Best Practice Pengg - GBEfactory

EXECUTIVE SUMMARY
As the only Austrian manufacturer of oil tempered spring steel wire, the Joh. Pengg AG in
Thörl/Styria, has specialised its product line for applications in the automotive, electrical and
machinery industries. Manufacturing oil tempered spring steel wire is an energy intensive process
with several heating and cooling process steps.
GBE FACTORY MODEL
The Project shows the potential of using
renewable resources and the energy amount that
could be saved through more efficiency in
producing processes.
Using a hydro-electric power plant for electricity
and a biomass plant for heat and hot water.
SPECIFIC PROJECT GOALS:
1. analyse the current energy flow (Sankey
diagram), to assess the possibilities
2. increase the energy conversion
efficiency
3. investigate the possibilities to increase
the use renewable energy sources.
BEST PRACTICE
Johann Pengg AG
QUICK FACTS
LOCATION: 8621 Thörl (Stmk)
ELECTRICITY TECHNOLOGY: Hydro-electric power
Quellen: Bayer, H., Angerer, E., Enzinger, P., et.all, 2003: Abwärmenutzung und Einsatz Erneuerbarer
Energieträger in einem metallverarbeitetnden Betrieb, von http://www.fabrikderzukunft.at/results.html/id1845?active=
Sowie: http://www.wire-pengg.com/kontakt_ag_e.html
plant
TECHNOLOGY/IES HEAT: Biomass, Heat recovery
SITE OWNERSHIP: Joh. Pengg AG
INVESTOR: Joh. Pengg AG
PROJECT COST: not known
KEY PARTNERS: Johanneum Research
CURRENT STATUS: ongoing

CURRENT ENERGY FLOW
Total energy consumption of 45,35 MWh/a
• 26% Electricity
• 74% Natural Gas
What is Electricity used for:
• 58% are used for mechanical energy to
operate the manufacturing lines
• 32% are used for process heat
• 6% are used for lightning
• 4% are used for pressurized air
What is Natural Gas used for?
• 60% are used for direct process heat in
the tempering process
• 29% are used for the production of hot
water process heat and to heat
production buildings
• 5% to operate the gas radiators
• 3% for heating offices and hot water
production
• 3% for auxiliary power and the exomat.
ENERGY CONVERSION
EFFICIENCY
During all the high energy productions steps new
concept of using waste heat were established.
To increase the use of renewable energy it was
suggested to replace the natural gas boiler by a
biomass fired boiler for the production of the
hot water process heat thus reducing the use of
natural gas by additional 9,9 MWh/a.
In addition production waste may be incinerated
in the boiler. The increased use of hydro
electricity is not recommended for economic
reasons.
ENERGY REDUCTION
POTENTIAL
The analysis of the energy conversion processes
identified measures leading to a reduction of
5,70 Mio kWh/a of natural gas and 1,13 Mio
kWh/a of electricity.
The biggest potential is seen in the use of waste
heat of the gas burners heating the wire at the
beginning of the tempering process for
supplying heat to the subsequent process steps
in an energy cascade.
Quellen: Bayer, H., Angerer, E., Enzinger, P., et.all, 2003: Abwärmenutzung und Einsatz Erneuerbarer
Energieträger in einem metallverarbeitetnden Betrieb, von http://www.fabrikderzukunft.at/results.html/id1845?active=
Sowie: http://www.wire-pengg.com/kontakt_ag_e.html

Quellen: Bayer, H., Angerer, E., Enzinger, P., et.all, 2003: Abwärmenutzung und Einsatz Erneuerbarer
Energieträger in einem metallverarbeitetnden Betrieb, von http://www.fabrikderzukunft.at/results.html/id1845?active=
Sowie: http://www.wire-pengg.com/kontakt_ag_e.html