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TEM Food and Drink Industry, 26th of March 2012
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Jürgen FluchAEE – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA
EINSTEIN Software and Method
EINSTEIN
Methodology and tool for a fast energy assessment
TEM Food and Drink Industry, 26th of March 2012
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Overview
� Introduction
� EINSTEIN: Idea and approach
� EINSTEIN: software
� EINSTEIN: method
� EINSTEIN: results
present state �������� proposals
� EINSTEIN: energy audits
TEM Food and Drink Industry, 26th of March 2012
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Energy consumption in EU27
� 25% of final energy consumption in EU27 (2006)
for space heating and cooling in buildings
� 28% of final energy consumption in EU27 (2006)
for industry
� 69.5% of final energy consumption in industry
for heat production
� 57% at low and medium temperature levels
at 400°C and less
Strategic Energy Review 2008; Quelle: EurostatData für 2003, 32 Länder: Quelle: ECOHEATCOOL (IEE ALTENER Project)
TEM Food and Drink Industry, 26th of March 2012
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Energy saving targets
� EU-targets by 2020 (20-20-20):
� Reduction of emissions by 20%
� Increase of energy efficiencies by 20%
� Increase of the use of renewable energies up to 20%
TEM Food and Drink Industry, 26th of March 2012
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??
Energy costs[€/a]
Real data of an Austrian brewery, 2008
Increasing energy costs
Energy demand [MWh/a]
201520082000 2006
TEM Food and Drink Industry, 26th of March 2012
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-25%
-25%
savings
Alternative proposal: reduction of energy demand
Energy costs[€/a]
Reduction of energy demand
Energy demand [MWh/a]
TEM Food and Drink Industry, 26th of March 2012
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Areas of application
�Industries and SMEs with large thermal energy
demand at low & medium temperature up to 400ºC
�Manufacturing sectors:
� Food industry,
� Breweries,
� Pharmaceutical, chemical,
� Pulp & paper,
� Textile,…
TEM Food and Drink Industry, 26th of March 2012
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Areas of application
�But also other medium and large scale consumers
of heat and cold:
� Large buildings (e.g. commercial centres, hospitals,
offices,...)
� District heating and cooling networks
� Other (e.g. desalination, etc.)
TEM Food and Drink Industry, 26th of March 2012
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Challenges in energy audits
� Optimised supply of thermal energy in industry is
complex:
� Developed infustructure in the industry without real data
available (esp. SME)
� Averaged data for different periods
� Cost and time consuming measurements necessary
� Processes at different temperature levels and different
operating times have to be integrated and combined
� Combination of different heat supply technologies for an
optimised energy supply
� High acquisition and evaluation demand while the
potentials can hardly be foreseen
TEM Food and Drink Industry, 26th of March 2012
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Approach of EINSTEIN (1)
� Development of a fast-audit to estimate
potentials
� Standardised data acquisition, modeling and audit steps
� Automated background calculations
� Holistic vision of energy supply and demand
� Process optimisation ���� demand reduction
measures
� Heat recovery
� Intelligent combination of heat and cold supply
technologies
� Implementation of renewables
TEM Food and Drink Industry, 26th of March 2012
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EINSTEINLOW COST THERMAL
AUDITS
-- easily affordable for SMEs-- high quality-- reliable-- user friendly
Standardisation• Standardised procedure• Standard process models• Standard modules for heat supply systems• Consideration of all
available energy efficienttechnologies
“Quick & dirty” fast estimation of missing data
• Tools for obtaining a complete data set based on fragmented and incomplete information
Semi-automated• Guided audit procedure• Decision aids for proposal generation• Automatic energy, economic, &
environmental evaluation• Automatic generation of reports
Data submission by distance• Fast audits based on data delivered via
email or questionnaire• Possibility of self assessment
Approach of EINSTEIN (2)
TEM Food and Drink Industry, 26th of March 2012
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Holistic vision…
Demand reduction
Process optimisation
Heat recovery and process integration
Heat exchangersPINCH-analysis
Heat exchanger networks
Thermal chillers and heat pumps
PolygenerationElectricity, Heat & Cold
CHP & trigeneration(engines, turbines, fuel cells)
RES
Efficient heat & coldsupply
Efficient equipment(boilers, burners, chillers)
No use of electricity for thermal processes
Heat and cold networks Efficient distribution(steam, etc.)
solar thermal
biomass
Approach of EINSTEIN (3)
TEM Food and Drink Industry, 26th of March 2012
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� Analysis of energy demand and availability in
terms of
� QUANTITY of energy
� QUALITY of energy - temperature
� Einstein enables evaluation of potential for
� heat recovery
� application of more efficient technologies at lower
temperature
Approach of EINSTEIN (4)
TEM Food and Drink Industry, 26th of March 2012
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10 EINSTEIN audit steps
Preliminary contacts: Inform and motivate
Pre - audit data acquisition
Processing of preliminary information
“Quick&Dirty” preliminary evaluation
On - site walk - through energy audit OR Detailed by - distance data acquisition
Analysis of the Status quo
Energy performance calculation & environmental anal ysis
Economic and financial analysis
Reporting and presentation of the proposal to the c ompany
Conceptual design of saving options and preliminary energy targets definition
PR
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ALU
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Of
ALT
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TEM Food and Drink Industry, 26th of March 2012
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REPORTING
DATA ACQUISITION(QUESTIONNAIRE)
CONSISTENCY CHECK
ENERGY STATISTICS
BENCHMARKING
PROCESS OPTIMISATION
HEAT RECOVERY
HEAT&COLD SUPPLY SYSTEMS
ENERGY AND ENVIRONMENTAL PERFORMANCES
ECONOMIC ANALYSIS
ALTERNATIVES COMPARISON
DATA ANALYSIS
ALTERNATIVEPROPOSALS:
DESIGN
ALTERNATIVEPROPOSALS:EVALUATION
REPORT
DATA ACQUISITION AND CHECK
Software
TEM Food and Drink Industry, 26th of March 2012
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EIN LEGEND
Heat recovery system
Heat & cold supply(“Equipments”)
Distribution & Storage(“Pipes”)
Processes
thermal energy flows (heat & cold)
available waste heat(from source)
external energy input
ConnectionPipes - Processes
ConnectionEquipes - Pipes
ConnectionsFuels/Elect. - Equipes
Final energy input
Waste Heat from Electrical Equipment
recovered waste heat (to sink)
connections of sub-systems
FETj
FETi
USHj
USHPipem
UPHk
QHXProc
QHXPipe
QHXEq
QWHQHX
QWHWHEE
QWHProc
QWHPipe
UPHProcm
QWHEq
Model of an energy system in EINSTEIN
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Model of the process
h po1r
Internal heatrecovery
Heating of circulating fluid
Heating of bath or oven
A
B
qm , i1
mc p
qm , o1
Thermal losses(UA)
h pi2
Thermal mass( )
T env
T pi1r
T po1
T po2r
T pi1
T p
T ps
T ps
T po2
qm , i2T pi2rT pi2 qm , o2
h po2r
T po1r
T pt1h pi1
h pi2r
h pi1r
T pt2
h po2
h po1
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – evaluation of the present state (1)
� Primary energy
consumption
� Total
� By fuel
� By equipment
TEM Food and Drink Industry, 26th of March 2012
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� Heat and cold demand
� By processes
� By temperature levels
� By time demand
EINSTEIN – evaluation of the present state (2)
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – results of a brewery
Presentstate
Saving
Primary energy consumption [MWh] 47,620 11,685
fuels [MWh] 20,020 -
electricity [MWh] 27,600 11,685
Share of renewable energy [%] - -
CO2 emissions[tons/a
]11,905 1,852
Investment costs [EUR] -
Payback period [years]
� Case study brewery
� 2 proposals evaluated
� 1 presented as final proposal
FET by equipment
UPH by process
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – heat recovery (1)
� Goal:
� Theoretical potential of energy savings by heat recovery
(prior to energy supply systems design)
� Save fuels and avoid over-dimensioning of supply
equipment
� Heat recovery potential
� Analysis of a minimal external heat and cold demand
� Potential for heat recovery
� Design of a heat exchanger network
� Design and optimisation of a heat exchanger network
� Reduced energy demand and required temperature level
as basis for exergetic optimised integration of heat and
cold supply
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – heat recovery (2)
� Method: Pinch-Analysis
� Hot and cold composite curves
� Grand composite curve
� Results
� Theoretical heat recovery potential
� Necessary external heat/cold supply at the different
temperature levels
TEM Food and Drink Industry, 26th of March 2012
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Pinch Analysis
� Hot and cold composite curve
� Pinch temperature – separation
of production system in two
halves:
• Above pinch – no cooling is
necessary
• Below pinch – no heating is
necessary
• No energy should be
transferred across the pinch
(efficient thermodynamic use
of energy)
Temperature [°°°°C]
Power [kJ/s]
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – results (1)
BE
FO
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AF
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Less heat
wasted
Waste heat recovered and used as input
Reducedexternal
input
energy input
reduced
Reduced energy demand
Non-renewable
share decreased
Renewable share
increased
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN – results (2)
� Comparison present state
and proposals
� Primary energy consumption
� Energetical evaluation
� Environmental evaluation
� Economical evaluation
� Report generation
TEM Food and Drink Industry, 26th of March 2012
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EINSTEIN - outlook
� EINSTEIN II:
� Performance of 72 energy audits in 10 European countries
(Austria, Germany, United Kingdom, Spain, Italy, France,
Luxembourg, Ireland, Slovakia, Bulgaria)
� Introductory and advanced trainings for energy
consultants and auditors in all named participating
countries
� National projects within additional audits are
performed
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EINSTEIN
�EINSTEIN is a free open source
software based on a GPL Lizenz:
•www.sourceforge.net/proje
cts/einstein
�EINSTEIN is independent from the
operating system
•Using Linux, Unix, Windows..
Source: http://solarenergie-investment.de/Dachborse.htm
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Jürgen Fluch
j.fluch@aee.atAEE – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA
EINSTEIN Software and Method
EINSTEIN
Methodology and tool for a fast energy assessment