1. Energy Management Systems: 2015/2016 Industrial Energy Use SGCIE Prof. Tânia Sousa taniasousa@ist.utl.pt

2. Final Energy Use in Industry in 2005 World Industrial final energy use in 2005 is 115EJ The bulk of industrial energy use is due to the production of a small number of energy intensive commodities: –Chemicals and petrochemicals and the iron and steel sector account for approximately half of all industrial energy used worldwide. Other sectors that account for a significant share of industrial energy use: –non-metallic minerals and the pulp and paper sector. Cement, ceramics, glass, lime Aluminium, copper, nickel Plastics and fertilizers GEA, 2012

3. Final Energy Use in Industry in 2005 The bulk of industrial energy use is in developing economies (80% pop.)

4. World production of key materials Higher growth rates from the 90’ and then from the 2000’ onwards Heterogeneous growth

5. World Production of key materials Growth rates between 2000-2007 –China and India show the highest growth rates. In 2007 China produces 37% of the world steel (48% in 2013) and 48% of the cement (59% in 2013)

6. World Production of key materials China is atypical Regional per-capita demand for materials –For most materials it increases with income and economic development and then stabilizes

7. Regional per-capita demand for materials –For some materials increases with income and economic development (paper and aluminium) World Production of key materials

8. Industrial Energy Intensity Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010): –It differs between different products and sectors

9. Industrial Energy Intensity Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010): –It changes in time due to technological inovations

10. Industrial Energy Intensity Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010): –It differs between countries for similar products Access to resources (steel from steel recycling is 0,19 toe/ton while from iron ore is 0,49 toe/ton and ammonia from coal is much more energy intensive than ammonia from natural gas) 0.5 Steel Energy intensity

11. Industrial Energy Intensity Industrial energy intensity - energy use per unit of production or VA (UNIDO, 2010): –It differs between countries for similar products Access to resources Energy Prices Plant size and age of capital stock Capital cost (more efficient capital is also more expensive - interest rates) Awareness of energy efficiency measures and opportunity cost Government policies

12. Benchmarking Industrial Energy Use Management tool to compare similar plants in energy use and energy efficiency Benchmarking curves (improvment potential)

13. Benchmarking Industrial Energy Use Management tool to compare similar plants in energy use and energy efficiency Benchmarking curves (improvment potential)

14. Industrial Energy Intensity

16. Benchmarking Industrial Energy Use Average 10-20% or 30-35% improvment potential –Lower than for other energy uses (e.g. in buildings is close to 50%)

17. Energy vs. Exergy efficiency

18. Industrial Energy Intensity Aggregated industrial energy intensity (energy use per unit of VA): –Depends on what?

19. Industrial Energy Intensity Industrial energy intensity (energy use per unit of VA): –Efficiency –Sectoral Structure

20. Energy Use in Industry

21. SGCIE (DL 71/2008) – Sistema de Gestão dos Consumos Intensivos de Energia (Energy Management System for Intensive Energy Consumers) –It promotes energy efficiency for big primary energy consumers –It promotes clean primary energy fuels mix SGCIE

22. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Domain of Application –All entities with an annual primary energy consumption higher than 500 toe (1 toe = 41868 MJ) –Exceptions: Cogeneration facilities, transport entities and buildings Supervision –DGEG Management –ADENE

23. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Obligations (for IEC entities) –Promote the registration of facilities –Perform Energy Audits Every 6 years for entities  1000 toe Every 8 years for entities from 500 to 1000 toe

24. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Obligations (for IEC entities) –Develop Energy Racionalization Plans Every measure with payback lower than 5 years must be implemented in the first 3 years for entities  1000 toe Every measure with payback lower than 3 years must be implemented in the first 3 years for entities from 500-1000 toe

25. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Obligations (for IEC entities) –Develop Energy Racionalization Plans Energy Intensity must decrease 6% in 6 years for entities  1000 toe Energy Intensity must decrease 4% in 8 years for entities from 500 to 1000 toe

26. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE What is the relationship between the Energy Intensity obtained using the definition in SGCIE and the energy specific consumption obtained with the block diagrams methodology?

27. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE The Energy Intensity obtained using the definition in SGCIE is the same obtained with the block diagrams methodology if: –The energy specific consumptions of the inputs is zero 8 (produção 1) A C D E B 2 1 F G 14 13 12 11 Electricity Fueloil

28. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Obligations (for IEC entities) –Develop Energy Rationalization Plans The carbon intensity must not increase –Why a goal on carbon intensity?

29. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Obligations (for IEC entities) –Develop Energy Rationalization Plans The carbon intensity must not increase –Why a goal on carbon intensity? Promote less polutant energy mixes (do not increase energy efficiency by replacing less polutant energy forms with more polutant ones)

30. SGCIE Conversion coefficients for CO 2 emissions and primary energy –Despacho nº 17313/2008

31. SGCIE Conversion coefficients for CO 2 emissions and primary energy –For primary fuels:

32. SGCIE Conversion coefficients for primary energy –For electricity (in kWh per toe)? BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricida de Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas

33. SGCIE Conversion coefficients for primary energy –For electricity: BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricida de Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas

34. SGCIE Conversion coefficients for primary energy –For electricity: –What would happen to this coefficient if we consider cogeneration? BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricida de Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas

35. SGCIE Conversion coefficients for primary energy –For electricity: BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricida de Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas BALANÇO ENERGÉTICO tep Total de Petróleo Gás Natural (*) Gases o Outros Derivado s Termo- electricidade Calor Resíduos Industriais Renováveis Sem Hídrica 2008 22= 15 + 21 23 30 = 24 a 29 35373846 = 39 a 45 Cogeração 6.7 834 520 626 392 24 379- 485 426-1 472 450 2 523 974 514

36. SGCIE Conversion coefficients for CO 2 emissions –For electricity (in kg CO 2 e per kWh)? BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricidade Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 4111.4 kg CO 2 e/toe 3236.4 kg CO 2 e/toe 2348.8 kg CO 2 e/toe

37. SGCIE Conversion coefficients for CO 2 emissions –For electricity (in kg CO 2 e per kWh) BALANÇO ENERGÉTICO tep Total de Carvão Total de Petróleo Gás Natural (*) Termo- electricidade Lenhas e Resíduos Vegetais Resíduos Sólidos Urbanos Biogás 2008 4 = 1 a 322= 15 + 212335404144 Electricidade 6.62 444 703 475 5711 970 751-2 325 570 61 957 182 765 19 729 4111.4 kg CO 2 e/toe 3236.4 kg CO 2 e/toe 2348.8 kg CO 2 e/toe

38. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Conversion coefficients for CO 2 emissions and primary energy –For electricity: –Conversão directa de kWh em tep?

39. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE SGCIE Conversion coefficients for CO 2 emissions and primary energy –For electricity: –Conversão directa de kWh em tep? 1kWh=3.6MJ=3.610 -3 /41.87 tep = 86 10 -6

40. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE

47. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE Exercise A factory produces 2 end products: P1 and P2. These products follow the production process shown in the diagram below, with P1 = 50000 ton/year and P2 = 30000 ton/year. The operation G treats the effluents from E and F. These two (E and F) are the only productive operations that generate waste, and S E = 1.2, S F = 1.3. In operation G, only 20% of the input effluent, exits the process as waste. The values of composition are as follows: f 4 = 0.4, f 6 = 0.5. The table presents the specific consumption of each operation. Consider that for electricity: 0.215 kgep/kWh & 0.47 kg CO 2 e/KWh and for fueloil 0.984 kgep/kg & 3236.4 kg CO 2 e/toe a)What is the carbon intensity of this factory? 8 (produção 1) A C D E B 2 1 F G 14 13 12 11 10 (produção 2) 3 4 5 6 7 9

48. Energy Management Class # 6 :: Block Diagrams (cont.) & LCA & SGCIE Exercise 8 (produção 1) A C D E B 2 1 F G 14 13 12 11 10 (produção 2) 3 4 5 6 7 9