prof. dr.-ing. rolf h. jansen hans pleuger german-asean...
TRANSCRIPT
Prof. Dr.-Ing. Rolf H. Jansen Hans Pleuger
German-ASEAN Sciences & Technology Network.
Case studies for integrated energy efficient solutions in the industry
and how to overcome mental barriers in the decision making process
Hans Pleuger
INSTec / RWTH
Structure
country partners
expert consultants
competence centres
expert scientific partners
INSTec / RWTH
German-ASEAN Sciences & Technology Network
What we do & Prof. Dr. Jansen / Hans Pleuger
• International network related to all types of smart energy
• Advice, holistic concepts and implementation
• R&D, cooperation with universities • Qualified firms of specialists • Alcion academy / know how transfer • International benchmarking
INSTec / RWTH
Business sectors
Rural communities • advice • concept •business plan • energy self
sufficiency • tool: SES.Ko
Manufacturing • advice • concept • implementation • energy
management systems
•monitoring • controlling • tools: SES.Pro.
eco.BUSINESS
Buildings • advice • concept • implementation •monitoring • controlling • tools: SES-Bil,
eco.AREAL
Office • advice • concept • tool: eco.OFFICE
Private • tool: eco.HOME
• + comprehensive solutions for industrial parks • + international know-how transfer
INSTec / RWTH
Integrated solutions
Customer
INSTec / RWTH
Advice, concept, implementation / A
• Energetic review, summary + evaluation of status quo as basis for integrated solutions
• using ALCION-unique software + tools for the analysis)
– covering all kinds of energy – electric, thermal, water, gas, waste
references: manufacturing
industry, buildings, rural communities, Fraunhofer Institute
INSTec / RWTH
Advice, concept, implementation / B
o Custom-tailored energy concepts, implementation,, monitoring, controlling, benchmarking
– Savings from integrated application of all specific, individual solutions – Energy-Management-System (DIN EU 500001) up to energy control room – Savings from changes in attitudes of use / energy-efficiency – Increasing / installing energy self sufficiency – Technical plus economical evaluation – Teamwork with all internal and external specialists and/or scientists – For e.g. manufacturing-, administration-, residential-, hospital-, school-,
R&D-buildings
references: manufacturing
industry, buildings, rural communities, Fraunhofer Institute
INSTec / RWTH
Advice, concept, implementation / C
o Specific solutions – Cooling with minimal electricity consumption – Energy recuperation from waste heat / waste water – Daylighting-Systems incl. Blue Buildings / latest LED illumination systems for industrial halls – Cogeneration installations (CHP) – Peakload management programs – Decentralized use of solar power, wind power, solar thermal power, water power – Water treatment systems with minimized consumption of electricity – Reduction of CO2 output – Combined solution for waste treatment + CHP + seawater-desalination (potable water),
decentralized and energy selfsufficient
references: manufacturing industry,
buildings, rural communities, Fraunhofer Institute
INSTec / RWTH
eco.BUSINESS / holistic energy concept
Vortrag Metropolregion Rhein-Neckar INSTec / RWTH
Pilot eco.AREA
INSTec / RWTH
SES.rural communities / self-sufficiency
Bio-natural gas
CHP
participating buildings Peakload burners
Wood
wood gasification
CHP
Biomass
CHP
biogas plant
district heating
Pro
cess
-hea
t
direct sales ?
to the grid
collecting thermal power
direct sales
Solar (PV)
Wind (turbines)
Water (turbines)
Other „citizens power“?
residues from fermentation
collecting electric power
manufacturing of fertilzer
INSTec / RWTH
7 steps towards higher energy-efficiency
Energetic initial position 1
Analysis of status quo of power technology 2
Energy concept 3
Planning 4
Implementation 5
Monitoring + control 6
Constant energy management 7
INSTec / RWTH
Systems & Tools • „Ko“ for communities • „Pro“ for manufacturing industry • „Bil“ for buildings • „Bu“ for offices • „Home“ for private homes • „Mo“ for electrification of transportation • „Grid“ for Smart Grids
SES.Ko SES.Pro SES.Bil SES.Bu SES.Home SES.Mo SES.Grid
•Energy-cockpit for business •Energy-cockpit for industrial parks •Energy-cockpit for offices •Energy-cockpit for private homes
eco-BUSINESS eco-AREAL eco-OFFICE eco-HOME
INSTec / RWTH
Integrated concept, twin goals
Improving cost effectiveness
INSTec / RWTH
Potential for savings in SMCs small + medium sized companies (from experience)
Analysis of current situation Energy concept Energy-management
Electricity demand reducing demand measuring, monitoring, controlling
Heat, cooling, compressed air optimising technology maintain achievements
Building optimising usage/behaviour on-going improvements
Power supply (contracts) optimising supplies
+ others + partial self-sufficiency
total ~ 30 % cost savings
INSTec / RWTH
INSTec / RWTH
Real cases
Intelligent cooling + ventilation systems,
“adiabatic”, evaporative
from recovered and/or renewable energy + comprehensive energy monitoring
minimised energy consumption for optimised efficiency
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
Reconstruction of a hotel into a „Mehr-Generationen-Haus“ (multi generation building)
before: 242 kWh / m2 p.a.
after: 48 kWh / m2 p.a.
Applied renewable technologies
(paid for by the savings):
• Combined heat and power
• Photovoltaic systems
• Solarthermal systems
• Water (recovery, treatment)
Energy efficiency, real case
© 2013 INSTec / RWTH 22 INSTec / RWTH
Floor- and ceiling-systems (cooling, heating, ventilation, lighting)
cost effectiveness and health
INSTec / RWTH
“A/C” by radiation (“Klima-Segel”, draught free, no dust, no germs)
INSTec / RWTH
Rethinking system technology: underfloor-cooling, -heating, -ventilation
INSTec / RWTH
Water treatment systems
cost effectiveness and health
INSTec / RWTH
Electrolysis technology (energy savings from input water temperature < 45°C)
INSTec / RWTH
Diaphragmalysis membrane technology
(optimal for adiabatic cooling systems)
INSTec / RWTH
Peakload- and facility energy management
how to recognise, plan and control energetic coherences
INSTec / RWTH
Energy efficiency / real case (energy management system:
saving 775.000 kWh / € 160.000 p.a.; payback in 4 months)
• Manufacturing company • Electric heating replaced by heat
from a highly efficient CHP plant and subsequent heat recovery
• CHP plant using natural gas • Energy savings: 775.000 kWh / p.a. • CO2 emission reduction • Installation of a heat recovery
system and utilisation of waste heat reducing demand for room heating by 70 %
• Amortisation period: 4 months / return on capital 300 %
• Total savings from energy costs p.a. = approx. Euro 160.000
INSTec / RWTH
Effects of peak loads in companies
The highest average demand value within a period of time determines the demand costs !
Demand rate 67,33 €/kW/a Peak load 800 kW 600 kW Costs 53.864 €/a 40.398 €/a
INSTec / RWTH
Energy efficient planning of manufacturing by using the construction kit ecoFLEX
System for collection of energy data
ecoFLEXIP
ERP PDM BDE
MES Fabrik-
planung . . .
IT-System related to manufacturing Knowledge base
Peak load- management
Smart Control and alerting
Planning for changing resources
INSTec / RWTH
Construction kit “ecoFLEX” for sustainable design and planning of manufacturing machines and processes
to optimise energy consumption
INSTec / RWTH
Capturing of energy data in a SME for injection moulding technology
(link to building automation systems)
INSTec / RWTH
Finetuning of order scheduling in line with peak load limitation
INSTec / RWTH
Finetuning of order schedules w/o peak load limitations
INSTec / RWTH
Corresponding prognosis of peak loads (with limitations) for finetuning the scheduling of orders
INSTec / RWTH
Finetuning of order scheduling and corresponding prognosis for peak loads w/o limitation
INSTec / RWTH
Use of building automation systems
INSTec / RWTH
Architectural contributions to bionic buildings
A few examples, realised from inside to outside – after
workshops with employees + management
INSTec / RWTH
Energetische + schallschutztechnische Sanierung eines Unigebäudes in Mannheim
Glasdoppelfassade, Zuluftkonditionierung über Erdkanal
Double-glass façade
INSTec / RWTH
Pleiad-Haus Speyer Südforum über drei Geschosse, Hypokaustensystem nutzt Betonmassenspeicher,
150 m Erdkanal zur Luftvorkonditionierung
INSTec / RWTH
Umbau und Erweiterung Helmholzgymnasium Karlsruhe
Energetische Optimierung des Bestandsgebäudes mit kompaktem Neubau – Nutzung ehemaliger Keller als Thermolabyrinth für Kühlung, Heizung und Lüftung
Thermo-labyrinth for cooling, heating and ventilation
INSTec / RWTH
Wettbewerb Wohnen 2000 RWE + BDA, 1.Preis und Überarbeitung
Kompaktes 3-FH mit EFH-Qualität, NEH > Passivhaus, Zentrale „Rote Wand“ für alle Installationen und Energiemodule vorbereitet
Central “Red Power-Wall”
INSTec / RWTH
Lighting Design
Contribution to Cost effectiveness, health, CI
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
Supermarket
Former installation 1.000 fluorescent tubes
Operating hours per day 15
operated p.a. 302 days
New installation 1.000 LED
Energy savings p.a. 208.380 kWh = 70%
Operating life > 11 years
Payback period 2,5 years
Cost savings p.a. *over the operating period at 0,15
€/kWh 24.075 €
Kumulierte Kosten Ersparnis
-100.000
0
100.000
200.000
300.000
Savings: 264.000
€
Energy efficiency, real case LED – illumination concept for a supermarket
INSTec / RWTH
Continous-row LED luminaire
INSTec / RWTH
Break even after 4 years
INSTec / RWTH
Longterm multipurpose thermal energy storage
- the missing link -
Renewable energy 365/24 - working prototype -
INSTec / RWTH
Buffering + managing power base vs. peak (including industrial waste heat)
INSTec / RWTH
• Solid mass storage system w/ high energy density of the used material (approx. 750 kWh/m3 = factor 10 compared to water)
• Input temperatures up to 1.000 °C • No heat-transfer medium, directly stored into mass • Easy + efficient extraction of power • Production of superheated steam directly from storage to
run multistage turbines • Heat-loss: 0,05 % /24 h • Cost: approx € 12,50 / kWh th • Practically maintenance-free • Efficiency factor: 40 – 75 %
INSTec / RWTH
Energy efficiency: real case Roof - Envelope Power Greenhouse
a combined solar power station and greenhouse
to produce energy and health food
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
too
Architecture Bionic & ID
+ Roof Power Greenhouse + storage systems
Indoor climate Cooling, ventilation,
heating, water treatment:
Innovative systems
Energy management
system
Tools IT + intelligent
hardware
Energy efficiency
Light blue buildings
daylighting, state of the art LED
ALL STAKEHOLDERS
Internal communication
ENERGY BILL: reduced / ENERGY AUTONOMY: increased
/HEALTH: improved
holistic approach
INSTec / RWTH
Interdisciplinary communication
INSTec / RWTH
Harmonized, better, measurable results
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH
INSTec / RWTH