1. - The Environmental Managers - Energy Efficiency Programs in Industrial Companies Energy Efficiency in IPPC Installations

2. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 2 DI Andreas Kollegger ALLPLAN GmbH Schwindgasse 10, A-1040 Wien fon: +43 1 505 37 07 53 fax: +43 1 505 37 07 27 andreas.kollegger@allplan.at http://www.allplan.at

3. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 3 Method Some Crucial Points Experience Clients Results Agenda

4. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 4 Analysis Calculations Saving potential Cost assessment of energy saving measures Calculation of savings Data gathering Existing data Measurements Optimum technical and economic solution Method

5. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 5 Some Crucial Points Comprehensive analysis Starting with an overview Identifying large energy flows and consumers Focusing on relevant areas Main production processes very often well optimised Concentrating on auxiliary processes “To boldly to go, where no man has gone before” (© Star Trek)

6. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 6 Example: Sankey Diagram Data Basis: Own measurements Company data Client´s measurements Own calculations

7. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 7 Example: Optimisation of Boilers Use of Waste Heat from Boilers

8. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 8 Comprehensive boiler analysis Optimisation of burners Reduction of radiation losses Reduction of CO content Decrease of flue gas temperature Flue gas condensation Optimisation

9. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 9 Example: Use of Waste Heat from a Production Process

10. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 10 Example: Change in Control Systems

11. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 11 Optimisation – Control Systems Highly sophisticated control systems installed Settings do not fit actual demand (due to adaptations / extensions of plants) Adjustment of control system to actual demand Continuous control of correct settings Retrofit of simple overhead control units No general rules possible due to many different types of control systems Trial and error procedures

12. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 12 Example: Optimisation of Compressed Air

13. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 13 Optimisation of Compressed Air Adaptation of control units pressure levels load to idle run ratio idle run time Upgrade or change of control units Compressors with frequency converters Exploitation of the inevitable waste heat Refurbishment of the distribution system Optimisation of pipe diameters

14. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 14 Example: “Free Cooling” of Tanks

15. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 15 Advantages of “Free Cooling” Requires only a small share of the electricity needed for common chillers Provision of additional annual cooling load Common chillers can fully be switched off under certain conditions Additional safety due to redundancy

16. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 16 Countries Austria Czech Republic Germany Hungary Netherlands Romania Slovakia Slovenia Economic Fields Pulp Production Paper Production Cardboard Production Ferrous Metal Production / Processing Non-Ferrous Metal Production / Processing Mineral Industry Food Industry Utilities more than 50 AEEP´s Our Clients - Examples

17. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 17 The Results – Heat & Electricity

18. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 18 The Results – Overall Financial Savings

19. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 19 The Results – CO 2 Reduction

20. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 20 Results of 28 AEEP´s (carried out in various Austrian industry companies) Saved Electricity:> 6.000.000 MWh/a Saved Heat Energy:> 25.000.000 MWh/a Saved Energy Costs:> 7.000.000 €/a Saved CO 2 Emissions:> 50.000 tCO 2 /a

21. - The Environmental Managers - Energy Efficiency in IPPC Installations Andreas Kollegger 21 DI Andreas Kollegger ALLPLAN GmbH Schwindgasse 10, A-1040 Wien fon: +43 1 505 37 07 53 fax: +43 1 505 37 07 27 andreas.kollegger@allplan.at http://www.allplan.at Thank you for your attention