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2021 | Buch

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Energy Efficiency in Industry

verfasst von: Markus Blesl, Alois Kessler

Verlag: Springer Berlin Heidelberg

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

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 of the original German 2nd 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.

Inhaltsverzeichnis

Frontmatter

1. Introduction

Abstract

In the introduction, a connection is made between industrial energy efficiency and the global problems of scarcity with 7.5 billion people on earth today. Energy efficiency is not understood as “saving at any price”, but as the targeted and economical use of all production factors—in addition to energy, also labour, capital and raw materials. Energy efficiency is therefore part of raw material efficiency and thus a contribution to sustainability.

Markus Blesl, Alois Kessler

2. Fundamentals of Energy Efficiency

Abstract

The fundamentals of energy efficiency include, in addition to some basic methods, in particular the legal framework. With the energy transition, a significant acceleration has taken place here with ever new laws and regulations at European and national level. The systematics of energy efficiency lead to the classification into basic technologies, cross-sectional processes and sectoral technologies, on which the book is subsequently based. Finally, methods for the technical and economic analysis of savings potentials are explained, which also appear important as a basis for the following chapters.

Markus Blesl, Alois Kessler

3. Electricity-Based Enabling Technologies

Abstract

Electricity-based enabling technologies include transformers, electric lighting, electric drives, and arguably the fluid machinery they power, such as fans and pumps. The technical fundamentals are briefly described in each case in order to create an understanding of the efficiency measures in detail. For each basic technology, the findings are summarized in recommendations. Finally, there is an outlook on electricity-based heat generation, which forms the transition to the following main chapter.

Markus Blesl, Alois Kessler

4. Fuel-Based Enabling Technologies

Abstract

This chapter describes the basic technologies involved in dealing with fuel-based heat generation and thus follows on directly from Sect. 3.6, which is devoted to electrical heat generation. In addition to the generation of heat, the transfer of heat for its recovery and the transport of heat are also of interest in this context. The recovery of (waste) heat takes place in many different devices and processes, which are discussed in Sect. 4.2. Heat transport by conduction, radiation and convection always leads to losses, which are usually reduced by installing thermal insulation, which is the subject of consideration in Sect. 4.3. The technical principles are briefly described in each case to provide an understanding of the efficiency measures described in detail. For each basic technology, the findings are summarised in recommendations.

Markus Blesl, Alois Kessler

5. Electricity-Based Cross-Section Processes

Abstract

Electricity-based cross-section processes include the operation of compressed air systems, the operation of data centres and galvanic surface coating. The technical fundamentals are briefly described in each case to provide an understanding of the efficiency measures described in detail. For each cross-cutting topic, the findings are summarized in recommendations.

After describing the “simple” electricity-based basic technologies in Chap. 3, this chapter turns to the more complex cross-sectional processes. Compressed air (CA) systems (see Sect. 5.1) consist of electric drives, compressors, piping, storage, control equipment and heat recovery. Data centres (see Sect. 5.2) include not only the hardware, but also ventilation and refrigeration systems in their respective complexity, but also, for example, lighting and a secure uninterruptible power supply (UPS). In electroplating plants (see Sect. 5.3), a direct current supply by means of converters is necessary. In addition, ventilation and hydraulic components are required, for example, for thermal coupling of the baths at different temperatures or for heat recovery.

Markus Blesl, Alois Kessler

6. Fuel-Based Cross-Sectional Processes

Abstract

Fuel-based cross-sectional processes include the operation of boiler plants, of industrial furnaces and drying plants, and the operation of paint shops. The technical fundamentals are briefly described in each case to provide an understanding of the efficiency measures described in detail. For each cross-sectional topic, the findings are summarized in recommendations.

Markus Blesl, Alois Kessler

7. Coupled and Other Cross-Sectional Processes

Abstract

Some important cross-sectional processes are hermaphrodites that are equally linked to electricity and heat. These coupled cross-sectional processes include cogeneration machines, but also many ventilation and air-conditioning systems as well as the generation of cooling—predominantly on the basis of electrical energy. The technical fundamentals are briefly described in each case to provide an understanding of the efficiency measures described in detail. For each cross-sectional topic, the findings are summarised in recommendations. Other cross-sectional processes that have so far hardly been considered from an energy point of view are outlined. These include conveyor technology, handling technology, industrial gases, welding processes, waste water treatment and vacuum technology.

In the case of heating, ventilation and air conditioning (HVAC) systems, the mostly fuel-based heating of the room air is just as important as the predominantly electricity-based transport of the supply and exhaust air. The heat supply can be combined with combined heat and power (CHP) technologies. Larger CHP plants in particular, however, are mainly used for the provision of process heat and are operated in a heat-controlled manner. For the thermal conditioning of indoor air, electrically driven chillers are often used, the waste heat of which can be additionally utilised. Against this background, it seems appropriate to group these processes in a separate chapter. Technologies which, conversely, are used more for electricity generation from waste heat also represent a coupling of electrical and thermal work, but are mainly used for waste heat recovery and are therefore assigned to Sect. 4.2.2.5.

Markus Blesl, Alois Kessler

8. Industries with Their Highly Specialized or Energy-Intensive Processes

Abstract

This chapter is dedicated in detail to the energy-intensive industries with their partly very specific technologies—partly at very high process temperatures. These industries include basic chemicals, metal production and processing, the manufacture of glass, ceramics and cement, the production of paper, the food industry and plastics processing. The technical fundamentals are briefly described in each case to provide an understanding of the efficiency measures described in detail. The findings are illustrated in each case in industry-specific savings potential curves.

Markus Blesl, Alois Kessler

9. Energy Efficiency from an Energy Economic Perspective

Abstract

After analysing the many potentials in detail, this chapter examines the prospects and potentials at German and European level. Potentials that have not yet been exploited, but which are certainly economic, lead to the question of which barriers can hinder the implementation of energy efficiency measures and how these barriers can be overcome. Here, energy efficiency networks can become increasingly important. Feedback effects such as the “rebound effect” or “carbon leakage“, which limit the effectiveness of efficiency efforts, are described in detail.

The implementation of the measures described in the previous chapters has complex consequences not only for individual companies, but also for Germany and Europe as a business location. First of all, the prospects for energy efficiency in the political context are discussed, followed by a quantitative estimate of the potential energy savings.

Markus Blesl, Alois Kessler

10. Summary and Perspectives

Abstract

Patterns emerge in the many hundreds of individual measures. Energy efficiency measures are always about questions of dimensioning, utilization, the use of efficient equipment, the avoidance of losses or the recovery of material and energy. In order to avoid wrong decisions, the available methods for economic efficiency calculation must be applied consistently. There is a particular need for further research into complex production processes and process chains, such as joining or coating processes.

Energy efficiency policy is a mainstay of German and European climate protection policy. With the Green Deal, the EU wants to become climate neutral by 2050 and reduce net GHG emissions to zero. Already by 2030, GHG emissions are to be reduced by 55% across the EU. With the novel Climate Protection Act, the German Federal Government decided in May 2021 to achieve climate neutrality by 2045. Accordingly, emissions are to be reduced by 65% by 2030 and by 88% by 2040. In order to achieve these goals, the existing instruments and laws (emissions trading system, EEG, GEG, KWKG, EVPG, BAT, EDL-RL, BImSchG, GEG …) must be continuously adapted. The variety of foreseeable necessary adjustments leads to uncertainty for the affected companies that should not be underestimated.

The reference to “industry” in the title of this book is a very vague formulation because there is no such thing as “industry”. There is a large number of process and production technologies, some of which are used as “cross-sectional technologies” in almost all sectors or manufacturing companies, while others are used very specifically only in certain sectors or even individual companies. In the meantime, the EU alone has published so-called “Reference Documents on Best Available Techniques” for more than 30 sectors—some of them still in draft form—each containing several hundred pages. Some of the new technologies can no longer be implemented in the European industrial complexes that have grown up over decades.

Markus Blesl, Alois Kessler

Backmatter

Titel: Energy Efficiency in Industry
verfasst von: Markus Blesl
Alois Kessler
Verlag: Springer Berlin Heidelberg
Electronic ISBN: 978-3-662-63923-8
Print ISBN: 978-3-662-63922-1
DOI: https://doi.org/10.1007/978-3-662-63923-8