Modelling for Industrial Energy Efficiency

Transcription

1 Energy Efficiency Benefits for Industry Seminar Limerick Institute of Technology April 1 st 2015 Modelling for Industrial Energy Efficiency Dr Rick Greenough De Montfort University 1 st April 2015

2 Modelling Simplification of reality to aid understanding Similar to real system, but simpler Trade-off between simplicity and realism Complex models increase realism, but cost more Skill is to add complexity where it gives most value Have to know what you are looking for A model is a product modelling is building it Simulation is a process using the model to study system behaviour and predict outcomes

3 Examples of models

4 Models of industrial energy flows Value Stream Mapping Life Cycle Analysis IDEF 0 Process modelling

5 Sankey diagram of US energy system (2009) This is an interactive Sankey diagram, that can be accessed here: 31% in 2008

6 Sankey diagram for a factory (EPFL, 2015)

7 Energy systems in industry (Herrmann & Thiede, 2009) Production system Process energy and ancillary processes Technical Building Services (TBS) Compressed air, gas, coolant, HVAC, etc. Building shell Daylight, thermal efficiency, weather effects Complex interactions!

8 Modelling industrial energy in THERM project External thermal Energy Air node Thermal zone (Factory) Drying tank Oven (air) Product Product Air Fan Fan HX Air HX Air Energy (Thermal) Thermal energy Air Elec Thermal energy Water CHP Water External Energy Water Air Material

9 Requirements for modelling TBS - Return Fan AIR HANDLING UNIT t oa + + Supply Fan t s HC HRU UH n + Extract n Inlet 1 Inlet 2 t a Extract 2 Building geometry, fabric, lighting etc. t hw Hot Water Pump Inlet n UH 1 UH Extract 1 E-Leg 1 System design and control logic

10 Simulation - calibrating the model Time consuming and computationally intensive because small changes in e.g. infiltration rate and setback temperature make a big difference

11 PV panels on Volvo factory roof Optimisation Parameters: Module size/orientation Tilt angle Distance between arrays Objectives: Minimise payback period (1,200 /kw installed 1, 0.1 /kwh consumed 2 ) Maximise annual electricity production 1 DECC Department of Energy and Climate Change: Solar PV cost update 2 Suggested to use by one of the Volvo managers

12 PV Plant optimisation

13 Results of solar PV analysis For 16% of time (~1440 hours) there is enough electricity generated by PV to cover manufacturing process requirements. Over 40% of annual manufacturing process electricity requirements can be obtained from PV Electric Equipment Electricity Consumption PV Potential

14 Another way to model factories - DES

15 REEMAIN ( EU 7th framework - 6.1M Renewable energy, energy reuse and energy management Industry partners: Bossa (textiles) Gullon (food) SCM (iron foundry) Fraunhofer IWU (energy storage) Link with US via Intelligent Manufacturing Systems (IMS)

16 Combining building and system modelling

17 Example energy system solar cooling Solar collector plant Backup heater Q G Rectifier G Refrigerant Vapour Q AC C Refrigerant Liquid SHX Expansion Device Hot water storage Weak Absorbent Solution A P Strong Absorbent Solution Refrigerant Vapour E Refrigerant Liquid + Vapour Absorption chiller Q E Cooling tower Backup chiller CD

18 Example energy system - ORC for waste heat

19 Organic Rankine Cycle at a foundry ORC pilot plant called ORCHID installed by Enertime at FMGC foundry in France

20 Renewable energy options for a foundry ORC pilot plant called ORCHID installed by Enertime at FMGC foundry in France

21 Renewable energy options for a foundry High temperature processes To melt iron needs 1600 C Aluminium melts at 660 C Use PV to power an electrical furnace? Use RES in core shop? Waste heat from cupola flue Organic Rankine cycle (ORC) to generate electricity at FMGC foundry in France Flue gases exchange heat with air and thermal fluid which drives ORC generator 5.6 MW of thermal power available Generates 1MWe (5000MWh per year)

22

23 Laundry with solar thermal hot water (Hess, 2014) Annual solar fraction = 23.2% Solar loop utilization ratio = 40.9% System utilization ratio = 35% (energy delivered by solar system/energy required) (solar heat charging the store/solar irradiation) (solar heat discharging from store/solar irradiation)