energy efficiency - Thomas Industrial Media

energy efficiency - Thomas Industrial Media

ExclusivE viEwpoint:

Eu commissioner



the greenest city

in europe

rate card 2012


puBlishing schedule,

advertising rates

Volume 1 - November 2011

energy efficiency


Financing EnErgy EFFiciEncy:

Breaking policy barriers

to mobilize private

capital page 30

orhan erenberk

Managing director

thomas industrial Media

Juergen ritzek

Business director


november 2011

dear reader,

Energy Efficiency: business & industry brings together two forces in European

energy efficiency; Thomas Industrial Media (TIM) and Energy Efficiency in

Industrial Processes (EEIP).

TIM is one of the strongest and most trusted voices in business communication

for industrial and process engineers. Since 1975 and through a number of

recognised magazines, TIM has connected industrial manufacturers and users

while remaining at the forefront of technical discussion and solution finding.

Digital versions of its magazines, comprehensive websites and a variety of

other e-media enable TIM to minimise its energy consumption yet increase

the frequency with which it provides technical information and product news


Brussels-based EEIP, on the other hand, is one of the newest organisations set

up to promote business dialogue and better industrial energy efficiency policy.

Established in April 2011 at the European Commission, the purpose of EEIP is

to set forward a business case for energy efficiency. Since then, EEIP has grown

to become one of the most influential voices in EU industrial energy efficiency


What brought these two organisations together is the belief that a more systemic

approach to industrial energy efficiency is necessary; one that involves

not only suppliers and users of energy saving technologies, but also financing,

information technologies, consultants and European policy makers. Furthermore,

our view is that the broadest engagement of all these parties, here in

the present magazine and also in social media, will lead to energy efficiency

policy and solutions which are driven by real business needs and technical


Energy Efficiency: business & industry’s goal is to highlight and showcase innovation

and best practices, and to identify and discuss challenges to industrial

energy efficiency - both technical and policy-related. The magazine will be

published twice per year and we invite and very much welcome your contributions

and suggestions.

The central theme of this first issue is the financing of energy efficiency. This

has frequently been recognised as the principal barrier to the uptake of energy

efficiency. The main feature looks at several funding schemes available in Europe

at this time and what the EU can do to help ‘mobilize the private capital’


Finally, TIM and EEIP would like to thank EU Energy Commissioner Guenther

Oettinger for his kind contribution.

Orhan Erenberk

Juergen Ritzek


energy efficiency | 3











industry news

eeiP eu Policy overview

ExclusivE: eu Commissioner Oettinger

Financing energy efficiency

FEaturE: Green City

Products & solutions



Publishing schedule

4 | energy efficiency november 2011

environmental technology

for a brighter future

Elkem is among the world’s leading companies in

environmentally friendly production of metals and

materials. Its main products are carbon, specialized

foundry alloys, microsilica and silicon qualities for

different applications such as aluminum alloys, silicones

and solar cells. Employing 2,500 individuals

worldwide, Elkem has operations on all continents.

With a continuous focus on research and development,

Elkem’s innovative and technology-intensive

environment has resulted in both radical and incremental

improvements in production processes.

The company’s flagship product is Elkem Solar

Silicon® (ESS), a high-purity silicon metal for the

solar industry. The production of ESS requires only

25 percent of the energy consumed in traditional

solar silicon production. ESS is only one of many

Elkem success stories. The company’s goal is to

produce all our products with the least amount of

energy consumption and with the highest amount

of energy recovery possible, continuously improving

our carbon foot print.

dalkia bolsters its leadership of the european

heating networks market with the

attribution of eu’s largest heating network

The European Commission has given the green light

for the purchase by Dalkia Polska, a 60%-owned

subsidiary of Dalkia International (60%) and IFM -

Industry Funds Management (40%), of an 85% stake

in SPEC SA (Stołeczne Przedsiębiorstwo Energetyki

Cieplnej), which manages the City of Warsaw’s

district heating network. This major foothold in Central

Europe bolsters Dalkia’s leadership in heating

networks and energy services.

november 2011

The deal signed on October 11, 2011 sets the seal

on the privatization process initiated by Warsaw’s

City authorities in February 2011, signaling recognition

of Dalkia’s knowhow in the management and

optimization of district heating networks. It will

strengthen Dalkia’s strategic position in Central

Europe, a region with exciting growth potential,

and confirm its standing as Poland’s no. 1 heating

market operator.

Warsaw’s heating network is the largest in the

European Union, covering more than 1,700 km, and

the third largest in the world after Moscow and

Saint Petersburg. It supplies 80% of the city’s buildings,

primarily apartment houses. More than 10,000

customers daily enjoy local, reliable, competitive

energy. Dalkia has been doing business in Poland

for over 14 years, managing the production and

local distribution of energy in almost forty cities,

including Lodz and Poznan, respectively the second

and fifth-largest in the country. In each of the

installations entrusted to it, Dalkia is deploying its

expertise to supply heat at competitive prices and

raise service standards.

Finnfjord as is now building the largest

industrial heat recovery plant in norway.

Based on the heat generated in 3 ferrosiliconproducing

furnaces the company will produce

340 GWh worth of electricity. This will effectively

reduce the company´s electricity consumption

by 40 %. The heat recovery plant, an investment

of EUR 93 million, will be ready for production

in october 2012. The main elements of the plant

are 2 Waste Heat Recovery Boilers and a Turbine

Condensing Plant (40,5 MW). These contracts

have been given to Aalborg Industries and Man

Diesel and Turbo respectively. The building of this

heat recovery plant is part of Finnfjord´s overall

strategy to become a climate efficient producer

of ferro-silicon, an alloying element, essential in

steel production.

industry neWs

energy efficiency | 5

Energy efficiency in industry has

improved by 30% at an annual average

rate of 1.9% per year with variation

between the member states. This trend

in improving energy efficiency has been

realised in most of industrial branches.

The European Union estimates that the

energy saving potential of the manufacturing

industry for further 25%. Several

ways to achieve this have been seen as

instrumental, like waste heat recovery in

process and manufacturing industry which

holds major energy saving potentials. The

Best Available Technologies (BAT)(see

below) are strongly promoted and encouraged,

and a cross-European exchange

of experiences and best practices will

provide a dynamic for this progress.

European Union published this August

their overview and analyses on energy

use in industry. See http://www.eea.


Energy audits

One of the very few measures EU Energy

Efficiency Directive is proposing is introduction

of mandatory energy audits for

larger companies. The benchmark is set

at companies over 250 employees and

either 50 million euro turnover or 43

million euro balance sheet total.

The European Union envisages these

energy audits to be carried out by

independent consultants, and should

contribute to the companies investment

decisions. The purpose of energy

eeip eu policy overvieW

By dusan Jakovljevic, policy director

potential savings from 1990 to 2008,

in eu-27 countries.

audits is to provide the needed energy

information and data analyses for

efficiency-related developments.

They should also comprise of advisory

services for company to optimise

energy use. Some examples on specific

industries can be found at http://www.


Energy management

Effective energy management has been

seen as the basis of substantive energy

efficiency in industry and reduction of

greenhouse gas (GHG) emissions worldwide.

It took the International Organization

for Standardization (ISO) over three

years to develop International Standard on

Energy Management System (EnMS) IS0

50001 which has widely been anticipated

as the cornerstone of developing comprehensive

understanding and effective energy

saving policies. These were aimed at all

sizes of businesses. Some national experts,

like Erik Gudbjerg of Danish Lokalenergi,

developed striped down concept where

EnMS can effectively be applied even at a

smallest organisation.

Intended purpose of the standardisation

process is to provide businesses with a

recognized framework for integrating

energy efficiency into their management

practices. Furthermore, multinational

companies have access to a single,

harmonised standard for application

across the organization with a effective

and consistent methodology for identifying

and implementing energy efficiency

improvements. The standard itself gives

guidance on benchmarking, measuring,

technical documenting, and reporting

energy intensity improvements.

The standard will, in combination with

energy auditing, provide a solid base

for measuring and assessing of energy

use in European businesses. Some

industry specific examples can be found




Across Europe there have been developed

several incentive and investment tools

to support uptake of energy efficiency at

companies. This has varied from voluntary

agreements between businesses and

national governments to government

direct support and loans. A significant

role in further development of financing

energy efficiency is given to Energy

Service Companies (ESCOs) which were

aimed to spread and ensure value of the

investments. In addition, some major

companies (Siemens, ABB and others)

have developed their own financial services

that will enable business to invest

in energy saving equipment.

Financial service and venture capital

have initially been slow to recognise

potential value and return of these

investments. This is very much changing.

Several major banks (HSBC, Unicredit

and others) are looking for beyond

general 'sustainability' investments or

renewable energies and are actively

developing energy efficiency portfolios.

In certain countries, we see very important

and innovative developments in

investment practices. Like social funds

in Germany, B.A.U.M. Zukunftsfonds has

developed into a major investment company

solely investing in energy efficiency



reAd MOre OnLine!

6 | energy efficiency november 2011

We know that our economic competitiveness

fully depends on a reliable energy

supply: a safe, secure, sustainable and

affordable energy supply is crucial to the

EU's economic and strategic interests as

a global player. The growing EU dependence

on imports from third countries

therefore represents a matter of great

concern, in particular for oil (85 %) and

gas (65 %) and explains why Energy Efficiency

is to be found at the heart of the

EU’s Energy Strategy 2020 adopted in

November last year.

In order to achieve the increase in

energy efficiency a comprehensive mix

of energy efficiency policies and supporting

measures have been implemented at

European and national level promoting a

more efficient use of energy in end-use

sectors such as buildings, household

appliances and industrial equipment,

transport, industry as well as in energy

generation. However, despite the major

progress made, recent Commission

estimates suggest that we are on course

to ac hieve only about half of our ambitious

objective for 2020. If no further

measures are taken, we will only cut our

estimated energy consumption by 10%

in 2020 - instead of our target of 20%. It

is therefore essential that the European

Union acts now to achieve its target and

to give a new impetus to the energy

efficiency agenda in the Member States.

In fact, there is still a vast amount of

untapped potential to save energy which

would save money for individuals and

businesses alike, and reduce waste.

To this end, the Commission decided to

take determined action in order to tap

eXclusive vieWpoint

By günther h. oettinger, european commissioner for energy

energy challenges are among the greatest europe

has to face in the coming decade.

november 2011

the considerable potential for higher

energy savings and energy efficiency

throughout the sectors by adopting a

comprehensive new Energy Efficiency

Plan in March this year.

The Plan puts a strong emphasis on the

buildings sector, where the greatest

challenge is to trigger and accelerate a

process of energy efficient renovations

to reduce energy consumption in our

existing building stock. It proposes that

each year 3% of existing buildings will be

renovated. This is double of the annual

rate for renovating buildings. But beyond

the public sector, there is a need to

create a European market for energy services.

With common standards, targeted

incentives and obligations, we would not

only see our energy costs fall, we would

create a dynamic market for new skills,

jobs and businesses.

As for the industrial sector, the Commission

proposes that large companies have

to do regular energy audits carried out in

an independent manner. Individual member

states are also encouraged to develop

incentives for companies that introduce

an energy management system as a

systematic framework for the rational use

of energy.

For financing of energy efficiency, the

proposed Directive includes provisions to

strengthen the energy services markets.

In these markets energy service companies

(ESCOs) would pay for the initial

investments and get their money back

from the savings on the energy bills. In

addition to energy savings, this will cre-

ate business opportunities and new jobs,

for example, for construction companies,

equipment providers. The energy service

market currently accounts for about ę 6

billion as compared to ę 30 billion in the

USA where it is more developed). The EU

potential for such market is estimated at

ę 25 billion.

Energy Efficiency also represents the

area where consumers can most directly

influence and benefit from the long term

sustainable energy system. Our energy

policies therefore aim to be consumertailored

with an emphasis on further

transparency and information. Consumers

should feel empowered in order to

optimize their energy consumption and

enjoy their right to basic energy needs at

all times, including in a supply crisis. Our

main challenge is to make these technologies

accessible and cost-effective to

the general public. The Energy Efficiency

Plan therefore focuses particularly on

measures improving the energy performance

of households and devices used

by consumers – such as appliances and

smart meters. This of course also requires

the development of appropriate standards

for meters and appliances, obligations

for energy suppliers to provide

consumers with clear information and

access to independent energy advice.


reAd MOre OnLine!

Financing energy eFFiciency

By Juergen ritzek, eeip

investing in energy saving and solutions has a potential to

significantly contribute to bringing europe out of the present

economic crisis, noted claude turmes, Mep.

Turmes called upon European Union,

governments and business to join forces

in realizing energy efficient Europe. He

concluded that investments in solutions

and projects, will not only create a multitude

of new jobs, lessen environmental

impact in Europe, but also form a solid

foundation for fast economic recovery and

ensure continuing growth.

Still, many questions remain unanswered.

How should policy ensure these developments

and secure investments?The

Energy Efficiency in Industrial Processes

(EEIP) finance round-table, ‘Mobilizing

Private Capital,’ aims to deal with these

questions. By drawing in views from

industry, finance professionals and policymakers

. This is an on-going process, and

industries and businesses are invited to



Industry in Europe works in a dynamic environment

that is increasingly global. To

remain competitive within the European

internal market or globally, industry has

to continually try to have an edge over

its rivals. In growing markets, it means

having the most advanced production

processes that increases output and

ensures quality. In stagnant markets,

as many are experiencing today, it is a

question of preparing for changing market

conditions. The last thing industry wants

to do is reduce the labour force, which

is often highly skilled. That can kill recovery

when it comes. But, there are other

options for reducing costs. Improved

energy management through a combination

of better procedures and more energy

efficient systems can make a big difference.

And, by doing so, it can enhance

the reputation of the enterprise. And it

can provide that competitive edge one

always seeks. Studies, such as a recent

one by the European Climate Foundation

, shows that there is still significant costeffective

potential for energy savings in

the industrial sector.

Why has there been a slow uptake on energy

efficiency projects in Europe? There

have been good government programmes

in many member states. There have

been various incentives. There has been a

myriad of voluntary schemes. So, what is

the problem? Next to availability of information,

and exchange of best practices,

finance has been again and again been

brought up as the main barrier for a significant

uptake of energy efficiency, both

in buildings and manufacturing industries.

Are there no funds available to invest in

energy efficiency? Who decides on these

investments? The prevalent view is that

investment decisions in energy efficiency

are conducted through traditional capital

budgeting analysis. Energy efficiency

investments do not differ. Investment risk

and return assessment, transaction costs,

all form the basis of decision-making


Should energy efficiency investments

have a different status within a company?

At least as they are often complemented

by several further factors Company organ-

isational culture and views on energy and

environmental matters, internal structure

and management priorities, link to core

business and customer communications.

These behavioural and organisational

factors supplement and, to various levels,

influence financial factors in investment


Snowflake problem: Assessing

the risk

One questions raised time and time again

is how to measure energy efficiency

and how to evaluate value brought by

8 | energy efficiency november 2011

the investment. The difficulty is, what

has been named a snowflake problem,

that every energy efficiency project is

different. Even within the same organisation,

different manufacturing installations

very often have different levels of

energy use and saving potentials. This

has been raised as a major issue for many

years and there is no clear cut answer

whether this is real or just an excuse. An

estimation of energy savings for investment

purposes partly depends on the

development of standardised energy

management systems and tools. This can

be supplemented, or form the basis of,

with energy auditing processes. Simplified

and standardised information will provide

a long way forward to lessening risk and


Energy management is business


A further barrier are internal company’s

management style and priorities. Very

often in the company, those responsible

for energy and resource management

and not the same as those running the

business. In fact, in large companies, that

would always be the case. Top level managers

tend to focus on core business, and

everything that is less-related receives

secondary attention. This ‘divided commitment’

also puts a strain on internal

economic responsibility and therefore on

perception of viability of the investment

project. Getting back to the points raised

earlier about growth priorities and cost

cutting priorities, business case for energy

efficiency needs to be built around the

core business. An approach that effective

energy management is an inseparable

part of effective business management

will increase investment certainty and

profitability. It has to be part of the strategic

thinking of a company, especially as

energy prices fluctuate (generally upward)

causing havoc for managing overall costs.

Three-line motorway

Where can money come for energy efficiency?

Depending on the priority energy management

is given, it can come from the

november 2011

same source that the company uses for its

day-to-day financial management. It also

comes indirectly through such options as

tax credits, accelerated depreciation allowances

(depending on the country) and

a host of other tax incentives available.

On the external side, companies can

already tap into full financial packages

as offered by e.g. Siemens or Johnson

Controls. This is very often even separated

from acquisition of equipment meaning

that users are free to follow advice and

select the most suitable solution. As in the

case of the UK, where Siemens Financial

Services have set up a dedicated GBP

550 million fund and teamed up with the

CarbonTrust to “manage” it, sometimes

these funds are operated by a third, often

no-for-profit, party. This model is based on

shift in suppliers’ business model from the

technology provider to service provision.

Investment funds for private or institutional

investors are another obvious source

and potentially the next big step in financing

energy efficiency. They offer low risk

and predictable cash flows, in other words

exactly what private and institutional investors

are looking for in today’s turbulent

times. However, there are still some “operational”

questions to be answered. How

can an institutional investors fund, e.g.

from SUSI Partners Switzerland, deliver a

track record and the ticket size requested

by a pension fund? Or in the case of a fund

offering an investment opportunity to

private investors, e.g. the BAUM Zukunftsfonds

in Germany: Their offer is “5

years, 5.000 Euro, 5% return” – but how

to communicate a marketing story, how to

convince banks to sell this bonds?

Potentially the fastest highway lane could

come from public guarantees. Instead of

paying for, a public authority would guarantee

the investment to the intermediate

who in turn can access favourable bank

credits. EnergiMidt of Danemark together

with the Danish Export Credit Fund is a

successful example. In many new Member

States, there are also special funds set

up by international financial institutions

such as the European Bank for Reconstruction

and Development.

Where next?

Financing energy efficiency must be

developed into a business case internally

in the company and externally from an

investor’s perspective. Internal energy

management will contribute to the assessment

of financial risk and benefits

by investors. Use of standardised and

effective measuring tools and assessment

methodologies in estimating energy savings

and increased value is a cornerstone.

Penetration of awareness on energy and

environmental issues is another one.

Finally, investment in energy efficiency

in Europe needs clear and comprehensive

strategy. One that will both include

initiatives and ideas from financial

sector and avoid one-size-fits-all

policy for industry. It is unfortunate that

discussions at the EU level are often

reduced on pro and contra mandatory

binding targets on energy efficiency.

Arguments that this will ensure investment

certainty are inconclusive and not

evidence-based. Open engagement of

this issue with the broadest range of

stakeholders will enable the EU access

to fresh thinking and functioning financial

mechanisms. This will also bind

together forces and efforts that will lead

to energy efficient Europe.

EEIPFin Roundtable

EEIPFin Roundtable is organised in

co-operation with the Confederation of

Danish Industry on 10 November 2011

in Brussels. It brings together relevant

stakeholder from policy and business as

well as the financial sector. Organisations

and companies involved include

Siemens, Dalkia, Johnson Controls,

Danfoss, EnergiMidt, Danish Representation

to the European Union, European

Bank for Reconstruction and Development

(EBRD), HSBC UK, SUSI Partners,

European Investment Bank (EIB), Commerzbank,

Danish Export Credit Fund,

European Investment Bank (EIB), Hudson

Clean Energy, Unicredit, European Commission

and the European Parliament.

energy efficiency | 9

At least according to the European Green

City Index, based on a study conducted

by the Economist Intelligence Unit and

sponsored by Siemens.

But why are cities relevant for industrial

energy efficiency? First some facts.

Globally, more than half of the population

lives already in cities. And cities are said

to be responsible for more than 80% of

humanity´s greenhouse gas emissions,

coming from transportation, heating and

the use of electricity. And here is the link

to industrial energy efficiency. Where

is the heat and electricity coming from

and what are concepts to use less and

greener heat and electricity?

The study analyzed 30 major cities in

Europe with roughly 75 million citizens.

Feature: green city

the greenest city in europe ?

and the winner is… copenhagen.

30 individual indicators and 8 sub

categories were used. The latter are

ranging from buildings, transport and

water to CO2 and energy.

District heating and cooling can play an

important role to reduce CO2 emissions

and to use energy in an efficient way –

while at the same time, industrial waste

heat recovery is still widely unexploited.

Although some companies “just” do it,

like Norwegian Finnfjord or Elkem, the

underlying business cases are very much

dependant on topics like access to

networks or legislation for grid access.

And Copenhagen? Copenhagen excels

in heat recovery from waste incineration

in CHP production and has an extensive


district heating network. And to make

this even smarter has therefore initiated

a Smart City project consortium with

other frontrunner cities and some

industry partners to participate in an EU

FP 7 project.

Last but not least, people matter: A

2008 Siemens study in conjunction

with McKinsey about what would help

London most to reach its long-term

carbon reduction targets found out

that 75% of all technological changes

depend on decisions of its citizens. Or

as Phillipe Mack, the Managing Director

from Pepite-Energymaestro, a globally

active data mining and energy efficiency

performance management company

stated: “The Europeans focus on figures,

the Americans on people”.

Studies referred to

The European Green City Index


Sustainable Urban Infrastructure




10 | energy efficiency november 2011

A leading worldwide supplier

of control systems and services

Johnson Controls delivers products, services

and solutions that increase energy efficiency

and lower operating costs in buildings for more

than one million customers. Operating from 500

branch offices in more than 150 countries, we

are a leading provider of equipment, controls and

services for heating, ventilating, air-conditioning,

refrigeration and security systems.

We know buildings and how to keep them

working efficiently and cost-effectively. From

preventive maintenance to retrofits to performance

contracting, our focus is on creating comfortable,

safe and productive environments.

Johnson Controls Inc.

Energy Solutions

Pegasus Business Park

De Kleetlaan 3

1831 Diegem, Belgium

Tel: +32 (0)2 709 40 00

Fax: +32 (0)2 709 44 18


aBB drives save pfizer

€28,000 a year on chiller applications

ABB motors and variable speed drives

(VSDs) are saving Pfizer ę28,000 a year on

electricity costs for its chiller applications

at its Ringaskiddy plant. Located in County

Cork, Ireland, the plant produces a wide

range of bulk pharmaceutical products for

shipping to other Pfizer facilities worldwide

for finishing and packaging.

The company had identified the plant chillers

as prime targets for improving energy

efficiency. The chillers use circulation

pumps to pump heat transfer fluid to and

from the cold storage tank. Pfizer process

engineers had identified potential improved

pumping efficiencies and had asked

ABB drives and motors vendor Caltech, in

association with EMSA Consultants, to investigate

the possibility of reducing energy

consumption on these drives.

An energy appraisal found that the application

included three 45 kW motors and

one 37 kW motor, all of them run with soft

starters. For best efficiency of the process,

the pumps needed to maintain a constant

flow rate of 185 m3/hr, but the pumps

were actually rated for 240 m3/hr. To

achieve the optimum flow rate, gate valves

were used to throttle the pumps.

Sean Lee of EMSA says: “In conjunction

with Pfizer Process Engineering we decided

that the best way of achieving both

the optimum flow and energy saving was

to open the valves fully and use variable

speed drives to maintain the optimum

flow. We found that we could achieve the

desired flow rate by running the motors at

35Hz rather than 50Hz.”

EMSA used ABB’s Pumpsave energy saving

calculation program, which predicted an

energy saving of 50 per cent per motor,

with cost savings for each motor of around

ę7,200, a total of over ę28,000 per year.

Based on a running time of 4,360 hours,

this would give a payback time of two and

a half years. Pfizer was also able to take

advantage of an Accelerated Capital Allowance

scheme run by the Irish government

that allows companies to write off 100 per

cent of the purchase value of qualifying

energy efficient equipment against their

profit in the year of purchase.

A full turnkey solution provided by Caltech

comprised new VSDs, installation, project

management and supervision, drawings,

commissioning and full handover to the

client. New high efficiency ABB EEx de

IE2 motors were also supplied and laser

aligned with the pumps.

As well as energy saving, the project has

had numerous other related benefits, such

as a reduction in CO2 emissions.

Says Lee: “Reliability will also be improved

as high efficiency motors are less likely to

break down and also should not require

rewinding or need their bearings replaced

for many years. Their cooler running temperature

will also mean less mechanical


As well as running the motors at lower

speed, VSDs can be controlled by external

signalling sources in order to maintain

the best flow conditions. Pfizer hopes to

eventually control the drives from the flow

meters on the coolant pipelines, giving

optimum flow control by matching the

speed of the pumps to exact flow demand

at all times.

Ô ABB drives

Frequency inverters & soft starters

Will provide energy savings and improved

reliability for desalination plant

A Spanish consortium is constructing

the Tlemcem-Honaine desalination

plant, located near the Algerian city of

Oran, close to the border with Morocco.

When complete the plant will be one

of the largest in the world.

Algeria is the second largest country in

Africa, with 33- million inhabitants, and

water is extremely scarce. The Sahara

desert, the largest in the world, covers

more than 90% of the national territory.

This means that the area Algeria

can set aside for crop cultivation is

very limited. Planning ahead for this

eventuality, the government of Algeria

is making large investments in seawater

desalination projects: specifically,

the construction of three large desalination

plants, with a total production

capacity of 500,000 cubic metres of

water a day, providing drinking water

for a population of three- million. Two

of these plants have already been built

and are operational, with the third,

the Tlemcem-Honaine plant, presently

under construction.

WEG’s role in this large scale project is

the supply of soft starters and frequency

inverters for the pumps that will extract

water from the Mediterranean Sea at

Honaine. The contract for the equipment

was secured by WEG Iberia,

12 | energy efficiency november 2011

Spain, through its distributor Flomitec,

a company specializing in drives &

controls for electric motors. The WEG

equipment has been integrated into

electrical control panels by Electricidad

Tebar, a company that specializes in the

assembly of electrical control panels for

use in water sector infrastructures. The

equipment has already been delivered

to the Algerian Energy Company: it will

provide soft starting and speed variation

for the extraction pumps, which will

result in higher efficiency, energy saving

and improved reliability. The investment

by Algeria in the three plants totals US$

400m. In an interview with the Algérie

Presse Service, the Minister delegate to

the State Minister of Interior and Local

Communities of Algeria, Daho Ould

Kablia, said that the country will invest

US$ 19- billion in the water supply

sector up to 2014, with the objective

of expanding the supply of water per

person to 165 litres per day. In addition

to desalination plants, further investments

will be made in the construction

of dams and for sanitation. According

to Daho Ould Kablia: “With the new

programme, the Algerian government

intends to find a balance between the

different regions of the country, and

provide a fair supply and distribution of

water and the services related to it.”

Fresh water is scarce in the world.

Although two- thirds of the planet is

made up of water, only around 3% is

fresh water suitable for consumption,

irrigation or for use in industry. However,

seawater is plentiful. For many

countries, the only policy is to make

large investments in technology to desalinate

sea water and use the resulting

liquid for consumption.

There are approximately 14,000 desalination

plants worldwide, most of them

in the Middle East. According to data

november 2011

from the International Desalination Association,

they produce today over 59.9

billion litres of water per day. The desalination

of water is achieved through

a process known as Reverse Osmosis.

High pressure pumps draw the solution

making it pass through semi-permeable

membranes, which are like filters. The

salt is retained in these membranes

and what comes out on the other side

is a “pure” water solution.


energy savings estimator

For frequency inverters

The majority of pump and fan applications

make use of an asynchronous

three-phase motor. The characteristic

feature of this type of motor is the

fact that its speed depends on the

frequency of the mains supply, which

in Western Europe is normally 50 Hz.

The motor is then dimensioned in

such a way to achieve the maximum

required output. However, as a pump

and a fan seldom have to deliver the

maximum delivery volume, users

install valves to limit the flow. This

means then that the lost energy is

often greater than the actual effective

energy. State-of-the-art frequency

inverters save a considerable

amount of this energy. Eaton'sEnergy

Savings Estimator is an easy-to-use

calculation tool that enables users

and planners to calculate the savings

potential of individual mechanically

controlled fans and pumps and

those controlled electronically with a

frequency inverter. Only some basic

specifications of the system in question

are required.

Energy Savings Estimator Software Tool

In order to compare different control

technologies in a system some

information needs to be entered. This

includes the energy costs per kWh, the

required output of the system and the

flow volumes over time. The Energy

Savings Estimator is a free software

tool that enables users to compare

the energy efficiency of pumps or fan

systems quickly and clearly with and

without a frequency inverter with only

a few entries required and print out the

results as a document for customers or

plant operators.

The Eaton Energy Savings Estimator

is a program that determines the

motor data, the load profile and the

operating hours with only a few inputs

required. The tool shows the following

savings options: Expected energy and

CO2 saving (foot print) as well as the

payback times when using alternative

drive solutions. The program takes all

important factors into account such

as running time, output requirements,

energy and investment costs. The

energy savings report also offers several

graphic representations that can

be selected by the user. The program

also creates additional charts that are

made available by simply clicking the

appropriate buttons. The Eaton tool can

be downloaded at:

moellerproducts, then enter Quicklink

ID: ES2306

Ô Eaton

energy efficiency | 13


automation solution unifies plc, it,

and motion functionalities

Helps maximize energy efficiency in

machine designs

Constituting the fourth pillar of the

MachineStruxure solution package for

machinery applications, PacDrive 3

system from Schneider Electric unifies

PLC, IT, and motion functionalities on

a single platform. The use of SERCOS

III gives the system a powerful, internationally

accepted, Ethernet-based

bus solution that also offers integrated

safety communication. Corresponding

safety controllers as well as components

for creating safe I/O systems are already

available. With the imminent introduction

of integrated ILM series servo drives

as a counterpart to the highly successful

iSH drives from the previous PacDrive M

generation, the PacDrive 3 system will

be enhanced to include all key components

for innovative automation solutions

with up to 99 servo axes or up to

30 robots. The MachineStruxure includes

the Modicon, Altivar, and Magelis series

controller families and can be used in a

variety of filling and packaging machines,

as well as feeding and handling

tasks based upon classic PLC designs,

either with or without positioning and

servo applications.

The extensive portfolio of automation

components and electrical equipment

offered by the company provides a

framework for complete system solutions

for all controllers. Machine builders

can use the same peripherals for both

PLC-controlled machines and robotassisted,

high-performance systems. The

idea of shared utility is also consistently

reflected in SoMachine, the engineering

workbench for MachineStruxure. SoMachine

includes all of the tools necessary

for the engineering, commissioning, and

servicing of automation solutions based

upon MachineStruxure.

The company offers machine builders

the wide range of engineering

and simulation tools, well-engineered

hardware and software products, and

appropriate measurement technology

that they need to develop energy-efficient

machinery. It also offers consulting

services to help its customers

explore options for maximizing energy

efficiency in their machine designs.

Ô Schneider

energy chain

Fast, quiet, low-vibration

Energy chain

expert igus

has completely


many features

of its “quiet

chain”, the

fast, quiet,


“E6” series.

The significant

weight saving of up to 37 percent

(compared to the existing “E6.29”) results

in greater dynamics and less drive force .

It is also 2 dB (A) quieter compared with

the “E6.29”. In addition, the new energy

chain is much more modular, it can be

extended and shortened as required by

simple clipping and can be assembled

and taken apart again quickly. The opening

cross-bars can now be swung open

to both sides by 115 degrees on both

the inner and outer radius and no longer

have to be removed completely, although

this is still possible if required.


embedded industrial pcs

with intel Atom processors

The Siemens SIMATIC IPCs in the

nano-format are particularly compact,

flexible and energy-saving. At the core

of the SIMATIC IPC227D Nanobox


Nanopanel PCs are the latest generation

of power-optimized Intel Atom

processors E6xx series. The Nano IPCs

are designed for maintenance-free,

24-hour service even when subjected

to high temperatures, vibration, shocks

and electromagnetic interference. The

units are suitable for simple control,

visualization and communication tasks

and can also be used as data loggers in

areas such as machine building, traffic

control, building automation systems

or energy transmission.

The product line starts with two basic

designs and a number of different versions:

Nanobox PCs with compact dimensions

of 191x100x60 mm (WxHxD)

and versatile installation and expansion

options and Nanopanel PCs with 7”,

9” and 12” high-resolution industrial

14 | energy efficiency november 2011

touch displays in widescreen format,

with a wide viewing angle and with

LED backlight which is dimmable up to

100%. Ready-to-run packages comprising

both computers and software

allow the units to be put into service



needle roller Bearings

system downsizing and reduced friction

enable more energy efficient systems

Enabling more

energy efficient

systems due

to downsizing

and reduced

friction, the

three new high

precision roller bearings, introduced by

The Schaeffler Group, include the X-life

machined needle roller bearing version

D; the X-life machined needle roller

bearing with TWin Cage; and a slimline

drawn cup needle roller bearing, which

has a radial section height of 1.5mm.

Benefiting from a new profiled steel

cage, the X-life machined needle

roller bearings version D offers an

increase in load ratings of up to 25%.

The number of needle rollers and the

length of needle rollers can be increased

without increasing the overall

dimensions of the bearing. The X-life

NK20/16-D-XL with a 20mm diameter

bore and a 16mm width, for example,

offers a higher load carrying capacity

than the X-life NK26/16-XL needle

roller bearing, which has a larger bore

diameter of 26mm. In addition to the

new X-life NK20/16-D-XL needle roller

bearing, the new range also includes

the NK55/25-D-XL, as well as three additional

sizes: the NK14/16-D-XL, the

NK28/16-D-XL and the NK37/20-D-XL.

november 2011

Together, these five bearing sizes offer

numerous downsizing options for radial

needle roller bearings, i.e. the enveloping

circle diameter of the new bearings

ranges from 14 up to 70mm. The

new machined needle roller bearings

with TWin Cage are manufactured in

plastic and provide higher efficiency as

a result of lower friction. Rather than

a single long length needle roller, this

new bearing uses two short needle

rollers, which are inserted next to

one another in a single cage pocket.

This unique combination of cage and

rolling elements reduces friction by

up to 25% compared to conventional

needle roller bearings. For example, the

power loss due to friction of an X-life

NK45/20-TV-XL machined needle roller

bearing with new TWin Cage operating

at 4,000rpm is 25W-30W less than a

bearing with conventional plastic cage.

This means that the use of only one

needle roller bearing with a TWin Cage

saves a similar amount of energy to

that required to operate a light bulb.

In addition, the new bearings operate

with reduced heat generation, resulting

in increased grease operating life and

therefore longer lubrication intervals. The

accuracy of the application also improves

due to reduced fluctuations in temperature.

The new slimline drawn cup needle roller

bearing also makes a significant contribution

towards lowering friction and improving

energy efficiency. The radial section

height of the new bearings is just 1.5 mm.

For a drawn cup needle roller bearings with

diameters from 15-50mm, a section height

of 1.5mm is the current limit in terms of

how small the bearing and cage can be

manufactured. Currently, the smallest

section height available from most other

bearing suppliers is around 2.5mm. This

means the new slimline drawn cup needle

roller bearings are equivalent to plain

bearings in terms of their external dimensions,

which makes them ideal for

replacing plain bearings, particularly in

automotive applications such as automatic

transmission systems and gearboxes. Other

advantages of slimline drawn cup needle

roller bearings are that they reduce friction

by up to 60% compared to conventional

plain bearings. They also help to simplify

any adjacent structures or components and

increase the accuracy and reliability of the

system. A fine oil mist is sufficient for these

bearings’ reliable operation as opposed to

the need for the plain bearings to receive

direct, adequate supply of oil from inside

the transmission. Thus, complex oil feed

systems are no longer required, whilst

any oil pumps within the system can be

replaced with smaller, more cost effective


For reliable operation, plain bearings

also require a load-bearing lubricant

film. The reduced frictional torque of a

rolling bearing compared to a sliding

lubricant film or layer results in

reduced breakaway torque during start

up. This means that slimline drawn

cup needle roller bearings offer higher

operational reliability, for example, in

start-stop applications. In addition, the

transmission oil will not be contaminated

by fine wear debris from the sliding

layer found in plain bearings. The

oil therefore remains cleaner if slimline

drawn cup needle roller bearings are

used. At the same time, accuracy also

increases because the bearing clearance

on the shaft also increases due to

abrasion or wear in the plain bearings.

The high accuracy of a drawn cup

needle roller bearing throughout its

operating life contributes to reduced

clearance of the gear teeth, which in

turn increases the reliability and operating

life of the transmission system.

Ô Schaeffler

energy efficiency | 15


oil-free rotary screw Z compressors

Certified 100% pure, clean air with

maximum energy saving features

Atlas Copco’s Z 55-900 VSD Pack and

Full Feature ranges power your production

with ultimate reliability and

efficiency under the harshest conditions.

The first air compressors in the

world to be certified Class 0 according

to ISO 8573-1, they ensure completely

oil-free air to protect your process and

end products. Several energy saving

features – Variable Speed Drive, energy-free

MD dryers and energy recovery

– are offered. Z 55-900 VSD compressors

are all-inclusive, plug-and-play

packages that ensure easy and low cost

installation and a quick start-up.

Ô Atlas Copco

Making buildings intelligent is becoming


no wires and no batteries

Making buildings intelligent is becoming

easier thanks to a new partnership

between GE Energy and German technology

company EnOcean. EnOcean's

battery free wireless technology is be-

ing integrated into GE's HabiTEQ building

control and automation systems

providing installers and architects with

the flexibility to install applications in

locations where it is not currently practical

to connect with existing devices.

HabiTEQ systems deliver enhanced

energy efficiency and consumer convenience

through the control of energy

usage in both domestic and commercial

buildings. Wireless systems make

installation cheaper and simpler and

also offer aesthetic and practical benefits

such as the ability to fit devices

such as sensors and ultra-thin switches

on glass panels or in historic buildings.

EnOcean equipped devices are zero

maintenance and "harvest" energy

from ambient heat and light or from a

switch being pressed which, together

with the reduced need for batteries,

makes them an environmentally

friendly way of increasing efficiency.

GE Energy's partnership with EnOcean

was announced during an event for

French press and trade, June 6, at the

Eiffel Tower in Paris, which showcased

pre-launch examples from the a range

of over fifty HabiTEQ wireless products

which will be made available in spring

2012. HabiTEQ is a flexible integrated

system that runs a building's functional

subsystems, including lighting, heating,

ventilation and security from a central

control unit operated via a control

panel or on-line. It can be programmed

with a personal computer and can also

operate automatically or in response to

environmental stimulus; e.g. changing

the heating in a room in response to

changes in external temperature, time

of day or human presence. This enables

the sort of energy efficient interaction

between the subsystems that is almost

impossible with conventional technology.

In addition most HabiTEQ devices

are equipped to measure energy usage,

enabling users to identify further opportunities

to reduce costs.

Each HabiTEQ system is bespoke made

to deliver the combination of flexibility,

energy efficiency and convenience that

each building and customer requires. It

can incorporate a building's electrical

protection and arrives on site as a pre

prepared "plug and play" system requiring

only a competent electrician to

get things up and running and can be

configured to manage renewable inputs

such as solar panels or electric vehicle

chargers and enable utilities implement

the smart energy technologies.

Ô GE Energy

three-phase ac Motors

reduce energy consumption by approximately

41 %

Lenze offers the new IE2 motors with

highly efficient axial and right-angle

gearboxes within the L-force drive

and automation platform. The use of a

geared L-force motor, consisting of an

IE2 three-phase AC motor and a GKR

bevel gearbox, can thus reduce energy

demand by approximately 41 percent

compared with a standard solution with

a worm gearbox and an IE1 three-phase

AC motor. The high efficiency reduces

the heat loss and thus prolongs the

service life of the components, including

longer maintenance intervals and,

in this way, an increasing availability.

Ô Lenze

16 | energy efficiency november 2011

think industrial, think thomas

At Thomas Industrial Media, we benefit from decades of experience and

publishing excellence, which we want you to benefit from as an advertiser.

Our goal is to bring buyers, suppliers and policy makers together, and to be

the solution provider for the whole industrial buying process. We achieve

this by creating awareness, supporting the identification of new suppliers,

providing up-to-date information on products, solutions and vendors, and

offering measurable benefits to advertisers and users.

Advertising with Thomas Industrial Media offers you a fully customizable

offer between print, online, and digital media, all across Europe.

We aim at maximizing the value of your media buy through our

multiple media packages.

energy efficiency: Business & industry’s

goal is to highlight and showcase innovation and best practices,

and to identify and discuss challenges to industrial energy efficiency -

both technical and policy-related.

regular columns will comprise:

• EU policy overview, laws and regulations

• Developments in energy efficiency financing

• Developments in energy efficiency technology

• Case studies and application stories on energy saving solutions

• News on energy saving products

• Research results on markets, changes and developments

november 2011

energy efficiency



EU Commissioner









ratecard 2012

Volume 1 - November 2011

energy efficiency



Breaking policy barriers

to mobilize private

capital page 30

energy efficiency | 17


the circulation of energy efficiency has been carefully selected from

thomas industrial Media’s database of 406,000 qualified industrial decison-makers

across europe, as well from eeip’s exclusive list of 4000+ members

total circulation : 20,000 copies



General and Corporate Management 11455

Product Design Engineering 2333

Systems Design Engineering 1522

Production Engineering 1783

Operations/Maintenance Engineering 2907

Total 20000



Industrial Chemicals 1878

Agricultural Chemicals 46

Pharmaceuticals 52

Plastics, Rubber, Petroleum 1291

Soap, detergents, cosmetics, paints, sealants 84

Food, drinks, tobacco 838

Textile, Apparel, leather 579

Lumber, wood, furniture 219

Paper & Printing 439

Stone, clay, glass 189

Primary Metals 351

Other Processing 331

Fabricated metal Products 697

Machinery (except electrical) 3422

Electric, electronic, computing 2129

Scientific, measuring, control 976

Automotive, aircraft, transportation 1095

Other Manufacturing 1280

Energy & Water supply 774

Engineering, consulting, contractors 3022

Public Administration, Government, Defense 307

Total 20000



Austria 228

Belgium 899

Denmark 215

Finland 135

France 3428

Germany 4848

Greece 296

Ireland 163

Israel 205

Italy 2022

Netherlands 1154

Norway 119

Portugal 339

Spain 995

Sweden 231

Switzerland 383

Turkey 561

UK 3032

Eastern Europe 746

Total 20000

18 | energy efficiency november 2011

publishing schedule & rates


Closing Mailing Shows / Events Dates

APRIL 16.03 11.04 Hannover Industry Fair, Hannover 23-27.04

Control, Stuttgart 08-11.05

Automatica, Munich 22-25.05

Sensor+Test, Nuremberg 22-24.05

Achema, Frankfurt 18-22.06

NOVEMBER 19.10 14.11 SPS/IPC/DRIVES, Nuremberg 27-29.11

Pollutec, Lyon 27-30.11

Ô A4 Sizes W x H 4C in Euro (Excl. VAT)

a. 1/1 180 x 262mm 9590

b. 1/1 Bleed 220 x 307mm 9590

c. 2/3 Vertical 119 x 262mm 7950

d. 2/3 Horizontal 180 x 171mm 7950

e 1/2 Page Island 119 x 170mm 7250

f. 1/2 page Horizontal 180 x 125mm 6850

g. 1/2 Page Horizontal Bleed 220 x 150mm 6850

h. 1/2 Page Vertical 88 x 262mm 6850

i. 1/2 Page Vertical Bleed 108 x 307mm 6850

j. 1/3 Horizontal 180 x 80mm 4050

k. 1/3 Horizontal Bleed 220 x 105mm 4050

l. 1/3 Vertical 57 x 262mm 4050

m. 1/3 Vertical Bleed 77 x 307mm 4050

n. 1/4 Page 88 x 125mm 2750

o. 1/8 88 x 57mm 1450

Inside Front Cover, Back Cover +15%

Special Positions +10%



Trim Size 210 x 297mm

Type Area 184 x 271mm


november 2011

Feature articles planned

for 2012

1. Industrial Energy Recovery:

Technological and market

barriers and saving potentials

2. Developments on Energy

Management: ISO 50001 in

manufacturing business

3. Financing Energy Efficiency

in Industry: public private


4. Energy Auditing: Basis for

saving energy?

5. Financing Energy Efficiency

in Industry: national schemes

(Germany, Italy and the UK) and

EU initiatives

6. Resource and Materials

Efficiency in Manufacturing:

Forthcoming EU policy

7. Financing Energy Efficiency in

Industry: Energy efficiency as

an asset class

8. EU Emission Trading Scheme

(ETS): Phase III (2013–20)

and how it will affect EU


9. ‘Factories of the Future’:

EU support in industrial design,

research and engineering

10. Eco-design - Products and

Processes: Building upon EU

policies on pumps and motors

11. Jobs of the Future: Education

and training in energy

efficiency in practice

a. b. c. d. e. f. g. h. i. j. k. l. m. n. o.

energy efficiency | 19


EU Commissioner









energy efficiency



Breaking policy barriers

to mobilize private

capital page 30

Energy Efficiency


Circulation: 20 000

IEN Europe


Circulation: 50 679

IEN Italia


Circulation: 14 024

Publisher of

TR -

Technische Revue


Circulation: 41 370


Produits Equipements Industriels


Circulation: 52 012

PCN Europe


Circulation: 40 222

Manutenzione Tecnica

e Management


Circulation: 9 005

Il Distributore Industriale


Circulation: 6 019

Power in Motion


Circulation: 27 241

Endüstri Dunyasi


Circulation: 8 190

your energy efficiency

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it, Finance & utilities:

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