Industrial Energy Efficiency and Energy Management

Presented by:

Prof. Arief Budiman, D.Eng.

Center for Energy Studies, Gadjah Mada University Yogyakarta, Indonesia

OUTLINE

INDUSTRIAL ENERGY

INDUSTRIAL ENERGY MANAGEMENT

ELECTRICAL ENERGY MANAGEMENT

THE NEW ELECTRO-TECHNOLOGIES

THERMAL ENERGY MANAGEMENT IN INDUSTRY

CONCLUSION

INDUSTRIAL ENERGY

The industrial sector is highly diverse

–Manufacturing

–Mining

–Construction

–Agriculture

These industries require energy to support their activities

Konsumsi energi Indonesia, 2009

Industri (51,3%)

Transportasi (30,3%)

Rumah tangga (10,7%)

Komersial (4,6%)

Sektor lain (3,1)

Sumber:

www.esdm.go.id

By developing and adopting more energy-efficiency technologies, industries can boost its productivity and competitiveness while strengthening energy security, improving the environment, and reducing emissions linked to global climate change.”

Energy-efficiency improvements in industry will require emphasis on:

energy-management activities as well as making capital investments in new plant processes and facilities improvements.

INDUSTRIAL ENERGY MANAGEMENT

PHASE I :

MANAGEMENT COMMITMENT

PHASE II :

AUDIT AND ANALYSIS

PHASE III :

IMPLEMENTATION

PHASE I : MANAGEMENT

COMMITMENT

Organizing for energy conservation programs

Assignment of an Energy-Management (E.M.) coordinator

Creation of an EM committee

Setting energy conservation goals

PHASE II : AUDIT AND ANALYSIS

Review of historical patterns of fuel and energy use

In-plant metering

Conduct facility energy audit, covering processes, facilities and equipment

Calculation of annual energy use based on audit results

Analysis and simulation step

Economic analysis of selected EM options

PHASE III : IMPLEMENTATION

Establish energy effectiveness goals for the organization and individual plants

Determine capital investment requirements and priorities.

Promote continuing awareness and involvement of personnel

Provide for periodic review and evaluation of overall E.M. program

ELECTRICAL ENERGY

MANAGEMENT

Electricity use in industry is primarily for: electric drives, electrochemical processes, space heating, lighting, and refrigeration

Energy management strategies for industry

can be grouped into 3 categories:

Operational and maintenance strategies

Retrofit or modification strategies

New design strategies

Once these “easy” savings have been realized, additional improvements in efficiency will require capital investments.

Electricity has certain characteristics that make it uniquely suitable for industrial processes.

New electro-technologies based on the properties of electricity are now finding their way into modern manufacturing.

THE NEW

ELECTRO-TECHNOLOGIES

In many cases, the introduction of electricity:

– reduces manufacturing costs,

– improves quality,

– reduces pollution,

–or has other beneficial results.

The New Electro-technologies

Microwave heating

Ion nitriding

Induction heating

Infrared drying

Magnetic forming

Advanced finishes

Plasma processing

RF drying and heating

UV drying and curing

Electron beam heating

MICROWAVE HEATING

Review on conventional heating

– Conventional heating along with a container (oven, furnace, pot, etc.) to which the heat is applied.

– There are certain irreversible losses associated with heat transfer in this process

Microwave heating avoids these losses due to the unique characteristics of electricity.

Timely control.

– The heat is applied directly when needed

Molecular interaction.

– By interacting at the molecular level, heat is deposited directly in the material to be heated

Selective application.

– By selectively applying heat only to the material to be heated, parasitic losses are avoided

Selective wavelength and frequency.

– Typically the frequency is greater than 2000 MHz

THERMAL ENERGY MANAGEMENT IN INDUSTRY

Industry uses a wide range of fuels,

including: –natural gas,

–petroleum,

– coal, and

– renewable

More efficient use of fuels means: – lowers production costs,

– conserves limited energy resources, and

– increases productivity.

Efficient use of energy also has positive impacts on the environment

Reductions in fuel use translate directly into decreased emissions of pollutants such as:

– sulfur oxides,

– nitrogen oxides,

– particulates, and

– greenhouse gases (e.g., carbon dioxide).

Commercial Options in Waste-Heat

Recovery Equipment

The equipment that is useful in recovering waste heat can be categorized as :

– heat exchangers,

– heat-storage systems,

– combination heat storage-heat exchanger systems, and

– heat pumps.

Waste-heat Boiler

WHB is used to produce saturated steam from high-temperature waste heat in gas streams.

The boiler tubes are often finned to keep the dimensions of the boiler smaller.

They are often used to strip waste heat from diesel engine exhausts, gas-turbine exhausts, and pollution-control incinerators or afterburners.

The internal of a typical

Waste-heat Boiler

CONCLUSION

Energy is the lifeblood of industry; Using this energy efficiently is a necessity to

keep industries competitive, clean, and at their peak of productivity.

A substantial opportunity is currently available

using better operational procedures and using improved equipment in industrial plants.