Figure 5: Major families of compressors...45 Figure 6: An example of a CA network...49 Figure 7: Major energy savings measures...53 Figure 8: Industry Electricity Factor for EU countries, US and Japan in Figure 9: Electricity Consumption for EU countries in Figure 10: LCC for two different sizes of compressors, indicating the significance of energy consumption...89 Figure 11: LCC of a compressor with variation of electricity prices...90 Figure 12: Evaluation matrix for proposed actions (covered potential and implementation time) Figure 13: Evaluation matrix for proposed actions (costs and covered potential) Figure 14: Evaluation matrix for proposed actions (Implementation time and costs) Figure 15: Construction of the Awareness Raising Programme (ARP) Figure 16: CAS electricity consumption according to scenario Figure 17: CAS electricity consumption by country, BAU scenario Figure 18: CAS electricity consumption by country, ARP scenario Figure 19: CAS electricity consumption by country, ERP scenario...117

9 V Compressed Air Systems List of Tables Table 1: Electricity consumption in compressed air systems Table 2: Number of air compressors installed Table 3: Number of air compressors installed in Table 4: Electricity consumption for CAS in Table 5: Growth rates for CAS in the EU Table 6: Compressed air system life cycle Table 7: Energy savings measures Table 8: Types of measuring systems Table 9: Energy savings measures Table 10: Some acronyms for energetic and economic parameters Table 11: Market Penetration Factor and Efficiency Gain Factor Table 12: Table 13: Table 14: Energy Savings and CAS Energy Savings Ratio for each proposed measure Energy Savings and CAS Energy Savings Ratio for the actions globally considered Reduction of energy costs for the actions globally considered Table 15: Reduction of operating costs for each proposed measure Table 16: Increment of Investment costs for each proposed measure Table 17: Payback Time, full realisation of techno-economic potential Table 18: Payback Time, moderate ARP scenario Table 19: Number of company-level measures for each proposed energy savings measure Table 20: Estimated annual sales of new / upgraded components Table 21: Table 22: Reduction of energy sales for electric utilities due to each of the proposed actions (medium price scenario) Reduction of energy sales for electric utilities due to the actions globally considered (medium price scenario) Table 23: Fuel savings Table 24: Global Energy Savings Ratio for each proposed measure... 75

10 Compressed Air Systems VI Table 25: Global Energy Savings Ratio for the action globally considered...75 Table 26: Energy and Fuel Savings for the moderate scenario...76 Table 27: Table 28: Table 29: Table 30: Electricity production in 1997 for various countries...78 Specific CO 2 emissions...79 Energy savings and CO 2 emission reduction for each of the proposed actions...80 Energy savings and CO 2 emission reduction in the moderate scenario...80 Table 31: Target groups of proposed actions Table 32: Table 33: Affected components of proposed actions Estimate of gained energy savings by the two programmes Table 34: Actions and action levels Table 35: Total CAS electricity consumption in TWh, per country...114