Transcript Perspectives of energy substitutions in industrial processes

The contribution of electro-technologies
to energy efficiency
Paul Baudry, Marie-Ann Evans
UIE (International Union for Electricity applications)
Conference on Energy Efficiency in IPPC installations – Vienna 21-22 October 2004
Outline
• Electricity and energy consumption
• The influence of energy accounting system
• Efficient electro-technologies in industry
• Conclusion
2
Global Trends in Energy use : 1970-2000
The sector of
manufacturing
(industry)
shows the
highest energy
intensity
decrease
Source : 30 years of
energy use in IEA
countries
3
Global Trends in Energy use
Final energy consumption by energy sources
Source : 30 years of energy use in IEA countries
4
Energy efficiency and electricity
electricity use follows the GDP
450
450
400
400
350
350
300
300
Mobility
OCDE
OCDE
Electricity
OCDE
Thermal
stationary
250
250
200
200
GDP US$95
150
150
100
100
50
50
0
0
5
Energy accounting system
primary to final energy
HEAT
USE
ELECTRICITY
combustion
FF (coal, oil, gas)
turbine
Mechanical
Electromagnetic
Natural geothermic
NUCLEAR
RENEWABLES
Coefficient of electricity generation
EU Average : 40 % or 1/2,5
6
Energy accounting system
primary to end-use energy
14 %
20 %
70 %
Final
Energy
Useful
Energy
40 %
Primary
Energy
100 %
ELECTRICITY
40 %
16 %
7
Energy Efficiency through Electro-technologies
in various industrial sectors
Sector
Established
Techniques
Emerging
Techniques
Food industry
- MVC (liquid concentration)
- Membranes (separation)
- Electric Tubular Heat Exchanger
- Heat Pump (heat and cold)
- High Electric Pulse Fields
- High Pressure
- Ohmic Heating
Chemical
industry
- Motors for basic chemicals (v.s.
turboengines)
- heating in small processes (resitances and
induction)
- Electric Tubular Heat Exchanger
-Electric Arc Furnace (steelmaking)
- Induction in foundry
- Resistance ovens (Thermal treatments)
- Heat pumps
- Electrofilters
- MVC
- Heat pump (drying)
- Membranes in refineries and
- Electrosynthsis
- Ohmic heating
- Immersion heater
Metals
Waste
management
industry
- MVC for liquid effluents
- Recycling with arc furnace
- Vacuum furnace
- Cold plasmas for VOC treatment
- induction on activated carbon for
VOC treatment - MVC
- Membranes
- Arc furnace for vitrification
8
Energy Efficiency through Electro-technologies
Technology
Membranes
MVR +
Heat Pumps
Induction
Consumption –
original plant
(GWh)
385
Consumption –
replacement plant
(GWh)
35
Compared
utilisation
efficiency
10-12
3.220
460
6-8
6.750
2.700
2-3
µW + HF + UV
585
260
2-2,5
IR
725
415
1,5-2
Motors
2.465
1.700
1,3-1,6
Resistance
11.640
9.700
1,1-1,3
25.770
15.270
1,1-12
TOTAL
9
Energy Efficiency through Electro-technologies
Steel industry
Fossil Energy route
Electric route
Technology
Blast furnace
Electric Arc Furnace
Raw materials
Iron ore
« Scraps » (+ DRI + pig iron)
Quality
High
Depends on scraps quality
Investment cost
High
Much lower
Flexibility
Low
High
CO2 emission
2 tCO2/tsteel
0.1 t CO2/tsteel
10
Energy Efficiency through electro-technologies
Various energy system solutions for the same end use
Energy
source
Electricity from grid +
Heat from fossil fuel
CHP from gas
(non seasonal)
Electricity from grid
> 90% Fossil mix
Same end-use
demand (MWh)
Conversion used
Electricity (light,
motors)
Heat (process)
100
Electricity (light,
motors)
Heat (process)
100
1 kWh e = 0,086 / 66% (average generation
efficiency by CHP)
100
CED = 13 + 13 = 26 tep
Electricity (light, motors)
Efficient electric process
100
<50
1 kWh e = 0,086 / 40% (electricity generation) /
90%(grid loss)
100
1 kWh th = 0,086 tep
1 kWh e = 0,086 / 40% (electricity generation) /
90% (grid loss)
CED = 23,9 + 8,6 = 32,5 tep
CED = 23,9 + 11,9 = <35,8 tep
Electricity from grid
Renewable / NFF
Electricity (light, motors)
Efficient electric process
100
<50
1 kWh e = 0,086 / > 100% (pointless, NFF)
/ 90% (grid loss)
CED = 9,5 + 4,8 = <14,3 tep
Electricity from grid
current mix
Electricity (light, motors)
Efficient electric technique
100
25
1 kWh e = 0,086 / 52% (electricity generation) /
90% (grid loss)
CED = 18,4 + 4,6 = 23 tep
11
Conclusion
• Electricity is a secondary but flexible energy. Industrial process
need this flexibility to increase productivity and quality
• Electricity and electro-technologies can contribute
significantly to energy efficiency
• Final to primary conversion factor and CO2 emissions depend
strongly on power generation systems, thus on local energy mix
• The whole energetic system has to be assessed from raw energy
product to end-use by an LCA approach
12