Energy Efficiency Through Process Automation: Effects Through ...

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Energy Efficiency Through Process Automation: Effects Through ...

Energy Efficiency Export Initiative

Energy Efficiency Through Process Automation:

Effects Through Application in Different Subsectors

Felix Seibl

Managing Director

Measurement and Process Automation Section

ZVEI – German Electrical and Electronic Manufacturers`Association

Bangkok, Thailand, October 16, 2012

www.efficiency-from-germany.info


ZVEI – German Electrical and Electronic Manufacturers`Association

One of the world's largest electrical and

electronics industry associations:

• 1,600 member companies

• Member companies representing more than

80 % of the German electrical and electronic

industry

• Expertise provided by 150 employees

• A network of competence comprising over

5,000 experts

2


Agenda

1. What is Process Automation about?

2. Energy Efficiency and Lifecycle Costs

3. Application in Different Subsectors

3


Electrical & Electronic Industry

̶ Turnover 2011 by sectors

4


What is Process Automation ?

Source: Sciencedirect.com

5


Measurement & Process Automation in Germany 2011

6


Process Automation: Market share of world production

2000 vs. 2010

7


User Sectors for Process Automation 2010 (in % worldwide turnover)

Manufacture of

refined petroleum

products

9%

Oil and natural gas

production

15%

Source: ZVEI

Chemical industry

19%

Power industry

15%

Pharmaceuticals

7% Foodstuffs, Bevera

ges

9%

Mechanical

engineering 8%

Water management

5%

Metals and

Mining10%

Pulp and Paper

3%

8


Final energy requirement per user sector (in Petajoule)

9


Agenda

1. What is Process Automation about?

2. Energy Efficiency and Lifecycle Costs

3. Application in Different Subsectors

10


Gross power production in Germany in 2011

11


German „Energiewende“ can only be managed by

increasing Energy Efficiency

12


Primary energy consumption per GDP of different countries

13


Energy efficiency potential is not being harnessed to the

full – especially in Industrial Processes

14


uInvestieren nd Sparen

Investment costs and savings through to 2050

15


Considering the Lifecycle Costs pushes Energy Efficiency

This is because energy efficiency pays off over the lifecycle of an

investment, and that strictly considering purchase costs or a payback

period calculation is too short-sighted.

While the Public Tender Ordinance includes consideration of lifecycle costs

and energy efficiency when choosing a solution, lack of appropriate

calculation methods means these factors are not paid adequate attention

in practice.

To strengthen consideration of lifecycle costs in the public and private

sectors, the ZVEI and Deloitte have developed a practical tool for various

user groups. This presents investment alternatives in a transparent

manner and makes it possible to compare them in terms of energy

efficiency and their economic effects.

16


Lifecycle Cost Evaluation: Wide variety of Applications

Examples of potential application areas include: Wastewater treatment

plants, Foodstuff and Bottling plants, Breweries, Waste incineration

facilities,Power plants , Cement plants, chemical plants, Buildings

17


Gründe, die Energieeffizienz von

Kläranlagen forciert zu betrachten

Practical example of a wastewater treatment plant

• Waste water treatment plants in Germany account for:

20% of the consumption of electrical energy of the municipalities

3 million tons of CO2-equivalents

Source: Umweltbundesamt, Studie 'Steigerung der Energieeffizienz auf kommunalen Kläranlagen(2006)

18


Beispiel 1 : Kläranlage Bachwis,

Fällanden, Schweiz

(Standard/Optimierung )

Example: Wastewater treatment plant – comparison

between standard and optimization

19


Data Input for Project II (Energy efficient optimization)

20


Wastewater treatment plant:

Analysis (Standard vs.Optimization)

21


Examples show: The payback period is often reached

after relatively short time 0,5 to 3 years

22


Public sector can act like a role model

• Lifecycle costs should be a central and contract-related criterion in

awarding public contracts.

23


Agenda

1. What is Process Automation about?

2. Energy Efficiency and Lifecycle Costs

3. Application in Different Subsectors

24


Versatile contribution of process automation to improving

energy efficiency

25


1.

Energiemonitoring/Energiemanagementsysteme

1. Energy Monitoring

26


2. Energy savings in hydraulic systems (pumps)

27


3. Detection of leaks in compresses air systems

28


4. Status monitoring at flow pipes

29


6. Energy efficiency in cement manufacturing

30


7. Energy efficiency in Breweries

CO 2 measurement

31


8. Energy production (biogas plants)

32


Biogas example: Palm Oil

The oil palm (Elaeis guineesis) is worldwide

the most efficient vegetable oil producing plant.

Nevertheless the oil content of the fruits is


Biogas example from Thailand: Vichitbhan Palmoil Co. Ltd

For them the palm fruit is 100% product. 30% vegetable

oil and 70% energy crop. In a special founded company,

they use the empty fruit bunches and the effluent from

the oil factory to produce biogas and green energy.

Source: Endress+ Hauser

34


Biogas is a win-win situation for the owner an the

environment

Treating the highly loaded effluent in the Biogas plant, fulfills the

tough CDM (Clean Development Mechanism) requirement from the

UNFCCC (United Nations Framework Convention on Climate

Change).

The so produced energy can be used in the own factory or sold to

local power grid.

The win starts with the emission reduction, the monitored CER’s

(Certified emission reduction) can be sold in to the emission trading

market.

An installed CDM monitoring system is key

in this concept.

The system ensures the reliable monitoring

of the captured Biogas.

Only this makes emission trading possible.

Source: Endress+ Hauser

35


Many examples can be found in this broschure

36


What areas will your company focus on to decrease costs?

37


Wir machen`s energieeffizient !

Thank you very much for your attention

For further questions:

Felix Seibl, Managing Director

Measurement and Process Automation Section

ZVEI – German Electrical and Electronic Manufacturers`Association

Lyoner Straße 9, D-60528 Frankfurt am Main

Germany

Phone: +49 (0)69-6302-451 Fax: +49 (0)69-6302-319

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