Energy Efficiency in Industry – How can I increase … · 2010-06-02 · Suggestions for next...

Jens Wegmann CEO I IS

Energy Efficiency in Industry –How can I increase competitiveness in times of rising energy costs?

Jens Wegmann

CEO

Siemens Industry Solutions

Istanbul, Turkey – June 1, 2010


Industry Sector – Industry Solutions Division

Metals Technologies Water Technologies Industrial Technologies

We create sustainable value for our customersby optimizing plant efficiency and productivity over the entire lifecycle.

New orders: €6.1 bn* Revenue: €6.8 bn* Profit: €360 m* Employees: ~31,000*

Industry Solutions is a leading solution and service provider for industrial and infrastructure facilities

* FY 2009 (as of September 30, 2009)

Water treatment

Water reuse

Wastewater treatment

Dewatering and residuals management

Mining

Iron making and Steel making

Casting and Rolling

Processing Lines

Metallurgical Services

Pulp and Paper

Cement

Marine Solutions

Infrastructure

Cross Industry


Turkey10% reduction of energy intensity till 2015

compared to 2008

ChinaReduction of 20% energy usage per GDP by

2010

IndiaEnergy Conservation Act 2001: Establish norms

EU-15/WE+20% energy savings by 2020

Eastern Europe

20% energy savings by 2020

GermanyAgreement between the German government and energy-intensive industries to reduce their

energy consumption by 30%

CISRussia targets 40% energy savings by 2020

USA17% energy savings by 2020

Development of energy costs

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

2030202520202015200520001995199019851980

Coal

Natural gas

Petroleum

Electricity

2007

Source: IEA, Annual Energy Outlook

Public regulations

The economical and ecological significance of energy efficiency is increasing


Worldwide energy consumption continues to rise

70

63

60

48

4

246

60

42

43

26

3

175

0 50 100 150 200 250 300

Total

Renewables

Electricity

Coal

Natural Gas

Liquids

Billiarden BTU

2006

2030

Source:

Derived from Energy Information Administration (EIA), International Energy Annual 2006 (June-December 2008).

Website www.eia.doe.gov. 2030: EIA, World Energy Projections plus (2009)

World industrial sector energy consumption by fuel


Sustainable business requires green solutions for all three main elements of environmental management

Energy Efficiency1

Pollution Control2

Water Management3


The Eco-Care Matrix supports the development of “Green Solutions” and Sustainable Engineering

Eco-Care Matrix (ECM)P

osit

ive E

nvir

on

men

tal

Imp

act

Customer Benefit (Productivity)

C

B

A

Reference

Grüne Lösung

B

C

Green Solution

Sustainable Engineeringnecessary

A

Source: I IS TI

Section A:

„Green Solutions“

Section B:

Advantage in productivity,

but disadvantage in

environmental Impact

(Eco Design)

Section C:Advantage in Environmental

Impact,

but Disadvantage in

Productivity

(Design-to-Cost)


Optimized Process Technology: Endless Strip Production (ESP)

Green Solution

Continuous process gives the opportunity to use the heat

of the hot steel for the process instead of waste heat at a

batch driven process.

Steel Industry

Conventional

Hot strip

ESP

Environmental Impact

Optimized Production with ESP

Customer Benefit

Customer Benefit (Productivity)E

nv

iro

nm

en

tal Im

pact


Optimized Process Technology: COREX/FINEX – hot metal producing technologies

Green Solution

Corex is an industrially and commercially proven

smelting-reduction process for the cost-efficient and

environmentally friendly production of hot metal from

iron ore and coal.Finex is an innovative iron making process for the

production of hot-metal based on the direct use of

iron-ore fines and non-coking coal.

Customer Benefit


Iron & Steel Industry

-1,0

0,0

1,0-1,00,01,0

Blast Furnace

COREX

FINEX

En

vir

on

men

tal Im

pact



Optimized Component:HTS-Generators and Drives for ships

Green Solution

HTS-Technology is described by the following Benefits

against conventional technology:

compact design (weight, size)

higher efficiency rate (95% 98%)

higher torque overload (1,5 7,5)

Customer Benefit


Ship Industry

High-Temperature-Superconducting(HTS)

Conventional

YachtCruise Ship


nv

iro

nm

en

tal Im

pact


Optimized Component:Process water produced out of sea water

Green Solution

MED:

Using the waste heat from the steel plant for producing

process water out of sea water.

ED/CEDI is the most eco-efficient approach to generate

process water out of sea water (under development).

Customer Benefit


Water Industry

En

vir

on

men

tal Im

pact


MSF

ED/CEDI

RO

MED(CHP)

MEDMSF(CHP)

Multi-Effect Distillation (MED)


Optimized Auxiliary Process: Reject Power – Energy instead of deposition

Green Solution

Using the heat of burned paper waste for electrical power

and heat generation instead of environmentally critical

deposition (example for W2E = Waste-to-Energy)

Customer Benefit


Pulp & Paper Industry

Deposition

Reject Power

Production Process with Reject Power


nv

iro

nm

en

tal Im

pact


We continuously expand our range of services

Energy systems and energy industry

Energy consultancy for manufacturing

facilities & buildings

Optimization of processes, machines

and systemsMeasurements and simulation analyses

Consultancy for energy purchase

Worldwide benchmark studies

Further training

International cooperation on development

Establishment of institutions for

the promotion of energy efficiency

and environmental protectionIdentification of “typical” energy

Development of suitable financing

models

Environ-mental protection &emissions trading

Support in preparing the application & the emission report

Setting up of monitoring methods &

introduction of monitoring systems

Development of a compliance strategy

Coaching of industrial plants in the

creation of energy concepts

International workshops and in-house seminars on the topics of energy

efficiency & climate protection

Training of energy auditors

offers consulting services in the

areas of energy and environment

has proven know-how in modern

practices, processes and systems

for industry and infrastructure, and possesses vast knowledge of the

national and international energy

and environmental policies


Cooperation of Industry Solutions and Building Technologies in the area of energy optimization

TargetCustomer

Areas ofResponsibility per

customer

Siemens

Text

Text

Buildings (Industrial / Office) Production Assets&

Balanced energy consumption between

Offices Sites

= BT

Production Sites

= IS

Building (BT)

Production (IS)

Onsite

generation

CHP

New CHP and Solar PV solution as part of energy efficiency projects up to 3 MW are BT business

Building (BT)Onsite

generation

CHP

Office Site Production Site

e.g. automotive, discrete manufacturing, pharmaceuticals


We create measurable customer benefits

Energy savings

1 Mio.

€/a

Energy cost reductionat a new installation

Energy savings

€ 460.000 /year

Improved energy efficiency

Mondi Packaging

Great Britain

TropicanaBelgium

Felix Schoeller jr.

Canada

- 5,5% €1 mio./year


Our project partners –Customers who already trust us

(GER, CAN)

(GER)

(GER)

(GER)

(NDL)(A)

(UK)

(BEL)

(CZE, POL, ROM)

(UK)

(UK)

(TAW)

(GER)

(UK)

(BEL)

(TUR)

(TUR)

(TUR)


Our holistic approach covers all areas of energy optimization of your industrial plant

GHG emissions

Waste heat

...

Onsite energy production

Energy

purchasing

(Power, gas, oil, …)

Energy

distribution

Drives

Water

Ventilation

…

Energy Data Collection and Archiving

Energy Supply Production Processes Output

Auxiliary Processes

Type of Business Operation, Maintenance, Logistics Subsidies

Electricity

Gas

Steam

Vacuum

Compressed air

...

Energy Forms


Awareness Analysis Feasibility ImplementationPhase

Approach EnergyHealth Check

Alignment

Concept, ROI and Feasibility

Technical Realization and

Verification

Energy Efficiency Measures

Added Value

Energy Optimization of Drives (EoD)

(Technical analysis of electrical energy consumption)

Computer-based

interview of practiced

energy management

resulting in >80%

accuracy of savings

potential estimation

Energy Optimization Services (EOS)

(Energy-form-independent technical analysis)

Energy Optimization – Guiding mental and technical improvements in energy management


If you don’t know the improvement potential within your facility,

we…

…raise the awareness for the optimization of your energy-related processes

…assess your energy management maturity level

…give you confidence to decide upon your next steps

…give a first estimation of the savings potential

Why Energy Health Check?Evaluation and benchmarking of all energy-related

aspects of your organization

The Energy Health Check provides an overview of the maturity level of your energy management


Pre-Questionnaire One day on site Report

Plant tour

Interviews

Computer-assisted workshop with senior and middle management (plant manager, financial manager, energy manager, etc.)

Final evaluation

Detailed report to management

Our deliverables

5 Star Rating

Key action points for improvement

Estimated energy savings potential(accuracy >80%)

Industry-specific benchmark (database with more than 2,300 companies worldwide)

Suggestions for next steps

Fill out questionnaire

Estimated savings potential

Estimated and realized energy savings

0

500.000

1.000.000

1.500.000

2.000.000

2.500.000

3.000.000

Project 1 Project 2 Project 3 Project 4 Project 5 Project 6

minimum savings (EHC) maximum savings (EHC) realized savings (EOS)

During our Energy Health Check, we conduct in-depth interviews with your management


The analysis phase is the starting point of our Energy Optimization Services

The analysis phase is the starting point of our Energy Optimization Services. It builds the basis for theimplementation phase by …

… identifying energy efficiency measures

… investigating the energy flows and GHG emissions of your plant

… assigning the energy consumption to its consumers

… estimating the costs and savings

… summarizing all results in a report

Why technical analysis? Assessment of …

Energy Data Collection and Archiving

Energy Supply

Production & Auxiliary Processes

Output(e.g. waste

heat)

All Energy Forms

Operation, Maintenance, Logistics

SubsidiesType of

Business


The analysis phase is based on the on-site visit of our experts

Preliminary information

5 to 10 dayson-site analysis

Report

Pre-Questionnaire(complementary to

Health Check)

Analysis & evaluation of results

Estimation of savings potential

Definition of improvementmeasures

Report

Sankey Chart

Load Profile

Kälte über Außentemperatur Juni, Juli

0

5

10

15

20

25

30

35

40

0 2.000 4.000 6.000 8.000 10.000 12.000 14.000

Kälte in KWh th

Au

ße

nte

mp

era

tur

Kälte über Außentemperatur Juni, Juli

0

5

10

15

20

25

30

35

40

0 2.000 4.000 6.000 8.000 10.000 12.000 14.000

Kälte in KWh th

Au

ße

nte

mp

era

tur

Our deliverables

Professional Analysis Graphical Analysis, Cost & Savings Estimation Report: Scenarios & Recommendations

EXAMPLE


In close coordination with your maintenance and production departments and suppliers, we …

… prioritize the identified measures

… fine-tune the ROIs calculated during the analysis phase

… check the technical feasibility

… set up an implementation concept and schedule in coordination with your operations and maintenance

… submit binding offers from Siemens or selected suppliers

… offer a performance-based model

Why Feasibility Study?Feasibility Study

Concept & Schedule

Our Energy Optimization Services assess thefeasibility of the suggested improvement measures


Our deliverables

Detailed technical & economic feasibility study

Overview of annual energy savings

Implementation concept

Report

20 to 100 days

- On-site - - Off-site -

Setting up a project team and steering

committee

Collecting additional necessary data

Prioritizing energy efficiency measures

Further site inspection and measurements

Regular alignment meetings

Evaluation and summary of feasibility results

Getting binding offers from Siemens or

selected suppliers (economic feasibility)

Implementation concept & schedule

Creation of report

Within 20 to 100 days, we provide a reliable feasibility study with implementation concept


Technical Realization(Plant Engineering)

Training

Verification Cost Reduction

50 to 200 days

Implementation of all identified measures

Modernization of the facility

Setting up of sustainable improvement process

Training of your staff on the new equipment, processes, …

Verification of your energy cost reduction

Feedback & final report

During the implementation phase, we accompany you until your objectives are achieved


A significant portion of electrical energy is consumed by drives.

If desired, you can order a focused analysis of your drive systems.

The process phases are in line with the Energy Optimization Services approach.

Why Energy Optimization of Drive Systems?

Analysis

Stochastic estimation of savings potential (free of charge

if motor list is provided)

First estimation of investment and ROI Report

Feasibility

Detailed technical and economic feasibility study

Preparation of an implementation concept

selection of suitable electrical components & project plan

Implementation

Project management, planning and engineering

Installation/assembly of frequency converters

Replacement of old technology by energy-saving systems

Optimization of the operating point and duration

Mechanical retrofitting for parts of the system (e.g. adjustment of pipe systems, lower-friction gaskets)

Constructional measures for better interconnection of

different energy types

1

2

3

Energy Optimization of Drive Systems is a service package specially customized to your drive systems


Our main focus is to reduce your energy consumption sustainably - not on selling products

We have a holistic approach - we consider all energy-related processes and forms of energy (heat, compressed air, steam), maintenance, operations, monitoring, CO2

emissions, management-awareness, subsidies, etc.

With each phase our continuous improvement processadds value to your plant

You have the decision-taking authority – after each phase you decide whether to continue or not

We can offer a performance-based agreement where risks and benefits are shared

Depending on the case, we can offer financing solutions

Benefits from sustainable energy efficiency improvement and reduced CO2 emission


Thank you for your attention.

Energy Efficiency in Industry – How can I increase … · 2010-06-02 · Suggestions for next...

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