Energy Efficiency - Made in Germany Contents Export Initiative Energy Efficiency, Istanbul Turkey Prof. Dr.-Ing.

Transcription

1 Energy efficiency and energy management: an integral view Export Initiative Energy Efficiency, Istanbul Turkey Prof. Dr.-Ing. Bernd Bungert Beuth Hochschule für Technik Berlin on behalf of the German Federal Ministry of Economics and Technology Contents Where and how is energy used in an enterprise? How is production controlled? Where are the highest achievable energy savings? Example: production management What is energy management? Energy Efficiency in the Enterprise Material (raw material, auxiliaries, utilities, Goods in Process) Energy usage Gebäude und Gebäudehülle Building (incl. Technische Gebäudeausrüstung) Auxiliary (logistics, storage, packaging) Products (Finshed goods) Where and how is energy used in an enterprise? Delivered energy (electricity, Oil, gas,...) Energy Energy conversion distribution Useful energy Energy supply Waste heat Waste water Exhaust air Waste 1

2 M aterial (Rohs toffe, Hilfs s tofe, Betriebss tofe, Unfertige Druckluftanlage Energieträger (Strom, Öl, Gas,..) Energienutz ung Energie- Verteilung Strom Licht Gebäude und Gebäudehüle Hilfsproz esse Produktionsprozesse D ampf Dampfkessel Produkte (Fertige Abwärme Abwasser Abluft Abfall M aterial (Rohs toffe, Hilfs s tofe, Betriebss tofe, Unfertige Druckluftanlage Energieträger (Strom, Öl, Gas,..) Energienutz ung Energie- Verteilung Strom Licht Gebäude und Gebäudehüle Hilfsproz esse Produktionsprozesse D ampf Dampfkessel Produkte (Fertige Abwärme Abwasser Abluft Abfall Material (raw material, auxiliaries, utilities, Goods in Process) Energienutzung Energy usage Energy Efficiency in the Enterprise Building Auxiliary (logistics, storage, packaging) Products (Finshed goods) Druckluft Warmwasser W asser Delivered energy 1) Electricity (customer generation/ market) ) Natural Gas ) District Heating ) Coal and solid fuels Delivered energy (electricity, Oil, gas,...) conversion Verteilung Energy Energie- Energy distribution Electricity Light Compressed air Compressor Warm water Steam Water Steam Boiler Waste heat Waste water Exhaust air Waste 5) Renewable Energies (Biomass, Waste, Other) 6) Water 7) Drinking Water 8) Nitrogen Electricity Air Cooling air Gas Water 9) Air Druckluft Warmwasser W asser Delivered energy and media: Fields of usage 1) Space heating ) Warm water ) Process heat/ cooling energy ) Mechanical energy 5) Lighting 6) Other media Delivered energy and media: Fields of usage Energy usage Delivered energy 1 Space heating Heating (warm water) Heating (hot air) Cooling (Cold water) Coolig (Cold air) Ventilation (air) Air conditioning (air, humidity) Warm water Water (Drinking water) Water (Sanitary) Process heat/ cooling energy Steam (10 bar, 16 bar, 6/ bar) Cooling brine/ Ethylene glycol Gas (for direct heating) Öl (for direct heating) Electricity Mechanical energy Electrical drives Pneumatical drives (compressed air 10 bar, 6 bar) Hydraulic drives Control air (, bar) Other compressed-air applications 5 Lighting Electricity/ Light 6 Other media Nitrogen Deionized water

3 Delivered energy and media: Fields of usage Material (raw material, auxiliaries, utilities, Goods in Process) Energienutzung Building Auxiliary (logistics, storage, packaging) Products (Finshed goods) How is production controlled? Energie- Verteilung Electricity Light Compressed air Warm water Steam Water Waste heat Waste water Exhaust air Waste Delivered energy (electricity, Oil, gas,...) Compressor Steam Boiler Electricity Air Cooling air Gas Water How is this production controlled? Control levels of an enterprise How is this production controlled? Control levels of an enterprise

4 How is this production controlled? Control levels of an enterprise Level : Corporate management (Accouting, Purchasing, Enterprisse ressource Level : Plant management Oder tracking, Process data management, Where are the highest achievable energy savings? Level : Process control (DCS, SPC, hand) Level : Corporate management (Accouting, Purchasing, Enterprisse ressource Level : Plant management Level : Process control (DCS, SPC, hand) Levels of Optimization Technical Systems Operating Procedures Information, Motivation, Business Oder tracking, Process data management, Level : Corporate management (Accouting, Purchasing, Enterprisse ressource Level : Plant management Level : Process control (DCS, SPC, hand) Levels of Optimization Technical Systems Operating Procedures Information, Motivation, Business Load profile, Load management, Energy procurement Heat Warehouse integration, management Waste-heat Oder tracking, usage, Operation Process data of management, Auxiliary Operation: Shutting of idling engines Equipment: Efficient pumps, Drives etc.

5 Levels of Optimization, potentials [PJ]/ usage [PJ] (Prognos study, Sector industry) Level : Energy Corporate Business Efficiency management - Made in Germany (Accouting, Purchasing, Enterprisse ressource Level : Plant management Operating Level : Process Procedures control (DCS, SPC, hand) Information, Level 1: Field Motivation, area Technical Systems Exchange of Unefficient motors 5/90 Energetical optimization 108/07 Adjustement to Effective need 6/90 Increase of efficiencyengines /0 Efficiency Increase of drives /90 Business : not taken into account Optimization Thermal >00 C 68/1101 Minimization of Losses, maintenance 5/90 Oder Heat tracking, recovery Process 6/6 data management, Lighting 0/5 Recovery of Mechanical energy of drives 5/65 Avoiding Overdesigned equipment 15/90 Σ 9 Σ 51 Σ 71 Levels of Optimization Level : Energy Corporate Business Efficiency management - Made in Germany (Accouting, Purchasing, Enterprisse ressource Business : not taken into account Energetical optimization Optimization Oder Heat tracking, recovery Level : Plant management Thermal Process 6/6 data 9 management, Σ 9 108/07 >00 C The highest potentials 68/1101 OperatingFor energy-efficiency increase Level : Process control Minimization of Procedures lie in the optimization of Adjustement to Losses, (DCS, SPC, hand) Information, Effective need maintenance 51 Σ 51 Level 1: Field Motivation, area 6/90 5/90 All measures Technical Increase of Lighting 5/59 = efficiencyengines 71 Σ 71 1,9% Systems /0 0/5 Avoiding Exchange of Efficiency Overdesigned Unefficient Increase Recovery of equipment motors of drives Mechanical 15/90 5/90 energy of drives /90 5/65 Example: production management Nat Gas Use of utilities/ energies - natural gas - cooling water - - compressed air How much? When? Base load? Peak load? Efficient use of equipment? 5

6 Nat Gas [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 1) Measure/ Record! Nat Gas R1 D1 V1 R D V M1 M Perform capacity analysis (i.e. batch mass balance): Detailed view of process possible Equipment utilization Basis for optimization 1) Measure/ Record! ) Analyze Nat Gas Steam consumption 1) Measure/ Record! ) Analyze ) Optimize [t/h] What is energy management? Time [h] Optimized process: Better equipment utilization Better energy efficiency of pumps and heat exchangers No more peak load: reduced energy price 6

7 What is energy management? Was ist Energiemanagement? Administrative law Policy measures Information/ Education (Energy labels,...) Market instruments Politics Market Conformance With (energy) laws Research of supply market Invest Procurement/ Metering, billing Reduction of Emissions: Invest vs. Buy CO certificates Feed in electricity Contracting Politics Market Conformance With (energy) laws Research of supply market - Value - Price - Costs - Make or Buy? - Suppliers - Market Commodity trade Network operator Invest Procurement/ Metering, billing - Demand planning, Load management - Prices for base load/ Peak load - Change of supplier - Smart Metering - Flexible tarifs Reduction of Emissions: Invest vs. Buy CO certificates Energy Feed in Exchange (EEX) Contracting - Energy supply - Energy efficiency - Finance & Lease - Operation management - Facility management Suppliers Metering-point operator Emissions trading (EU-ETS) Conclusions Thank you Energy Efficiency can be achieved on all levels of an enterprise Energy Efficiency must be seen as an integral task for the whole enterprise Increase of Energy Efficiency is a business process that needs to be initiated by management Thank you for your attention! 7