1. Energy Management Systems: 2015/2016
Industrial Energy Use SGCIE
Prof. Tânia Sousa

2. From Primary Energy to Service
Cullen & Allwood, 2010

3. Direct vs. Embodied Energy
Cullen & Allwood, 2010

4. Direct vs. Embodied Energy
Cullen & Allwood, 2010

5. Energy & Material Energy Services
materials
Cullen & Allwood, 2010

6. 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.
Plastics and fertilizers
Aluminium, copper, nickel
Cement, ceramics, glass, lime
GEA, 2012

7. Final Energy Use in Industry in Portugal

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

9. World Production of key materials
Steel
Cement
Paper
Aluminium
Plastics
Gutowski TG, Sahni S, Allwood JM, Ashby MF,Worrell E The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand. Phil Trans R Soc A 371:

10. World production of key materials
Higher growth rates from the 90’ and then from the 2000’ onwards
Heterogeneous growth (cement)

11. World Production of key materials
Growth rates between
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)

12. World Demand of key materials
Regional per-capita demand for materials
For some materials it increases with income and economic development and then stabilizes
China is atypical
Stock = 10 ton/capita

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

14. World Stock of key materials
Article in Environmental Science and Technology 47(20):  · September 2013
DOI: /es402618m · Source: PubMed

15. Forecasts Material Demand

16. Industrial Energy Intensity
Embodied Energy
How do we estimate total energy use?

17. Energy vs. Exergy
Embodied Energy or Cumulative Energy Consumption (CEC): it is the total (direct and indirect) amount of (primary) energy needed to generate product k.
Cumulative exergy consumption (CExC): it is the total (direct and indirect) amount of (primary) exergy needed to generate product k.
What is the difference?

18. Energy vs. Exergy efficiency

19. Industrial Energy Intensity
It differs between different products

20. Industrial Energy Intensity
It differs between different materials
Steel
Cement
Paper
Aluminium
Plastics
Gutowski TG, Sahni S, Allwood JM, Ashby MF,Worrell E The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand. Phil Trans R Soc A 371:

21. Industrial Energy Intensity
For high diluted metals it depends on the ore grade
Iron
Aluminium
Energy intensity controled by the chemical reduction step
Energy intensity controled by the mining & separation steps
Gutowski TG, Sahni S, Allwood JM, Ashby MF,Worrell E The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand. Phil Trans R Soc A 371:

22. Chemical reduction steps
Iron
2Fe2O3(s) + 3C(s) → 4Fe(l) + 3CO2(g)
Fe2O3(s) + 3CO(s) → 2Fe(l) + 3CO2(g)
CaCO3(s) → CaO(s) + CO2(g)
CaO(s) + SiO2(s) → CaSiO3(l)

23. Industrial Energy Intensity
It changes in time due to technological inovations

24. Thermodynamic limits Iron
The ΔG˚ for the chemical reaction is 1.4 MJ/kg Fe
2Fe2O3(s) + 3C(s) → 4Fe(l) + 3CO2(g)

25. Industrial Energy Intensity
Steel
Gutowski TG, Sahni S, Allwood JM, Ashby MF,Worrell E The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand. Phil Trans R Soc A 371:

26. Industrial Energy Intensity
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)
Steel Energy intensity
0.5
0.5

27. Industrial Energy Intensity
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

28. Benchmarking Industrial Energy Use
Management tool to compare similar plants in energy use and energy efficiency
Benchmarking curves (improvement potential)
Specific energy consumption
Energy Efficiency Index
Best Practice Technology

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

30. Industrial Energy Intensity

31. Industrial Energy Intensity

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

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

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

35. Energy Use in Industry

36. Material Efficiency
Material efficiency means providing material services but using less material:
Light-weight design:
Reducing yield losses
Diverting manufacturing scrap:
Re-using components:
Longer-life products
More intense use

37. SGCIE
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

38. SGCIE Domain of Application Supervision Management
All entities with an annual primary energy consumption higher than 500 toe (1 toe = MJ)
Exceptions: Cogeneration facilities, transport entities and buildings
Supervision
DGEG
Management
ADENE

39. 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

40. 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 toe

41. 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

42. 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?

43. 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
Electricity
8 (produção 1) A C D E B 2 1 F G 14 13 12 11
Fueloil

44. SGCIE Obligations (for IEC entities)
Develop Energy Rationalization Plans
The carbon intensity must not increase
Why a goal on carbon intensity?

45. 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)

46. SGCIE Conversion coefficients for CO2 emissions and primary energy
Despacho nº 17313/2008

47. SGCIE Conversion coefficients for CO2 emissions and primary energy
For primary fuels:

48. SGCIE Conversion coefficients for primary energy
For electricity (in kWh per toe)?
Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729

49. SGCIE Conversion coefficients for primary energy For electricity:
Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729

50. SGCIE Conversion coefficients for primary energy For electricity:
What would happen to this coefficient if we consider cogeneration?
Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729

51. SGCIE Conversion coefficients for primary energy For electricity:
Thermoelectricity produced with coal, oil, natural gas, biomass, urban waste and biogas
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729
BALANÇO ENERGÉTICO tep
Total de Petróleo
Gás Natural (*)
Gases o Outros Derivados
Termo-electricidade
Calor
Resíduos Industriais
Renováveis Sem Hídrica
2008
22= 23
30 = 24 a 29 35 37 38
46 = 39 a 45
Cogeração
6.7
24 379
2 523

52. SGCIE Conversion coefficients for CO2 emissions
For electricity (in kg CO2 e per kWh)?
kg CO2 e/toe
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729
kg CO2 e/toe
kg CO2 e/toe

53. SGCIE Conversion coefficients for CO2 emissions
For electricity (in kg CO2 e per kWh)
kg CO2 e/toe
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 3
22= 23 35 40 41 44
Electricidade
6.6
61 957
19 729
kg CO2 e/toe
kg CO2 e/toe

54. SGCIE Conversion coefficients for CO2 emissions and primary energy
For electricity:
Conversão directa de kWh em tep?

55. SGCIE Conversion coefficients for CO2 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

63. Exercise
A factory produces 2 end products: P1 and P2. These products follow the production process shown in the diagram below, with P1 = ton/year and P2 = 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 SE = 1.2, SF = 1.3. In operation G, only 20% of the input effluent, exits the process as waste. The values of composition are as follows: f4 = 0.4, f6 = 0.5. The table presents the specific consumption of each operation. Consider that for electricity: kgep/kWh & 0.47 kg CO2e/KWh and for fueloil kgep/kg & kg CO2e/toe
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

64. Exercise 8 (produção 1) A C D E B 1 F G 13 10 (produção 2) 3 4 5 6 7 9A C D E B 2 1 F G 14 13 12 11
10 (produção 2) 3 4 5 6 7 9