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Industrial Insulation: Energy and CO2 savings potential in EU27
 

Industrial Insulation: Energy and CO2 savings potential in EU27

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Expert experiences show that in industrial plants about 10% or more of the equipment is uninsulated or covered with damaged insulation. Furthermore, the level of insulation applied is typically based ...

Expert experiences show that in industrial plants about 10% or more of the equipment is uninsulated or covered with damaged insulation. Furthermore, the level of insulation applied is typically based on a minimum investment decision following requirements regarding the maximum surface temperature to avoid personal injuries, minimum process needs or based on generic maximum heat loss rates only.

Requirements like cost-effectiveness or maximum energy efficiency of the insulation system are therefore often not considered. In the past, when fuel prices were lower energy efficient insulation would not have led to a large difference. Nowadays, the price of energy is higher and is expected to grow even further. As a result there is an increasing gap between current and cost-effective insulation levels. Additional costs for CO2 emission allowances will accelerate this trend and further increase the savings potential.

The total cost-effective savings potential amounts to about 480 PJ and 37 Mt CO2 per year for industry. In other words, more than 4% of total industry fuel consumption and emissions. The savings potential exists across all regions, sectors, equipment and operating temperatures.

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    Industrial Insulation: Energy and CO2 savings potential in EU27 Industrial Insulation: Energy and CO2 savings potential in EU27 Presentation Transcript

    • 25.04.2013EiiF PresentationEuropean Industrial Insulation Foundationwww.eiif.org
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org2EiiF European Industrial Insulation FoundationWho is EiiF?Independent and non-profit FoundationRegistered in Emmen (Luzern) with offices in Gland (near Geneva),SwitzerlandArticle 2Purpose of the foundationThe Foundation engages itself throughout Europe, exclusively and irrevocably,on a non-profit basis for the deployment of sustainable insulation systems inindustrial plants and in the industrial environment with the aim of saving energy,reducing CO2 emissions and realizing the best possible noise and fire controlsystems.
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org3We Power Sustainability
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org4Source:PaulaReyGarcía,DGEnergy,EuropeanCommission
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org5Source:PaulaReyGarcía,DGEnergy,EuropeanCommission
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org6Source:PaulaReyGarcía,DGEnergy,EuropeanCommission
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org7EiiF strategy to stop energy lossesProof (facts & figures)• EU-Study• Best practise examplesBuilding Awareness (awareness &knowledge)• Communication• Coordination & networkingTIPCHECK Programme• TIPCHECK engineers• TIPCHECK audits
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org8Split responsibilities between:Project manager,Maintenance managerMaintenance budgetAdditional investmentin insulationEnergy CostsEnergy budgetInvestonlyonceSaveeveryyear!Split responsibilities & budgetsEnergy ManagerCEO & CFO
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org9EU-Study: Climate protection with rapid paybackCurrent (A) Cost-effective (B) Energy-efficient (C)
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org10Result: 620 PJ Energy Savings PotentialThe annual cost-effectivesavings potential is 620 PJ=Energy consumption of theentire Dutch industry.
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org11Result: 620 PJ Energy Savings PotentialThe annual cost-effective savingspotential is 620 PJ=The Energy consumption of10 millionhouseholds
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org12Result: 620 PJ Energy Savings PotentialIn return 15 coal-fired power plants of 500 MW could be switched off15
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org13Result: 49 Mt CO2 Reduction PotentialThe annual CO2 reductions potential is equivalent to the emissions of18 million middle class cars (running 12 500 kilometres per year)18 million cars
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org14No LimitsThe savings potential exists across all:• Regions• Sectors• Equipment• operating temperatures.
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org15Attractive payback timesUninsulated and damaged partsoffer attractive payback times:Payback times are typicallyless than one year(life time = 15 years)
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org16One-time Investments offer high annual Savings3.5 billion euro900 million euroInsulating bare surfaces to cost-effective levels and repairing damaged insulationwould save about 460 PJ = about 75% of the entire Savings PotentialOne time investment: High annual Savings:
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org17Quick Calculation of typically un-insulated partsSize HeatlossBare pipe 25 mm 80 mm ∆ bare, 80mm ∆ 25 mm, 80 mm ∆ bare, 80mm / ∆ 25 mm, 80 mm[inch] [W/m] [W/m] [W/m] [W/m] [W/m] [-]8 2657 220 92 2565 128 2010 3197 281 111 3086 170 1812 3664 297 127 3537 170 21Savings potential of insulatingun-insulated vs. improvingexisting insulation (25mm)approx. 20 times higher
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org18Quick Calculation of typically un-insulated partsAchievable savingsSizeInsulationThicknessspecifiedEnergysavingCO2-emissionreductionTotalsaving[inch] [mm] [W/m] [kg/m/a] €/a8 80 2565 5133 70010 80 3086 6140 82512 80 3537 7078 950Calculation for Singapore average weather conditions(Source: NEA Meteorological Services)Temperature medium: 200 °CAmbient temperature (annual average): 27.2 °CWind velocity: 2 m/sSteam generation efficiency: 75 %Price of energy: 8 €/GJTrading value CO2-emissions: 7 €/tonne
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org19Quick Calculation of typically un-insulated partsHow many un-insulated parts do you have on your plants?Nr. of items X 800,- € = large savings500 X 800,- € = 400’000,- €SizeInsulationThicknessspecifiedEnergysavingCO2-emissionreductionTotalsaving[inch] [mm] [W/m] [kg/m/a] €/a8 80 2565 5133 70010 80 3086 6140 82512 80 3537 7078 950
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org20TIPCHECK StandardTIPCHECK = Technical Insulation Performance ChecksA. Standardised energy auditing tool to evaluateindustrial insulation systems with the aim to improvethe energy efficiency of industrial processes-> standardized TIPCHECK auditsB. Qualification programme for Insulation engineers-> certified TIPCHECK engineers(Minimum Requirements: 4 years experience, university degree in engineering, ability to calculate& design industrial insulation systems, EiiF member, participate in one week training course, passtest, refresh certificate every 3 years)
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org21Missing insulation to protect cold processes
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org2222Proof Best Practice examples Cold
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org23Typical situation onsite
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org24Typical situation onsite
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org25Typical situation onsite
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org26TIPCHECK examplesChemical Plant in FranceKey facts:• 1 employee equiped with a thermografic camera• 2 weeks on-site• 400 pictures taken and used for the audit reportKey findings:• Safety: Burn risk due to missing insulation• Financial: Money savings due to reduced energy loss• Energy Efficiency: Energy/heat loss
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org27TIPCHECK example: Chemical Plant, FranceNon-insulated parts of equipment:Detected burn danger:Surface temperatures above 280°C bare a great risk of severe burn injuries for staffProposed insulation solution:Installment of mattress insulation to assure surface temperatures below 50°CAction:About 30 similar valves were identified and insulatedKey findings - Safety
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org28TIPCHECK example: Chemical Plant, FranceKey findings – Energy Efficiency1. Storage tanks35 Storage tanks with uninsulated roof topsSurface approx. 28m2Temperature of stored liquids: 150˚CUnnecessary energy loss per year approx. 12.000 MWh2. Valves30 Uninsulated valves (see Safety):Internal temperature: approx. 300 °CUnnecessary energy loss per year approx. 600 MWh
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org29TIPCHECK example: Chemical Plant, FranceSavings potential:Total unnecessary annual energy loss (valves+tanks): approx. 12.600 MWhTotal annual financial saving potential (4ct/kWh): approx. 505.000 EURInvestment:TIPCHECK: approx. 10.000 EURInsulation instalment and material costs: approx. 90.000 EURTotal investment: approx. 100.000 EURPayback time: approx. 2,4 monthsKey findings – Financial
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org30TIPCHECK example: Refinery, ItalyRefinery in ItalyDoubling the insulation thickness and using bettermaterial cut the heat losses in half.Energy Savings: 1.021.958 kWh/aFinancial Savings: 75.000,00 EURPayback time: 1-3 years**The new insulation system had to improve the fire protection, whichlead to more expensive materials than those that would have beenused for energy efficiency only. This higher investement extended thepayback in this example from 1 to 3 years.
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org31TIPCHECK example: Processing plant, Germany• Tube, ferritic steel, thickness: 5 mm• Width 1,70 m• Depth 0,760 m• Hight 26 m• Surface 127,92 m2• Average heatprice 0,033 €/kWh• Operating hours: 1‘500• Insulation investment 12.792 EUR• Energy savings 1.450 MWh/a• Financial savings 47.800 EUR/a• Payback time < 3 monthsInsulation of an asphalt boiler in Germany
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org32TIPCHECKYourSavings Potential
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org33How does a TIPCHECK contribute to our Sustainability programme?FAQ– Insulation is the first step of initiating measures to reduce energy loss, CO2emissions and contribute to a cleaner environment– Besides energy savings potentials insulation offers significant life-cycle costreduction potentials
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org34FAQWhy should we start to insulate un-insulated fittings, valves,flanges, etc.?– EiiF study has proven that by insulating bare surfaces we can reduce up to 95 % ofour energy losses and significantly reduce CO2 emissions.– We all care about the environment; this is an important step to tap into the energysavings potential of industrial insulation.– Insulation investments usually have a payback period of less than one year.
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org35How do we approach this energy efficiency programme?FAQ– Our certified TIPCHECK engineers will analyse the present situation andcome up with a road map to energy savings.What steps need to be taken in order to implement the road map to energysavings?– Our certified TIPCHECK engineers will work closely with all stakeholdersincluding production, plan/asset integrity, site maintenance, mechanical,energy management, etc. to define the correct implementation andexecution strategy for your facility.How long will it take?– The duration of the project depends very much on the size and scope.Therefore a detailed project plan will be set up according to client’s needs.FAQ
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org36What is the impact on daily operations?FAQ– By working in close conjunction with all relevant stakeholders we will mitigatedisruption.– The work is non-intrusive and all measurements or changes can be done on fullyoperational units and therefore will not interfere with on-going production.What are the technical and operational challenges we’ll have to deal with?– How to detect and control leaks from valves and flanges?– How to insure mechanical integrity (e.g. bolts tensioning, mechanical designtemperature limits) of newly insulated parts?– How to avoid water ingress?– How to insure mechanical rigidity of insulation covers?These topics will be addressed in close conjunction with the maintenance andoperations department by the TIPCHECK engineer and his company.FAQ
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org37What is expected from everyone working on site?FAQ– A careful and professional handling of insulated systems in order to ensure energysavingsWhat are the advantages for associates?– An even safer working environment by substantial reduction of cold or hot hazardoussurfaces– Better working conditions due to reduced heat radiation– Personal contribution to a cleaner environmentFAQ
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org38SummaryThe Savings Potential of Industrial Insulation isThis Savings Potential is highlyThe Savings Potential can belargecost-attractivetapped today
    • 25.04.2013EiiF presentation forEuropean Industrial Insulation Foundationwww.eiif.org39European Industrial Insulation FoundationAvenue du Mont-Blanc 331196 Gland (Geneva)SwitzerlandAndreas GürtlerFoundation Directort: +41 22 99 500 - 70f: +41 22 99 500 - 71m: +41 78 69 63 662e: andreas.guertler@eiif.orgwww.eiif.orgEiiF Contact