EINSTEIN Fluch...

TEM Food and Drink Industry, 26th of March 2012

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Jürgen FluchAEE – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA

EINSTEIN Software and Method

EINSTEIN

Methodology and tool for a fast energy assessment


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Overview

� Introduction

� EINSTEIN: Idea and approach

� EINSTEIN: software

� EINSTEIN: method

� EINSTEIN: results

present state �� proposals

� EINSTEIN: energy audits


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Energy consumption in EU27

� 25% of final energy consumption in EU27 (2006)

for space heating and cooling in buildings

� 28% of final energy consumption in EU27 (2006)

for industry

� 69.5% of final energy consumption in industry

for heat production

� 57% at low and medium temperature levels

at 400°C and less

Strategic Energy Review 2008; Quelle: EurostatData für 2003, 32 Länder: Quelle: ECOHEATCOOL (IEE ALTENER Project)


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Energy saving targets

� EU-targets by 2020 (20-20-20):

� Reduction of emissions by 20%

� Increase of energy efficiencies by 20%

� Increase of the use of renewable energies up to 20%


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Energy costs[€/a]

Real data of an Austrian brewery, 2008

Increasing energy costs

Energy demand [MWh/a]

201520082000 2006


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-25%

-25%

savings

Alternative proposal: reduction of energy demand

Energy costs[€/a]

Reduction of energy demand

Energy demand [MWh/a]


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Areas of application

�Industries and SMEs with large thermal energy

demand at low & medium temperature up to 400ºC

�Manufacturing sectors:

� Food industry,

� Breweries,

� Pharmaceutical, chemical,

� Pulp & paper,

� Textile,…


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Areas of application

�But also other medium and large scale consumers

of heat and cold:

� Large buildings (e.g. commercial centres, hospitals,

offices,...)

� District heating and cooling networks

� Other (e.g. desalination, etc.)


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Challenges in energy audits

� Optimised supply of thermal energy in industry is

complex:

� Developed infustructure in the industry without real data

available (esp. SME)

� Averaged data for different periods

� Cost and time consuming measurements necessary

� Processes at different temperature levels and different

operating times have to be integrated and combined

� Combination of different heat supply technologies for an

optimised energy supply

� High acquisition and evaluation demand while the

potentials can hardly be foreseen


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Approach of EINSTEIN (1)

� Development of a fast-audit to estimate

potentials

� Standardised data acquisition, modeling and audit steps

� Automated background calculations

� Holistic vision of energy supply and demand

� Process optimisation �� demand reduction

measures

� Heat recovery

� Intelligent combination of heat and cold supply

technologies

� Implementation of renewables


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EINSTEINLOW COST THERMAL

AUDITS

-- easily affordable for SMEs-- high quality-- reliable-- user friendly

Standardisation• Standardised procedure• Standard process models• Standard modules for heat supply systems• Consideration of all

available energy efficienttechnologies

“Quick & dirty” fast estimation of missing data

• Tools for obtaining a complete data set based on fragmented and incomplete information

Semi-automated• Guided audit procedure• Decision aids for proposal generation• Automatic energy, economic, &

environmental evaluation• Automatic generation of reports

Data submission by distance• Fast audits based on data delivered via

email or questionnaire• Possibility of self assessment



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Holistic vision…

Demand reduction

Process optimisation

Heat recovery and process integration

Heat exchangersPINCH-analysis

Heat exchanger networks

Thermal chillers and heat pumps

PolygenerationElectricity, Heat & Cold

CHP & trigeneration(engines, turbines, fuel cells)

RES

Efficient heat & coldsupply

Efficient equipment(boilers, burners, chillers)

No use of electricity for thermal processes

Heat and cold networks Efficient distribution(steam, etc.)

solar thermal

biomass



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� Analysis of energy demand and availability in

terms of

� QUANTITY of energy

� QUALITY of energy - temperature

� Einstein enables evaluation of potential for

� heat recovery

� application of more efficient technologies at lower

temperature



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10 EINSTEIN audit steps

Preliminary contacts: Inform and motivate

Pre - audit data acquisition

Processing of preliminary information

“Quick&Dirty” preliminary evaluation

On - site walk - through energy audit OR Detailed by - distance data acquisition

Analysis of the Status quo

Energy performance calculation & environmental anal ysis

Economic and financial analysis

Reporting and presentation of the proposal to the c ompany

Conceptual design of saving options and preliminary energy targets definition

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REPORTING

DATA ACQUISITION(QUESTIONNAIRE)

CONSISTENCY CHECK

ENERGY STATISTICS

BENCHMARKING

PROCESS OPTIMISATION

HEAT RECOVERY

HEAT&COLD SUPPLY SYSTEMS

ENERGY AND ENVIRONMENTAL PERFORMANCES

ECONOMIC ANALYSIS

ALTERNATIVES COMPARISON

DATA ANALYSIS

ALTERNATIVEPROPOSALS:

DESIGN

ALTERNATIVEPROPOSALS:EVALUATION

REPORT

DATA ACQUISITION AND CHECK

Software


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Heat recovery system

Heat & cold supply(“Equipments”)

Distribution & Storage(“Pipes”)

Processes

thermal energy flows (heat & cold)

available waste heat(from source)

external energy input

ConnectionPipes - Processes

ConnectionEquipes - Pipes

ConnectionsFuels/Elect. - Equipes

Final energy input

Waste Heat from Electrical Equipment

recovered waste heat (to sink)

connections of sub-systems

FETj

FETi

USHj

USHPipem

UPHk

QHXProc

QHXPipe

QHXEq

QWHQHX

QWHWHEE

QWHProc

QWHPipe

UPHProcm

QWHEq

Model of an energy system in EINSTEIN


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Model of the process

h po1r

Internal heatrecovery

Heating of circulating fluid

Heating of bath or oven

A

B

qm , i1

mc p

qm , o1

Thermal losses(UA)

h pi2

Thermal mass( )

T env

T pi1r

T po1

T po2r

T pi1

T p

T ps

T ps

T po2

qm , i2T pi2rT pi2 qm , o2

h po2r

T po1r

T pt1h pi1

h pi2r

h pi1r

T pt2

h po2

h po1


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EINSTEIN – evaluation of the present state (1)

� Primary energy

consumption

� Total

� By fuel

� By equipment


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� Heat and cold demand

� By processes

� By temperature levels

� By time demand

EINSTEIN – evaluation of the present state (2)


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EINSTEIN – results of a brewery

Presentstate

Saving

Primary energy consumption [MWh] 47,620 11,685

fuels [MWh] 20,020 -

electricity [MWh] 27,600 11,685

Share of renewable energy [%] - -

CO2 emissions[tons/a

]11,905 1,852

Investment costs [EUR] -

Payback period [years]

� Case study brewery

� 2 proposals evaluated

� 1 presented as final proposal

FET by equipment

UPH by process


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EINSTEIN – heat recovery (1)

� Goal:

� Theoretical potential of energy savings by heat recovery

(prior to energy supply systems design)

� Save fuels and avoid over-dimensioning of supply

equipment

� Heat recovery potential

� Analysis of a minimal external heat and cold demand

� Potential for heat recovery

� Design of a heat exchanger network

� Design and optimisation of a heat exchanger network

� Reduced energy demand and required temperature level

as basis for exergetic optimised integration of heat and

cold supply


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EINSTEIN – heat recovery (2)

� Method: Pinch-Analysis

� Hot and cold composite curves

� Grand composite curve

� Results

� Theoretical heat recovery potential

� Necessary external heat/cold supply at the different

temperature levels


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Pinch Analysis

� Hot and cold composite curve

� Pinch temperature – separation

of production system in two

halves:

• Above pinch – no cooling is

necessary

• Below pinch – no heating is

necessary

• No energy should be

transferred across the pinch

(efficient thermodynamic use

of energy)

Temperature [°°°°C]

Power [kJ/s]


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EINSTEIN – results (1)

BE

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Less heat

wasted

Waste heat recovered and used as input

Reducedexternal

input

energy input

reduced

Reduced energy demand

Non-renewable

share decreased

Renewable share

increased


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EINSTEIN – results (2)

� Comparison present state

and proposals

� Primary energy consumption

� Energetical evaluation

� Environmental evaluation

� Economical evaluation

� Report generation


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EINSTEIN - outlook

� EINSTEIN II:

� Performance of 72 energy audits in 10 European countries

(Austria, Germany, United Kingdom, Spain, Italy, France,

Luxembourg, Ireland, Slovakia, Bulgaria)

� Introductory and advanced trainings for energy

consultants and auditors in all named participating

countries

� National projects within additional audits are

performed


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EINSTEIN

�EINSTEIN is a free open source

software based on a GPL Lizenz:

•www.sourceforge.net/proje

cts/einstein

�EINSTEIN is independent from the

operating system

•Using Linux, Unix, Windows..

Source: http://solarenergie-investment.de/Dachborse.htm


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Jürgen Fluch

[email protected] – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA

EINSTEIN Software and Method

EINSTEIN

Methodology and tool for a fast energy assessment

EINSTEIN Fluch...

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