Energy Efficiency in Industry

✍ Scribed by Markus Blesl, Alois Kessler

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 512
• Category: Library

✦ Synopsis

This book quantifies the potential for greater energy efficiency in industry on the basis of technology- and sector-related analyses. Starting from the methodological fundamentals, the first part discusses the electricity- and heat-based basic technologies and cross-sectional processes on the basis of numerous application examples. In addition to classic topics such as lighting and heat recovery, the study also covers processes that have received less attention to date, such as drying and painting. The second part is devoted to energy-intensive industries, in particular metal production and processing, the manufacture of the non-metallic materials cement and glass, and the chemical, paper, plastics and food industries. Both parts are concluded by placing them in a larger energy and economic context. The findings are condensed into checklists at many points and summarized in the overall view at the end to form generally applicable recommendations.

This book is a translation ofthe original German 2^nd edition Energieeffizienz in der Industrie by Markus Blesl and Alois Kessler, published by Springer-Verlag GmbH Germany, part of Springer Nature in 2017. The translation was done with the help of artificial intelligence (machine translation by the service DeepL.com). A subsequent human revision was done primarily in terms of content, so that the book will read stylistically differently from a conventional translation. Springer Nature works continuously to further the development of tools for the production of books and on the related technologies to support the authors.

✦ Table of Contents

Foreword
Preface by the Authors to the 1st edition
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Contents
Abbreviations
List of Formula Symbols Used
List of Figures
List of Tables
1: Introduction
2: Fundamentals of Energy Efficiency
2.1 Legal Framework
2.2 Considerations on the Systematics of Energy Efficiency
2.2.1 General Measures to Improve Energy Efficiency
Example: Waste Water Treatment and Heat Recovery in the Textile Industry
2.3 Methods
2.3.1 Technical Analyses
2.3.2 Economic Analyses
2.3.3 Stationary and Mobile Measurement Technology
Literature
3: Electricity-Based Enabling Technologies
3.1 Electrical Power Supply
3.1.1 Transformers
3.1.1.1 Basics
3.1.1.2 Power Factor Correction
3.1.1.3 Uninterruptible Power Supply
3.1.1.4 Cable Dimensioning
3.1.2 Recommendations
3.2 Electric Lighting
3.2.1 Basics
3.2.2 Measures
3.2.2.1 Energy-Efficient Light Sources and Lighting Technology
3.2.2.2 Lighting Management
3.2.3 Recommendations
3.3 Electric Drives
3.3.1 Basics
3.3.2 The Economic Efficiency of Drive Systems
3.3.3 Measures
3.3.3.1 Optimising the Efficiency of the e-Machine
3.3.3.2 Optimising the Efficiency of the Drive System
3.3.4 Recommendations
3.4 Fans
3.4.1 Basics
3.4.2 Measures
3.4.2.1 Correct Dimensioning
Example: Renovation of the Ventilation System in Wiesbaden Castle (Müller 2014)
3.4.2.2 Use of Efficient Fans
3.4.2.3 Speed Adjustment
3.4.2.4 Maintaining Performance Through Maintenance
3.4.3 Recommendations
3.5 Pumps
3.5.1 Basics
3.5.2 Measures
3.5.2.1 Dimensioning the Pump
Example: Energy Saving by Adapting a Pump Impeller
3.5.2.2 Optimisation of the Pump System and the Control System
3.5.2.3 Optimisation of Existing Pump Systems
Example
3.5.3 Recommendations
3.6 Electricity-Based Basic Technologies for Heat Generation
Literature
4: Fuel-Based Enabling Technologies
4.1 Heat Generation by Means of Burners
4.1.1 Basics
4.1.2 Measures
4.1.2.1 Substitution of a Cold Air Burner by a Hot Air, Recuperator or Regenerator Burner
4.1.2.2 Substitution of a Regenerator, Recuperator, Hot Air or Cold Air Burner by an Oxygen Burner
4.1.2.3 Substitution of a Recuperator or Hot Air Burner by a FLOX Burner
4.1.2.4 Substitution of a Recuperator Burner by a Regenerator Burner
4.1.2.5 Further Measures
4.1.3 Recommendations
4.2 Heat Exchangers for Heat Recovery and Waste Heat Utilisation
4.2.1 Basics
4.2.2 Measures
4.2.2.1 Maintenance and Cleaning
4.2.2.2 Feeding into Heat Networks
Example: Waste Heat from Exhaust Air After Burning Feeds District Heating Network
4.2.2.3 Mobile Thermal Storage Units
4.2.2.4 Use of Waste Water Heat
Example: Waste Water Heat Utilisation in the Production of Cardboard Boxes
4.2.2.5 Electricity Generation from Waste Heat
4.2.3 Recommendations
4.3 Heat and Cold Insulation
4.3.1 Basics
4.3.2 Measures
4.3.3 Recommendations
Literature
5: Electricity-Based Cross-Section Processes
5.1 Compressed Air
5.1.1 Basics
5.1.2 Measures
5.1.2.1 Dimensioning of Compressed Air Systems
5.1.2.2 Use of Speed-Controlled Compressor Drives
5.1.2.3 Leakage in Compressed Air Systems
5.1.2.4 Maintenance
5.1.2.5 Waste Heat Recovery from Compressed Air Systems
5.1.2.6 Substitution of Compressed Air Applications
5.1.2.7 Organisational Measures
5.1.3 Recommendations
5.2 Data Centers
5.2.1 Basics
5.2.2 Measures
5.2.2.1 Efficient Use of Efficient IT Hardware
5.2.2.2 Efficient Storage and Data Management
5.2.2.3 Cooling Optimisation
5.2.2.4 Optimisation of the Power Supply
5.2.3 Recommendations
5.3 Electroplating
5.3.1 Basics
5.3.2 Measures
5.3.2.1 Reduction of Voltage Losses
5.3.2.2 Optimisation of the Airflow
Example: Partial Bath Tank Cover
Example: Night Reduction of Air Extraction
Example: Heat Recovery from Exhaust Air
5.3.2.3 Process Heating
5.3.2.4 Process Cooling
5.3.2.5 Optimisation of the Rectifier
Example: Conversion of Selenium to Silicon Diodes
5.3.3 Recommendations
Literature
6: Fuel-Based Cross-Sectional Processes
6.1 Boilers for Steam Generation
6.1.1 Basics
6.1.2 Measures
6.1.2.1 Installation of a Caustic Expansion and Cooling System
6.1.2.2 Installation of an Economiser
Example: Installation of an Economiser in the Textile Finishing Industry
6.1.2.3 Benefits of Condensing Boiler Technology
6.1.2.4 Installation of a Closed Condensate Return System
6.1.2.5 Heat Recovery from Steam
6.1.2.6 Stepless Burner Control
6.1.2.7 Measures from Other Basic and Cross-Cutting Technologies
Example: Teutoburger Mineralbrunnen GmbH and Co KG
6.1.3 Recommendations
6.2 Industrial Furnaces
6.2.1 Basics
6.2.2 Measures
6.2.2.1 Improvement of the Wall Structure by Means of Insulation
Example: Use of Microporous Insulation
6.2.2.2 Heating and Optimisation of Burner Technology
6.2.2.3 Waste Heat Recovery
Example: Waste Heat Utilisation in a Contract Heat Treatment Plant
6.2.2.4 Intelligent Control and Regulation Technology
6.2.3 Recommendations
6.3 Drying Plants
6.3.1 Basics
6.3.2 Measures
6.3.2.1 Mechanical Pre-Drying
Example: Sugar Processing
6.3.2.2 Optimisation of Heating and Insulation
6.3.2.3 Hot Steam drying Instead of Fresh Air Drying
6.3.2.4 Dry Air Drying by Means of Refrigeration Dryers
Example: Conversion of an Adhesive Water Dryer in a Paint Shop
6.3.2.5 Improving Process Control
6.3.2.6 Alternative Drying Processes
6.3.3 Recommendations
6.4 Painting Systems
6.4.1 Basics
6.4.2 Measures
6.4.2.1 Planning and Organisational Measures
Example: Alternative Coil and Sheet Coating
Example: Switching Off the Atomization During Interruptions of Operation
6.4.2.2 Optimisation of Pre-treatment
Example: Clean-Laser
6.4.2.3 Optimisation in the Area of Paint Application
Example: Heat and Moisture Recovery from Spray Booth Exhaust Air
6.4.2.4 Optimisation of the Paint Drying/Curing Process
6.4.3 Recommendations
Literature
7: Coupled and Other Cross-Sectional Processes
7.1 Combined Production and Use of Electricity and Heat
7.1.1 Basics
7.1.1.1 Combined Heat and Power Plants
7.1.1.2 Steam Turbine
7.1.1.3 Heat Pumps and Chillers
Example 1: Waste Heat Utilisation at the Rolling Mill Plettenberg
Example 2: Absorption Heat Pump at Cologne/Bonn Airport
7.1.2 Measures
Example: Combination of a CHP and a Heat Pump for Malt Production
7.1.3 Recommendations
7.2 Heating, Ventilation and Air-conditioning Systems for Industrial Buildings
7.2.1 Basics
7.2.2 Measures
7.2.2.1 Heat Recovery
Example: Retrofitting of a Cross-Flow Plate Heat Exchanger
7.2.2.2 Maintenance and Servicing
7.2.2.3 Ceiling Spotlights
Example: Installation of Radiant Ceiling Panels at the EvoBus Company in Neu-Ulm
7.2.2.4 Optimisation of Building Operation
7.2.3 Recommendations
7.3 Refrigeration
7.3.1 Basics
7.3.2 Measures
7.3.2.1 Drawing up an Inventory of Refrigeration Systems and Operating Methods
7.3.2.2 Minimisation of the Cooling Demand
7.3.2.3 Reduction of Electricity Consumption for Refrigeration
7.3.2.4 Control Optimisation of Refrigeration Systems
Example 1: Optimization of a Food Refrigeration Plant
Example 2: Optimization of a Process Refrigeration Plant
Example 3: Simulatively Optimized Control Strategy
7.3.2.5 Optimisation of Power, Pressure and Temperature Levels
7.3.3 Recommendations
7.4 Other Cross-Cutting Processes
7.4.1 Conveyor Technology
7.4.2 Handling Technology
7.4.3 Industrial Gases
Example: Water Bath Evaporator in Steel Plant
7.4.4 Welding
7.4.5 Waste Water Treatment
7.4.6 Vacuum Technology
Literature
8: Industries with Their Highly Specialized or Energy-Intensive Processes
8.1 Manufacture of Basic Chemicals
8.1.1 The Sector
8.1.2 Fundamentals of the Technology
8.1.3 Individual Processes and Measures
8.1.3.1 Ethylene
8.1.3.2 Propene
8.1.3.3 Methanol
8.1.3.4 Benzene
8.1.3.5 Chlorine
8.1.3.6 Ammonia
8.1.3.7 Soda Ash
8.1.3.8 Phosphoric Acid
8.1.4 Recommendations for Energy Optimisation in the Chemical Industry
8.1.5 Savings Potential Curve
8.2 Manufacture of Iron and Steel
8.2.1 The Sector
8.2.1.1 Fundamentals of the Technology
8.2.2 Individual Processes and Measures
8.2.2.1 Dry Coke Cooling
8.2.2.2 Gas Recirculation on Sintering Equipment
8.2.2.3 Energy Efficiency Measures at the Blast Furnace and Steelworks
8.2.2.4 Energy Efficiency Measures for Electric Arc Furnaces
Example: Badische Stahlwerke, Kehl
8.2.2.5 Alternative Reduction Processes
8.2.2.6 Secondary Metallurgy, Primary Forming, Rolling, Bending, Surface Treatment
8.2.2.7 Cross-Process Energy Efficiency Measures
8.2.2.8 Recommendations for Energy Optimisation in Iron/Steel Production
8.2.3 Savings Potential Curve
8.3 Production of Aluminium and Non-ferrous Metals
8.3.1 The Sector
8.3.2 Fundamentals of the Technology
8.3.3 Individual Processes and Measures
8.3.3.1 Energy Efficiency Measures in Primary Aluminium Electrolysis
8.3.3.2 Efficiency Potentials in Anode Production
8.3.3.3 Optimisation of Copper Production
8.3.4 Recommendations for the Energetic Optimisation of Metal Production
8.3.5 Savings Potential Curve
8.4 Manufacture of Glass and Ceramics
8.4.1 The Sector
8.4.2 Fundamentals of the Technology
8.4.2.1 Optimum Composition of the Charge
8.4.3 Individual Processes and Measures
8.4.3.1 Optimisation of the Furnace and Firing System
8.4.3.2 Recommendations for the Energetic Optimisation of Glass Production
8.4.4 Savings Potential Curve
8.5 Production of Cement
8.5.1 The Sector
8.5.2 Fundamentals of the Technology
8.5.3 Individual Processes and Measures
8.5.3.1 Burning Clinker in the Kiln Process
8.5.3.2 Grinding of Clinker and Additives to Cement
8.5.3.3 Overall Process Optimisation
8.5.3.4 Recommendations for Energy-Efficient Cement Production
8.5.4 Savings Potential Curve
8.6 Manufacture of Mechanical Pulp, Paper and Paperboard
8.6.1 The Sector
8.6.2 Fundamentals of the Technology
8.6.3 Individual Processes and Measures
8.6.3.1 Optimised Paper Drying Through Adjusted Temperature and Pressure Parameters
8.6.3.2 Optimisation of the Paper Machine Operation
8.6.3.3 Thermal Recovery of Black Liquor
8.6.3.4 Recommendations for Energy-Efficient Paper Production
8.6.4 Savings Potential Curve
8.7 Processing of Metals
8.7.1 Casting
8.7.1.1 Optimisation of Melting and Furnace Technology
8.7.1.2 Optimisation of the Ladle Economy
8.7.1.3 Avoidance of Heat Loss
8.7.1.4 Optimisation of Mould and Core Production
8.7.1.5 Increasing Yield and Quality
8.7.1.6 Heat Recovery
Example: Additional Waste Heat Utilisation at a Cupola Furnace of the Georg Fischer Company
8.7.1.7 Recommendations for the Energetic Optimisation of the Casting Process
8.7.2 Solid Forming
8.7.2.1 Increase of the Material Utilisation Rate
8.7.2.2 Reduction of the Heating Energy Used
8.7.2.3 HR and Waste Heat Utilisation
8.7.2.4 Use of Efficient Equipment and Equipment Components
8.7.2.5 Recommendations for the Energetic Optimisation of the Solid Forming Process
8.7.3 Sheet Metal Forming
8.7.3.1 Use of Efficient Equipment and Equipment Components
8.7.3.2 Increase of the Material Utilisation Rate
Example: Offcut Optimisation
8.7.3.3 Use of Lubricants
8.7.3.4 Consideration of the Entire Process Chains and Application of New Processes
8.7.3.5 Recommendations for the Energetic Optimisation of the Sheet Metal Forming Process
8.8 Processing of Foodstuffs
8.8.1 The Sector
8.8.2 Fundamentals of the Technology
8.8.3 Dairies
8.8.4 Breweries
8.8.5 Meat Processing Industry
8.8.6 Industrial Bakeries
8.8.7 Savings Potential Curve
8.9 Processing of Plastics
8.9.1 The Sector
8.9.2 Fundamentals of Technology
8.9.2.1 Production Process Steps in Plastics Processing
8.9.2.2 Methods of Shaping
8.9.3 Individual Processes and Measures
8.9.3.1 Pre-Treatment Measures
8.9.3.2 Measures in the Field of Extrusion
8.9.3.3 Measures in the Field of Injection Moulding
8.9.3.4 Measures in the Blow Moulding Sector
8.9.3.5 Measures in the Field of Thermoforming
8.9.4 Savings Potential Curve
Literature
9: Energy Efficiency from an Energy Economic Perspective
9.1 Prospects for Energy Efficiency in Germany and Europe
9.2 Potentials
9.2.1 Energy Savings Potential for Germany
9.2.2 Potential Energy Savings for the EU28
9.3 Barriers to the Implementation of Energy Efficiency Measures
9.3.1 Causes of Market Failure
9.3.2 Overcoming the Barriers
9.3.2.1 Approaches to Overcoming Barriers Using the Example of the Swedish Iron and Steel Industry
9.3.2.2 Energy Efficiency Networks
9.4 Energy and Economic Effects of a Stronger Energy efficiency Strategy
9.4.1 Rebound Effect
9.4.2 Carbon Leakage
9.4.3 Employment Effect
Literature
10: Summary and Perspectives
10.1 Generalised Motives Guiding Action
10.2 Need for Further Research
Appendix
A1: Figures for Figs. 2.1 and 2.2 for the year 2015
A1: Figures for Fig. 5.2 for the year 2015
Index