Efficiency in industry through electro-technologies

Paul Baudry, EDF / R&D

The future of Energy in Enlarged Europe, Warsaw 7-8th october 2004

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Outline

• European policy related to energy efficiency

• Energy efficiency and electricity

• The influence of energy accounting system

• Efficient electro-technologies in industry

• Conclusion

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European policy on energy efficiency

Drivers- Reduction of greenhouse gas emissions

- Security of energy supply

Target- Annual energy savings : 1% of final energy

European directives- Proposal for a Directive on energy end-use efficiency and

energy services

- Directive on energy efficiency in buildings

- Directive on Integrated Prevention and Pollution Control

- Directive on tradable CO2 emission permits

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Global Trends in Energy use : 1970-2000

The manufacturing sector (industry) exhibits the highest energy intensity decrease

Source : 30 years of energy use in IEA countries

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Global Trends in Energy useTotal final energy consumption by fuel

Source : 30 years of energy use in IEA countries

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Energy Efficiency and electricity As global energy intensity decreases, electricity grows with GDP

OCDE

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197119751979198319871991199519992003200720112015201920232027

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OCDE

GDP US$95

Electricity

Mobility

Thermal stationary

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Energy accounting system primary and final energy

ELECTRICITY

PRODUCT OR SERVICE

FOSSIL ENERGY(coal, oil, gas)

NON FOSSIL ENERGY(nuclear,hydro, Ren. En.)

Ren. Heat

Life Cycle Assessment (LCA) is the accurate method for energy accounting

Two main LCA impact indicators for energy efficiency :- primary energy consumption- CO2

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Usual conventional coefficient for primary energy to electricity conversion : ~2.5

This coefficient is an average of the different power generation systems

IEA convention for final to primary energy conversion :- 33% for nuclear- electricity / fossil fuel : energy content for coal and gas

power generation systems- 100 % for renewable energy

Accurate final to primary energy coefficient are different in each country and for each electricity supplier

Energy accounting system primary and final energy

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Energy accounting system CO2 emissions for power generation with Life Cycle Assessment

Power Generation system

CO2 content

(g CO2 / kWh)

Nuclear 5

Hydro 6

Coal 1000

Wind 15 - 20

Gas Turbine (Combined Cycle)

450

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Energy Efficiency through Electro-technologies in various industrial sectors

Sector Established Efficient Electro-technologies

Emerging Efficient Electro-technologies

Food industry - MVC (liquid concentration) - Membranes (separation) - Electric Tubular Heat Exchanger - Heat Pump (heat and cold)

- High Electric Pulse Fields - High Pressure - Ohmic Heating

Chemical industry

- Motors for basic chemicals (v.s. turboengines) - heating in small processes (resitances and induction) - Electric Tubular Heat Exchanger

- Membranes in refineries and - Electrosynthsis - Ohmic heating - Immersion heater

Metals -Electric Arc Furnace (steelmaking) - Induction in foundry - Resistance ovens (Thermal treatments) - Heat pumps

- MVC for liquid effluents - Recycling with arc furnace - Vacuum furnace

Waste management industry

- Electrofilters - MVC - Heat pump (drying)

- Cold plasmas for VOC treatment - induction on activated carbon for VOC treatment - MVC - Membranes - Arc furnace for vitrification

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Final Energy Efficiency through Electro-technologies

ReplacementTechnology

Consumption –fossil fuel plant

(GWh)

Consumption – replacement plant

(GWh)

Compared utilisation efficiency

Membranes 385 35 10-12

MVC + Heat Pumps

3.220 460 6-8

Induction 6.750 2.700 2-3

µW + HF + UV 585 260 2-2,5

IR 725 415 1,5-2

Motors 2.465 1.700 1,3-1,6

Resistance 11.640 9.700 1,1-1,3

TOTAL 25.770 15.270 1,1-12

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Energy Efficiency through Electro-technologies Steelmaking industry

Fossil Energy route Electric route

Technology Blast furnace Electric Arc Furnace

Raw materials Iron ore « Scraps » (+ DRI + pig iron)

Quality High Depends on scraps quality

Investment cost High Much lower

Flexibility Low High

CO2 emission 2 tCO2/tsteel 0.1 t CO2/tsteel

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Energy Efficiency through electro-technologiesVarious energy system solutions for the same end use

Energy source

Same end-use demand (MWh)

Cumulated Energy Demand (CED)

Electricity from grid +Heat from fossil fuel

Electricity (light, motors)Heat (process)

100

100

1 MWh th = 0,086 tep1 MWh e = 0,086 / 40% (electricity generation) / 90% (grid loss)

CED = 23,9 + 8,6 = 32,5 tepCHP from gas(non seasonal)

Electricity (light, motors)Heat (process)

100

100

1 kWh e = 0,086 / 66% (average generation efficiency by CHP)

CED = 13 + 13 = 26 tep

Electricity from grid> 90% Fossil mix

Electricity (light, motors)Efficient electric process

100<50

1 MWh e = 0,086 / 40% (electricity generation) / 90%(grid loss)

CED = 23,9 + 11,9 = <35,8 tep

Electricity from gridRenewable / NFF

Electricity (light, motors) Efficient electric process

100<50

1 MWh e = 0,086 // 90% (grid loss)

CED = 9,5 + 4,8 = <14,3 tep

Electricity from gridcurrent mix

Electricity (light, motors) Efficient electric technique

10025

1 MWh e = 0,086 / 52% (electricity generation) / 90% (grid loss)

CED = 18,4 + 4,6 = 23 tep

1 MWh th = 0.086 tep

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Conclusion

• During the 30 last years, the use of electricity has grown while energy intensity was decreasing in IEA countries

• The energy efficiency can be evaluated by an LCA approach with two main impact indicators : primary energy and CO2 emissions

• Final to primary energy coefficient and CO2 emissions depend strongly on power generation systems, then on the geographic location and on the electricity suppliers

• Electro-technologies in industry can contribute significantly to improve energy efficiency

• Electricity is a secondary but flexible energy. Industrial processes need this flexibility which helps to increase productivity and product quality.