tracking industrial energy efficiency and co emissions
TRANSCRIPT
IINTERNATIONAL ENERGY AGENCY
Tracking Industrial
Energy Efficiency and
CO2 Emissions
In support of the G8 Plan of Action
ENERGY INDICATORS
Introduction
Manufacturing Industry Energy Use and CO2 Emissions 2
General Industry Indicators Issues 3
Table
Chemical and Petrochemical Industry
Iron and Steel Industry
Non-Metallic Minerals
Pulp, Paper and Printing Industry
Non-Ferrous Metals
Systems Optimisation
Life Cycle Improvements Options
Annexes
TRACKING INDUSTRIALENERGY EFFICIENCY AND CO, EMISSIONS _
Foreword 3
Acknowledgements 5
Table of Contents 7
List of Figures 13 List of Tables 15
Executive Summary 19
Chapter 1 ~ INTRODUCTION 31
Scope of Indicator Analysis 31
Energy and CO2 Saving Potentials 33
Next Steps 36
Chapter 2 ~ MANUFACTURING INDUSTRY ENERGY USE AND CO EMISSIONS 392
Chapter 3 GENERAL INDUSTRY INDICATORS ISSUES 45
Energy Indicators Based on Economic and Physical Ratios 45
Methodological Issues 46 Definition of Best AvailableTechnique and Best Practice 48 Data Issues 49
Practical Application of Energy and CO2 Emission Indicators 51
Pulp, Paper and Printing 51 Iron and Steel 52 Cement 52 Chemicals and Petrochemicals 53 Other Sectors / Technologies 53
International Initiatives: Sectoral Approaches to Developing Indicators ..... 54
Intergovernmental Panel on Climate Change Reference Approach 54 Pulp and Paper Initiatives 55 Cement Sustainability Initiative 55 Asia-Pacific Partnership on Clean Development and Climate 56 Benchmarking in the Petrochemical Industry 56
Chapter 4 ~ CHEMICAL AND PETROCHEMICAL INDUSTRY 59
Introduction 60
Global Importance and Energy Use 61
Petrochemicals Production 64
Steam Cracking: Olefins and Aromatics Production 66
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Propylene Recovery in Refineries and Olefins Conversion 71 Aromatics Extraction 71 Methanol 72 Olefins and Aromatics Processing 74
Inorganic Chemicals Production 75
Chlorine and Sodium Hydroxide 76 Carbon Black 77 Soda Ash 78 Industrial Gases 80
Ammonia Production 82
Combined Heat and Power 85
Plastics Recovery Options 86
Energy and CO2 Emission Indicators for the Chemical and Petrochemical Industry 87
Energy Efficiency Index Methodology 88 CO 2 Emissions Index 91 Life Cycle Index 93
Energy Efficiency Potential. 94
Chapter 5 ~ IRON AND STEEL INDUSTRY 95
Introduction 96
Global Importance and Energy Use 96
Indicator Issues 99
System Boundaries 99 Product and Process Differentiation 99 Allocation Issues 99 Feedstock Quality Issues 101
Energy Indicators 102
Energy Intensity Indicators and Benchmarks 102 Energy Intensity Analysis 103 Efficiency Improvements 106
Coke Ovens 108
Coke Oven Gas Use 111 Coke Dry Quenching 111
Iron Ore Agglomeration 113
Ore Quality 115
Blast Furnaces 116
Coal and Coke Quality 119 Coal Injection 120
TRACKINGINDUSTRIALENERGY EFFICIENCY AND CO, EMISSIONS _ r= Plastic Waste Use Charcoal Use Top-Pressure Recovery Turbines Blast Furnace Gas Use Blast Furnace Slag Use Hot Stoves
Basic Oxygen Furnaces
Basic Oxygen Furnace Gas Recovery Steel Slag Use
Electric Arc Furnaces
Cast Iron Production
Direct Reduced Iron Production
Steel Finishing
Energy Efficiency and CO 2 Reduction Potentials
Chapter 6 ~ NON-METALLIC MINERALS
Introduction
Cement
Global Importance and Energy Use Cement Production Process Energy and CO 2 Emission Indicators for the Cement Industry
Lime
Overview Lime Production Process Energy Consumption and CO2 Emissions from Lime Production
Glass
Overview Glass Production Process Energy Consumption and CO 2 Emissions from Glass Production
Ceramic Products
Overview Ceramics Production Process Energy Consumption and CO 2 Emissions from Ceramics Production
Indicators for Lime, Glass and Ceramics Industries
Chapter 7 ~ PULP, PAPER AND PRINTING INDUSTRY
Global Importance and Energy Use
Methodological and Data Issues
121 121 123 123 124 126
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127 127
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140 140 162
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163 164 166
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166 167 168
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169 172 173
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Pulp and Paper Production and Demand Drivers 178
Energy Use in the Pulp and Paper Industry 180
Pulp Production 182
Paper Production 183 Printing 185
Energy Indicators 187
Energy Intensity Indicators versus Benchmarking 187
Energy Efficiency Index Methodology 187
Expanding Indicators Analysis in the Pulp and Paper Industry 195
Combined Heat and Power in the Pulp and Paper Industry 196
Paper Recycling and Recovered Paper Use 198
Use of Technology to Increase Energy Efficiency and Reduce CO2 Emissions 200
Differences in Energy Intensity and CO2 Emissions across Countries 201
Energy Efficiency Potentials 204
Chapter 8 ~ NON-FERROUS METALS 207
Introduction 207
Global Importance and Energy Use 207
Aluminium Production 208
Copper Production 213
Energy Efficiency and CO2 Reduction Potentials 216
Chapter 9 ~ SYSTEMS OPTIMISA"nON 217
Introduction 217
Industrial Systems 218
Industrial System Energy Use and Energy Savings Potential 218
Motor Systems 220
Steam Systems 227 Barriers to Industrial System Energy Efficiency 231
Effective Policies and Programmes 231
Combined Heat and Power 236
Benefits of CHP 238
Barriers to CHP Adoption 239
CHP Statistics 240 Indicators for CH P Energy Efficiency Benefits 242
TRACKING INDUSTRIALENERGY EFFICIENCY AND CO, EMISSIONS _
Chapter 10 ~ LIFE CYCLE IMPROVEMENT OPTIONS 247
Introduction 247
Indicator Issues 247
Trends in the Efficiency of Materials and Product Use 249
Buildings 252 Packaging 252 Transportation Equipment 254
Recycling and Reuse 256
Petrochemical Products 259 Paper 262 Aluminium 264 Steel 265
Energy Recovery 268
Petrochemical Products 271 Paper 273 Wood 273
Annexes ~ Annex A • Process Integration 275
Annex B • Industry Benchmark Initiatives 283
Annex C • Definitions, Acronyms and Units 287
Annex D • References 303
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252 252 254
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259 262 264 265
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271 273 273
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.287
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___________________________TABLE OF CONTENTS
LIST OF FIGURES
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
~ MANUFACTURING INDUSTRY ENERGY USE AND CO2 EMISSIONS
2.1 Industrial Final Energy Use, 1971 - 2004 41 2.2 Materials Production Energy Needs, 1981 - 2005 42 2.3 Industrial Direct CO 2 Emissions by Sector, 2004 44
GENERAL INDUSTRY INDICATORS ISSUES
3.1 Possi ble Approach to Boundary Issues for the Steel Industry 47 3.2 Allocation Issues for Combined Heat and Power 48
~ CHEMICAL AND PETROCHEMICAL INDUSTRY
4.1 World Chemical and Petrochemical Industry Energy Use, 1971 - 2004 61 4.2 The Ethylene Chain 65 4.3 Ethylene Plants by Feedstock and Region 67 4.4 Average Steam Cracker Capacity 68 4.5 Steam Cracking Energy Consumption Index per unit of Product, 2003 70 4.6 Carbon Black Production by Region, 2004 77 4.7 Industrial Gas Demand by Market Segment 81
~ IRON AND STEEL INDUSTRY
5.1 Global Steel Production by Process, 2004 97 5.2 Steel Production Scheme 98 5.3 Final Energy Intensity Distribution of Global Steel Production, 2004 106 5.4 CO2 Emissions per tonne of Crude Steel 108 5.5 Use of Coke Dry Quenching Technology, 2004 112 5.6 Energy Balance of a Typical Efficient Blast Furnace 116 5.7 Blast Furnace Reductant Use, 2005 117 5.8 Pulverised Coal Injection in Blast Furnace Use by Region, 2005 120 5.9 Electricity Use for Electric Arc Furnaces 131 5.10 Global Direct Reduced Iron Production, 1970 - 2004 133 5.11 Trend of Average Steel Yields, Germany, 1960 - 2005 136
~ NON-METALLIC MINERALS
6.1 Energy Efficiency of Various Cement Clinker Production Technologies 143 6.2 Cement Production from Vertical Shaft Kilns in China, 1997 - 2003 144 6.3 Chemical Composition of Cement and Clinker Substitutes 146 6.4 Clinker-to-Cement Ratio by Country and Region, 1980 - 2005 149 6.5 Energy Requirement per tonne of Clinker by Country
including Alternative Fuels 152 6.6 Energy Requirement per tonne of Clinker for Non-OECD Countries
and New EU Accession Countries 154 6.7 Impact of Alternative Fuels and Raw Materials on Overall
CO2 Emissions 155 6.8 Alternative Fuel Use in Clinker Production by Country 156
TRACKING INDUSTRIALENERGY EFFICIENCY AND CO2
EMISSIONS _
6.9 Electricity Consumption per tonne of Cement by Country, 1980 - 2005 158
6.10 Total Primary Energy Equivalent per tonne of Cement by Country, 1990 - 2004 159
6.11 CO2 Emissions from Energy Consumption (including electricity) per tonne of Cement by Country, 1990 - 2005 160
6.12 Process and Energy (including electricity) C02 Emissions per tonne of Cement by Country, 1990 - 2005 161
Chapter 7 ~ PULP, PAPER AND PRINTING INDUSTRY
7.1 Energy in Pulp and Paper Production 181
7.2 Pulp Production Mix in Canada, 2004 185
7.3 Paper and Board Product Mix in Canada, 2004 186
7.4 Number of Pulp and Paper Mills by Capacity in China 189
7.5 Heat Consumption in Pulp and Paper Production versus Best Available Technology, 1990 - 2003 192
7.6 Electricity Consumption in Pulp and Paper Production versus Best Available Technology, 1990 - 2003 193
7.7 CO2 Emissions per tonne of Pulp Exported and Paper Produced, 1990 - 2003 194
7.8 Waste Paper Collection Rate versus Use Rate 199
7.9 World Paper Production, Processing and Recycling Balance, 2004 200
7.10 Energy Consumption and CO2 Emissions Index in Japan 203
Chapter 8 ~ NON-FERROUS METALS
8.1 Regional Specific Power Consumption in Aluminium Smelting 211
Chapter 9 ~ SYSTEMS OPTIMISATION
9.1 Conventional Pumping System Schematic 220
9.2 Estimated Industrial Motor Use by Application 224
9.3 Energy Efficient Pumping System Schematic 225
9.4 Steam System Schematic 227
9.5 Steam System Use and Losses 228
9.6 Distribution of Industrial CHP Capacity in the European Union and United States 239
9.7 Global CHP Capacity, 1992 - 2004 241
9.8 Current Penetration of Industrial CHP 244
Chapter 10 ~ LIFE CYCLE IMPROVEMENT OPTIONS
10.1 Apparent Steel Consumption Trends percapita, 1971 - 2005 249
10.2 Apparent Cement Consumption Trends per capita, 1971 - 2005 250
10.3 Apparent Paper and Paperboard Consumption Trends per capita, 1971 - 2005 251
10.4 Floor Area per unit of GOP for OECD Countries 253
10.5 Packaging by Market Segment 253
10.6 Global Car Ownership Rates as a Function of per capita GOP, 2005 255
10.7 Global Car Sales, 1980 - 2005 255
__________________________TABlE OF CONTENTS
10.8 Car WeightTrends, 1975 - 2005 256 10.9 World Petrochemical Mass Balance, 2004 260 10.10 World Pulp and Paper Mass Balance, 2004 264 10.11 World Aluminium Mass Balance, 2004 265 10.12 World Steel Mass Balance, 2005 266 10.13 Global Steel Scrap Recovery, 1970 - 2005 267 10.14 Global Steel Obsolete Scrap Recovery Rate, 1970 - 2005 268
Annexes ~ Annex A • Process Integration
A.1 Results/Savings from Process Integration Schemes 278
A.2 Savings from Process Integration Schemes by Industry 279
LIST OF TABLES
Chapter 1 ~ INTRODUCTION
1.1 Savings from Adoption of Best Practice Commercial Technologies in Manufacturing Industries 35
Chapter 2 ~ MANUFACTURING INDUS"rRY ENERGY USE AND CO2 EMISSIONS
2.1 Industrial Final Energy Use, 2004 40 2.2 Final Energy Use by Energy Carrier, 2004 43
Chapter 3 GENERAL INDUSTRY INDICATORS ISSUES
3.1 Summary of Indicators for Each Industry Sector 54
Chapter 4 ~ CHEMICAL AND PETROCHEMICAL INDUSTRY
4.1 Energy Use in the Chemical and Petrochemical Industry, 2004 62 4.2 World Production Capacity of Key Petrochemicals, 2004 63 4.3 Energy Use versus Feedstock for Ethylene 66 4.4 Specific Energy Consumption for State-of-the-Art I\laphtha Steam
Cracking Technologies 68 4.5 Ultimate Yields of Steam Crackers with Various Feedstocks 69 4.6 Methanol Production, 2004 73 4.7 Global Ethylene Use, 2004 74 4.8 Global Propylene Use, 2004 74 4.9 European Energy Use and Best Practice 75 4.10 Worldwide Chlorine Production, 2004 76 4.11 Energy Efficiency of Chlorine Production Processes 76 4.12 Soda Ash Production, 2004 78 4.13 Typical Energy Use for Energy Efficient Soda Ash Production
Using Best Available Technology 79
4.14 Global Soda Production Capacity, 2000 80 4.15 Energy Consumption in Ammonia (NH 3) Production, 2005 83
TRACKINGINDUSTRIAL ENERGY EFFICIENCY AND CO, EMISSIONS _
864.16 CHP Use in the Chemical and Petrochemical Industry 874.17 Plastic Recycling and Energy Recovery in Europe
4.18 Best Practice Technology Energy Values, 2004 89
4.19 Indicator Use for Country Analysis of Global Chemical and Petrochemical Industry 91
924.20 Carbon Storage for Plastics in Selected Countries, 2004
4.21 Total CO2 Emissions and CO2 Index, 2004 93
4.22 Energy Savings Potential in the Chemical and Petrochemical Industry 94
Chapter 5 ~ IRON AND STEEL INDUSTRY
5.1 Energy and CO2 Emission Impacts of System Boundaries 101
5.2 Pig Iron Production, 2005 104
5.3 Steel Production, 2005 105
5.4 Net Energy Use per tonne of Product 107
5.5 Energy Balance of Slot Ovens for Coke Production 109
5.6 Heat Recovery Options in Various Steel Production Steps 114
5.7 Iron Ore Mining and Ore Quality, 2004 115
5.8 CO2 Emissions of Chinese Blast Furnaces asa Function of Size, 2004 118
5.9 Average CO2 Emissions from Steel Production in Brazil, 2005 123
5.10 Global Blast Furnace Gas Use, 2004 124
5.11 Use of Blast Furnace Slag, 2004 125
5.12 Residual Gas Use in China 127
5.13 Steel Slag Use 128
5.14 Energy Use for Electric Arc Furnaces with Different Feed and with/without Preheating 129
5.15 Natural Gas-based DRI Production Processes 133
5.16 DRI Production, 2004 134
5.17 Technical Energy Efficiency and CO2 Reduction Potentials in Iron and Steel Production 137
6.1 Energy Use, CO2 Emissions and Short-Term Reduction Potentials
Chapter 6 ~ NON-METALLIC MINERALS
in the Chinese Building Materials Industry, 2006 141
6.2 Global Cement Production, 2005 142
6.3 Heat Consumption of Different Cement Kiln Technologies 145
6.4 Typical Composition of Different Cement Types 147
6.5 Current Use and Availability of Clinker Substitutes 150 6.6 Cement Technologies and Fuel Mix by Region 151
6.7 Indicators for the Cement Industry 162
6.8 Typical Specific Energy Consumption for Various Types of Lime Kilns 165
6.9 Energy Consumption of Main Kiln Types in the Bricks and Tile Industry in China, 2006 171
6.10 Energy Consumption per weight unit for Different Types of Ceramic Products 173
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Chapter 7 ~ PULP, PAPER AND PRINTING INDUSTRY
7.1 Paper and Paperboard Production, 2004 178
7.2 Chemical and Mechanical Wood Pulp Production, 2004 179
7.3 Global Paper and Paperboard Consumption, 1961 and 2004 180
7.4 Typical Energy Consumption in Paper Production for a Non-integrated Fine Paper Mill 183
7.5 Typical Electricity Consumption for the Production of Various Types of Paper 183
7.6 Breakdown of Energy Use in Paper Production in the United States 184
7.7 Benchmarking Results for Canadian Pulp & Paper Industry 186
7.8 Best Available Technology 188
7.9 Paper Production by Type of Paper and by Country, 2004 190
7.10 CHP Use in the Pulp and Paper Industry 196
7.11 CHP Adjusted Energy Efficiency Indicators, 2003 197
7.12 Data Required for CHP Analysis in the Pulp and Paper Industry 198
7.13 Energy Savings Potential in the Pulp and Paper Industry 205
Chapter 8 ~ NON-FERROUS METALS
8.1 Estimated Energy Consumption in Primary Non-Ferrous Metals Production, 2004 208
8.2 Regional Average Energy Use of Metallurgical Alumina Production 209
8.3 Global Primary Aluminium Production, 2004 210
8.4 Regional Average Energy Use for Primary Aluminium Production, 2004 212
8.5 Global Primary Copper Production, 2004 214
8.6 Energy Use for Copper Production in Chile 215
Chapter 9 ~ SYSTEMS OPTIMISATION
9.1 Motor Efficiency Performance Standards and the Market Penetration of Energy Efficient Motors 223
9.2 Percent Energy Savings Potential by Compressed Air Improvement 226
9.3 Percentage Steam Use by Sector - Top Five US Steam-Using Industrial Sectors 228
9.4 Steam System Efficiency Improvements 229
9.5 Motor System Energy Savings Potential 234
9.6 Steam System Energy Savings Potential 235 9.7 Summary of CHP Technologies 237
9.8 CHP Use in Selected Countries 242
a..,.., 10 ~ LIFE CYCLE IMPROVEMENT OPTIONS
10.1 Global Recycling Rates and Additional Recycling Potential 258 10.2 CO2 Impacts of Plastic Waste Recovery Optionsversus
Land fill Disposal 261
10.3 Plastic Waste Recycling by Country 263
10.4 Global Incineration Rates and Additional Potential, 2004 269
TRACKINGINDUSTRIALENERGY EFFICIENCY AND CO, EMISSIONS _
10.5 Efficiency of European Waste Incinerators 270 10.6 MSW Incineration with Energy Recovery, 2004 271 10.7 Energy Needs for Fuel Preparation for Plastics Co-combustion
in Coal-fired Power Plants 272
Annexes ~ Annex A • Process Integration
A.1 Process Integration SUNey Results 277