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Energy Management Systems:

2017/2018

Energy & Material Services

Industrial Energy Use

SGCIE

Prof. Tânia Sousa

[email protected]

• SGCIE (DL 71/2008) – Sistema de Gestão dos

Consumos Intensivos de Energia (Energy

Management System for Intensive Energy Consumers)

– It promotes energy efficiency for big primary

energy consumers

– It promotes clean primary energy fuels mix

SGCIE

Energy Management

Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE

SGCIE

• Domain of Application

– All entities with an annual primary energy consumption higher than 500 toe (1 toe = 41868 MJ)

– Exceptions: Cogeneration facilities, transport entities and buildings

• Supervision

– DGEG

• Management

– ADENE

Energy Management


Energy Management


SGCIE

• Obligations (for IEC entities)

– Promote the registration of facilities

– Perform Energy Audits

• Every 6 years for entities 1000 toe

• Every 8 years for entities from500 to 1000 toe

Energy Management


SGCIE


– Develop Energy Racionalization Plans

• Every measure with payback lower than 5 years must be implemented in the first 3 years for entities 1000 toe

• Every measure with payback lower than 3 years must be implemented in the first 3 years for entities from 500-1000 toe

Energy Management


SGCIE


– Develop Energy Racionalization Plans

• Energy Intensity must decrease 6% in 6 years for entities 1000 toe

• Energy Intensity must decrease 4% in 8 years for entities from 500 to 1000 toe

Energy Management


SGCIE

• What is the relationship between the Energy Intensity obtained using the definition in SGCIE and the energy specific consumption obtained with the block diagrams methodology?

Operation Am2

m3

mR

EA

Materials

lnput Production

Energy

consumption

Residues

m1 3 A 1 23

3 3

E E +E +ECE = =

m m

Energy Management


SGCIE

• The Energy Intensity obtained using thedefinition in SGCIE is the same obtained with theblock diagrams methodology if:

– The energy specific consumptions of the inputs is zero

8 (produção 1)A

C

D

E

B2

1

F

G 1413

1211

Electricity

Fueloil

Energy Management


Embodied energy

• Cumulative amount of commercial energy invested to extract, process and manufacture a product and transport it to its point of use.

– The energy used indirectly might be more important that the energy used directly

Auto-industry assembly line

Electricity

Paint

Embodied energy in a car: 270 GJ

Energy Management


SGCIE


– Develop Energy Rationalization Plans

• The carbon intensity must not increase

– Why a goal on carbon intensity?

Energy Management


SGCIE


– Develop Energy Rationalization Plans

• The carbon intensity must not increase

– Why a goal on carbon intensity?

• Promote less polutant energy mixes (do not increase energy efficiency by replacing less polutant energy forms with more polutant ones)

Energy Management


SGCIE

• Conversion coefficients for CO2 emissions and

primary energy

– Despacho nº 17313/2008

SGCIE

• Conversion coefficients for CO2 emissions and

primary energy

– For primary fuels:

SGCIE

• Conversion coefficients for primary energy

– For electricity (in kWh per toe)?

BALANÇO ENERGÉTICO

tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricida

de

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729

Thermoelectricity produced with coal, oil,

natural gas, biomass, urban waste and biogas

SGCIE


– For electricity:


tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricida

de

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729



06

2 325 57045%

2 444 703 475 571+1 970 751 61 957+1 82 765+1 9 729

0.45 41868kWh

0.45toe 0.45 41868MJ 3.6 5234kWh toe1toe toe toe

1kWh needs 191 10 toe

SGCIE



– What would happen to this coefficient if we

consider cogeneration?


tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricida

de

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729



06

2 325 57045%

2 444 703 475 571+1 970 751 61 957+1 82 765+1 9 729

0.45 41868kWh

0.45toe 0.45 41868MJ 3.6 5234kWh toe1toe toe toe

1kWh needs 191 10 toe

SGCIE




tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricida

de

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729




tep

Total de

Petróleo

Gás

Natural

(*)

Gases o

Outros

Derivado

s

Termo-

electricidadeCalor

Resíduos

Industriais

Renováveis

Sem Hídrica

200822= 15 +

2123

30 = 24

a 2935 37 38 46 = 39 a 45

Cogeração6.7

834 520 626 392 24 379 - 485 426 -1 472 450 2 523 974 514

SGCIE

• Conversion coefficients for CO2 emissions

– For electricity (in kg CO2 e per kWh)?


tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricidade

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729

4111.4 kg CO2 e/toe3236.4 kg CO2 e/toe

2348.8 kg CO2 e/toe

SGCIE

• Conversion coefficients for CO2 emissions

– For electricity (in kg CO2 e per kWh)


tep

Total de

Carvão

Total de

Petróleo

Gás Natural

(*)

Termo-

electricidade

Lenhas e

Resíduos

Vegetais

Resíduos

Sólidos

Urbanos

Biogás

2008 4 = 1 a 3 22= 15 + 21 23 35 40 41 44

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 61 957 182 765 19 729

4111.4 kg CO2 e/toe3236.4 kg CO2 e/toe

2348.8 kg CO2 e/toe

2

2

4111.4 2 444 703 3236.4 475 571 2348.8 1 970 751 kg CO e

2 325 570 41868kWh

3.6

0.6kg CO e kWh

IC

IC

Energy Management


SGCIE

• Conversion coefficients for CO2 emissions and primary energy


– Conversão directa de kWh em tep?

Energy Management


SGCIE

• Conversion coefficients for CO2 emissions and primary energy


– Conversão directa de kWh em tep?

• 1kWh=3.6MJ=3.610-3/41.87 tep = 86 10-6

Energy efficiency of materials

• Reducing embodied energy (MJ/ton)

Energy vs. Exergy

• Embodied Energy or Cumulative Energy Consumption

(CEC): it is the total (direct and indirect) amount of

(primary) energy needed to generate product k.

• Cumulative exergy consumption (CExC): it is the total

(direct and indirect) amount of (primary) exergy

needed to generate product k.

• What is the difference?

Operation Am2

m3

mR

EA

Materials

lnput Production

Energy

consumption

Residues

m1

3 A 1 23

3 3

E E +E +ECE = =

m m

Cement Industry

Exergetic efficiency various formulations

Final Energy Use in Industry in 2005

• World Industrial final energy

use in 2005 is 115EJ

• The bulk of industrial energy

use is due to the production of a

small number of energy

intensive commodities:

– Chemicals and petrochemicals and

the iron and steel sector account for

approximately half of all industrial

energy used worldwide.

• Other sectors that account for a

significant share of industrial

energy use:

– non-metallic minerals and the pulp

and paper sector.

Cement,

ceramics,

glass, lime

Aluminium,

copper, nickel

Plastics and fertilizers

GEA, 2012

Final Energy Use in Industry in Portugal

Final Energy Use in Industry in 2005

The bulk of industrial energy use is

in developing economies (80% pop.)

World Production of key materials

Gutowski TG, Sahni S, Allwood JM, Ashby MF,Worrell E. 2013 The energy required to produce

materials: constraints on energy-intensity improvements, parameters of demand. Phil Trans R Soc A

371: 20120003.

http://dx.doi.org/10.1098/rsta.2012.0003

Steel

Cement

Paper

Aluminium

Plastics

World production of key materials

• Higher growth rates from the

90’ and then from the 2000’

onwards

• Heterogeneous growth

(cement)

World Production of key materials

• Growth rates between 2000-2007

– China and India show the highest growth rates.• In 2007 China produces 37% of the world steel (48% in 2013) and 48% of

the cement (59% in 2013)

World Demand of key materials

China is atypical

• Regional per-capita demand for materials

– For some materials it increases with income and

economic development and then stabilizes

Stock = 10 ton/capita

• Regional per-capita demand for materials

– For some materials increases with income and

economic development (paper and aluminium)

World Demand of key materials

Why do we need materials?

• To provide Services


Cullen & Allwood, 201042

World Stock of key materials

Article in Environmental Science and Technology 47(20):11739-11746 · September 2013

DOI: 10.1021/es402618m · Source: PubMed

https://www.researchgate.net/deref/http%3A%2F%2Fwww.ncbi.nlm.nih.gov%2Fpubmed%2F24053762

Industrial Energy Intensity

• It differs between different products

Material Energy MJ per kg

Bricks (common) 3

Steel (general, av. recycled content) 20.1

Stainless steel 56.7

Cork insulation 26

Aluminium (general & incl 33%

recycled)155

PVC (general) 77.2

Wallpaper 36.4

Iron (general) 25

Copper (average incl. 37% recycled) 42

Lead (incl 61% recycled) 25.21

Ceramic sanitary ware 29

Paint - Water-borne 59

Paint - Solvent-borne 97


• It differs between different materials



371: 20120003.


Steel

Cement

Paper

Aluminium

Plastics


• For high diluted metals it depends on the ore

grade



371: 20120003.


Iron

Aluminium

Energy intensity

controled by the

mining &

separation steps

Energy intensity

controled by the

chemical

reduction step

Chemical reduction steps

• Iron

2Fe2O3(s) + 3C(s) → 4Fe(l) + 3CO2(g)

Fe2O3(s) + 3CO(s) → 2Fe(l) + 3CO2(g)

CaCO3(s) → CaO(s) + CO2(g)

CaO(s) + SiO2(s) → CaSiO3(l)


• It changes in time due to technological inovations

Thermodynamic limits

• Iron

– The ΔG˚ for the chemical reaction is 1.4 MJ/kg Fe

2Fe2O3(s) + 3C(s) → 4Fe(l) + 3CO2(g)


• Steel



371: 20120003.



• It differs between countries for similar products

– Access to resources (steel from steel recycling is

0,19 toe/ton while from iron ore is 0,49 toe/ton)

Steel Energy intensity


• It differs between countries for similar products

– Access to resources

– Energy Prices

– Plant size and age of capital stock

– Capital cost (more efficient capital is also more

expensive - interest rates)

– Awareness of energy efficiency measures and

opportunity cost

– Government policies

Benchmarking Industrial Energy Use

• Management tool to compare similar plants in

energy use and energy efficiency

• Benchmarking curves (improvement potential)

SECEEI

BPT

Specific

energy

consumption

Best

Practice

Technology

Energy

Efficiency

Index


• Management tool to compare similar plants in

energy use and energy efficiency

• Benchmarking curves (improvement potential)

SECEEI

BPT


• Average 10-20% or 30-35% improvement potential

– Lower than for other energy uses (e.g. in buildings is close to

50%)


• Aggregated industrial energy intensity (energy

use per unit of VA):

– Depends on what?


VA


• Industrial energy intensity (energy use per unit

of VA):

– Efficiency

– Sectoral

Structure


VA


• To provide Services

Energy & Material Services


Direct Energy


direct

energy

“Direct” Energy efficiency of

transport

• Depends on what?

15.7 l/100km4.7 l/100km


transport

Thermodynamic

efficiency 38%


transport

Passive System

The passive system

Material efficiency

• Reducing embodied energy in passive system (MJ/ton)

• Improving passive system reducing direct energy per unit of

service

Stock vs. Flow Materials

J Ind. Ecol. 2014 May; 18(3): 407–420.

Stock vs. Flow Materials

Material Service Optimization

• Reducing embodied energy in passive system (MJ/ton)

• Improving passive system reducing direct energy per unit of

service

Energy vs. Exergy efficiency

Energy Management


Exercise

• A factory produces 2 end products: P1 and P2. These products follow the production process shown in the diagram below, with P1 = 50000 ton/year and P2 = 30000 ton/year. The operation G treats the effluents from E and F. These two (E and F) are the only productive operations that generate waste, and SE = 1.2, SF = 1.3. In operation G, only 20% of the input effluent, exits the process as waste. The values of composition are as follows: f4 = 0.4, f6 = 0.5. The table presents the specific consumption of each operation. Consider that for electricity: 0.215 kgep/kWh & 0.47 kg CO2e/KWh and for fueloil 0.984 kgep/kg & 3236.4 kg CO2e/toe

a) What is the carbon intensity of this factory?

A B C D E F G H

Electricidade (kWh/ton produto) 100 20 30 20 20 20

Thick Fuel Óleo (kg/ton produto) 50 60 50

8 (produção 1)A

C

D

E

B2

1

F

G 1413

1211

10 (produção 2)

3

4

5

6

7

9

Energy Management


Exercise

8 (produção 1)A

C

D

E

B2

1

F

G 1413

1211

10 (produção 2)

3

4

5

6

7

9

3 4 5 6

7 9 10 11 12 2

3 4 8

8 8 10 10

100 20 300.215 0.47

20 20 20 kg CO

50 60 0.984 3.2364

CE CE kgoe

m m m m

m m m m m

m m mCI

m m

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