Energy efficiency in industry Energy efficiency in industry
Energy efficiency in industry November 2008 Laurent LEVACHER EDF-R&D-ECLEERIndustry
1
Summary 1.
World energy context
2.
Energy saving potentialities in the world industry
3.
Energy efficiency in European industry
4.
EDF Group & ECLEER : how to proceed
5.
Examples : 5.1 Facilities & Examples : classic approach 5.2 Processes and heat recovery Æ required new approach Examples 5.3 Heat recovery with High Temperature Heat Pump
1. World energy context
3
Facing a major issue… World consumption trends in energy (Mescalito – medium scenario)
25
To be found! Renewables
Gtep
20
Nuclear Coal Gas Oil
15
- 0,5%
1,4%
?
1,9%
10 5
4,6%
« R&D » community will have to find new answers ! 4
2100
2090
2080
2070
2060
2050
2040
2030
2020
2010
2000
1990
1980
1970
1960
1950
0
2. Energy saving potentialities in the world industry
5
Final energy in industry /Total world (source Enerdata)
Background history
45%
40%
Industry : 1/3 of the final demand, slow decreasing 35%
20 07
20 05
20 03
20 01
19 99
19 97
19 95
19 93
19 91
19 89
19 87
19 85
19 83
19 81
19 79
19 77
19 75
19 73
19 71
30%
Gross Domestic Product World population
3Gtep
2004 main industry : 73% of total energy (France : 65%)
6
The growth of production of intermediate products since 25 years is specially cement and steel in China
The growth of chemical and paperboard is more in OECD (Europe and North America) 7
Chemical and petro-chemical industry : strong growth of demand, high use of energy
Strong growth of the final consumption (same growth GDP-PIB)
Half of the use for non energetic uses : intermediate products such as ethylene, aromatic products, ammoniac, … ¾ petrol (about 10% world consumpt.) ¼ natural gas
Petro-chemical industry and part of mineral chemical industry (chlorine, soda, …) are mainly localised in OECD countries. Not the same for ammoniac (mainly used for fertilizer and done with petrol, natural gas and coal) The energy represents 60% of the cost of fabrication, between 70 up to 90% for ammoniac 8
Cast Iron and steel : stabilization of the demand (400-600 kg per person per year), stabilization of the recycling Cost of half product in steel : 250-500 $/t, where energy represents 10-20% for iron scrap and 4070% iron ore (2005). In 2005 about 20% of the world production has been exported through maritime transportation Today half part of Iron is coming from recycling. Even the price of iron scrap increases, the ratio of recycling is about 85%.
Production d'acier 2005 en Mt 0
-Cast Iron and steel : obsolete processes in Russia, Ukraine Small sites and low quality of iron ore in China
Chine Japon USA Russie Corée Allemagne Ukraine Inde Reste du monde
9
100
200
300
400
Cement : demand per person, slow growth in OECD and strong growth in China
Cost of fabrication of cement : 35-50$/t, about 60% for energy (2005). Only 5% of world production change of country. 2005 : 46% of world cement product in China, then 6% in India.
Mainly the coal is used, except in Russia (natural gas) and in Europe (use of waste such as oil, carcasses, tyres, plastic, …) This increase in the world
Reduction of the ratio clinker to cement very different by country
10
Paper and paperboard : the demand should increase in China. The sector is very different country by country
50% of the needs of energy of the sector is given by the valorisation of waste (biomass and black liquor). In North America the sector uses co-generation. North America, China and Japan represent more than half of the world production. In 2007 : paper is between 500 and 1000 $/t. 25% of the expensive paper is exported Historically the consumption per person is proportional to GDP (PIB)
NAM
OCDE Asie-P. EU Chine CIS
11
Half part of the paperboard is recycled. Other way to valorise the product in end-life : incineration
Aluminium : three time more expensive than steel, same consumption in electrolyse of alumina everywhere, potential gain in recycling
Aluminium represent more than half part of the energy consumption of non ferrous. Cost of fabrication : about 1500 $/t, with 30% of energy. ¾ of the energy cost are for electrolyse of alumina, rest for calcination of bauxite. Only 7% of production has been exported in 2007 (growth).
12
Estimation of potential energy saving in energy intensive processes : between 13% and 19% of there primary energy consumption
Total potential primary energy saving by year : 300 à 400 Mtep
13
Estimation of potential energy saving in energy intensive processes : between 300 and 500 Mtep of there primary energy consumption
Electrical motors (pumps, fan, air compressed…) : variable speed and high efficiency : gain of 20 up to 25%
Cogeneration : about 50% Boilers and steam networks : gain of 10 up to 15%
Development of incineration of industrial wastes to use the energy 14
Improvement of the products after end-life : growth of recycling of paper, plastic, aluminium, …
Tools to optimise the processes, heat recovery, exergetique analyses, …
To conclude : the diffusion of the best practices should decrease the consumption of primary energy of 18% up to 26%
15
3. Energy efficiency in European industry
16
Energy consumption and CO2 emissions
Buildings 42% Agriculture
2%
Industry
24%
Transport
32%
Final energy used
37% Domestic 13% Other 21% Industry 29% Transport Source: DTI Dukes long term energy trends 2005
Buildings
28%
Agriculture
19%
Industry
23%
Transport
30%
17
CO2 equiv. emiss’n
27% Domestic 18% Other 28% Industry 28% Transport Source: DEFRA / AEA Energy & Environment 2005
Energy in industry in Europe
1/3
2/3
70%
of electricity consumption
of oil, gas, coal consumption
of energy used in heat production
Good progress in efficiency, potential for improvement still high More profitable and safe production practices, competitiveness 5 to 6% / year of equipment renewal
Identifying opportunities is still complex 18
Energy savings in industry : technical potential Compressed air and Plasturgy
15%–20% energy savings potential with existing technologies and dedicated energy management (80 TWh in France)
HEAT = 85%
Heat recovery 26%
Furnaces 20%
1% 1% Cold 3% Lighting 4% Motors 5% Drying 11%
Boilers 14%
HVAC 13%
known energy savings Boilers, furnaces, drying, heat recovery, HVAC 19
Energy savings potentials
Fundamentals of energy efficiency in 6 European countries Similar kind of industry, main activities split between : • Energy efficiency actions on boilers, cold, compressed air for approximately 50% of potentials • High efficiency industrial processes : furnaces and dryers (40%) • Development of energy management systems (10%)
Strong chemical industry and steel metallurgy, focus on : • Induction heating • Chemical processes
A strong materials industry (glass industry, ceramics, etc) • Heat recovery on furnaces • Heat exchangers optimisation • Energy management systems 20
4. EDF Group & ECLEER How to proceed ?
21
Energy Issue / EDF Group and Energy Efficiency New challenges: • Security of energy supply - Enduring pressure on hydrocarbons resources
• Acting against climate change
Energy efficiency set to be an important issue over the long term
Ambitious objectives by 2020: • Reducing CO2 emissions by 20% • Reducing energy consumption by 20% • Increasing renewable energy to 20%
EDF Group: active in energy efficiency 3 driving forces: 1. EDF Group values : sustainable developm’t 2. EU directives & French laws : obligations 3. EDF Group business : advice & services
22
ECLEER : context and objectives European Centre and Laboratories for Energy Efficiency Research In the context of a « post peak-oil » economy : CO2 emission reduction (factor 4 by 2050) Energy independence (imported fossil fuel)
EDF Group and two of its high level scientific partners: Ecole des Mines de Paris Ecole Polytechnique Fédérale de Lausanne
have decided to create an European research centre on energy efficiency : dedicated to buildings and industry … Main objectives 1 2
increase and speed up innovation gather complementary skills
For energy eco- efficiency 23
Industry : to federate different types of actors (exemples) Institutions Technological centers
… …
… … Induction InductionHUTTINGER, HUTTINGER, AJAX TOCCO MAGNETHERMIE,
ADEME ADEME
AJAX TOCCO MAGNETHERMIE, INDUCTOTHERM, GH ELECTROTERMIA, INDUCTOTHERM, GH ELECTROTERMIA, EFD, CELES, JUNKER, ATM EFD, CELES, JUNKER, ATM
GRETh GRETh … …
CETIAT CETIAT
CMV CMV
KMU, RIDEL KMU, RIDEL
CTP CTP NIZO NIZO
ControlControlcommand command EUROTHERM, AEG, AKA
CETIM CETIM
ENITIAA ENITIAA
CNRS CNRS (thermique) (thermique)
University Research centers 24
… …
SAS, STEIN, LBE, KROMSCHROEDER, TERMIDOR, ESPATHERM, TERMIDOR, ESPATHERM, SERTHEL et LETIGUEL SERTHEL et LETIGUEL
Aubert Aubert et Schneider et Duval Duval Schneider
LAGEP LAGEP
ARCELOR ARCELOR Padova Padova
KTH KTH
INRA INRA
Furnaces gas, Furnaces gas,elec elec SAS, STEIN, LBE, KROMSCHROEDER,
EUROTHERM, AEG, AKA
CTCPA CTCPA
INSA INSALyon Lyon EPFL EPFL Mines Minesde deParis Paris
Equipments manufacturers
Bel Bel
… … … …
R&D industry
Is industry really complex ? Ex. of an Energy flow mapping ENERGIES
Centralised Utilities
Cross-cutting Uses
Process Furnace
Fuel and coal
Gas
Boiler
Cogeneration Cold prduction Electricity Air compressor
Drying
m Stea
Cold Warehouse
Refrigeration se Compres dair
Motors
Lighting 25
Concentration
Premisses heating
Tool machine
ical n a h c Me force
EDF R&D research topics on main barriers Energy assessment and strategies (efficiency opportunities global, sub sectors and sites)
Energy management systems
Smart equipment
Induction heating systems
Tools and methods for energy audits (analysis and process rethinking, system oriented energy design, etc) 26
Cold production
High performance technologies for heat recovery
Reduce energy demand thru energy mgmt
Use highest performing energy systems Heat recovery, process integration
5.1. Facilities & examples, classic approach
27
The general methodology
Detection of savings on site
Calculation of savings generated + Financial balancing of Energy Saving Contract
1 4
Set up improvements on sites
2
3 Control for effective set up
(calculations, measurements) + Identification of problems and corrective actions
28
The usual “suspects” … Compressed air Heating, ventilation, air conditioning Refrigeration Boilers Heating processes (direct heating, induction, arc furnace,IR …) Combined heat and power production Electrical networks Drying incl. mechanical vapour recompression Lighting Water treatment Wastes treatment … 29
Example : heat recovery on compressed air Technical potential :
300 GWh/year
For lubricated screw compressors only (60% of installed equipments) Take into account a need for low temperature heat A part is already implemented
Achievable potential : 200 GWh/year Technical barrier : a need of heat has to be close to air compressor. Return on investment : >2 years for 20% of equipments
Annual market potential : Annual compressor sales : 7 to 8 % per year
30
Tools to optimize HVAC units OpTHUM : Optimization of energetical consumptions of a HVAC unit with Temperature and Humidity control
15 CONFIGURATIONS OF HVAC UNITS • Heating : gas boilers, hot water network, electrical heating • Cooling : refrigeration unit, thermofrigopump using subterranean water, thermofrigo-heatpump • Humidification : steam or water • Heat recovery on exhaust air : plate heat exchangers, exchangers with glycoled water, caloducs 31
Customer cases : automotive industry Examples of savings measures, approved and implemented (% of value base on 1,8 M€/year) Process: smelting – 2% Environment – 3% Cold – 3% Process: heating systems TTS – 3%
Water – 2%
Compressed air 25%
Process: cataphoresis – 4% Ventilation – 4%
Heating – 9%
Boiler systems 18%
Process: paint – 12% 32
EJP – 15%
Reduce energy demand
1
EDF R&D research topics on main barriers Energy Management
An example : Chocolate Manufacturer - 20% Energy Bill reduction < 1 year ! Return on investment
Focus on typical ratios, implantation of models for the main energy uses : compressed air, boiler, water
8-10% of energy savings for industry
Research and development on :
100 € Sensors and and data acquisition
Smart Systems with modelling of main energy uses : boilers, compressed air, cold production but also furnaces, HVAC,…
33
5. 2 Processes and heat recovery Æ required new approach Examples
34
Energy Minimal Required
Re
qu ire Fo d en r th erg ep y ro c ess
Product fabrication Refroidissement des moules Moules (55 ?C) Vulcanisation Latex (25 ?C) Vapeur 7,5 bar 230 ?C 4 t/h
Démoulage 80 ?C
Eau froide 70 l/h
Post Vulcanisation maintien à 100 ?C
Produit final
Refroidissement air ambiant
Matelas Latex humide 80 ?C
Vapeur 7,5 bar 230 ?C 2 t/h Matelas sec 98/100 ?C
Séchage série de 10 sécheurs
Air chaud
Rinçage eau froide
Essorage
Pré séchage
Total energy 35
es s s Lo
Use high efficiency systems
2
EDF R&D research topics on main barriers Use high efficiency systems
An example : optimisation of the production of aluminium heat exchangers for cars Energy consumption / 5 No scrap Compactness : 5 m compared to 35 m Electric Furnace replaced by an induction heating system for the an aluminium brazing application
Some MtCO2/year potential savings for industry in France with induction To heat metals … and food
X2 potential energy savings if we are successful Key : auto-adaptive multi-coil supply. It will give much more flexibility to induction heating, allowing it to automatically adapt to a wide range of products.
36
Recover heat losses
3
EDF R&D research topics on main barriers Waste Energy Recovery
An example : Milk concentration 80% of energy saved, < 1 year ! ROI
Produit
Vapeur comprimée
A 3 stages evaporator replaced by a Mechanical Vapour Recompression
Buées
Some MtCO2/year potential
Moteur
Compresseur de vapeur
savings with Heat recovery with heat pumps steel industry, heat treatment of steel, food industry, chemical industry Condensats
Research and development on : High temperature heat pumps for industry Higher COP Software to asses where are heat recovery potentials and cost effectiveness : exergy based modelling of industrial processes
37
Concentré
5.3 Heat recovery with High Temperature Heat Pump
38
Heat recovery on fluid Casing
Gas waste
Liquid waste
The final product
The energy is recovery on … Heat recovery after the process or the facilities
Exchangers smoke / water
Heat exchangers dirties
…
HP
Heat recovery « box »
Transportation or storage Conversion of energy at the level required
39
Main strategic sectors (Germany) (process and building warming)
Sectors under 80°C : 64 TWh +10°C Æ + 3 TWh
Sectors under 100°C +20°C Æ+ 44 TWh
Potentialities for heat pump in Germany industry under 100°C To replace 15% of the energy demand To replace 30% of the building warming To reduce of 6% the CO2 emission reduction 40
Priorities
3 main sectors Paper Food Chemical + metal, cars, plastic, textile
Buildings warming
41
2008 : to find new answers The energy cost increases and CO2 emissions have to be reduced Æ The solutions proposed in 1994 become more profitable
More constraints on refrigerant Objective : GWP < 150 New refrigerant and adapted compressors are required for high temperature
Î New opportunities for Industrial Heat Pump Technical investments become possible New sectors have to be involved
42
Thank you for your attention
1
Summary 1.
World energy context
2.
Energy saving potentialities in the world industry
3.
Energy efficiency in European industry
4.
EDF Group & ECLEER : how to proceed
5.
Examples : 5.1 Facilities & Examples : classic approach 5.2 Processes and heat recovery Æ required new approach Examples 5.3 Heat recovery with High Temperature Heat Pump
1. World energy context
3
Facing a major issue… World consumption trends in energy (Mescalito – medium scenario)
25
To be found! Renewables
Gtep
20
Nuclear Coal Gas Oil
15
- 0,5%
1,4%
?
1,9%
10 5
4,6%
« R&D » community will have to find new answers ! 4
2100
2090
2080
2070
2060
2050
2040
2030
2020
2010
2000
1990
1980
1970
1960
1950
0
2. Energy saving potentialities in the world industry
5
Final energy in industry /Total world (source Enerdata)
Background history
45%
40%
Industry : 1/3 of the final demand, slow decreasing 35%
20 07
20 05
20 03
20 01
19 99
19 97
19 95
19 93
19 91
19 89
19 87
19 85
19 83
19 81
19 79
19 77
19 75
19 73
19 71
30%
Gross Domestic Product World population
3Gtep
2004 main industry : 73% of total energy (France : 65%)
6
The growth of production of intermediate products since 25 years is specially cement and steel in China
The growth of chemical and paperboard is more in OECD (Europe and North America) 7
Chemical and petro-chemical industry : strong growth of demand, high use of energy
Strong growth of the final consumption (same growth GDP-PIB)
Half of the use for non energetic uses : intermediate products such as ethylene, aromatic products, ammoniac, … ¾ petrol (about 10% world consumpt.) ¼ natural gas
Petro-chemical industry and part of mineral chemical industry (chlorine, soda, …) are mainly localised in OECD countries. Not the same for ammoniac (mainly used for fertilizer and done with petrol, natural gas and coal) The energy represents 60% of the cost of fabrication, between 70 up to 90% for ammoniac 8
Cast Iron and steel : stabilization of the demand (400-600 kg per person per year), stabilization of the recycling Cost of half product in steel : 250-500 $/t, where energy represents 10-20% for iron scrap and 4070% iron ore (2005). In 2005 about 20% of the world production has been exported through maritime transportation Today half part of Iron is coming from recycling. Even the price of iron scrap increases, the ratio of recycling is about 85%.
Production d'acier 2005 en Mt 0
-Cast Iron and steel : obsolete processes in Russia, Ukraine Small sites and low quality of iron ore in China
Chine Japon USA Russie Corée Allemagne Ukraine Inde Reste du monde
9
100
200
300
400
Cement : demand per person, slow growth in OECD and strong growth in China
Cost of fabrication of cement : 35-50$/t, about 60% for energy (2005). Only 5% of world production change of country. 2005 : 46% of world cement product in China, then 6% in India.
Mainly the coal is used, except in Russia (natural gas) and in Europe (use of waste such as oil, carcasses, tyres, plastic, …) This increase in the world
Reduction of the ratio clinker to cement very different by country
10
Paper and paperboard : the demand should increase in China. The sector is very different country by country
50% of the needs of energy of the sector is given by the valorisation of waste (biomass and black liquor). In North America the sector uses co-generation. North America, China and Japan represent more than half of the world production. In 2007 : paper is between 500 and 1000 $/t. 25% of the expensive paper is exported Historically the consumption per person is proportional to GDP (PIB)
NAM
OCDE Asie-P. EU Chine CIS
11
Half part of the paperboard is recycled. Other way to valorise the product in end-life : incineration
Aluminium : three time more expensive than steel, same consumption in electrolyse of alumina everywhere, potential gain in recycling
Aluminium represent more than half part of the energy consumption of non ferrous. Cost of fabrication : about 1500 $/t, with 30% of energy. ¾ of the energy cost are for electrolyse of alumina, rest for calcination of bauxite. Only 7% of production has been exported in 2007 (growth).
12
Estimation of potential energy saving in energy intensive processes : between 13% and 19% of there primary energy consumption
Total potential primary energy saving by year : 300 à 400 Mtep
13
Estimation of potential energy saving in energy intensive processes : between 300 and 500 Mtep of there primary energy consumption
Electrical motors (pumps, fan, air compressed…) : variable speed and high efficiency : gain of 20 up to 25%
Cogeneration : about 50% Boilers and steam networks : gain of 10 up to 15%
Development of incineration of industrial wastes to use the energy 14
Improvement of the products after end-life : growth of recycling of paper, plastic, aluminium, …
Tools to optimise the processes, heat recovery, exergetique analyses, …
To conclude : the diffusion of the best practices should decrease the consumption of primary energy of 18% up to 26%
15
3. Energy efficiency in European industry
16
Energy consumption and CO2 emissions
Buildings 42% Agriculture
2%
Industry
24%
Transport
32%
Final energy used
37% Domestic 13% Other 21% Industry 29% Transport Source: DTI Dukes long term energy trends 2005
Buildings
28%
Agriculture
19%
Industry
23%
Transport
30%
17
CO2 equiv. emiss’n
27% Domestic 18% Other 28% Industry 28% Transport Source: DEFRA / AEA Energy & Environment 2005
Energy in industry in Europe
1/3
2/3
70%
of electricity consumption
of oil, gas, coal consumption
of energy used in heat production
Good progress in efficiency, potential for improvement still high More profitable and safe production practices, competitiveness 5 to 6% / year of equipment renewal
Identifying opportunities is still complex 18
Energy savings in industry : technical potential Compressed air and Plasturgy
15%–20% energy savings potential with existing technologies and dedicated energy management (80 TWh in France)
HEAT = 85%
Heat recovery 26%
Furnaces 20%
1% 1% Cold 3% Lighting 4% Motors 5% Drying 11%
Boilers 14%
HVAC 13%
known energy savings Boilers, furnaces, drying, heat recovery, HVAC 19
Energy savings potentials
Fundamentals of energy efficiency in 6 European countries Similar kind of industry, main activities split between : • Energy efficiency actions on boilers, cold, compressed air for approximately 50% of potentials • High efficiency industrial processes : furnaces and dryers (40%) • Development of energy management systems (10%)
Strong chemical industry and steel metallurgy, focus on : • Induction heating • Chemical processes
A strong materials industry (glass industry, ceramics, etc) • Heat recovery on furnaces • Heat exchangers optimisation • Energy management systems 20
4. EDF Group & ECLEER How to proceed ?
21
Energy Issue / EDF Group and Energy Efficiency New challenges: • Security of energy supply - Enduring pressure on hydrocarbons resources
• Acting against climate change
Energy efficiency set to be an important issue over the long term
Ambitious objectives by 2020: • Reducing CO2 emissions by 20% • Reducing energy consumption by 20% • Increasing renewable energy to 20%
EDF Group: active in energy efficiency 3 driving forces: 1. EDF Group values : sustainable developm’t 2. EU directives & French laws : obligations 3. EDF Group business : advice & services
22
ECLEER : context and objectives European Centre and Laboratories for Energy Efficiency Research In the context of a « post peak-oil » economy : CO2 emission reduction (factor 4 by 2050) Energy independence (imported fossil fuel)
EDF Group and two of its high level scientific partners: Ecole des Mines de Paris Ecole Polytechnique Fédérale de Lausanne
have decided to create an European research centre on energy efficiency : dedicated to buildings and industry … Main objectives 1 2
increase and speed up innovation gather complementary skills
For energy eco- efficiency 23
Industry : to federate different types of actors (exemples) Institutions Technological centers
… …
… … Induction InductionHUTTINGER, HUTTINGER, AJAX TOCCO MAGNETHERMIE,
ADEME ADEME
AJAX TOCCO MAGNETHERMIE, INDUCTOTHERM, GH ELECTROTERMIA, INDUCTOTHERM, GH ELECTROTERMIA, EFD, CELES, JUNKER, ATM EFD, CELES, JUNKER, ATM
GRETh GRETh … …
CETIAT CETIAT
CMV CMV
KMU, RIDEL KMU, RIDEL
CTP CTP NIZO NIZO
ControlControlcommand command EUROTHERM, AEG, AKA
CETIM CETIM
ENITIAA ENITIAA
CNRS CNRS (thermique) (thermique)
University Research centers 24
… …
SAS, STEIN, LBE, KROMSCHROEDER, TERMIDOR, ESPATHERM, TERMIDOR, ESPATHERM, SERTHEL et LETIGUEL SERTHEL et LETIGUEL
Aubert Aubert et Schneider et Duval Duval Schneider
LAGEP LAGEP
ARCELOR ARCELOR Padova Padova
KTH KTH
INRA INRA
Furnaces gas, Furnaces gas,elec elec SAS, STEIN, LBE, KROMSCHROEDER,
EUROTHERM, AEG, AKA
CTCPA CTCPA
INSA INSALyon Lyon EPFL EPFL Mines Minesde deParis Paris
Equipments manufacturers
Bel Bel
… … … …
R&D industry
Is industry really complex ? Ex. of an Energy flow mapping ENERGIES
Centralised Utilities
Cross-cutting Uses
Process Furnace
Fuel and coal
Gas
Boiler
Cogeneration Cold prduction Electricity Air compressor
Drying
m Stea
Cold Warehouse
Refrigeration se Compres dair
Motors
Lighting 25
Concentration
Premisses heating
Tool machine
ical n a h c Me force
EDF R&D research topics on main barriers Energy assessment and strategies (efficiency opportunities global, sub sectors and sites)
Energy management systems
Smart equipment
Induction heating systems
Tools and methods for energy audits (analysis and process rethinking, system oriented energy design, etc) 26
Cold production
High performance technologies for heat recovery
Reduce energy demand thru energy mgmt
Use highest performing energy systems Heat recovery, process integration
5.1. Facilities & examples, classic approach
27
The general methodology
Detection of savings on site
Calculation of savings generated + Financial balancing of Energy Saving Contract
1 4
Set up improvements on sites
2
3 Control for effective set up
(calculations, measurements) + Identification of problems and corrective actions
28
The usual “suspects” … Compressed air Heating, ventilation, air conditioning Refrigeration Boilers Heating processes (direct heating, induction, arc furnace,IR …) Combined heat and power production Electrical networks Drying incl. mechanical vapour recompression Lighting Water treatment Wastes treatment … 29
Example : heat recovery on compressed air Technical potential :
300 GWh/year
For lubricated screw compressors only (60% of installed equipments) Take into account a need for low temperature heat A part is already implemented
Achievable potential : 200 GWh/year Technical barrier : a need of heat has to be close to air compressor. Return on investment : >2 years for 20% of equipments
Annual market potential : Annual compressor sales : 7 to 8 % per year
30
Tools to optimize HVAC units OpTHUM : Optimization of energetical consumptions of a HVAC unit with Temperature and Humidity control
15 CONFIGURATIONS OF HVAC UNITS • Heating : gas boilers, hot water network, electrical heating • Cooling : refrigeration unit, thermofrigopump using subterranean water, thermofrigo-heatpump • Humidification : steam or water • Heat recovery on exhaust air : plate heat exchangers, exchangers with glycoled water, caloducs 31
Customer cases : automotive industry Examples of savings measures, approved and implemented (% of value base on 1,8 M€/year) Process: smelting – 2% Environment – 3% Cold – 3% Process: heating systems TTS – 3%
Water – 2%
Compressed air 25%
Process: cataphoresis – 4% Ventilation – 4%
Heating – 9%
Boiler systems 18%
Process: paint – 12% 32
EJP – 15%
Reduce energy demand
1
EDF R&D research topics on main barriers Energy Management
An example : Chocolate Manufacturer - 20% Energy Bill reduction < 1 year ! Return on investment
Focus on typical ratios, implantation of models for the main energy uses : compressed air, boiler, water
8-10% of energy savings for industry
Research and development on :
100 € Sensors and and data acquisition
Smart Systems with modelling of main energy uses : boilers, compressed air, cold production but also furnaces, HVAC,…
33
5. 2 Processes and heat recovery Æ required new approach Examples
34
Energy Minimal Required
Re
qu ire Fo d en r th erg ep y ro c ess
Product fabrication Refroidissement des moules Moules (55 ?C) Vulcanisation Latex (25 ?C) Vapeur 7,5 bar 230 ?C 4 t/h
Démoulage 80 ?C
Eau froide 70 l/h
Post Vulcanisation maintien à 100 ?C
Produit final
Refroidissement air ambiant
Matelas Latex humide 80 ?C
Vapeur 7,5 bar 230 ?C 2 t/h Matelas sec 98/100 ?C
Séchage série de 10 sécheurs
Air chaud
Rinçage eau froide
Essorage
Pré séchage
Total energy 35
es s s Lo
Use high efficiency systems
2
EDF R&D research topics on main barriers Use high efficiency systems
An example : optimisation of the production of aluminium heat exchangers for cars Energy consumption / 5 No scrap Compactness : 5 m compared to 35 m Electric Furnace replaced by an induction heating system for the an aluminium brazing application
Some MtCO2/year potential savings for industry in France with induction To heat metals … and food
X2 potential energy savings if we are successful Key : auto-adaptive multi-coil supply. It will give much more flexibility to induction heating, allowing it to automatically adapt to a wide range of products.
36
Recover heat losses
3
EDF R&D research topics on main barriers Waste Energy Recovery
An example : Milk concentration 80% of energy saved, < 1 year ! ROI
Produit
Vapeur comprimée
A 3 stages evaporator replaced by a Mechanical Vapour Recompression
Buées
Some MtCO2/year potential
Moteur
Compresseur de vapeur
savings with Heat recovery with heat pumps steel industry, heat treatment of steel, food industry, chemical industry Condensats
Research and development on : High temperature heat pumps for industry Higher COP Software to asses where are heat recovery potentials and cost effectiveness : exergy based modelling of industrial processes
37
Concentré
5.3 Heat recovery with High Temperature Heat Pump
38
Heat recovery on fluid Casing
Gas waste
Liquid waste
The final product
The energy is recovery on … Heat recovery after the process or the facilities
Exchangers smoke / water
Heat exchangers dirties
…
HP
Heat recovery « box »
Transportation or storage Conversion of energy at the level required
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Main strategic sectors (Germany) (process and building warming)
Sectors under 80°C : 64 TWh +10°C Æ + 3 TWh
Sectors under 100°C +20°C Æ+ 44 TWh
Potentialities for heat pump in Germany industry under 100°C To replace 15% of the energy demand To replace 30% of the building warming To reduce of 6% the CO2 emission reduction 40
Priorities
3 main sectors Paper Food Chemical + metal, cars, plastic, textile
Buildings warming
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2008 : to find new answers The energy cost increases and CO2 emissions have to be reduced Æ The solutions proposed in 1994 become more profitable
More constraints on refrigerant Objective : GWP < 150 New refrigerant and adapted compressors are required for high temperature
Î New opportunities for Industrial Heat Pump Technical investments become possible New sectors have to be involved
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Thank you for your attention
