Energy consulting for industrial clients - current data analytic methods Examples in food & beverage Michael Tenner, May 9 th 2017, Chicago

Transcription

1 Energy consulting for industrial clients - current data analytic methods Examples in food & beverage Michael Tenner, May 9 th 2017, Chicago

2 ÖKOTEC - Our Services Optimisation by Projects Continous Optimisation Energy Analysis Identifying and priorisation of measures Energy Concept Planning reliability for maximum savings at minimum investment Implementation Verifiable energy saving Energy Management (EnM) Continuous improvement process with ISO Networks Energy efficiency by exchange of experience and joint learning EnergyEfficiency- Controlling (EnEffCo ) Software and services for systematic assessment, optimisation and control Training Knowledge transfer and qualification in energy related topics Research and Development (R&D) Development of new concepts and applied research on energy topics in cooperation with universities, research institutes and industrial companies

3 References Meat Processing Sweets Foods Beverages and Drinks

4 Systematics

5 Collecting Data on Site Measuring Equipment

6 Example Boiler Waste Heat Recovery Initial Situation Cost of gas ca. 650 T /a Exhaust gas temperature ~ 250 C Measure Addition of a exhaust gas heat exchanger to pre heat feed water and decarbonated water Advantage Standardized solution Long operating periods Difficulties Finding an adequate heat sink Steam Boiler Deaerator Condensate Economic Viability Cost Savings T /a Estimated Investment T Pay-back period 2,5-4,5 a IRR %

7 Example - Chiller Lowering Condensation Temperature Current Situation In a dairy chillers with a cooling capacity of 500 kw th are installed. Annual power demand: 1,100 MWh el /a. Condensation temperature is fixed at 35 C (95 F). Measure Reduction of condensation temperature depending on the ambient temperature. Power demand of cooling tower is increased slightly but each Kelvin leads to reduction power demand for the chiller Economic Viability Cost Savings T /a Estimated Investment T Pay-back period 1,0-2,0 a IRR %

8 COP Example Free cooling vs. mechanical cooling Cooling tower Air Außentemperatur Temperature [ C] COP Freikühler BA I

9 Example Free Cooling 20 C Cooling Kühlturm Tower 21 C Kondensator Condenser K1 Verdampfer Evaporat K1 or Water Vorlauf- Supply Becken 18 C Return Rücklauf- Basin Becken 22 C 16 C 16 C 16 C M

10 Example Free Cooling Air Temp. Energy Saving Potential 100% Free-Cooling Energy Saving Potential Integrated Cooling Mechanical Cooling Saving Potential ~ 40 T /a

11 EnPI - Consolidation of complex data Performance indicators are a component of ISO & Advantages of EnPIs Reduction to a reduced number of values Simplified evaluation of plant efficiency Used for benchmarking improvement target Challenges with EnPIs Correct system boundaries Influencing factors should be considered Baseline period Reporting period

12 Example - Compressed Air Volume flow Power of compressors Relation: Effort/Benefit Expected:

13 Example - Understanding a Meat Production Process Electric energy Product A1 Product A2

14 Example: Energy Efficiency Comparison of four Chillers I

15 Example: Energy Efficiency Comparison of four Chillers II Measure: Mainly use Chiller Initial state: COP = 4.3 (213 KW el ) After Implementation : COP = 4.5 (205 KW el ) Savings: approx. 12T /a

16 R&D Project EnEffReg Project Funded by ministry of economics and energy Combined Closed-loop energy efficiency control Challenge Supply systems are subject to constant fluctuations due to structural changes in the production, permanent changes in operation and climate conditions Operation of facilities is not dynamically optimized towards its environment and requirements Goal Automatization of measurement, evaluation of EnPI s and optimal operation Usage of overall efficiency in connected systems to reduce costs and carbon emissions Constant calculation of best fit parameters and data transmission to control facilities

17 Michael Tenner ÖKOTEC Energiemanagement GmbH EUREF-Campus Berlin Torgauer Straße Berlin Fon: +49 (30) Fax: +49 (30)