Industry demand side energy management in Pulp&Paper
Transcript of Industry demand side energy management in Pulp&Paper
AUTOMAATIOSEURAN VOIMALAITOSJAOKSEN KEVÄTSEMINAARI, 31.5.2018
Industry demand side energymanagement in Pulp&PaperCase TMP energy optimization
Jukka Kostiainen, Product Manager
How to Get Savings in Energy Costs
Production output
Total Energy ConsumedEnergy ConsumptionMWh / Units
Unit Energy Cost $
Production UnitsEnergy CostEffectiveness (eE)Units / e$
Price you pay$ / MWh
Decrease
Reduce
Increase
Average Unit PriceEnergy consumption
eE is a KPI = Units per energy dollar
Energy Efficiency / Energy Cost
Usage Optimization
Price Optimization
May 28, 2018 Slide 2
High energy intensiveindustries
iDSM: industrial Demand Side ManagementBackground and Motivation
Demand Side Management
Market LiberalizationRenewables Expansion Demand & Supply
Variable electricity prices (2)Smart
grid
windsolar
GRID STABILITY AND RELIABILITY ENVIRONMENTAL IMPACTS AND INVESTMENTCOSTS
Need for peak load (1)
HIGH ENERGY COSTS
Sources: (1)Pina et. Al, 2012;(2) EPEX SPOT ,2012
Energy Efficiency Load Management
May 28, 2018 Slide 3
New opportunities of industrial demand side management (iDSM)Saving cost with intelligent planning
iDSM allows important cost savings
Shifting loads of energy intensive process steps tolow cost times
Using process flexibility for iDSM
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EEX Day Ahead Price 17.3.2015
May 28, 2018 Slide 4
Prerequisites for demand side management (DSM) in industryFlexibility in energy intensive production steps enables demand side management
DSM offers saving potential in many industries
Elektrolysis
Cement mills, paper mills, …
Electric Arc Furnaces
Refrigeration (cold storage houses, …)
Heating (heaters, furnaces, steam, …)
Compressors, pumps
…
All energy intensive processes not running 24/7.
Metalls Cement
Pulp and paper Electrolysis
Process flexibility enables DSM
…
May 28, 2018 Slide 5
Industrial demand side management in pulp and paper industry
May 28, 2018 | Slide 6
Storages and tanks offer flexibilities for industrial demand side management
Typical (simplified) pulping process in an integrated pulp and paper mill
Woodchips
Pulp refiner
Pulp refiner Reject pulprefiner
Pulp tank PapermachinePulp tank Bleaching
Big electricity consumer
Storage for intermediateproduct
Co-ordination of production planning and energy management
16. April 2015
Industrial demand side management in pulp and paper industryCoordination of production planning and energy management
Continuous production withintermediate storages
Pulp production is highly integratedwith other parts of paper plant
Paper output of plant is not reduced
Pulp production
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Elec
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Wh]
Time [hours]
Spot Market Hourly Prices
Reduced pulpproduction
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t1 t5 t9 t13
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t101
t105
t109
t113
t117
t121
t125
t129
t133
t137
t141
t145
t149
t153
t157
t161
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Running Tasks with iDSM
Slide 7
Production Process:
• Two board machines
• RMP plant (Refined Mechanical Pulp),10 MWe power, feeds board machines
• Reserve pulper for purchased pulp
• Storage tank between RMP plant andboard machines
Objectives:
• Minimize the electricity costs byoptimizing the RMP operation accordingto electricity spot price
• Provide power consumption forecast forelectricity purchase
Case Mill, RMP Optimization
May 28, 2018 Slide 8
Production Process and Objectives
Processarea
Site
Enterprise
Cloud Cloud based applications
Plant or corporate process data lakeLocal applications
Site level datacollectors
Ability hybridcloud solution
General architecture
Increase data symmetry byconsolidating process datato one place
Applications increasing awarenessIntelligent applications optimizingperformance
ABB Ability, cpmPlus Energy Manager
May 28, 2018 Slide 8
• RMP stock level 0 … 100 %
• RMP to BM1
• RMP to BM2
• RMP power
• Electricity spot price(-20 … +100 EUR/MWh)
• RMP plant must run with fullspeed when pulp need is high. Thetime when the process can beoptimized is shown with greenarrows.
Industrial Demand Side Management (iDSM) in Mechanical Pulping Process
May 28, 2018 Slide 10
Results – Weeks 37 Before and Week 49 After Start-up
Before (wk 37/2017)
• Spot price is not followed
• Stock level is constantlyhigh
After (wk 49/2017)
• Spot price is followedquite well
• Stock is utilized and levelgoes up/down withindefined limits
• RMP stock level 0 … 100 %
• RMP to BM1
• RMP to BM2
• RMP power
• Electricity spot price(-20 … +100 EUR/MWh)
• Time when optimization ispossible (OP)
• Time when optimization ispossible and followed (OPF)
Industrial Demand Side Management (iDSM) in Mechanical Pulping Process
May 28, 2018 Slide 11
Results – Weeks 49 and 51 After Start-up
Week 49/2017:
• OPF period:6.12. 07:00 – 7.12. 7:00
• Savings during this period= 7.3 % (*
Week 51/2017
• OPF period:19.12. 04:00 – 21.12. 12:00
• Savings during this period= 16.0 % (*
Total savings of the twoOPF periods = 14.5 % (**
(***
*) Savings calculated comparing the actual cost vs. the cost with average spot price during the OPF period
**) Weighed balance
***) 24.12.2017 00:00 – 07:00 Electricity spot price was -55.47 … -85.73 EUR/MWh