Potential and Application of Renewables and Energy …...Dipl.-Ing. Sabine Piller Berliner...

Dipl.-Ing. Sabine Piller

Berliner Energieagentur GmbH

Workshop on Energy Efficiency

Istanbul, 28. September 2010

Potential and Application of Renewables and

Energy Efficiency in Industry

© Berlin Energy Agency, September 2010

Overview

BEA – facts and figures

Potential for energy efficiency and Renewables

Most promising measures to increase energy efficiency

Application of energy efficiency

Application of Renewables in industry

Conclusions

Potential and Application of Renewables

and Energy Efficiency in Industry


Established

in 1992 as Public Private Partnership

Shareholders

Federal State of Berlin

Vattenfall Europe

GASAG

KfW Banking Group

Equity

2.5 million €

Annual total output

9 million €

Company earnings (EBIT)

609 k €

Know-how

55 members of staff

Energy Services

Contracting

Consulting

International Know-How Transfer

Premises

Französische Straße 23

10117 Berlin

Phone: (030) 29 33 30 - 0

e-mail: [email protected]

Internet: www.berliner-e-agentur.de

BEA – Facts and Figures

© Berliner Energieagentur GmbH


Fields of Activities

• Contracting:

Planning, financing, construction, and operation of: CHP and heat

stations; special supply components such as emergency power,

cooling energy and compressed air; solar energy; lighting systems

• Consulting:

Advice on all aspects of efficient energy use for customers from

industry and commerce as well as private housing, service and public

sector

• International Know-how Transfer:

Transfer of successful models of efficient use of energy and

implementation of renewable energy to international markets

BEA – Facts and Figures

© Berliner Energieagentur GmbH


Economical and Political Framework – Energy Efficiency

Energy price increase: 2006-2009 in four years 25% (Germany)

considerable cost factor in industry

Estimate of saving potential in Turkish industry via energy efficiency

measures: 20 %

Energy Efficiency Directive (EU)

1% yearly energy savings in the retail, supply and distribution of electricity,

natural gas, urban heating, and other energy products including transport fuels.

Ecodesign Directive (EU)

rules for improving the environmental performance of energy related products,

e.g. ventilation/air conditioning, lighting, electric motors etc.

Strategic plan Ministry of Energy and Natural Resources (Turkey)

support for increase in energy efficiency and reduction of energy density

and establishment of energy management




0

100

200

300

400

500

600

700

800

900

1000

1100

1200

19

90

19

91

19

92

19

93

19

94

19

95

19

96

19

97

19

98

19

99

20

00

20

01

20

02

20

03

20

04

20

05

20

06

20

07

Mill

ion tonnes o

f oil

equiv

ale

nt

Agriculture and

other sectors

Services

Households

Industry

Transport

27.9%

32.6%

24.6%

11.2%

Shares in 2007

3.7%

Final Energy Consumption in Industry



Turkey:

34 % (2007)

Source: European Environment Agency

European Union


Total Final Energy Consumption 2007



Source: IEA

Turkey

Transport

Residential

Commercial and

Public Services

Industry

Agriculture /

Forestry

0

5.000

10.000

15.000

20.000

25.000

in t

ho

usan

d t

on

nes o

f o

il e

qu

ivale

nt

(kto

e)

34%

23%

29%

9%

5%


Total Final Energy Consumption 2007



Source: IEA

Germany

Industry

Transport Residential

Commercial and

Public Services

Agriculture /

Forestry

Non-Specified

0

10.000

20.000

30.000

40.000

50.000

60.000

70.000

in t

ho

us

an

d t

on

ne

s o

f o

il e

qu

iva

len

t (k

toe

)

28%

26%27%

10%

1%

6%


Investing in energy efficiency achieves several goals simultaneously:

It reduces greenhouse gas emissions

It improves energy security

It decreases specific and overall energy cost and contributes to

economic growth

Energy efficiency a triple win




Energy efficiency – a mix of measures for success



Technologies

• CHP

• Air compression

• HVAC

• Insulation

• Lighting

Control and

Measurement

• Regular inspections

• O & V methods

• Energy certificates

• Building owners

• Facility managers

• Eng., contractors

• Authorities

• Tax incentives

• Grant schemes

• Soft loans

Guidelines/

Campaigns

Financial

Incentives

Energy efficiency

mix


Preparation of investments in energy efficiency:

Knowledge of (major) energy consumption

Provision for monitoring to demonstrate benefits

Establishment of energy management

Energy Efficiency Energy management




Austria

BelgiumCyprus

France

Germany

Greece

Hungary

Italy

Poland

Portugal

Spain

Sweden

UK

Norway

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0,10

0,11

0,12

0,13

40% 50% 60% 70% 80% 90% 100%

Ratio clinker / cement production

unit c

onsum

ption (

toe/t)

Final Energy Consumption in EU



energy unit consumption of cement in EU countries as a function of the share of clinker:

the higher this ratio, the higher the specific energy consumption

© Berlin Energy Agency, September 2010Source: European Environment Agency


Final Energy Consumption in EU



unit energy consumption per ton of paper as a function of the ratio pulp production to

paper production: the higher the ratio, the higher the energy unit consumption

Austria

Belgium

Finland

France

GermanyItaly

Spain

Sweden

UK

Estonia

Hungary

PolandCzech Republic

Slovakia

Slovenia Bulgaria

EU-27

Norway

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0% 20% 40% 60% 80% 100% 120%

Ratio pulp / paper production

un

it c

on

su

mp

tio

n (

toe

/t)

© Berlin Energy Agency, September 2010Source: European Environment Agency


Companies and enterprises – Total energy consumption and potentials

Process heat

14%

Warm water

3%

Losses

6%

Manufacturing

facilities

15%

Compressed air

2%

IT (PCs, EDPC + AC)

9%

Canteen and minor

devices

4%

Lighting

12%

HVAC

8%

Space heating and

warm water

pumps and motors

3%

Space heat

24%



Exampel:

Distribution of Energy

consumption in a mechanical

engineering company

(incl. administration building)


Catalogue of measures




Ventilation / Air conditioning

High energy consumption: especially electricity for transport (fans) and cooling

Optimize the building: insulation, sun protection and inner loads

Allow low temperature in winter and high in summer according to a comfort range

Heat recovery

Energy efficient fans and low distribution losses

Maintenance and operation hours

Energy saving potential mostly 10-50 %




Compressed air

Minimal pressure for applications

High leak tightness for new systems

(compressor, distribution, armatures)

Use of the exhaust heat

Energy efficiency compressor (with variable

drive) and low distribution losses (no spiral

pipes, broad diameter)

Maintenance and operation hours

Energy saving potential mostly 10-50 %




Lighting: Optimisation of fluorescent tubes



Energy

1. step

2. step

3. step

4. step

Savings

80%

Source: Osram (translation: BEA)

Modern luminaire

with reflecting grid

T8 lamp

Electronic ballast

(EVG) T5 lamp

Day light

sensors




Energy efficiency in IT centres

IT = energy consumption = heat

IT components are very

sensitive to heat• In the past: 35 °C

• Now: 38-42°C

• In future: ? ?

Cooling • Room temperature in the past: 19 °C

• Now: 20-22°C

• In future: 26 °C

Cooling = additional energy

consumption

Safety of operationHot spots in data centres

Source: IBM


Server: up to 60 % (Blade server, virtualisation)

Room temperature (up to 26 °C): 10-40%

Energy efficient cooling / optimised air flow: 10-40%



Saving potential – IT rooms


Implementation of energy efficiency in glass processing

Company:

• Glass processing company with ca. 100

employees in Berlin Marienfelde

• Total area 10.000 m²

• Production and processing of single-

pane safety glass and laminated safety

glass

• Use of temperature and pressure in

autoclaves, discontinuous

• Mechanical handling

Motivation:

! Increasing energy costs with constant

product quantities

! No data regarding the energy situation

Quelle: BEA

Example:

Glass processing company Bartelt & Sohn

oHG, Berlin, since 2005




Measures:

• Heat supply and implementation of a energy management system by BEA

• central electronic control of energy consumer

• Analysis and evaluation of savings potentials

• Reduction of energy demand

• Reduction of compressed air and waste water demand

+ Implementation as operator model / Contracting

+ Investment and saving risks outsourced

source: BEA

Successes

Primary energy input - 50 %

Compressed air demand - ca. 40 %

Power consumption - ca. 10 %

Waste water costs - 20 %



Implementation of energy efficiency in glass processing


Best Practice – Berliner Immobilienmanagement GmbH

Re-tender after expiration of first energy performance contracting (EPC)

“Pool 24”: 18 office buildings (approx. 300,000 m² GFA)

Baseline 2007: 2.07 million €/a

Guaranteed savings: 21 % = 433,757 €/a

Investment: approx. 2.4 million €

CO2-reduction: 2,208 t/a

Duration: 10 years

Measures (selected): boiler replacement,

CHP-unit, optimizing of ventilation

systems, renewal of CBCS

Special feature: obligation of maintenance of all old systems






Energy efficiency second to none!

EU-wide economical saving potential of 20 % of current total energy consumption in industry branches

Top cost-cutting potential by efficiency measures – economically especially interesting for companies

High level of acceptance: 40 % of the medium-sized companies in Germany wanted to invest in energy efficiency measures in 2009. One of six companies plans on investing over 1 Mio. EUR.

source: Umfrage der Deutschen Bank 400 Unternehmen/ Innovationsreport 02/09

Fields of application of renewable energies

Renewable energies are the logical second step!

Renewable energies can (partly) cover the remaining energy demand.

Environmental advantage, relief of energy costs, competitive advantage ...


Companies and enterprises – Total energy consumption and potentials

Potentials for renewable energies in companies

so far very limited distribution of renewable energies in industry and commerce

(e.g. just ca. 90 facility for solar process heat generation world wide)

high share of total energy consumption, of which are ca. 2/3 heat and 1/3

electricity

Process heat in low and medium temperature level (up to ca. 400 °C) has to

be covered by renewable energies = ca. 60% of required process heat!

Wide range for possible applications of different energy technologies with

renewable energies

Energy intensive branches can develop a competitive advantage by

decoupling form the oil price increase

Renewable energies themselves are a important future relevant branch!




Facility:

• medium-sized company in the field of surface finishing

• Galvanic bath with temperature levels of 75 °C – high energy demand for production processes

• Solar thermal system with 100 m² vacuum collectors for heating of galvanising basins and sinks

motivation and effects:

+ Competitiveness by relief of energy costs

+ Image improvement

source: GROSOL-Studie

Example No. 1: solar thermal

Heat supply for electro plating

Jörg Schiffner GmbH & Co. KG, Menden

2003





Technical concept:

• Establishing a biogas facility in an

suburban industrial estate

• Electricity feed-in and heat supply of

a local heat distribution network of a

candle factory (process heat) and

neighbouring residential buildings

• contracting, CHP (ca. 500 kW) on

the premises of the candle factory

Motivation and effect:

+ Added value for the region and

potential development in rural areas

+ Association of commune, farmers,

operator and factory

+ Image improvement

Quelle: www.bioheat.net

Example No. 2: use of biogas

Candle factory and local heating supply

Feasibility study Altmarkkreis Salzwedel





Facility:

• Transport company, primarily

employed by automobile enterprises

• At the moment 150 trucks in the fleet

• 4 own rapseed oil filling stations with

qualitity tests

• furthemore several efficiency

measures: driver trainings, bonus

system, low-friction oils and –tires

Motivation and effect:

+ Winner of the Green Freight &

Logistics Award Germany

+ Innovation and quality as a unique

selling proposition

Quelle: www.sauberer-fuhrpark.de

Example No. 3: biogenic fuels

Use of vegetable oil for the fleet

AFT H. Altmann Fahrzeugtransporte GmbH

Use of vegetable oil since 2003





Facility:

• Waste water heat exchanger and heat

pump

• Heat use: offices, production

• Heating requirement: 350 kW

• Cooling requirement: 160 kW

• 77 % of energy production is waste

water energy

• Real estate development: GVV

Städtische Wohnbaugesellschaft mbH,

Singen

Motivation und Effekt:

+ Safe, long-term reasonable heat supply

+ Pilot project with participation of the

most important decision makers

Quellen: www.rabtherm.com; www.uhrig-bau.eu

Example No. 4: Waste water heat utilisation

High duty units for heating and cooling of office, commerce and industrial buildings

Schaffhausen (Schweiz), 2006







How can companies implement the use of renewable energies?

Consulting and audits:

Looking for funding of initial auditis

Pilot projects:

Implementation of demonstration facilities are assisted and technically

supported by several programmes

Energy services:

Contracting for implementation of efficiency measures and Renewables

Development and exchange of know-how:

Development of internal decision-making authority of environmental and energy

management

Participation in industry networks („energy tables“)

Recommendations


Conclusion

Various fields of application of energy efficiency measures and renewable

energy technologies

Implementation of efficient motors and low losses in distribution

systems

Insulation and sun protection are very important

Cooling requirements have to be re-consider

Utilisation of waste heat

Implementation of Renewables

Energy management is crucial for best decision




Conclusion

High energy consumption of industry and commerce, rising energy prices

increase the pressure on companies to act

Increasing number of realised projects (best practice) provide security of

action, however, especially organisational obstacles still slow down the

market trend

By involving experts, use of supporting funding and network development

companies can implement energy efficiency and renewable energies



Energy efficiency and Renewables are an investment in the future.

The future of the company and the environment!


Thank you for your attention!

For more information please visit:

www.berliner-e-agentur.de

[email protected]

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Potential and Application of Renewables and Energy …...Dipl.-Ing. Sabine Piller Berliner...

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