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.
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.