Energy Management: 2014/2015 Industrial Energy Use SGCIE and Primary Energy Evaluation Methods Class...

Energy Management: 2014/2015

Industrial Energy UseSGCIE

and Primary Energy Evaluation Methods

Class # 9

Prof. Tânia [email protected]

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-ferrous metals, 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 2005

The bulk of industrial energy use isin developing economies (80% pop.)

World production of key materials

• Higher growth rates from the 90’ and then from the 2000’ onwards

• Heterogeneous growth

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)


China is atypical

• Regional per-capita demand for materials – For most materials it increases with income and

economic development and then stabilizes

• Regional per-capita demand for materials – For some materials increases with income and

economic development (paper and aluminium)


Industrial Energy Intensity

• Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010):– It differs between different products and sectors

Material Energy MJ per kg

Bricks (common) 3

Steel (general, av. recycled content) 20.1

Stainless steel 56.7Cork insulation 26

Aluminium (general & incl 33% recycled)

155

PVC (general) 77.2Wallpaper 36.4

Iron (general) 25

Copper (average incl. 37% recycled) 42

Lead (incl 61% recycled) 25.21Ceramic sanitary ware 29

Paint - Water-borne 59Paint - Solvent-borne 97


• Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010):– It changes in time due to technological inovations


• Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010):– 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 and ammonia from coal is much more energy intensive than ammonia from natural gas)

0.50.5

Steel Energy intensity


• Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010):– 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 (improvment potential)

SECEEI

BPT



Benchmarking Industrial Energy Use

• Average 10-20% or 30-35% improvment 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?

Industrial Energy Use

VA


• Industrial energy intensity (energy use per unit of VA):

– Efficiency

– Sectoral Structure

Industrial Energy Use

VA

Energy Use in Industry

• 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


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 from 500 to 1000 toe

Energy Management


SGCIE

• Obligations (for IEC entities)– 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

• Obligations (for IEC entities)– 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

EAMaterials

lnput Production

Energyconsumption

Residues

m1 3 A 1 23

3 3

E E +E +ECE = =

m m

Energy Management


SGCIE

• The Energy Intensity obtained using the definition in SGCIE is the same obtained with the block diagrams methodology if:– The energy specific consumptions of the inputs is zero

8 (produção 1)

A

C

D

E

B

2

1

F

G

1413

1211

Electricity

Fueloil

Energy Management


SGCIE

• Obligations (for IEC entities)– Develop Energy Rationalization Plans

• The carbon intensity must not increase

– Why a goal on carbon intensity?

Energy Management


SGCIE

• Obligations (for IEC entities)– 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)

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 ENERGÉTICOtep

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

• Conversion coefficients for primary energy– For electricity:


Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricida

de



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 7290.45 41868

kWh0.45toe 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?


Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricida

de



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 7290.45 41868

kWh0.45toe 0.45 41868MJ 3.6 5234kWh toe1toe toe toe

1kWh needs 191 10 toe

SGCIE



Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricida

de



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



Total de Petróleo

Gás Natural

(*)

Gases o Outros

Derivados

Termo-electricidade

CalorResíduos

IndustriaisRenováveisSem Hídrica

2008 22= 15 +

2123

30 = 24 a 29

35 37 38 46 = 39 a 45

Cogeração 6.7

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)?


Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricidade



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)


Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricidade



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 e2 325 570 41868

kWh3.6

0.6kg CO e kWh

IC

IC

Energy Management


SGCIE

• Conversion coefficients for CO2 emissions and primary energy– For electricity:

– Conversão directa de kWh em tep?

Energy Management


SGCIE

• Conversion coefficients for CO2 emissions and primary energy– For electricity:

– Conversão directa de kWh em tep?• 1kWh=3.6MJ=3.610-3/41.87 tep = 86 10-6

Energy Management


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

B

2

1

F

G

1413

1211

10 (produção 2)

3

4

5

6

7

9

Energy Management


Exercise

8 (produção 1)

A

C

D

E

B

2

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

Primary Energy Valuation Methods

• Primary Energy flows that are not heat are not easily compared with the heat that fuels can deliver (e.g. ….)

Primary Energy used for Electricity

• What is the primary energy associated with the electricity production in 2008?


Total de Carvão

Total de PetróleoGás Natural

(*)Gases o Outros

DerivadosTotal de

EectricidadeCalor

Resíduos Industriais

RenováveisSem Hídrica

TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 23 30 = 24 a 29 36 = 31 a 35 37 38 46 = 39 a 4547=4+22+23+30+36+3

7+38+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754

PRODUÇÃO DOMÉSTICA 2. 1 142 338 39 800 3 190 679 4 372 817

VARIAÇÃO DE "STOCKS" 3. - 223 603 315 673 5 960 - 837 97 193

SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162

CONSUMO DE ENERGIA PRIMÁRIA 5. 2 525 873 12 612 050 4 157 207 1 953 404 39 800 3 173 882 24 462 216

PARA NOVAS FORMAS DE ENERGIA 6. 2 444 703 1 079 137 2 597 143 -2 810 996 -1 472 450 1 120 1 367 391 3 206 048

Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 24 379 - 485 426 -1 472 450 2 523 974 514 504 452

CONSUMO DO SECTOR ENERGÉTICO 7. 475 376 56 103 605 301 270 736 3 1 407 519

CONSUMO COMO MATÉRIA PRIMA 1 275 842 1 275 842

DISPONÍVEL PARA CONSUMO FINAL 8. 81 170 9 781 695 1 503 961 4 159 099 1 201 714 38 680 1 806 488 18 572 807


Total de Carvão


(*)Gases o Outros

DerivadosTotal de

EectricidadeCalor



TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 23 30 = 24 a 29 36 = 31 a 35 37 38 46 = 39 a 4547=4+22+23+30+36+3

7+38+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754



SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162



Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 24 379 - 485 426 -1 472 450 2 523 974 514 504 452





• What is the primary energy associated with the electricity production in 2008?


• Is there other primary energy associated with the electricity production in 2008?


Total de Carvão


(*)Gases o Outros

DerivadosTotal de

EectricidadeCalor



TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 23 30 = 24 a 29 36 = 31 a 35 37 38 46 = 39 a 4547=4+22+23+30+36+3

7+38+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754



SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162



Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 24 379 - 485 426 -1 472 450 2 523 974 514 504 452





Total de Carvão


(*)Gases o Outros

DerivadosTotal de

EectricidadeCalor



TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 23 30 = 24 a 29 36 = 31 a 35 37 38 46 = 39 a 4547=4+22+23+30+36+3

7+38+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754



SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162



Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 24 379 - 485 426 -1 472 450 2 523 974 514 504 452





• Is there other primary energy associated with the electricity production in 2008?


• What is the primary energy associated with the electricity production in 2008?– Primary energy associated with fuels that produce

(only) thermoelectricity is not problematic

– Primary energy associated with fuels that produce thermoelectricity & heat is more problematic

• Why?





• Why?

• How to split primary energy into primary energy associated with 1) heat production and 2) electricity production?





• All primary energy is attributed to electricity production

• The primary energy needed to produce electricity with that fuel (in dedicated electricity production)

• The % of primary energy associated with electricity is equal to the % of electricity in the output (roughly 25%)

SGCIE



Total de Carvão

Total de Petróleo

Gás Natural(*)

Termo-electricida

de



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



Total de Petróleo

Gás Natural

(*)

Gases o Outros

Derivados

Termo-electricidade

CalorResíduos


2008 22= 15 +

2123

30 = 24 a 29

35 37 38 46 = 39 a 45

Cogeração 6.7

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

06

06

36.9% 1kWh needs 233 10 toe

48.8% 1kWh needs 176 10 toe





• All primary energy is attributed to electricity production

• The primary energy needed to produce electricity with that fuel (in dedicated electricity production)

• The % of primary energy associated with electricity is equal to the % of electricity in the output (roughly 25%)

– What about primary energy associated with primary renewable electricity? (in the PEB?)


• What is the primary energy associated with 1 kWh of (different types) of primary renewable electricity?

Methods Wind Electricity

Photovoltaic Hydro Electricity

GeothermalElectricity

“electricity produced” Electricity (1 kWh) Electricity (1 kWh) Electricity (1 kWh) Electricity (1 kWh)



• What would be the method if we were using the concept of Primary Energy?





“measure of fossil energy” 0 0 0 0






“as it is found in nature” Kinetic energy Radiation Potential Energy Heat



Physical Content Method (IEA)

• “The primary energy is the 1st energy form downstream for which multiple energy uses are pratical”

• Heat (nuclear, geothermal and solar thermal)– Conversion from heat to electricity in

geothermal is 10% and in nuclear is 30%• Electricity for wind, tide/wave/ocean and solar

photovoltaic (100%)



– Physical Content Method: primary energy is the first form of comercial energy available (IEA)







Physical Content Method Electricity (1 kWh) Electricity (1 kWh) Electricity (1 kWh) Heat (1/0.1 kWh)

Partial Substitution Method (EIA)

• The amount of energy that would be necessary to generate and identical amount of electricity in conventional thermal power plants– Uses an average generating efficiency (40%) to

convert electricity to primary energy



– Physical Content Method: primary energy is the first form of comercial energy available (IEA)

– Partial Substitution Method: primary energy is the amount of conventional energy that would have to be used (EIA)







Physical Content Method Electricity (1 kWh) Electricity (1 kWh) Electricity (1 kWh) Heat (1/0.1 kWh)

Partial Substitution Method Fuel (1/0.4 kWh) Fuel (1/0.4 kWh) Fuel (1/0.4 kWh) Fuel (1/0.4 kWh)

Renewable Primary Energy

• What is the primary energy associated with the renewable electricity production in 2008 (toe)?




Portuguese Energetic Balance

495 102 3 268 627 456 16 512

Physical Content Method

Partial Substitution Method



• What are the 1) total primary energy consumption & 2) fractions of renewable primary energy





495 102 3 268 627 456 16 512

Physical Content Method 495 102 3 268 627 456 165 120

Partial Substitution Method 495 102/0.4 3 268/0.4 627 456/0.4 16 512/0.4

Methods Ren. Electricity + Other Ren.

Total Fraction of renewables



Partial Substitution Method

Total primary energy consumption & renewable primary energy consumption?


Total de Carvão

Total de Petróleo

Gás Natural(*)

Total de Eectricidade

CalorResíduos


TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 2336 = 31 a

3537 38

46 = 39 a 45

47=4+22+23+30+36+37+38

+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754



SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162



Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 - 485 426 -1 472 450 2 523 974 514 504 452




Total primary energy consumption & renewable primary energy consumption?


Total de Carvão

Total de Petróleo

Gás Natural(*)

Total de Eectricidade

CalorResíduos


TOTAL GERAL

2008 4 = 1 a 3 22= 15 + 21 2336 = 31 a

3537 38

46 = 39 a 45

47=4+22+23+30+36+37+38

+46

IMPORTAÇÕES 1. 2 327 219 16 608 384 4 163 167 923 984 24 022 754



SAÍDAS 4. 24 949 3 680 661 112 918 17 634 3 836 162



Electricidade 6.6 2 444 703 475 571 1 970 751 -2 325 570 264 451 2 829 906

Cogeração 6.7 834 520 626 392 - 485 426 -1 472 450 2 523 974 514 504 452






• What are the 1) total primary energy consumption & 2) fractions of renewable primary energy





495 102 3 268 627 456 16 512

Physical Content Method 495 102 3 268 627 456 165 120

Partial Substitution Method 495 102/0.4 3 268/0.4 627 456/0.4 16 512/0.4

Methods Ren. Electricity + Other Ren.

Total Fraction of renewables

Portuguese Energetic Balance 4316220 24462216 17.6%Physical Content Method

4464828 24610824 18.1%Partial Substitution Method

6029727 26175723 23%

Comparison of Methods

• Neither the Physical Content Method nor the Partial Substitution Methods are a measure of primary fossil energy

• Growth of wind, hydro or solar to produce electricity leads to primary energy savings with the Physical Content Method


• Energy intensity (energy use per unit of GDP):– What is the meaning of the indicator?

Primary Energy

GDP


• Energy intensity (energy use per unit of GDP):– A measure of the efficiency of a country in using

energy

– Low values correspond to environmental and economic advantages

• What happens to this indicator if a country that only uses electricity (produced with coal) as final energy replaces all thermoelectric power plants with dams?– With the partial substitution method?

– With the physical content method?

Primary Energy

GDP



Cegonho, 2011


Partial Substitution MethodNominal efficiency is the yearly efficiency of fossil fuel power plants

Cegonho, 2011


BP Substitution MethodNominal efficiency is 38 % (typical of a fossil fuel power plant)

Cegonho, 2011


NL Substitution MethodNominal efficiency is the yearly efficiency of fossil fuel and nuclear power plants

Cegonho, 2011

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