Industry energy optimization: A case study in a biodiesel production site

This paper presents a case study of heat exchanger network (HEN) retrofit with the objective to reduce the utilities consumption in a biodiesel production process. Pinch analysis studies allow determining the minimum duty utilities as well the maximum of heat recovery. The existence of heat exchangers for heat recovery already running in the process causes a serious restriction for the implementation of grassroot HEN design based on pinch studies. Maintaining the existing HEN, a set of alternatives with additional heat exchangers was created and analysed using some industrial advice and selection criteria. The final proposed solution allows to increase the actual 18 % of recovery heat of the all heating needs of the process to 23 %, with an estimated annual saving in hot utility of 35 k(sic)/y.

Utilisation of biomass for energy production in the North-West Russian forest industry

Traditionally, fossil fuels have always been the major sources of the modern energy production. However prices on these energy sources have been constantly increasing. The utilization of local biomass resources for energy production can substitute significant part of the required energy demand in different energy sectors. The introduction of the biomass usage can easily be started in the forest industry first as it possesses biomass in a large volume. The forest industry energy sector has the highest potential for the fast bioenergy development in the North-West Russia. Therefore, the question concerning rational and effective forest resources use is important today as well as the utilization of the forestry by-products. This work describes and analyzes the opportunities of utilising biomass, mainly, in the form of the wood by-products, for energy production processes in general, as well as for the northwest Russian forest industry conditions. The study also covers basic forest industry processes and technologies, so, the reader can get familiar with the information about the specific character of the biomass utilization. The work gives a comprehensive view on the northwest forest industry situation from the biomass utilisation point of view. By presenting existing large-scale sawmills and pulp and paper mills the work provides information for the evaluation of the future development of CHP investments in the northwest Russian forest industry.

Assessment of Energy Conservation in Indian Cement Industry and Forecasting of Co2 Emissions

Cement industry ranks 2nd in energy consumption among the industries in India. It is one of the major emitter of CO2, due to combustion of fossil fuel and calcination process. As the huge amount of CO2 emissions cause severe environment problems, the efficient and effective utilization of energy is a major concern in Indian cement industry. The main objective of the research work is to assess the energy cosumption and energy conservation of the Indian cement industry and to predict future trends in cement production and reduction of CO2 emissions. In order to achieve this objective, a detailed energy and exergy analysis of a typical cement plant in Kerala was carried out. The data on fuel usage, electricity consumption, amount of clinker and cement production were also collected from a few selected cement industries in India for the period 2001 - 2010 and the CO2 emissions were estimated. A complete decomposition method was used for the analysis of change in CO2 emissions during the period 2001 - 2010 by categorising the cement industries according to the specific thermal energy consumption. A basic forecasting model for the cement production trend was developed by using the system dynamic approach and the model was validated with the data collected from the selected cement industries. The cement production and CO2 emissions from the industries were also predicted with the base year as 2010. The sensitivity analysis of the forecasting model was conducted and found satisfactory. The model was then modified for the total cement production in India to predict the cement production and CO2 emissions for the next 21 years under three different scenarios. The parmeters that influence CO2 emissions like population and GDP growth rate, demand of cement and its production, clinker consumption and energy utilization are incorporated in these scenarios. The existing growth rate of the population and cement production in the year 2010 were used in the baseline scenario. In the scenario-1 (S1) the growth rate of population was assumed to be gradually decreasing and finally reach zero by the year 2030, while in scenario-2 (S2) a faster decline in the growth rate was assumed such that zero growth rate is achieved in the year 2020. The mitigation strategiesfor the reduction of CO2 emissions from the cement production were identified and analyzed in the energy management scenarioThe energy and exergy analysis of the raw mill of the cement plant revealed that the exergy utilization was worse than energy utilization. The energy analysis of the kiln system showed that around 38% of heat energy is wasted through exhaust gases of the preheater and cooler of the kiln sysetm. This could be recovered by the waste heat recovery system. A secondary insulation shell was also recommended for the kiln in the plant in order to prevent heat loss and enhance the efficiency of the plant. The decomposition analysis of the change in CO2 emissions during 2001- 2010 showed that the activity effect was the main factor for CO2 emissions for the cement industries since it is directly dependent on economic growth of the country. The forecasting model showed that 15.22% and 29.44% of CO2 emissions reduction can be achieved by the year 2030 in scenario- (S1) and scenario-2 (S2) respectively. In analysing the energy management scenario, it was assumed that 25% of electrical energy supply to the cement plants is replaced by renewable energy. The analysis revealed that the recovery of waste heat and the use of renewable energy could lead to decline in CO2 emissions 7.1% for baseline scenario, 10.9 % in scenario-1 (S1) and 11.16% in scenario-2 (S2) in 2030. The combined scenario considering population stabilization by the year 2020, 25% of contribution from renewable energy sources of the cement industry and 38% thermal energy from the waste heat streams shows that CO2 emissions from Indian cement industry could be reduced by nearly 37% in the year 2030. This would reduce a substantial level of greenhouse gas load to the environment. The cement industry will remain one of the critical sectors for India to meet its CO2 emissions reduction target. India’s cement production will continue to grow in the near future due to its GDP growth. The control of population, improvement in plant efficiency and use of renewable energy are the important options for the mitigation of CO2 emissions from Indian cement industries

Assessment of the impact of the European CO2 emissions trading scheme on the Portuguese chemical industry

This paper describes an assessment of the impact of the enforcement of the European carbon dioxide (CO2) emissions trading scheme on the Portuguese chemical industry, based on cost structure, CO2 emissions, electricity consumption and allocated allowances data from a survey to four Portuguese representative units of the chemical industry sector, and considering scenarios that allow the estimation of increases on both direct and indirect production costs. These estimated cost increases were also compared with similar data from other European Industries, found in the references and with conclusions from simulation studies. Thus, it was possible to ascertain the impact of buying extra CO2 emission permits, which could be considered as limited. It was also found that this impact is somewhat lower than the impacts for other industrial sectors.

Eco-efficiency approaches towards a sustainable composite materials manufacturing industry’

In this study the potential eco-efficiency performance of a pultrusion manufacturing company was assessed. Indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures in the production process of glass fibre reinforced polymers (GFRP) pultrusion profiles. Two different approaches were foreseen: 1)Adoption of a new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; and 2) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Potential for ORC application in the Portuguese manufacturing industry

Dissertação para obtenção do Grau de Mestre em Engenharia do Ambiente, perfil Gestão e Sistemas Ambientais

Wastewater Treatment and Deinking Sludge Utilization Possibilities for Energy and Material Recovery in the Leningrad Region

Operation of pulp and paper mills generates waste including wastewater treatment sludge and deinking sludge. Both sludge types are generated in large amounts and are mainly disposed of in landfills in the Leningrad Region resulting in environmental degradation. The thesis was aimed at seeking new sustainable ways of sludge utilization. Two paper mills operating in the Leningrad Region and landfilling their sludge were identified: “SCA Hygiene Products Russia” and “Knauf”. The former generates 150 t/day of deinking sludge, the latter – 145 t/day of secondary sludge. Chemical analyses of deinking sludge were performed to assess applicability of sludge in construction materials production processes. Higher heating value on dry basis of both sludge types was determined to evaluate energy potential of sludge generated in the Leningrad Region. Total energy output from sludge incineration was calculated. Deinking sludge could be utilized in the production process of “LSR-Cement” or “Slantsy Cement Plant Cesla” factories, and “Pobeda” and “Nikolsky” brick mills without exceeding current sludge management costs.

The dynamics of industrial energy consumption in Latin America and their implications for sustainable development

Includes bibliography

Effectiveness and effects of attempts to regulate the UK petrol industry

This paper evaluates the impact that investigation and regulation of the UK petrol industry has had on the profitability of the companies. Using a gross margin for petrol, we estimate a series of variable parameter autoregressive processes. The results demonstrate that the 1979 Monopolies and Mergers Commission investigation into the industry, caused a long term decline in profit margins in the industry, despite the fact that no recommendations or undertakings were made. This cannot however be said for subsequent investigations.

Hotel Sustainability Benchmarking Index 2016: Energy, Water, and Carbon

Several studies have been undertaken or attempted by industry and academe to address the need for lodging industry carbon benchmarking. However, these studies have focused on normalizing resource use with the goal of rating or comparing all properties based on multivariate regression according to an industry-wide set of variables, with the result that data sets for analysis were limited. This approach is backward, because practical hotel industry benchmarking must first be undertaken within a specific location and segment.1 Therefore, the CHSB study’s goal is to build a representative database providing raw benchmarks as a base for industry comparisons.2 These results are presented in the CHSB2016 Index, through which a user can obtain the range of benchmarks for energy consumption, water consumption, and greenhouse gas emissions for hotels within specific segments and geographic locations.

Energy Audit for an Old Industrial Building in Gävle

(English)The Swedish industrial sector has overcome the oil crisis and has maintained the energy use constant even though the production has grown. This has been achieved thanks to the development of several energy policies, by the Swedish government, towards the 2020 goals. This thesis carries on this path and performs an energy audit for an old industrial building in Gävle (Sweden) in order to propose different energy efficiency measures to use less energy while maintaining the thermal comfort. The building is in quite a bad shape and some of the areas are unused making them a waste of money. By means of the invoices provided by different companies, the information from the staff and some measures that have been carried out in-situ, the energy balance has been calculated from where conclusions have been drawn. Although it is an industrial building, the study is not going to be focused in the industrial process but in the building’s envelope and support processes, since the unit combines both production and office areas. Therefore, the energy balance is divided in energy supplies (district heating, free heating and sun irradiation) and energy losses (transmission, ventilation hot tap water and infiltrations). The results show that the most important supply is that of the DH whereas the most important losses are the transmission and infiltration. Thus, the measures proposed are focused on the reduction of this relevant parameters. The most important measures are the renovation of the windows, heating systems valves and the ventilation. The glazing of the dwelling is old and some of it is broken accounting for quite a large amount of the losses. The radiator valves are not properly working and there does not exist any temperature control. Therefore the installation of thermostatic valves turns out to be a must. Moreover, some part of the building has no mechanical ventilation but conserves the ducts. These could be utilized if they are connected to the workshop’s ventilation which is capable of generating sufficient flow for the entire building. Finally, although other measures could also be carried out, the ones proposed appear to be the essential ones. A further analysis should be carried out in order to analyze the payback time or investment capability of the company so as to decide between one measure or another. A market study for possible new tenants for the unused parts of the building is also advisable.

Auditorias de energia em instalações industriais do setor automóvel

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Optimização energética das estufas de secagem de uma indústria de cerâmica

A gestão de energia é um dos factores chave do sucesso de uma empresa e como qualquer outro factor de produção deve ser gerido continuamente e eficazmente. A gestão correcta do consumo de energia assume-se como crucial nas empresas do sector cerâmico pois exigem grande consumo de gás natural. Também a tendência de aumento do custo do gás natural tem induzido a necessidade de minimização do consumo de combustível nas indústrias e favorecido o desenvolvimento de novas abordagens para a optimização deste recurso natural. O trabalho apresentado nesta tese teve como objectivo a optimização da energia nas estufas de secagem na Fábrica de Cerâmica de Valadares S.A. A actividade desta empresa consiste na produção de louça sanitária envolvendo um consumo elevado de energia. Realizou-se um levantamento das condições técnicas/operacionais dos equipamentos em estudo e elaborou-se uma ferramenta de simulação que foi aplicada para realizar um balanço energético detalhado e diagnóstico da situação existente. No seguimento, foi efectuada uma análise de mercado, para elaboração do estudo económico da implementação das medidas sugeridas, nomeadamente, a recuperação dos gases de combustão que saem das três estufas que secam os moldes para as estufas de louça cerâmica. Optou-se por esta medida uma vez que reduzirá significativamente, em cerca de 50%, o consumo de combustível (gás natural) nas estufas de secagem. O tempo de retorno do investimento necessário para adquirir o equipamento é de, aproximadamente, 10 meses.

Auditoria Energética a Instalação Comercial

O setor da indústria destaca-se como um dos maiores consumidores de energia final em Portugal, representando cerca de 30% do consumo. Para fazer face a esta situação e no âmbito da Estratégia Nacional para a Energia foi criado, pelo Decreto-Lei n.º 71/2008, o Sistema de Gestão dos Consumos Intensivos de Energia (SGCIE), regulamento que classifica como Consumidoras Intensivas de Energia (CIE) as indústrias com um consumo anual superior aos 500 tep. Prevendo a elaboração de Planos de Racionalização dos Consumos de Energia (PREn), estabelecendo-se acordos de racionalização dos consumos com a Direção Geral de Energia e Geologia (DGEG) [1]. Atuando ao nível da eficiência energética o consumo de energia na indústria pode diminuir significativamente, para tal é necessário proceder-se à execução de auditorias energéticas e determinar as soluções mais adequadas de forma a reduzir os desperdícios e custos associados ao consumo de energia. Nesta dissertação apresenta-se a realização de uma auditoria energética a uma instalação comercial, que assenta essencialmente em quatro etapas, nomeadamente: planeamento da intervenção, trabalho de campo, tratamento e análise da informação recolhida, elaboração do relatório da auditoria. A aplicação desta metodologia constitui uma grande ajuda na realização de auditorias energéticas conferindo uma maior qualidade à sua execução. De forma a validar a metodologia utilizada nas auditorias energéticas foi realizado o estudo a uma instalação comercial que registou no ano 2013, um consumo energético inferior a 500 tep, contudo aderiu de forma voluntária ao Sistema de Gestão dos Consumos Intensivos de Energia (SGCIE), sendo obrigado a racionalizar o seu consumo de energia de acordo com as metas estabelecidas no SGCIE.