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Institute of Energy and Sustainable Development
Modelling for Industrial Energy
Efficiency
Dr Rick Greenough – De Montfort University
1st April 2015
Energy Efficiency Benefits for Industry Seminar
Limerick Institute of Technology
April 1st 2015
Institute of Energy and Sustainable Development
Modelling
• Simplification of reality to aid understanding
– Similar to real system, but simpler
– Trade-off between simplicity and realism
– Complex models increase realism, but cost more
– Skill is to add complexity where it gives most value
– Have to know what you are looking for
• A model is a product – ‘modelling’ is building it
• Simulation is a process – using the model to
study system behaviour and predict outcomes
Institute of Energy and Sustainable Development
Examples of models
Institute of Energy and Sustainable Development
Models of industrial energy flows
• Value Stream Mapping
• Life Cycle Analysis
• IDEF0
• Process modelling
Institute of Energy and Sustainable Development
Sankey diagram of US energy system (2009)
31% in
2008
This is an interactive Sankey diagram, that can be accessed here:
http://needtoknow.nas.edu/energy/interactive/our-energy-system/
Institute of Energy and Sustainable Development
Sankey diagram for a factory (EPFL, 2015)
Institute of Energy and Sustainable Development
Energy systems in industry (Herrmann & Thiede, 2009)
• Production system
– Process energy and
ancillary processes
• Technical Building
Services (TBS)
– Compressed air, gas,
coolant, HVAC, etc.
• Building shell
– Daylight, thermal
efficiency, weather
effectsComplex interactions!
Institute of Energy and Sustainable Development
Modelling industrial energy in THERM project
Air
Air
node
External thermal Energy
Thermal zone (Factory)
Material
Air
Oven (air)
External
Energy
Product
Energy
(Thermal)
Product
Air Fan
Elec
Air
WaterCHPWater
Thermal energy
Thermal energyHX
Fan HX
Drying tank
Water
Air
Air
Institute of Energy and Sustainable Development
Requirements for modelling TBS
+
++
+
UH 1 UH 2
UH n
ta
ts
thw
toa
Hot Water
Pump
Inlet 1
Inlet 2
Inlet n
Extract n
Extract 1
Extract 2
AIR HANDLING UNIT
HC
Supply
Fan
Return
Fan
E-Leg 1
+
-
HRU
Building geometry, fabric,
lighting etc.
System design and control logic
http://www.kap-project.eu/
Institute of Energy and Sustainable Development
Simulation - calibrating the model
Time consuming and computationally intensive because small changes
in e.g. infiltration rate and setback temperature make a big difference
http://www.kap-project.eu/
Institute of Energy and Sustainable Development
PV panels on Volvo factory roof
• Optimisation
• Parameters:
– Module size/orientation
– Tilt angle
– Distance between arrays
• Objectives:
– Minimise payback period (1,200 €/kW installed1,
0.1 €/kWh consumed2)
– Maximise annual electricity production
1 DECC 2012. Department of Energy and Climate Change: Solar PV cost
update
2 Suggested to use by one of the Volvo managers
Institute of Energy and Sustainable Development
PV Plant optimisation
Institute of Energy and Sustainable Development
Results of solar PV analysis
• For 16% of time
(~1440 hours) there is
enough electricity
generated by PV to
cover manufacturing
process requirements.
• Over 40% of annual
manufacturing
process electricity
requirements can be
obtained from PV
1
11
21
31
41
51
61
71
81
91
101
111
121
131
141
151
161
171
181
191
201
211
221
231
241
251
261
271
281
Electric Equipment Electricity
Consumption
PV Potential
Institute of Energy and Sustainable Development
Another way to model factories - DES
Institute of Energy and Sustainable Development
REEMAIN (www.reemain.eu/)
• EU 7th framework - €6.1M
• Renewable energy, energy reuse and energy management
• Industry partners:– Bossa (textiles)
– Gullon (food)
– SCM (iron foundry)
– Fraunhofer IWU (energy storage)
• Link with US via Intelligent Manufacturing Systems (IMS)
Institute of Energy and Sustainable Development
Combining building and system modelling
Institute of Energy and Sustainable Development
Example energy system – solar cooling
Solar collector
plant
Backup heater
ExpansionDevice
RefrigerantLiquid + Vapour
RefrigerantLiquid
C
QAC
E
QE
ARefrigerant
Vapour
QG
SHX
WeakAbsorbentSolution
StrongAbsorbentSolution
P
RectifierRefrigerant Vapour
G
Absorption chiller
Backup chiller
CD
Cooling tower
Hot water storage
Institute of Energy and Sustainable Development
Example energy system - ORC for waste heat
Institute of Energy and Sustainable Development
Organic Rankine Cycle at a foundry
ORC pilot plant called ORCHID
installed by Enertime at FMGC
foundry in France
Institute of Energy and Sustainable Development
Renewable energy options for a foundry
ORC pilot plant called ORCHID
installed by Enertime at FMGC
foundry in France
Institute of Energy and Sustainable Development
Renewable energy options for a foundry
• High temperature processes– To melt iron needs 1600C
– Aluminium melts at 660C
• Use PV to power an electrical furnace?
• Use RES in core shop?
• Waste heat from cupola flue
• Organic Rankine cycle (ORC) to generate electricity at FMGC foundry in France– Flue gases exchange heat with air and thermal fluid
which drives ORC generator
– 5.6 MW of thermal power available
– Generates 1MWe (5000MWh per year)
Institute of Energy and Sustainable Development
Institute of Energy and Sustainable Development
Laundry with solar thermal hot water (Hess, 2014)
Annual solar fraction = 23.2% (energy delivered by solar system/energy required)
Solar loop utilization ratio = 40.9% (solar heat charging the store/solar irradiation)
System utilization ratio = 35% (solar heat discharging from store/solar irradiation)
