- The Environmental Managers -
Energy Efficiency Programs in Industrial Companies
Energy Efficiency in IPPC Installations
Energy Efficiency in IPPC Installations Andreas Kollegger 2
- The Environmental Managers -
DI Andreas Kollegger
ALLPLAN GmbHSchwindgasse 10, A-1040 Wien
fon: +43 1 505 37 07 53fax: +43 1 505 37 07 27
[email protected]://www.allplan.at
Energy Efficiency in IPPC Installations Andreas Kollegger 3
- The Environmental Managers -
Method
Some Crucial Points
Experience
Clients
Results
Agenda
Energy Efficiency in IPPC Installations Andreas Kollegger 4
- The Environmental Managers -
Analysis
Calculations
Saving potential
Cost assessment of energy saving
measures
Calculation of savings
Data gathering Existing data
Measurements
Optimum technical and economic
solution
Method
Energy Efficiency in IPPC Installations Andreas Kollegger 5
- The Environmental Managers -
Some Crucial Points
Comprehensive analysis
Starting with an overview
Identifying large energy flows and consumers
Focusing on relevant areas
Main production processes very often well optimised
Concentrating on auxiliary processes
“To boldly to go, where no man has gone before”(© Star Trek)
Energy Efficiency in IPPC Installations Andreas Kollegger 6
- The Environmental Managers -
Example: Sankey Diagram
Data Basis: Own measurements Company data Client´s measurements Own calculations
Energy Efficiency in IPPC Installations Andreas Kollegger 7
- The Environmental Managers -
Example: Optimisation of Boilers Use of Waste Heat from Boilers
Energy Efficiency in IPPC Installations Andreas Kollegger 8
- The Environmental Managers -
Comprehensive boiler analysis
Optimisation of burners
Reduction of radiation losses
Reduction of CO content
Decrease of fluegas temperature
Flue gas condensation
Optimisation
75%
85%
95%
105%
115%
0 100 200 300 400flue gas temperature [°C]
effi
cien
cy
75%
85%
95%
105%
115%
0 100 200 300 400flue gas temperature [°C]
effi
cien
cy
Energy Efficiency in IPPC Installations Andreas Kollegger 9
- The Environmental Managers -
Example: Use of Waste Heat from a Production Process
Scheme
electrostatic filter
transportation air
water
Variant 190°C70°C
bypassM
bricks
brick cooling system
electrostatic filter
transportation air
waterwater
Variant 190°C70°C
Variant 190°C70°C
bypassMM
bricks
brick cooling system
Energy Efficiency in IPPC Installations Andreas Kollegger 10
- The Environmental Managers -
Example: Change in Control Systems
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
110%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%Relative Flow
Rel
ativ
e P
ow
er
Flow Control via Throttle
Flow Control via FC
Energy Efficiency in IPPC Installations Andreas Kollegger 11
- The Environmental Managers -
Optimisation – Control Systems
Highly sophisticated control systems installed
Settings do not fit actual demand(due to adaptations / extensions of plants)
Adjustment of control system to actual demand
Continuous control of correct settings
Retrofit of simple overhead control units
No general rules possible due to many different types of control systems
Trial and error procedures
Energy Efficiency in IPPC Installations Andreas Kollegger 12
- The Environmental Managers -
Example: Optimisation of Compressed Air
no-load operation
full operation
no operationno-load operation
full operation
no operation
Energy Efficiency in IPPC Installations Andreas Kollegger 13
- The Environmental Managers -
Optimisation of Compressed Air
Adaptation of control unitspressure levels load to idle run ratio
idle run time
Upgrade or change of control units
Compressors with frequency converters
Exploitation of the inevitable waste heat
Refurbishment of the distribution system
Optimisation of pipe diameters
Energy Efficiency in IPPC Installations Andreas Kollegger 14
- The Environmental Managers -
Example: “Free Cooling” of Tanks
Energy Efficiency in IPPC Installations Andreas Kollegger 15
- The Environmental Managers -
Advantages of “Free Cooling”
Requires only a small share of the electricity needed for common chillers
Provision of additional annual cooling load
Common chillers can fully be switched off under certain conditions
Additional safety due to redundancy
Energy Efficiency in IPPC Installations Andreas Kollegger 16
- The Environmental Managers -
Countries Austria
Czech Republic
Germany
Hungary
Netherlands
Romania
Slovakia
Slovenia
Economic Fields Pulp Production
Paper Production
Cardboard Production
Ferrous Metal Production / Processing
Non-Ferrous Metal Production / Processing
Mineral Industry
Food Industry
Utilities
more than 50 AEEP´s
Our Clients - Examples
Energy Efficiency in IPPC Installations Andreas Kollegger 17
- The Environmental Managers -
The Results – Heat & Electricity
0
1
2
3
4
5
6
7
8
9
10
Maximum Potential Average Weighted Average
Sa
vin
g P
ote
nti
al [%
]
HeatElectricity
>20%
Energy Efficiency in IPPC Installations Andreas Kollegger 18
- The Environmental Managers -
The Results – Overall Financial Savings
0
1
2
3
4
5
6
7
8
9
10
Maximum Potential Average Weighted Average
Sav
ing
Po
ten
tial
[%
]
>15%
Energy Efficiency in IPPC Installations Andreas Kollegger 19
- The Environmental Managers -
The Results – CO2 Reduction
0
1
2
3
4
5
6
7
8
9
10
Maximum Potential Average Weighted Average
Sa
vin
g P
ote
nti
al [%
]
>30% (due to a Fuel Switch)
Energy Efficiency in IPPC Installations Andreas Kollegger 20
- The Environmental Managers -
Results of 28 AEEP´s(carried out in various Austrian industry companies)
Saved Electricity: > 6.000.000 MWh/a
Saved Heat Energy: > 25.000.000 MWh/a
Saved Energy Costs: > 7.000.000 €/a
Saved CO2 Emissions: > 50.000 tCO2/a
Energy Efficiency in IPPC Installations Andreas Kollegger 21
- The Environmental Managers -
DI Andreas Kollegger
ALLPLAN GmbHSchwindgasse 10, A-1040 Wien
fon: +43 1 505 37 07 53fax: +43 1 505 37 07 27
[email protected]://www.allplan.at
Thank you for your attention
Top Related