Opportunities for High Temperature Heat Pump in

French industry

Opportunities for High Temperature Heat Pump in

French industry

14th October 2008

Energy context

EDF Group & ECLEER

Energy context

EDF Group & ECLEER

3

Facing a major issue…World consumption trends in energy

(Mescalito – medium scenario)

0

5

10

15

20

25

1950

1960

1970

1980

1990

2000

2010

2020

2030

2040

2050

2060

2070

2080

2090

2100

Gte

p

To be found!RenewablesNuclearCoalGasOil

?

4,6%

1,9%

1,4% - 0,5%

« R&D » community will have to find new answers !

4

Energy Issue / EDF Group and Energy Efficiency Energy Issue / EDF Group and Energy Efficiency

New challenges:• Security of energy supply

- Enduring pressure on hydrocarbons resources

• Acting against climate change

Ambitious objectives by 2020:• Reducing CO2 emissions by 20%• Reducing energy consumption by 20%• Increasing renewable energy to 20%

EDF Group: active in energy efficiency

3 driving forces: 1. EDF Group values : sustainable developm’t2. EU directives & French laws : obligations 3. EDF Group business : advice & services

Energy efficiency set to be an important issue over the long term

5

ECLEER : context and objectivesECLEER : context and objectives

In the context of a « post peak-oil » economy :CO2 emission reduction (factor 4 by 2050)

Energy independence (imported fossil fuel)

EDF Group and two of its high level scientific partners:Ecole des Mines de Paris

Ecole Polytechnique Fédérale de Lausanne

have decided to create an European research centre on energy efficiency :

ECLEER : European Centre and Laboratories for Energy Efficiency Research

dedicated to buildings and industry …

Main objectives1 increase and speed up innovation2 gather complementary skillsFor energy eco- efficiency

6

CO2 emissions for European UtilitiesCO2 emissions for European Utilities

Year 2004, kg/MWh(consolidated data)

7

Energy consumption and CO2 emissions – France Energy consumption and CO2 emissions – France

Buildings 42%

Transport 32%

Industry 24%

Agriculture 2%

Buildings 28%

Transport 30%

Industry 23%

Agriculture 19%CO2

equiv.emiss’n

Final energyused

Source: DEFRA / AEA Energy & Environment 2005

8

Energy efficiency in industry Energy efficiency in industry

9

of total energy used generating heat

70%

Energy use in industryEnergy use in industry

39% Furnace & dryers

29% Boilers

11% Motors

7% HVAC

6% Compressed air & cold

8% Raw materials

Energy use in industry (France)

1/3of electricityconsumption

2/3of oil, gas, coalconsumption

Good progress in efficiency, potential for improvement still high

– More profitable and safe production practices, competitiveness

– 5 to 6% / year of equipment renewal

Identifying opportunities is still complex

10

Boiler

Cold prduction

Air compressor

Cogeneration

Lighting

Motors

Furnace

Concentration

Drying

Premisses heating

ColdWarehouse

Tool machine

Gas

Fuel and coal

Electricity

ENERGIES CentralisedUtilities

Cross-cuttingUses Process

Is industry really complex ? Ex. of an Energy flow mapping

Mechanical

force

Compressedair

Refrigeration

Steam

11

Energy savings in industry : technical potential Energy savings in industry : technical potential

HEAT = 85%known energy savings

Boilers, furnaces, drying, heat recovery, HVAC

15%–20%energy savings potential with existing technologies and dedicated energy management(80 TWh in France)

Energy savings potentials

Heat recovery26%

Furnaces20%

Boilers14%

HVAC13%

Drying11%

Motors5%

Lighting4%

Cold 3%

Compressedair and Plasturgy

1%1%

12

Energy efficiency in industry in France (example)

Energy potential savings (TWh)

0

5

10 30 50 70 90 110 130 150Energy Consumption

Cos

t(E/

MW

h)

Boilers

Motors

Furnaces

DryersHVAC

ColdHeatrecovery

Ligth

Compressed air

72% of energy savings on fuels28% on electricity

13

EDF R&D research topics on main barriers EDF R&D research topics on main barriers

Reduce energy

demand thruenergy mgmt

Use highest

performingenergy systems

Heat recovery, process

integration

Energy management systems

Smart equipment

High performance technologies for heat recovery

Induction heating systems

Cold production

Energy assessment and strategies

(efficiency opportunities global, sub sectors and sites)

Tools and methods for energy audits

(analysis and process rethinking, system oriented energy design, etc)

14

Our research challenges

Industrial Technologies R&D to increase energy efficiencySmart furnace : technologies to decrease by 20% energy consumption of existing furnacesInnovative chiller systems : with water as refrigerant and producing ice slurry

1

2

4

3

Key industrial processes and technologies for 2020To divide by 4 GHG emissions of industrial furnacesEnergy Loss Reduction and Recovery in Industrial Energy Systems : identify R&D priorities for energy lossreduction and recovery, and identify new software tools for development., …

Industry Demand side forecast and technological prospective studiesTo develop a model of energy demand projection in industryDescribing and assessing the main industrial technology developments expected to occur up to 2050 in order to identify promising technologies where R&D investments would be cost-effective.

Energy Management on industrial sites : tools and methods R&DTo divide by ten the cost of sensors and information processing : a key of success for energy management systems on industrial sitesTo develop an innovative energy savings assements method : minimum energy required for the product – The goal is to optimise the flow of energy supply, demand, and losses in industry

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Heat recovery in industry

Heat Pump

Heat recovery in industry

Heat Pump

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The energy is recovery on …Heat recovery after the process or the facilities

Transportation or storage

Conversion of energy at the level required

Casing Gas waste Liquid waste The final product

HP Heat recovery « box »

Exchangers smoke / water

Heat exchangers

dirties…

HeatHeat recoveryrecovery on on fluidfluid

17

Water or gas wastes

Heat exchangers

T<5°C

Heat pumps

30°C<T<50°C

Hot water pre heating Pre heating product

Exchanger :Water wastes / water

Water wastes / air

T>50°C

High temperature

MVR

Concentration

The The marketmarket –– condensingcondensing temperaturetemperature interactioninteraction

Energy needsEnergy needs

Energy saving by heat Exchangers: passive heat recovery

4 TWh

Energy savingpotential

Tomorrow

7 TWh

Heat Pump and Optimised Chillers

Futur

High temperature energy saving and VHT HP

Impact on the Energy saving potential> 10 TWhEnergy needs

18

28 TWh

71 TWh

Market process 0° to 200°C 10 times market 0 to 70°C

Market 100 to 200°C 2,5 market 0 to 100°C

French French marketmarket of of heatheat needsneeds

19

Under 100°C :

Heat of liquid (food industry)

Between 100 and 200°C : drying (paper)

Main Main strategicstrategic sectorssectors (France)(France)

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7 sectors under 100°C:

Food + paper + chemical

64% of the market

9 sectors between 100 and 200°C :

food + paper + chemical :

68 % of the market

Main Main strategicstrategic sectorssectors (France)(France)

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Main differences between residential and industrial Heat Pump Main differences between residential and industrial Heat PumpIndustrial Heat Pump

• Necessity to have a global analysis of the industrial site, process by process

• Evaporating temperature between 25 and 65°C

• High temperature : condensing temperature according to the process (80°C to 200°C) & High power (more than 1 MW)

•Low constraints : noise, space

• Necessity to demonstrate the energy and economical gain (Return of investment)

• Number of sales lower than residential HP (each case bigger)

Residential Heat Pump

• Standard product for hot water or space heating

• Evaporating temperature between –20°C and 12°C

• Condensing temperature required up to 65°C (15 KW)

• Necessity of small size, low cost, no noise

• High potential of sales but high cost to access to the customers

• Return of investment more long

Opportunities : size of the system permit technological innovations

22

Experiences, Potential and global environmental benefits (1994) Experiences, Potential and global environmental benefits (1994)

ContextIndustrial Heat Pumps can provide a number of process-related benefitsDespite these potential benefits, the number of IHPs installed is low Why ? : lack of knowledge, lack of experience with IHP technology and with the

coupling with the process

Program (data of more than 100 industrial processes, 5 industrial sectors, 5 categories of IHPs studied)

Closed-cycle compression, Mechanical vapor recompression, Thermal vapor recompression, Absorption heat pump, Heat transformer or absorption heat pump

ConclusionsReduce total industrial process heat pump energy consumption : 2-4%Reduce process heat energy consumption for individual process : 66% (depending

on the industry and process)35 different industrial processesPotential increasing of refrigerant emissions by some 93-190 t/y

estimation of potential global environmental benefits of IHPsEach industrial site has to be analyzed case by case

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2008 : to find new answers2008 : to find new answers

The energy cost increases and CO2 emissions have to bereduced

The solutions proposed in 1994 become more profitable

More constraints on refrigerantObjective : GWP < 150 New refrigerant and adapted compressors are required for high

temperature

New opportunities for Industrial Heat PumpTechnical investments become possibleNew sectors have to be involved

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Integration of Heat PumpIntegration of Heat Pump

NecessityNecessity to  analyse  the to  analyse  the  processprocess ((energyenergy and and  exergyexergyintegrationintegration)  to )  to  integrateintegrate the the HeatHeat PumpPump and and modifymodify the  cold the  cold and and heatheat sources.sources.

ConsequencesConsequencesNecessityNecessity to to  calculatecalculate the global the global  energyenergy efficiencyefficiency of  the of  the  processprocess and and not not onlyonly the COP of the the COP of the equipmentequipment

ThenThen genericgeneric applications for the applications for the HeatHeat PumpsPumps••

EveryEvery

wastewaste

withwith

a a 

temperaturetemperature

more more 

highhigh

thanthan

the the 

environmentenvironment

cancan bebe

usedused

as cold source.as cold source.

••

EveryEvery

production of production of steamsteam

by combustion by combustion whichwhich

isis

usedused

underunder

9090°°C C cancan bebe

replace by a replace by a HeatHeat

PumpPump

••

EveryEvery

refrigerationrefrigeration

machine machine couldcould

bebe

a a ««

thermothermo‐‐frigofrigo‐‐heatheat‐‐pumppump

»»

25

Some technological challengesSome technological challenges

LubrificationLubrificationAdaptation of the Adaptation of the lubricicationlubricication oiloil for for temperaturetemperature more more highhigh ((fromfrom 60 to 10060 to 100°°C)C)CoolingCooling of the machine, of the machine, recoveryrecovery of the of the energyenergy, , developmentdevelopment of machines of machines withoutwithout oiloil, , ……

To select To select fluidsfluids withwith a GWP a GWP lowerlower ((underunder 150 ?)150 ?)StudyStudy of new of new fluidsfluids (mixed), adaptation of the system, (mixed), adaptation of the system, wastewaste fofo fluidsfluids, , ……

Variable speedVariable speedFew technologies Few technologies existexist

DifficultyDifficulty

to to adaptadapt

existingexisting

equipmentsequipments

NecessityNecessity to to  developdevelop global  system global  system  withwith variable  speed  of  the variable  speed  of  the  compressorcompressor, ,  pumpspumps and and coolingcooling, new , new regulationregulation

HeatHeat transformer transformer withwith micro tubesmicro tubes