Published on March 27, 2014
www.fire-italia.orgwww.fire-italia.org Energy efficiency in the energy intensive industry Dario Di Santo, FIRE Workshop at British Embassy in Roma - Energy efficiency: where will it lead us?
26 March 2014, Roma The
www.fire-italia.org FIRE The Italian Federation for the Rational use of Energy is a no-profit association that promotes energy efficiency, supporting energy manager, ESCOs and other companies dealing with energy. ! Besides the activities directed to its nearly 500 members, FIRE operates under an implementing agreement with the Ministry of Economic Development to manage the Italian energy manager network since 1992. ! In order to promote energy efficiency FIRE cooperates and deals with public authorities, energy technology and service companies, consultants, medium and large consumers, universities and associations to promote best practices and improve the legislation. www.fire-italia.org EGE certification Energy Management Experts UNI CEI 11339 www.secem.eu Gestione Energia magazine
www.fire-italia.org FIRE activities and projects Besides to dedicated meetings, FIRE organizes the Enermanagement conference, workshops, and training courses. It implements dissemination campaigns, surveys, market analysis and studies. Among the subjects with which FIRE has cooperated there are ENEA (national energy agency), GSE (manager of incentive mechanisms), RSE, large companies, universities, associations, agencies and trade fairs organizers. www.hreii.eu/demo www.esd-ca.eu Among completed projects: - www.soltec-project.eu - www.enforce-een.eu - www.ener-supply.eu - www.e-quem.enea.it - www.eu-greenlight.org - Eurocontract Whaves Starting soon! Enspol Starting soon! SME energy check-up Starting soon!
www.fire-italia.org Framework Energy managers Tools for EE Final energy consumption in industry !4 !"!!!! !1.000!! !2.000!! !3.000!! !4.000!! !5.000!! !6.000!! !7.000!! !8.000!! Metallurgy! Mechanical! Chemical! Construc>on!materials! Food!and!tobacco! Paper!and!prin>ng! Glass!and!ceramics! Tex>les!and!clothing! Other!manufacturing! Petrolchemical! Non!metalliferous!minerals! Construc>on!industry! Mining!and!extrac>ve!industry! ktoe%% Industrial%ﬁnal%energy%consump5on% Total%ﬁnal%consump5on:%30.2%Mtoe% Source:!FIRE!on!MSE!data!
www.fire-italia.org Framework Energy managers Tools for EE Final energy consumption in industry !5 23,6%& 13,3%& 12,5%&11,6%& 9,0%& 8,6%& 7,8%& 4,0%& 3,2%& 2,9%& 2,5%& 1%& 0,4%& Industrial+ﬁnal+energy+consump4on+ Total+ﬁnal+consump4on:+30.2+Mtoe+ Metallurgy& Mechanical& Chemical& Construc?on&materials& Food&and&tobacco& Paper&and&prin?ng& Glass&and&ceramics& Tex?les&and&clothing& Other&manufacturing& Petrolchemical& Non&metalliferous&minerals& Construc?on&industry& Mining&and&extrac?ve&industry& Source:&FIRE&on& MSE&data&
www.fire-italia.org Framework Energy managers Tools for EE Source: RAEE 2011 ENEA. But only some sectors improved their energy efficiency !6 RAEE 2011 – Executive Summary Figura 8 - Efficienza energetica nell’industria manifatturiera (1990=100) Fonte: elaborazione ENEA su dati MSE (ODYSSEE) 50 60 70 80 90 100 110 120 130 140 150 160 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 industria manifatturiera Siderurgia Metalli non ferrosi Meccanica Alimentare Tessile Minerali non metalliferi cemento Chimica Carta Best performance for the chemical and steel sectors.
www.fire-italia.org Framework Energy managers Tools for EE White certificates and energy efficiency in industry: 2005-2012 !7 Source: FIRE on data from ENEA. STEEL% METALLURGICAL% PETROCHEMICAL% PHARMACEUTICAL% CHEMISTRY% BUILDING%MATERIALS% AGRO4FOOD% ENERGY%/%SERVICES%/% WASTE%TREATMENT% RESIDENTIAL% COMMERCIAL% GLASS% PAPER%AND%PRINTING% ICT% AUTOMOTIVE% MECHANICS%WOOD% TEXTILE%AND% TANNING% Sector'breakdown'for'number'of'PPPMs' www.ﬁre4italia.org%
www.fire-italia.org Framework Energy managers Tools for EE Final energy consumption in industry !8 0,0# 1,0# 2,0# 3,0# 4,0# 5,0# 6,0# 7,0# Chemical# Construc9on#industry# Construc9on#materials# Food#and#tobacco# Glass#and#ceramics# Mechanical# Metallurgy# Mining#and#extrac9ve# industry# Non#metalliferous#minerals# Other#manufacturing# Paper#and#prin9ng# Petrolchemical# Tex9les#and#clothing# Heat%to%electricity%ra,o% Source:#FIRE#on#MSE#data#
www.fire-italia.org Framework Energy managers Tools for EE Source: H-Reii project. The importance of heat recovery: Hreii project estimated potential !9 7 catalyze investment in the energy efficiency market, helping to reach the objective of 20% reduction in energy consumption. The figure 3 depicts the priority in the utilization of waste heat recovery. Moreover, during the energy audit, special attention should be placed in the gas cooling - often compulsory before the waste gas treatment – as it is possible to put heat exchanger(s) and a Rankine cycle instead of adding air to cool down. This way, the electricity consumption of the waste treatment can be covered. Figure 3: Waste heat recovery priority 8 M. Lowe, G. Gereffi, Recycling Industrial Waste Energy, Chapter 7. Report prepared for the Environmental Defense Fund (EDF), Center on Globalization, Governance & Competitiveness (CGGC), Duke University, 2009 Legend: DHW: Domestic Hot Water ORC: Organic Rankine Cycle Typical cement production plants have a production capacity between 2.000 and 8.000 10 kg per day, with energy consumption ranging from 3,5 to 5 GJ/103 kg of clinker produced (10–15% in the form of electricity). The cement production process involves lime decarbonizing reactions (endothermic) and requires great amounts of heat and high temperatures to take place. The temperature of the gaseous sources after the internal use in the process (available for the recovery of heat) is relatively low (about 250 - 350 ° C). The unused heat supplied for these reactions can be found in the combustion gas – or kiln gas – (after the raw material pre-heating) and in the clinker cooler air flow. These flows could, via thermal oil heat recovery circuits, be the heat sources feeding the ORC to generate power. Gas from the kiln are characterized by a substantial content of dust (typically 10 to 50 g/Nm3 ) nevertheless several applications of heat recovery – with both steam turbine and ORC technology – in cement industry are currently working: a clear proof of the feasibility of heat recovery. Recovery potential of the cement industry in Italy POTENTIALITY plants to install (estimation) n 25 power to install MWelectric 30,3 energy to produce MWhelectric/year 196.950 ENVIRONMENTAL IMPACT CO2 emissions avoided 10 3 kg/year 125.260 Electric energy saved MWhelectric/year 196.950 Primary energy saved toe/year 36.830 The estimation of the potential is still on going for non ferrous materials, oil&gas, etc. The cumulative potential of electricity generation from waste heat for the iron and steel, cement and glass, with an average value of 6.500 h/y at rated power, is estimated in over 800 GWhelectric/year (Figure 4) and the associated greenhouse gas savings in 500.000*103 kgCO2/year (Figure 5). Turboden s.r.l. via Cernaia,10 25124 Brescia Italy t. +390303552001 f. +390303552011 firstname.lastname@example.org www.turboden.it C.F./P.I. 02582620981 capitale sociale Euro 1.800.000,00 i.v. registro delle imprese C.C.I.A.A. di Brescia REA 461817 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 Glass Cement Steel Total MWhelectric/year Energy production MIN MWh electric/year MAX MWh electric/year Turboden s.r.l. via Cernaia,10 25124 Brescia Italy t. +390303552001 f. +390303552011 email@example.com www.turboden.it C.F./P.I. 02582620981 capitale sociale Euro 1.800.000,00 i.v. registro delle imprese C.C.I.A.A. di Brescia REA 461817 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 Glass Cement Steel Total MWhelectric/year Energy production MIN MWh electric/year MAX MWh electric/year Recovery potential of the cement industry in Italy POTENTIALITY plants to install (estimation) n 25 power to install MWelectric 30,3 energy to produce MWhelectric/year 196.950 ENVIRONMENTAL IMPACT CO2 emissions avoided 10 3 kg/year 125.260 Electric energy saved MWhelectric/year 196.950 Primary energy saved toe/year 36.830 The estimation of the potential is still on going for non ferrous m of electricity generation from waste heat for the iron and steel, c h/y at rated power, is estimated in over 800 GWhelectric/year (Fig in 500.000*103 kgCO2/year (Figure 5). Figure 4 Italian potential of electricity generation from heat rec Figure 5 Italian potential of CO savings due to electricity gene via Cer t. +39030 info@ C.F./P.I. 02582620981 registro delle impr 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 Glass Cement Steel Total MWhelectric/year Energy production MIN MWh electric/year MAX MWh electric/year 0 100.000 200.000 300.000 400.000 500.000 600.000 700.000 glass cement steel 103kg/year CO2 saved CO2 saved MIN 10^3kg/year CO2 saved MAX 10^3kg/year via Ce t. +3903 info@ C.F./P.I. 0258262098 registro delle im 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 Glass Cement Steel Total MWhelectric/year Energy production MIN MWh electric/year MAX MWh electric/year 0 100.000 200.000 300.000 400.000 500.000 600.000 700.000 glass cement steel Total 103kg/year CO2 saved CO2 saved MIN 10^3kg/year CO2 saved MAX 10^3kg/year
www.fire-italia.org Framework Energy managers Tools for EE Even energy intensive sectors have non energy intensive users !10 L'importanza dei dati…Distribuzione dell'incidenza dei Costi Energetici sul fatturato delle Imprese Chimiche Incidenza % Costo Energia/ Fatturato Incidenza sul Fatturato Incidenza sul Fatturato al netto rivendita prodotti (20%) 6,4 8,0 Frequenza Energy cost intensity in the chemical sector. Source: Federchimica. Energy cost intensity Energy cost intensity not considering the supply of energy products Energy cost intensity Frequency
www.fire-italia.org Framework Energy managers Tools for EE Energy is usually not the core business… Low impact of energy costs on turnover of most of the companies. !11 (Fonte: http://trend.cestec.eu) Energy costs are usually among 2-6% of the turnover. In Italy almost 3,000 industries are in the energy intensive list VS 425,000 companies in the manufacturing industry
www.fire-italia.org Framework Energy managers Tools for EE Discounts for energy intensive industries !12 In Germany the “discount” for the energy intensive industry is: 53 €/MWh EEG levy exemption for ISO 50001 or EMAS organizations; 20,5 €/MWh electricity tax exemption for a list of energy intensive companies plus ISO 50001 (audit for SMEs) and voluntary CO2 reduction targets. A much higher discount, but at least not given for free. Requirements in Italy to access the discount: 2.4 GWh energy consumption; energy cost intensity over 3%.
www.fire-italia.org Framework Energy managers Tools for EE Energy management system around the World According to the result of a DIN survey on the implementation ISO 50001 certified energy management systems, there were in February 2014 more then 3,100 certified organizations and over 6,600 certified sites. ! ! ! ! ! ! ! ! ! The results in Italy are far from the German ones, but it should be also considered the absence of incentives so far. !13 !3.063!! !937!! !407!! !338!! !220!! !198!! !190!! !138!! !121!! !107!! !103!! !91!! !714!! ISO$50001$cer+ﬁed$sites$ February$2014$8$Source:$FIRE$based$on$DIN$data.$ Germany! France! Netherlands! UK! Italy! Spain! Sweden! India! Korea! Turkey! Taiwan! Ireland! www.ﬁreGitalia.org!www.ﬁreGitalia.org! !1.640!! !183!! !154!! !99!! !85!! !78!! !73!! !70!! !68!! !64!! !57!! !43!! !508!! ISO$50001$cer+ﬁed$organiza+ons$ February$2014$;$Source:$FIRE$based$on$DIN$data.$ Germany! Italy! Spain! India! Sweden! Turkey! Taiwan! UK! France! Austria! Denmark! Ireland! Altri!www.ﬁreFitalia.org!
www.fire-italia.org Framework Energy managers Tools for EE A lot of available projects with a good ROI Examples extracted from enterprises in the chemical and the paper sectors. !14 www.fire-italia.org Premessa Il sistema L’efficienza Strumenti Interventi Audit e Costi Comunicazione Unità di misura 130 Un’industria chimica. Fonte: Armstrong. Individuazione degli interventi “Expect many enjoyable experiences!” David M. Armstrong “Expect many enjoyable experiences!” David M. Armstrong 3,0% %diRisparmiosulbudgetAnnuodivapore 2,5% 2,0% 1,5% 1,0% 0,5% 0,0% 0 0,5 1 1,5 2 2,5 3 3,5 Tempi di Ammortamento (Anni) Sintesi delle potenziali ottimizzazioni 6 Economizzatore Acqua d'alimento Recuperi di Calore Progetti avanzati alto livello d'Ingegnerizzazione Investimenti Richiesti Alti Progetti semplici basso livello d'Ingegnerizzazione Investimenti Richiesti Bassi Riduzione BD Perdite Vapore Varie Coibentazione Livelli Pressione Scaricatori in perdita Recupero Calore da BD Recupero vapori di Flash Condensazione dei Vent Controllo Automatico Ossigeno Recupero della Condensa Progetti standard Medio livello d'Ingegnerizzazione Investimenti Richiesti Medi Economizzatori a condensazione Caldaie in stand-by Energy efficiency means three actions: avoiding losses and waste of energy; using energy efficiency technologies; adopting renewable energy sources.
www.fire-italia.org Framework Energy managers Tools for EE Source: Politecnico di Milano and ENEL Foundation. And this is confirmed for horizontal technologies !15 High penetration rate Low penetration rate Interesting investment Not interesting investment The blue labels are for the industry
www.fire-italia.org Framework Energy managers Tools for EE !16 To avoid energy waste To use energy efficient technologies To adopt renewables The three steps of energy efficiency
www.fire-italia.org Framework Energy managers Tools for EE Energy management issues !17 The energy manager is a key figure for managing energy efficiently in a company or an institution. Until a few years ago these were the typical problems to be faced... No energy policy in the company Lack of management There is no energy manager Lack of money or other resources Issue “0” Issue 1 Issue 2 Issue 3 Source: FIRE.
www.fire-italia.org Framework Energy managers Tools for EE Energy manager: the origin and the Italian mandatory approach The figure of the energy manager was born in the industry sector in the the seventies, at the time of the first oil crisis. ! Law 373/1977 is the first example of a national public regulation on energy efficiency, integrated and followed by law 9 and 10 of 1991 and the strong flow of new European regulations. ! In the eighties the first voluntary associations were born: AIGE (Italian Association of Energy managers) The Energy Manager Club (EMC) for the State-owned industries ! Law 308/1982 established the obligation for all industrial enterprises with a consumption over 10.000 toe/year and with over 1.000 employees to appoint a person “in charge for the rational use of energy”. ! In 1987 AIGE and EMC merged in FIRE as founder members, together with ENEA. !18
www.fire-italia.org Framework Energy managers Tools for EE The evolution of the role of the energy manager Law 10/1991 extended the mandatory requirements appointment of such “technician” (energy manager) to all the industrial enterprises over 10.000 toe/year and for the organizations of civil (residential and services) and transportation sectors over 1.000 toe/year. ! According to law 10/1991 the tasks of the energy manager are: • identify actions, measures, procedures and whatever else is needed to promote the rational use of energy; • ensure the preparation of energy balances also in accord to the economic parameters and the final energy uses; • prepare energy data to verify the measures implemented with the contribution of the State. ! This role evolved with the opening of the energy markets, the continuing evolution of the legislation on various levels (European, national, local), technical standards and harmonized standards, contracts increasingly complex (Energy performance contract, etc.), markets increasingly competitive, the international context. !19
www.fire-italia.org Framework Energy managers Tools for EE Energy manager: the Italian mandatory approach These are the appointed energy managers according to the law 10/91, whose obligation is unfortunately largely ignored by the public administration. !20 SECTORS SUBSECTORS)AND)NOTES EM)) Agriculture!(of!which!35!are!!land!reclamation!authorities) 41)))))))))))))))) Industria 587)))))))))))))) Extraction*of*minerals*from*quarries*and*mines 5****************** Manufacturing*activities 406************** Supply*of*electricity,*gas,*steam*and*air*conditioning 94**************** Supply*of*water,*sewerage*networks,*management*activities*of*waste*rehabilitation 78**************** Constructions 4****************** Transport!(of!which!70!publicly!owned) 324)))))))))))))) Pubblic)Sector!(ministries,!central!government,!regions,!local!authorities,!etc.)! 144)))))))))))))) P.S.)enlarged 143)))))))))))))) Healthcar 110************** University 19**************** Research 9****************** Territorial*utilities 5****************** Private)tertiary 223)))))))))))))) Energy)service 69)))))))))))))))) TOTAL)APPOINTED)E.M. 1.531))))))))))) Energy)manager)(EM))appointed)in)2013)in)accordance)with)article)19)of)the)law)10/91 Source:!FIRE!data.!For!further!information:!www.fireEitalia.org Note about appointments and appointed: the table shows only the data on obliged parties who have appointed an energy manager according to the law, does not take into account any energy manager of multisite venues (399 local EM), nominations received beyond the statutory deadline (143 EM, 17 local EM) and those from nonPobligated parties*(530*EM,*102**local*EM).
www.fire-italia.org Framework Energy managers Tools for EE The work of the energy manager FIRE periodically makes surveys on energy managers. Those are the results on the typical efficiency/renewables measures implemented according to the 2013 survey: ! !21 led lighting, heat recovery, free cooling, HVAC with heat recovery, condensing boilers, power factor correction, solar cooling, high efficiency electric motors and variable speed drivers, piping insulation, combined beat and power, trigeneration solar PV, use of biomass, compressed air, UPS, energy distribution, macchine ventilanti, optimization of wells water extraction, efficiency of the production process (iron & steel, cement, glass), heat pumps, industrial automation, smart motor management, behavioral change programs, measures on buildings envelope, energy recovery on elevators, efficient lighting, energy management software, fuel efficiency, building automation, data center efficiency, ground water source heat pumps, recycle of scraps.
www.fire-italia.org Framework Energy managers Tools for EE SECEM: the first accredited body for the UNI CEI 11339 standard The first body to be accredited to release a third party certification for energy management experts was SECEM (within FIRE). Since then other two bodies have been accredited by Accredia. ! ! ! ! ! ! ! ! ! ! ! ! ! ! www.secem.eu !22 30/05/13 11:17Home CERTIFICAZIONE Risorse Umane Chi siamo La struttura SECEM Accreditamento Perché certificarsi Perchè scegliere SECEM Soggetti interessati Profilo attitudinale IL PROCESSO DI CERTIFICAZIONE Come certificarsi Rinnovo della certificazione Regolamento SECEM Tariffario SECEM Requisiti per l'ammissione Procedure di valutazione BANDI E PROGRAMMI DEGLI ESAMI Bando giugno 2013 Bando aprile 2013 Bando gennaio 2013 ELENCO PROVE D'ESAME Sessione aprile 2013 Sessione gennaio 2013 Sessione giugno 2012 Sessione gennaio 2012 Sessione giugno 2011 Sessione gennaio 2011 Sessione giugno 2010 Sessione gennaio 2010 Bando SECEM 25 giugno 2013 Pubblicata la nuova revisione del Files: Bando SECEM giugno 2013 2013-05-08 Italian 293.9 KB 242 relativo alla sessione d'esame del 25 giugno 2013. Pubblicato il Decreto Legislativo relativo al sistema nazionale di certificazione delle competenze Entra in vigore il 2 marzo 2013 il Decreto Legislativo n. 13/2013 (G.U. n. 39 del 15 febbraio 2013) che - in attuazione dell'articolo 4, commi 58 e 68, della Legge Fornero (L. n. 92/2012) - disciplina l'attività di individuazione, validazione e certificazione delle competenze acquisite dalla persona in contesti non formali e informali, ossia durante la sua storia di vita, di studio e di lavoro. Il provvedimento individua nei Ministeri dell'Istruzione, dell'Università e della Ricerca, del Lavoro e delle Politiche sociali e dello Sviluppo economico e nelle Regioni, gli "enti pubblici titolari" a regolamentare i servizi di individuazione, validazione e certificazione delle competenze, e individua negli "enti titolati" i soggetti pubblici o privati che possono erogare tali servizi. E' specificato all'articolo 4, comma 5, che tali enti, nel caso in cui eroghino il servizio di certificazione delle competenze in conformità alle norme tecniche UNI, dovranno essere in possesso dell'accreditamento rilasciato da ACCREDIA. Saranno oggetto di certificazione unicamente le competenze riferite a qualificazioni ricomprese in un repertorio nazionale costituito da tutti i repertori codificati a livello nazionale e regionale pubblicamente riconosciuti. SECEM rientra tra i soggetti privati (ente titolato) che possono erogare tali servizi, come definito dall'art. 2 comma 1) lettera g. Questo provvedimento, che segue la Legge 4/2013 sulle professioni non organizzate, apre la possibilità ad eventuali accordi di SECEM con tutti gli "enti pubblici titolari". Riconoscimento delle professioni non regolamentate News ELENCO EGE Elenco esperti certificati RICONOSCIMENTO CORSI Modalità di riconoscimento corsi Elenco Corsi Riconosciuti TROVA UN EGE Abruzzo Basilicata Calabria Campania Emilia Romagna Lazio Liguria Lombardia Marche Molise Piemonte Puglia Sardegna Sicilia Toscana Trentino-Alto Adige Umbria Valle D'Aosta Veneto Friuli Venezia-Giulia Sei qui: Home Cambio sede Si informa che SECEM dal mese di dicembre ha trasferito i propri uffici in Via Anguillarese, 301 presso l’ENEA Casaccia. Nella sezione contatti... Read Sistema Europeo per la Certificazione in Energy Management HOME CONTATTI FAQ NEWS GLI EGE SU ACCREDIA FORUM EGE
www.fire-italia.org Framework Energy managers Tools for EE Directives and technical standards !23Source: E. Piantoni revised by FIRE Directive 2009/72/EU E. Energy Directive 2009/73//EU Nat. Gas Directive 2006/32/EU E. Efficiency Directive 2012//27/EU E. Efficiency Energy Efficiency Directive 2004/8/EU Cogeneration Directive 2009/28/EU RED Market Liberalization Directive 2009/125/EU Ecodesign Directive 2010/31/EU Building Energy PerformanceClimate and Energy Package 20-20-20 Directive 2010//30/EU Energy labelling ISO 14001 Environmental Management System EN 16001 Energy Management Systems EN 15900 Energy Efficiency Services ISO 50001 Energy Management Systems EN 16247 Energy Audit EN 16231 Energy Benchmarking EN 16212 Energy Saving Calculation EN 16235 Guarantees of origin for electricity 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 Building efficiency Renewable Energy Directive 2004/18/EU Public Procurement Directive 2004/17/EU Public Procurement Italian ! standards UNI CEI 11339! EGE UNI CEI 11352! ESCO
www.fire-italia.org Framework Energy managers Tools for EE Energy management issues: solved? !24 The energy manager is a key figure for managing energy efficiently in a company or an institution. Until a few years ago these were the typical problems to be faced... No energy policy in the company Lack of management There is no energy manager Lack of money or other resources Issue “0” Issue 1 Issue 2 Issue 3 ISO 50001 ISO 50001 Business models ISO 50001 Source: FIRE.
www.fire-italia.org Abbreviation list DSO: Distribution System Organisation ENEA: Italian National Agency for New Technologies, Energy and Sustainable Economic Development. CEI: Italian electrical standardization body EN: European technical standard ESCO: Energy Service Company FIRE: Italian Federation for Rational use of Energy GME: Electric Market Manager GSE: Energy Service Manager RSE: Research on Electric System SSE: Energy service provider company toe: ton of oil equivalent UNI: Italian standardization body WhC: White Certificate
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