Energy Efficiency in Industry – How can I increase … · 2010-06-02 · Suggestions for next...
Transcript of Energy Efficiency in Industry – How can I increase … · 2010-06-02 · Suggestions for next...
Jens Wegmann CEO I ISPage 1
Energy Efficiency in Industry –How can I increase competitiveness in times of rising energy costs?
Jens Wegmann
CEO
Siemens Industry Solutions
Istanbul, Turkey – June 1, 2010
Jens Wegmann CEO I ISPage 2
Industry Sector – Industry Solutions Division
Metals Technologies Water Technologies Industrial Technologies
We create sustainable value for our customersby optimizing plant efficiency and productivity over the entire lifecycle.
New orders: €6.1 bn* Revenue: €6.8 bn* Profit: €360 m* Employees: ~31,000*
Industry Solutions is a leading solution and service provider for industrial and infrastructure facilities
* FY 2009 (as of September 30, 2009)
Water treatment
Water reuse
Wastewater treatment
Dewatering and residuals management
Mining
Iron making and Steel making
Casting and Rolling
Processing Lines
Metallurgical Services
Pulp and Paper
Cement
Marine Solutions
Infrastructure
Cross Industry
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Turkey10% reduction of energy intensity till 2015
compared to 2008
ChinaReduction of 20% energy usage per GDP by
2010
IndiaEnergy Conservation Act 2001: Establish norms
EU-15/WE+20% energy savings by 2020
Eastern Europe
20% energy savings by 2020
GermanyAgreement between the German government and energy-intensive industries to reduce their
energy consumption by 30%
CISRussia targets 40% energy savings by 2020
USA17% energy savings by 2020
Development of energy costs
0
2
4
6
8
10
12
14
16
18
20
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26
28
30
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2030202520202015200520001995199019851980
Coal
Natural gas
Petroleum
Electricity
2007
Source: IEA, Annual Energy Outlook
Public regulations
The economical and ecological significance of energy efficiency is increasing
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Worldwide energy consumption continues to rise
70
63
60
48
4
246
60
42
43
26
3
175
0 50 100 150 200 250 300
Total
Renewables
Electricity
Coal
Natural Gas
Liquids
Billiarden BTU
2006
2030
Source:
Derived from Energy Information Administration (EIA), International Energy Annual 2006 (June-December 2008).
Website www.eia.doe.gov. 2030: EIA, World Energy Projections plus (2009)
World industrial sector energy consumption by fuel
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Sustainable business requires green solutions for all three main elements of environmental management
Energy Efficiency1
Pollution Control2
Water Management3
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The Eco-Care Matrix supports the development of “Green Solutions” and Sustainable Engineering
Eco-Care Matrix (ECM)P
osit
ive E
nvir
on
men
tal
Imp
act
Customer Benefit (Productivity)
C
B
A
Reference
Grüne Lösung
B
C
Green Solution
Sustainable Engineeringnecessary
A
Source: I IS TI
Section A:
„Green Solutions“
Section B:
Advantage in productivity,
but disadvantage in
environmental Impact
(Eco Design)
Section C:Advantage in Environmental
Impact,
but Disadvantage in
Productivity
(Design-to-Cost)
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Optimized Process Technology: Endless Strip Production (ESP)
Green Solution
Continuous process gives the opportunity to use the heat
of the hot steel for the process instead of waste heat at a
batch driven process.
Steel Industry
Conventional
Hot strip
ESP
Environmental Impact
Optimized Production with ESP
Customer Benefit
Customer Benefit (Productivity)E
nv
iro
nm
en
tal Im
pact
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Optimized Process Technology: COREX/FINEX – hot metal producing technologies
Green Solution
Corex is an industrially and commercially proven
smelting-reduction process for the cost-efficient and
environmentally friendly production of hot metal from
iron ore and coal.Finex is an innovative iron making process for the
production of hot-metal based on the direct use of
iron-ore fines and non-coking coal.
Customer Benefit
Environmental Impact
Iron & Steel Industry
-1,0
0,0
1,0-1,00,01,0
Blast Furnace
COREX
FINEX
En
vir
on
men
tal Im
pact
Customer Benefit (Productivity)
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Optimized Component:HTS-Generators and Drives for ships
Green Solution
HTS-Technology is described by the following Benefits
against conventional technology:
compact design (weight, size)
higher efficiency rate (95% 98%)
higher torque overload (1,5 7,5)
Customer Benefit
Environmental Impact
Ship Industry
High-Temperature-Superconducting(HTS)
Conventional
YachtCruise Ship
Customer Benefit (Productivity)E
nv
iro
nm
en
tal Im
pact
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Optimized Component:Process water produced out of sea water
Green Solution
MED:
Using the waste heat from the steel plant for producing
process water out of sea water.
ED/CEDI is the most eco-efficient approach to generate
process water out of sea water (under development).
Customer Benefit
Environmental Impact
Water Industry
En
vir
on
men
tal Im
pact
Customer Benefit (Productivity)
MSF
ED/CEDI
RO
MED(CHP)
MEDMSF(CHP)
Multi-Effect Distillation (MED)
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Optimized Auxiliary Process: Reject Power – Energy instead of deposition
Green Solution
Using the heat of burned paper waste for electrical power
and heat generation instead of environmentally critical
deposition (example for W2E = Waste-to-Energy)
Customer Benefit
Environmental Impact
Pulp & Paper Industry
Deposition
Reject Power
Production Process with Reject Power
Customer Benefit (Productivity)E
nv
iro
nm
en
tal Im
pact
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We continuously expand our range of services
Energy systems and energy industry
Energy consultancy for manufacturing
facilities & buildings
Optimization of processes, machines
and systemsMeasurements and simulation analyses
Consultancy for energy purchase
Worldwide benchmark studies
Further training
International cooperation on development
Establishment of institutions for
the promotion of energy efficiency
and environmental protectionIdentification of “typical” energy
Development of suitable financing
models
Environ-mental protection &emissions trading
Support in preparing the application & the emission report
Setting up of monitoring methods &
introduction of monitoring systems
Development of a compliance strategy
Coaching of industrial plants in the
creation of energy concepts
International workshops and in-house seminars on the topics of energy
efficiency & climate protection
Training of energy auditors
offers consulting services in the
areas of energy and environment
has proven know-how in modern
practices, processes and systems
for industry and infrastructure, and possesses vast knowledge of the
national and international energy
and environmental policies
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Cooperation of Industry Solutions and Building Technologies in the area of energy optimization
TargetCustomer
Areas ofResponsibility per
customer
Siemens
Text
Text
Buildings (Industrial / Office) Production Assets&
Balanced energy consumption between
Offices Sites
= BT
Production Sites
= IS
Building (BT)
Production (IS)
Onsite
generation
CHP
New CHP and Solar PV solution as part of energy efficiency projects up to 3 MW are BT business
Building (BT)Onsite
generation
CHP
Office Site Production Site
e.g. automotive, discrete manufacturing, pharmaceuticals
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We create measurable customer benefits
Energy savings
1 Mio.
€/a
Energy cost reductionat a new installation
Energy savings
€ 460.000 /year
Improved energy efficiency
Mondi Packaging
Great Britain
TropicanaBelgium
Felix Schoeller jr.
Canada
- 5,5% €1 mio./year
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Our project partners –Customers who already trust us
(GER, CAN)
(GER)
(GER)
(GER)
(NDL)(A)
(UK)
(BEL)
(CZE, POL, ROM)
(UK)
(UK)
(TAW)
(GER)
(UK)
(BEL)
(TUR)
(TUR)
(TUR)
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Our holistic approach covers all areas of energy optimization of your industrial plant
GHG emissions
Waste heat
...
Onsite energy production
Energy
purchasing
(Power, gas, oil, …)
Energy
distribution
Drives
Water
Ventilation
…
Energy Data Collection and Archiving
Energy Supply Production Processes Output
Auxiliary Processes
Type of Business Operation, Maintenance, Logistics Subsidies
Electricity
Gas
Steam
Vacuum
Compressed air
...
Energy Forms
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Awareness Analysis Feasibility ImplementationPhase
Approach EnergyHealth Check
Alignment
Concept, ROI and Feasibility
Technical Realization and
Verification
Energy Efficiency Measures
Added Value
Energy Optimization of Drives (EoD)
(Technical analysis of electrical energy consumption)
Computer-based
interview of practiced
energy management
resulting in >80%
accuracy of savings
potential estimation
Energy Optimization Services (EOS)
(Energy-form-independent technical analysis)
Energy Optimization – Guiding mental and technical improvements in energy management
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If you don’t know the improvement potential within your facility,
we…
…raise the awareness for the optimization of your energy-related processes
…assess your energy management maturity level
…give you confidence to decide upon your next steps
…give a first estimation of the savings potential
Why Energy Health Check?Evaluation and benchmarking of all energy-related
aspects of your organization
The Energy Health Check provides an overview of the maturity level of your energy management
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Pre-Questionnaire One day on site Report
Plant tour
Interviews
Computer-assisted workshop with senior and middle management (plant manager, financial manager, energy manager, etc.)
Final evaluation
Detailed report to management
Our deliverables
5 Star Rating
Key action points for improvement
Estimated energy savings potential(accuracy >80%)
Industry-specific benchmark (database with more than 2,300 companies worldwide)
Suggestions for next steps
Fill out questionnaire
Estimated savings potential
Estimated and realized energy savings
0
500.000
1.000.000
1.500.000
2.000.000
2.500.000
3.000.000
Project 1 Project 2 Project 3 Project 4 Project 5 Project 6
minimum savings (EHC) maximum savings (EHC) realized savings (EOS)
During our Energy Health Check, we conduct in-depth interviews with your management
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The analysis phase is the starting point of our Energy Optimization Services
The analysis phase is the starting point of our Energy Optimization Services. It builds the basis for theimplementation phase by …
… identifying energy efficiency measures
… investigating the energy flows and GHG emissions of your plant
… assigning the energy consumption to its consumers
… estimating the costs and savings
… summarizing all results in a report
Why technical analysis? Assessment of …
Energy Data Collection and Archiving
Energy Supply
Production & Auxiliary Processes
Output(e.g. waste
heat)
All Energy Forms
Operation, Maintenance, Logistics
SubsidiesType of
Business
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The analysis phase is based on the on-site visit of our experts
Preliminary information
5 to 10 dayson-site analysis
Report
Pre-Questionnaire(complementary to
Health Check)
Analysis & evaluation of results
Estimation of savings potential
Definition of improvementmeasures
Report
Sankey Chart
Load Profile
Kälte über Außentemperatur Juni, Juli
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Kälte in KWh th
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Kälte über Außentemperatur Juni, Juli
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Our deliverables
Professional Analysis Graphical Analysis, Cost & Savings Estimation Report: Scenarios & Recommendations
EXAMPLE
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In close coordination with your maintenance and production departments and suppliers, we …
… prioritize the identified measures
… fine-tune the ROIs calculated during the analysis phase
… check the technical feasibility
… set up an implementation concept and schedule in coordination with your operations and maintenance
… submit binding offers from Siemens or selected suppliers
… offer a performance-based model
Why Feasibility Study?Feasibility Study
Concept & Schedule
Our Energy Optimization Services assess thefeasibility of the suggested improvement measures
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Our deliverables
Detailed technical & economic feasibility study
Overview of annual energy savings
Implementation concept
Report
20 to 100 days
- On-site - - Off-site -
Setting up a project team and steering
committee
Collecting additional necessary data
Prioritizing energy efficiency measures
Further site inspection and measurements
Regular alignment meetings
Evaluation and summary of feasibility results
Getting binding offers from Siemens or
selected suppliers (economic feasibility)
Implementation concept & schedule
Creation of report
Within 20 to 100 days, we provide a reliable feasibility study with implementation concept
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Technical Realization(Plant Engineering)
Training
Verification Cost Reduction
50 to 200 days
Implementation of all identified measures
Modernization of the facility
Setting up of sustainable improvement process
Training of your staff on the new equipment, processes, …
Verification of your energy cost reduction
Feedback & final report
During the implementation phase, we accompany you until your objectives are achieved
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A significant portion of electrical energy is consumed by drives.
If desired, you can order a focused analysis of your drive systems.
The process phases are in line with the Energy Optimization Services approach.
Why Energy Optimization of Drive Systems?
Analysis
Stochastic estimation of savings potential (free of charge
if motor list is provided)
First estimation of investment and ROI Report
Feasibility
Detailed technical and economic feasibility study
Preparation of an implementation concept
selection of suitable electrical components & project plan
Implementation
Project management, planning and engineering
Installation/assembly of frequency converters
Replacement of old technology by energy-saving systems
Optimization of the operating point and duration
Mechanical retrofitting for parts of the system (e.g. adjustment of pipe systems, lower-friction gaskets)
Constructional measures for better interconnection of
different energy types
1
2
3
Energy Optimization of Drive Systems is a service package specially customized to your drive systems
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Our main focus is to reduce your energy consumption sustainably - not on selling products
We have a holistic approach - we consider all energy-related processes and forms of energy (heat, compressed air, steam), maintenance, operations, monitoring, CO2
emissions, management-awareness, subsidies, etc.
With each phase our continuous improvement processadds value to your plant
You have the decision-taking authority – after each phase you decide whether to continue or not
We can offer a performance-based agreement where risks and benefits are shared
Depending on the case, we can offer financing solutions
Benefits from sustainable energy efficiency improvement and reduced CO2 emission
Jens Wegmann CEO I ISPage 27
Thank you for your attention.