enhancing industrial energy efficiency and energy
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1
Enhancing Industrial Energy Efficiency and Energy Management Systems
Tareq Emtairah, Marco Matteini
Department of Energy
Promoting Sustainable Energy Solutions and Clean Technologies in CIS Countries
23 November 2017
Vienna International Centre
2
1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
3
Industry is responsible for 40% of global final energy consumption (IEA, 2015)
Industry is the single largest source of GHG emissions, accounting for about 32% of global emissions
Over last two decades industry emissions have largely grown in Lower and Upper Mid Income Countries
Source: IPPC Working Group III – Mitigation of CC, 2014
Greenhouse Gas Emissions by Economic Sectors
Industry Energy and Carbon Footprints
4
Cumulative CO2 reductions by sector and technology in the 2DS to 2050
Industrial Energy Efficiency and Climate Change
Source: IEA, 2015
5 5
ENERGY
CONSUMPTION
DATA
TECHNOLOGY PEOPLE
Behaviour
Operations
Leadership
Competence
Best Available Technology
EE Investment
Weather
Reaction
Analysis
Production
Product Mix
Energy Consumption and Efficiency in Industry
DRIVING
FACTORS
Source: W. McLaughlin for UNIDO
6
1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
7
• Management focus is on production & volumes, not on EE
• Lack of information and understanding of own energy performance
• Lack of adequate skills for identifying, assessing, developing and implementing EE measures and projects
• Poor or misused monitoring systems and data
• First costs more important than recurring costs disconnection between capital and operating budgets
• Staff behavior and attitude
• Financing constraints
• Lack or limited availability of IEE services and product
BARRIERS to Energy Efficiency in Industry
8 8 8
Sector or Product Developed countries
Developing countries
Petroleum refineries 10-15 70
Steam cracking 20-25 25-30
Ammonia 11 25
Alumina production 35 50
Iron and Steel 10 30
Cement 20 25
Glass 30-35 40
Pulp and Paper 25 20
Food and beverage 25 40
Other sectors 10-15 25-30
Energy Savings potential from EE (%)
Source: UNIDO, 2011
Benchmarking study in Foundry Sector
- 57%
- 43%
Better management & low cost initiatives
Average efficiency
Capital investment
Best performance
Product Costs
Resource Savings
Source: Adapted from IFC, 2010
Where are opportunities for EE improvement?
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Problem: Energy efficiency is not integrated into daily management practices of industry.
Solution: A systematic approach is needed and staff at all levels within an organization need to be engaged
in management of energy on an ongoing basis.
Energy Efficiency in Industry
Evidence: Most energy efficiency in industry is achieved through and depends on how energy is managed rather than through installation of new technologies
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1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
11
Purpose of EnMS-ISO 50001
“..to enable an organization to follow a systematic approach in achieving continual improvement of energy performance, ..”
Scope of EnMS-ISO 50001
It is applicable to organizations of all sizes
ISO 50001 does NOT prescribe specific performance criteria or targets with respect to energy.
Energy Management System in line with ISO 50001
facilities equipment personnel
systems processes procurement
measurement design doc. & report
ISO 50001 targeted to
• Industry
• Power sector
• Commercial & buildings
• Transport
• Others
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Source: ISO 50001:2011
Energy policy
Energy planning
Implementation
and operation
Checking
Nonconformities, correction, corrective and preventive action
Internal audit of
the EnMS
Management
review
Monitoring, measurement and
analysis
Continual improvement
Policy Management Review
Implementation
& Operation
Planning
Checking
Day to day
operations
Management
participation
Yes Management
Responsibility
Source: UNIDO EnMS Programme
ISO 50001 - EnMS Structure
13 13 13
kWh ($ + CO2)
Commit to
change
Plan the
changes
Make the
changes
Check the
results
ISO 50001 - EnMS Simplified
Source: W. McLaughlin for UNIDO
14 14
kWh ($ + CO2)
EnMS – Managing and improving all 3 pillars
Source: W. McLaughlin for UNIDO
15
EnMS - Productive Change & Continual Improvement
Top management engage in EE
Challenge operations and established practices
Build internal technical skills
Data and analysis discipline
Focus on no/low-cost measures
Continual improvement
SUSTAINED ENERGY SAVINGS & INVESTMENTS!
EE INTEGRATED
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1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
17 17
• Energy savings
• Energy cost savings
• Non-energy benefits (water savings, material savings, maintenance costs reduction, etc.)
EnMS Quantitative Achievements
Most industrial enterprises that implemented EnMS achieved average annual energy intensity reductions of 2-3% against 1% reduction of business as usual (IRL, NET, DEN, SWE, USA)
For companies new to energy management, savings during the first 2 years are 10-20%
UNIDO experience: organization-wide energy savings in first 1-2 years range from 4% to 15%, with little or no capital investments
• GHG and other pollutants emission reductions
• Resources for EE
• Reduced response time to dev.
• ………………………….
18 18
• Management focus for energy efficiency
• Informed decision making
• Improved control of production operations and energy/power demand
• Staff competencies development
• Behavioral/cultural change for EE and continual performance improvement
• Continuity of performance through changes of personnel, products and processes
• Improved quality of production
• Systematic and structured activities
• Positive company/corporate image (operational excellence, environmental stewardship, social responsibility, etc.)
• …………………………..
EnMS Qualitative Achievements
19 19
COREX
DR-Plant
Steel shop
Mills RHF Electricity demand : 160 MW
Manpower: 548 permanent employees
Sales output: 1,2 million ton HRC/annum
Arcelormittal Saldanha Works
Energy Efficiency Achievements 2011
Energy Management System Implemented
No. of Projects/Measures 11
Total Capital Investment (USD) 0
2011 Gross Financial Savings (USD) 9,076,000
Overall Payback Period (in years) 0
2011 Energy Savings Norm. (GWh) 79.95
2011 GHG Reductions (tons CO2) 77,000
Adjustments/optimization of production operations, energy systems optimization, fuels switching, etc.....
driven by EnMS!
2012 Energy Savings (Norm.) > 100 GWh
Example 1 : Iron and Steel – South Africa
20 20
Open joint stock company (about 10% on Moldovan market)
185 employees
Management started to look into EE in 2009 to reduce production costs and impact of increased energy prices
LACTIS improvements 2012
Energy Management System Implemented
No. of Measures/Projects 11
Total Capital Investment (USD) 6,900
Gross Monetary Savings (USD) 22,000
Overall Payback Period (in years) 0.32
2012 Energy Savings Norm. (MWh) 328
2012 GHG Reductions (tons CO2) 160
LACTIS J.S.C
Value of EnMS/EE investments planned in 2012 for 2013-2014 was 410,000 USD
80% implemented
Example 2 : Dairy – Moldova
21 21
Example 3 : Power Generation – Macedonia
Mining and Energy Combine (REK) Bitola meets over 70% of country’s demand for electricity
Coal-lignite thermal power plant, total installed generating capacity of 700 MW and annual generation of 4,000 GWh
Production in 2016 was 2,685 GWh; own consumption was 286.2 GWh
REK BITOLA
REK BITOLA improvements in 2016
Energy Management System Implemented
No. of Measures/Projects 4
Total Capital Investment (EUR) 0
Gross Monetary Savings (EUR) 322,000
Overall Payback Period (in years) 0.00
2016 Energy Savings Norm. (MWh) 8,502
2016 GHG Reductions (tons CO2) 10,528
2.97% of total consumption
In 2016 EnMS limited to power generation facilities, in 2017 EnMS extended to include mining operations
In 2017 EnMS implementation being replicated in all branches of ELEM, the national largest power utility
Payback time: 22-24 days
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1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
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Structure and Stakeholders
EnMS implementation and energy performance improvement
Policy Makers
Policy Implemen. Enterprises
EnMS Consultants
Financiers & Investors
Third-party certification to ISO 50001
ISO 50001 Lead Audit.
Certification Bodies
Accreditatio Bodies
EnPerform. Verifiers
Supply and value chain for EnMS-ISO 50001
Policies & Regulations
24 24 24
EnMS implementation and energy performance improvement
Policy Makers
Policy Implemen. Enterprises
EnMS Consultants
EnPerform. Verifiers
Policies & Regulations
Financiers & Investors
Lead Audit
3rd-party certification to ISO 50001
Cert. Body
Accr. Body
• Ministries
• Energy Agencies
• Power utilities & energy suppliers
• Others
• Energy Eff. consultant
• ESCOs
• Manage. system consultant
• Power utilities & energy suppliers
• Others
• Energy Eff. consultant
• Energy Agencies
• IPMVP certified experts
• ESCOs
• Others
Structure and Stakeholders
Supply and value chain for EnMS-ISO 50001
• Industry
• Transport
• Power & Water Utilities
• Buildings
• Logistics
• Cities
• Others
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1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
26
Success Factors for EnMS-ISO 50001 Deployment
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Level and quality of policy support, including regulation, for promotion & implementation of EnMS/ISO50001
Availability of competent EnMS workforce on the “Supply” and the “Demand” sides
Credible demonstration to organizations and the market of EnMS/ISO50001 tangible benefits
Policies & Institutions
Conformity Assessment
EnMS Skills, Implement. &
Services
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Policies that can support EnMS-ISO 50001
Sticks Energy or Carbon taxes Environmental legislation Mandatory implementation Energy Saving Obligation Schemes and White Certificates Mandatory competencies/professional requirements Carrots Tax avoidance and rebates Cost-free or subsidized EnMS expert assistance and/or energy audits Funding schemes for energy management systems Long-term voluntary agreements Training and qualification programmes Tambourine Peer-to-peer networks Award and recognition programmes Adapted from Clemens Rohde
28 28
Germany
Energy taxes
Mandatory energy audits for non-SME
Funding schemes for energy management systems
Energy efficiency networks
Netherland
Environmental law obligation to make IEE investments
Long-Term Agreements
including
TA for EnMS
Subsidies for audits
Financial incentives
Ireland
Energy Agreements Programme including
Training
Financial support
Expert advice and assistance for implementation
Examples of Policies Frameworks for EnMS-ISO 50001
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Policies Frameworks for EnMS-ISO 50001
EU Energy Efficiency Directive – Article 7 & Article 8
…………………. ………………….
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FYR of Macedonia
Examples of Policies Frameworks for EnMS-ISO 50001
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Combining Skills Development and Results The UNIDO EnMS Capacity Building and Implementation Programme
COMMITTraining
PLANNING Training
Results: • Energy Policy • Roles &
Responsibility matrix • Significant Energy
Uses • Baseline • Energy Performance
Indicators • Opportunities list &
action plans • Energy savings & …
Results: • Staff trained on
selected SEUs • Operations &
controls improved • Procurement plan • EE measures
implemented • Energy & cost
savings • Performance
improvements
Results: • Energy performance
checked, verified and reported
• Energy performance reviewed by top management
• Decisions for next period based on internal audit
• Energy savings & … • Performance impr.
Results: • Trainee qualified
as Energy Management System Expert
• EnMS implemented in PE
• Energy & cost savings
• Performance improvements
time
1-2 months 3 days 4 days 3 days 3 days 4-6 months 4-6 months 2-3 months 1.5-2 months
Results: • Draft Energy Policy • Draft Roles &
Responsibility matrix
• Initial data collection
IMPLEM. Training
CHECKING Training
PE team work to implement EnMS
PE team work to implement EnMS
PE team work to implement EnMS
PE team work to implement EnMS EXAM
½ day
Preparation
Legend
Ongoing and periodic communication through webinars, emails and phone calls between international trainers and PE teams to review progress, discuss issues and provide guidance.
PE team A Partner Enterprise (PE) team is formed by the PE’s staff participating in the EXPERT program plus 1-2 national consultants trainees.
Plant visits by national EE consultants trainees
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UNIDO EnMS CBI Programme
Costs and Benefits Analysis – UNIDO Pilot in FYR of Macedonia
12 Partner enterprises (65% success rate)
23 Nat. Consultants/Expert Trainees
Full cost/value of Nat. Consultants
Include Progr. develop. and implementation
No inclusion of UNIDO staff & support costs
Energy Savings 1 Yr: 13.19 GWh (67% no cost)
Energy Savings 5 Yr: 165 GWh
Money savings 1 Yr: 862,700 USD (55% no cost)
Money savings 5 Yr: 10,792,000 USD
Without considering non-energy benefits!
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Partnerships for Scaling-up
Utility Programme in FYR of Macedonia
Partnership UNIDO IEE Project and EVN Macedonia (Power Utility)
6+2 new companies implementing EnMS, including EVN Macedonia
6 UNIDO Qualified National EnMS Experts
7 new EnMS Expert Trainees, 2 from EVN Macedonia
Cost-sharing of Qualified National EnMS Experts
• 1/3 UNIDO project; 1/3 EVN Macedonia; 1/3 Beneficiary company
75% National Trainers – 25% International Trainers
EVN Macedonia’s Goals Start providing EnMS-EE Services to Clients
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1. Context
2. Barriers to and Opportunities for EE in Industry
3. Energy Management Systems (EnMS) and ISO 50001
4. What EnMS-ISO 50001 can achieve
5. Supply and value chain for EnMS-ISO 50001
6. Programmes to promote and support EnMS-ISO 50001
7. Final considerations
Content
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Designing Programmes to support EnMS-ISO 50001
What do you want to achieve?
• How are you going to monitor and evaluate it?
• Segment/select carefully your target “clients”
Take in due account the existing country baselines for IEE-EnMS
• Awareness, skills, market services, technology providers, etc.
Take in due account the complexity of EnMS supply/value chain
Strive for long-term programmatic framework perspective
• Take into account resistance to change
• Market creation and transformation
• 3 years project or 10 years programme
Who is going to pay
Who is going to benefits
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THANK YOU!
Mr. Marco MATTEINI
Industrial Development Officer
E-mail: M.Matteini@unido.org
Industrial Energy Efficiency Division
Department of Energy
UNIDO
For more information:
37
ADDITIONAL INFORMATION
Mr. Marco MATTEINI
Industrial Development Officer
E-mail: M.Matteini@unido.org
Industrial Energy Efficiency Division
Department of Energy
UNIDO
For more information:
38
UNIDO’s EnMS-ISO 50001 journey
2008 2007
Mar
ANSI-ABNT NWI Proposal to ISO
TMB
May
2009 2010 2011
UNIDO EGM on EnMS in Industry
2007
EGM = Expert Group Meeting
39
UNIDO’s EnMS-ISO 50001 journey
2008 2007
Mar
ANSI-ABNT NWI Proposal to ISO
TMB
Launch of UNIDO Project on promotion of international EnMS standards
Jul
May
Sep
ISO TMB establishes ISO PC 242
Feb
Apr
UNIDO-SAC EGM on EnMS Standards in Beijing
ISO PC 242 1st Meeting Washington
Sep
Aug
UNIDO-ABNT EGM on EnMS Standards in Sãu Paulo
ISO PC 242 1st CD
ISO 50001
Oct
Incorporating many of UNIDO Framework for Action findings
2009 2010
DEVELOPMENT & IMPLEMENTATION OF UNIDO EnMS PORTFOLIO
UNIDO-DPI EGM on EnMS in Thailand
Ongoing promotion with counterparts of EnMS and engagement in ISO 50001 development
2011
Release of ISO 50001:2011
Jun
developed in < 3 years!
EnMS projects started/to start in 11 countries
Jun
UNIDO EGM on EnMS in Industry
2007
EGM = Expert Group Meeting
40
DEVELOPMENT & IMPLEMENTATION OF UNIDO EnMS PORTFOLIO
2011
Release of ISO 50001:2011
Jun
developed in < 3 years!
Jun
2012 2013 2014 2015 2016
Apr
UNIDO EnMS Internal EGM in Vienna
EnMS programs started/to start in 11 countries
Apr
UNIDO Intern. EGM “Sustainable Energy Standards” in Vienna
EnMS programs in 12 countries
Jun
EnMS programs in 17 countries
Oct May
UNIDO Intern. EGM on EnMS in Vienna
UNIDO continued participation to experts discussion and standards development
Development of ISO 50002, ISO 50003, ISO 50004, ISO 50006 and ISO 50015 …….
Development HLS ISO 50001 …………………………………..……..
UNIDO’s EnMS-ISO 50001 journey
Jun
1st Meeting of ISO TC 301
2017
May
UNIDO Operating
Agent of EMWG
41
Planned
activities
South Africa Moldova Russia Turkey Ecuador Malaysia Thailand Viet Nam Philippines
Indonesia Egypt Iran Ukraine Colombia Macedonia Myanmar India Georgia
Operational in 18 countries
Planned activities in 10+ countries
Other donors Swiss State Secretariat for Economic Affairs
UK Department for International Development
Government of South Africa
Government of Italy
Government of Austria
Projects ongoing
UNIDO Global EnMS-ESO Programme – June 2017
42
2008
2012 2016
Decision-makers reached
Enterprises trained in EnMS
Consultants trained in EnMS
Enterprises with EnMS
250 +
35
200 +
600 +
600 +
2,000 +
6,000 +
400 +
Operational in 18 countries (as of Sep 2017)
12 Countries at the end of 2012
Cumulative direct final energy savings (GWh)
7,000 +
UNIDO-GEF Global EnMS-ISO 50001 Programme
30 +
43 43
How much energy is 7,000 GWh?
Annual energy
consumption of
1,150,000
EU households
Annual energy production
of 2,000 MW of installed
wind power
CO2 emissions of
1,750,000 middle class
cars (running 12,500 km
per year)
Annual cost savings of beneficiaries companies in 2015 exceeded USD 100,000,000 without considering non-energy benefits
Direct GHG emission reductions of more than 4.3 million tCO2
44 44
Denmark Vol Yes* Yes Yes* Yes Yes Yes Yes Lim 60%
Ireland Vol Yes Yes No Yes Yes Yes Yes Yes 25%
Sweden Vol Yes** Yes Yes** Yes Yes No Yes No 50%e
United States Vol No Yes No Yes No Yes No Yes <5%
Source: 2007, A. McKane for UNIDO
The importance of a Programmatic Policy Approach
45 45
Germany
Examples of Policies Frameworks for EnMS-ISO 50001
Policy Instrument Type of
Instrument Areas of
Application Description Remarks
Eco tax cap for manufacturing industry
Financial Large enterprises SME Energy audits EnMS
Aimed to reduce electricity tax burdens on companies in the manufacturing sector. Companies need to prove that they have implemented an EnMS. For SMEs, an alternative system is enough (e.g. DIN EN 16247-1).
Energy Intensity as indicator. Assessment being conducted.
Special equalization scheme
Financial Electricity-intensive enterprises
EnMS
It provides for reduction of renewable surcharge for energy intensive companies. A prerequisite to obtain the reduction is to have an operating certified energy or environmental management system ( in line with ISO 50001, formerly EN 16001 or EMAS)
Companies with < 5 GWh can operate DIN EN 16247-1 or other systems for EE.
BAFA support program for EnMS
Financial Large enterprises SME EnMS
Aimed to support certification of EnMS for companies. Funding for initial certification, for purchasing metering technology and/ Or software for an EnMS; for external energy consultant; for training costs of employees. Limited to EUR 20 000 in 36 months.
Energy efficiency networks
Information Large enterprises SME
Networks of companies with energy costs > EUR 500k from different sectors come together to enhance their energy efficiency and share their best practice - focus is on cross-cutting technologies.
EnMS piloted in Mexico in 2016.
46 46
Denmark
Examples of Policies Frameworks for EnMS-ISO 50001
Policy Instrument Type of
Instrument Areas of
Application Description Remarks
Voluntary agreement scheme
Voluntary agreement
Large enterprises SME EnMS
Since 1996 companies were reimbursed CO2 tax if they implemented an EnMS. The new scheme (2013) reimburses part of the public service obligation (PSO) tariff. It has stricter conditions to be considered and applies to SMEs and large enterprises.
Energy management light
Information SME EnMS
System and guideline targeted to SMEs on how to implement an EnMS in line with EN 16001 or part of it
Energy saving obligation targeted at energy companies
Financial Large enterprises SME Energy audits
Energy companies need to ensure energy savings amounting to 12.2 PJ per year. Savings can come from agreements with end users. Energy companies may provide energy audits or grants connected to energy savings, making more attractive for SMEs and large enterprises to do EE.
Established in 1995. Denmark EEOS is the only one with top savings in Industry
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CBA - FYR of Macedonia Projected Replication
10 Partner enterprises
12 UNIDO National EnMS Expert
Include Progr. preparation and implementation
No inclusion of UNIDO staff & project support costs
Target Final Energy Savings 1 Yr: 10 GWh
Target Money Savings 1 Yr: 650,000 USD (50% no cost)
Without considering non-energy benefits!
UNIDO EnMS CBI Programme
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