1 Energy Solutions for Production Supported by: The sole responsibility for the content of this presentation lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein.

2 Heating Air Radiator Hall heating by bright radiators Advantages: Good thermal comfort High efficiency Low energy consumption No draught (airflow) Oriented heating in selective sections Quick heat-up No dust whirl Low noise Precise controlling system Flexible fields of application Low weight

3 Comparison of Radiator System High maintenanceLow maintenance because of fewer radiators Only heating systemCombination of heating and ventilation possible Different temperature zonesBalanced heating at the shop floor Usage of production heat Not possible Usage of production heat - reduction of running hours of incineration efficiency: < 70%efficiency > 93% Dark radiatorAir radiator Heating

4 A Company's Energy Consumption in One Year Heat generation by company 1,2 GWh Usable heatLoss 10,8 GWh Power generation by power plant CurrentLoss 7,8 GWh 4,2 GWh Energy usage by current / heat production Heating

5 Co-Generation Conventional Source: ASUE losses Heating electricity heat electricity heat Co- generation unit Flue gas

6 Example – Water Curtain Cooling

7 Refurbishment of Ventilation System Heat recovery system Cooling Production Heat exchanger Outlet air Inlet air

8 Source: Energieagentur NRW Cooling Exemplary structure of an air conditioned plant Absorption cooling machine Cooling tower Solar collector heater Heat reservoir Cold reservoir

9 Utilization Of Energy – 85% Heat Losses Source: Fa Kaeser Waste heat Motor (9%) Waste heat Motor (9%) Heat oil- cooling (72%) Heat oil- cooling (72%) Re-cooling compressed air (13%) Re-cooling compressed air (13%) Electrical capacity 100% Electrical capacity 100% Radiation to surroundings (2%) Radiation to surroundings (2%) Heat in the compressed air (4%) Heat in the compressed air (4%) Compressed Air

10 Cost Situation Within 5 Years Compressed Air consumption maintenance

11 Annual Costs of Compressed Air Leaks * 1 bar = 14,5 psi (pounds per square inch) Leak Diameter [mm] Leak Diameter [mm] Air Losses Air Losses Energy Losses Costs Costs 1 = 0,04 in 3 = 0,12 in 5 = 0,2 in 10 = 0,4 in 6 bar 12 bar 1,2 1,8 6 bar 12 bar 6 bar 12 bar 0,3 1, ,1 20,8 3,1 12, ,9 58,5 8,3 33, ,8 235, psi 174psi 87psi 174psi 87psi 174psi Compressed Air

12 ? 6 bar 7 bar 8 bar 9 bar 10 bar 11 bar 12 bar 13 bar Operating pressure Recommendation: each additional bar increase in pressure costs % energy 100 % 114 % 130 % 148 % 169 % 193 % 220 % 251 % Energy costs Compressed Air

13 Improvements and Economies  cleaning machinery with compressed air is inefficient, as dust is not removed, merely circulated  it is extremely expensive (remember the low energy efficiency of 4-6%) cleaning machinery by means of suction is much cheaper and more efficient Compressed Air

14 Waste Heat Usage Source: Fa Kaeser Warm- Water Boiler Heat Exchanger Compressor Example: Power:45 kW ( 6,5 m³/min) 43 Btu/s Cost saving: (0,60 €/l): 4.100,00 €/a Usable heat (70%): kWh/a (with Full load-h/a) 215 Bill Btu/a Saving potential fuel:7.000l/a gal/a Compressed Air

15 Heat recovery air / air Air/Air Heat exchanger Supply air Condensate Source: LfU-Leitfaden Textilveredelungsindustie Example Textile Drying - Vaporization Process Heat

16 Steam Boiler System Steam

17 Electrical Power high energy consumption on Sunday discovered - although no production Electrical Power (bad practice)

18 Peak Load Management Without Load Management: High power load, if several machines are in operation at the same time Consequences:  Higher costs  Stress of the technical equipment With Load Management: Control of operation times to reduce the power load Electrical Power

19 Lighting high ceiling with high windows work place nearby daylight window glass with high light transmission bright and even walls and ceilings using also the ceiling for daylight Daylight as Planning Aspect

20 Comparison of Lamps Lighting