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Opportunities for High Temperature Heat Pump in
French industry
Opportunities for High Temperature Heat Pump in
French industry
14th October 2008
Energy context
EDF Group & ECLEER
Energy context
EDF Group & ECLEER
3
Facing a major issue…World consumption trends in energy
(Mescalito – medium scenario)
0
5
10
15
20
25
1950
1960
1970
1980
1990
2000
2010
2020
2030
2040
2050
2060
2070
2080
2090
2100
Gte
p
To be found!RenewablesNuclearCoalGasOil
?
4,6%
1,9%
1,4% - 0,5%
« R&D » community will have to find new answers !
4
Energy Issue / EDF Group and Energy Efficiency Energy Issue / EDF Group and Energy Efficiency
New challenges:• Security of energy supply
- Enduring pressure on hydrocarbons resources
• Acting against climate change
Ambitious objectives by 2020:• Reducing CO2 emissions by 20%• Reducing energy consumption by 20%• Increasing renewable energy to 20%
EDF Group: active in energy efficiency
3 driving forces: 1. EDF Group values : sustainable developm’t2. EU directives & French laws : obligations 3. EDF Group business : advice & services
Energy efficiency set to be an important issue over the long term
5
ECLEER : context and objectivesECLEER : context and objectives
In the context of a « post peak-oil » economy :CO2 emission reduction (factor 4 by 2050)
Energy independence (imported fossil fuel)
EDF Group and two of its high level scientific partners:Ecole des Mines de Paris
Ecole Polytechnique Fédérale de Lausanne
have decided to create an European research centre on energy efficiency :
ECLEER : European Centre and Laboratories for Energy Efficiency Research
dedicated to buildings and industry …
Main objectives1 increase and speed up innovation2 gather complementary skillsFor energy eco- efficiency
6
CO2 emissions for European UtilitiesCO2 emissions for European Utilities
Year 2004, kg/MWh(consolidated data)
7
Energy consumption and CO2 emissions – France Energy consumption and CO2 emissions – France
Buildings 42%
Transport 32%
Industry 24%
Agriculture 2%
Buildings 28%
Transport 30%
Industry 23%
Agriculture 19%CO2
equiv.emiss’n
Final energyused
Source: DEFRA / AEA Energy & Environment 2005
8
Energy efficiency in industry Energy efficiency in industry
9
of total energy used generating heat
70%
Energy use in industryEnergy use in industry
39% Furnace & dryers
29% Boilers
11% Motors
7% HVAC
6% Compressed air & cold
8% Raw materials
Energy use in industry (France)
1/3of electricityconsumption
2/3of oil, gas, coalconsumption
Good progress in efficiency, potential for improvement still high
– More profitable and safe production practices, competitiveness
– 5 to 6% / year of equipment renewal
Identifying opportunities is still complex
10
Boiler
Cold prduction
Air compressor
Cogeneration
Lighting
Motors
Furnace
Concentration
Drying
Premisses heating
ColdWarehouse
Tool machine
Gas
Fuel and coal
Electricity
ENERGIES CentralisedUtilities
Cross-cuttingUses Process
Is industry really complex ? Ex. of an Energy flow mapping
Mechanical
force
Compressedair
Refrigeration
Steam
11
Energy savings in industry : technical potential Energy savings in industry : technical potential
HEAT = 85%known energy savings
Boilers, furnaces, drying, heat recovery, HVAC
15%–20%energy savings potential with existing technologies and dedicated energy management(80 TWh in France)
Energy savings potentials
Heat recovery26%
Furnaces20%
Boilers14%
HVAC13%
Drying11%
Motors5%
Lighting4%
Cold 3%
Compressedair and Plasturgy
1%1%
12
Energy efficiency in industry in France (example)
Energy potential savings (TWh)
0
5
10 30 50 70 90 110 130 150Energy Consumption
Cos
t(E/
MW
h)
Boilers
Motors
Furnaces
DryersHVAC
ColdHeatrecovery
Ligth
Compressed air
72% of energy savings on fuels28% on electricity
13
EDF R&D research topics on main barriers EDF R&D research topics on main barriers
Reduce energy
demand thruenergy mgmt
Use highest
performingenergy systems
Heat recovery, process
integration
Energy management systems
Smart equipment
High performance technologies for heat recovery
Induction heating systems
Cold production
Energy assessment and strategies
(efficiency opportunities global, sub sectors and sites)
Tools and methods for energy audits
(analysis and process rethinking, system oriented energy design, etc)
14
Our research challenges
Industrial Technologies R&D to increase energy efficiencySmart furnace : technologies to decrease by 20% energy consumption of existing furnacesInnovative chiller systems : with water as refrigerant and producing ice slurry
1
2
4
3
Key industrial processes and technologies for 2020To divide by 4 GHG emissions of industrial furnacesEnergy Loss Reduction and Recovery in Industrial Energy Systems : identify R&D priorities for energy lossreduction and recovery, and identify new software tools for development., …
Industry Demand side forecast and technological prospective studiesTo develop a model of energy demand projection in industryDescribing and assessing the main industrial technology developments expected to occur up to 2050 in order to identify promising technologies where R&D investments would be cost-effective.
Energy Management on industrial sites : tools and methods R&DTo divide by ten the cost of sensors and information processing : a key of success for energy management systems on industrial sitesTo develop an innovative energy savings assements method : minimum energy required for the product – The goal is to optimise the flow of energy supply, demand, and losses in industry
15
Heat recovery in industry
Heat Pump
Heat recovery in industry
Heat Pump
16
The energy is recovery on …Heat recovery after the process or the facilities
Transportation or storage
Conversion of energy at the level required
Casing Gas waste Liquid waste The final product
HP Heat recovery « box »
Exchangers smoke / water
Heat exchangers
dirties…
HeatHeat recoveryrecovery on on fluidfluid
17
Water or gas wastes
Heat exchangers
T<5°C
Heat pumps
30°C<T<50°C
Hot water pre heating Pre heating product
Exchanger :Water wastes / water
Water wastes / air
T>50°C
High temperature
MVR
Concentration
The The marketmarket –– condensingcondensing temperaturetemperature interactioninteraction
Energy needsEnergy needs
Energy saving by heat Exchangers: passive heat recovery
4 TWh
Energy savingpotential
Tomorrow
7 TWh
Heat Pump and Optimised Chillers
Futur
High temperature energy saving and VHT HP
Impact on the Energy saving potential> 10 TWhEnergy needs
18
28 TWh
71 TWh
Market process 0° to 200°C 10 times market 0 to 70°C
Market 100 to 200°C 2,5 market 0 to 100°C
French French marketmarket of of heatheat needsneeds
19
Under 100°C :
Heat of liquid (food industry)
Between 100 and 200°C : drying (paper)
Main Main strategicstrategic sectorssectors (France)(France)
20
7 sectors under 100°C:
Food + paper + chemical
64% of the market
9 sectors between 100 and 200°C :
food + paper + chemical :
68 % of the market
Main Main strategicstrategic sectorssectors (France)(France)
21
Main differences between residential and industrial Heat Pump Main differences between residential and industrial Heat PumpIndustrial Heat Pump
• Necessity to have a global analysis of the industrial site, process by process
• Evaporating temperature between 25 and 65°C
• High temperature : condensing temperature according to the process (80°C to 200°C) & High power (more than 1 MW)
•Low constraints : noise, space
• Necessity to demonstrate the energy and economical gain (Return of investment)
• Number of sales lower than residential HP (each case bigger)
Residential Heat Pump
• Standard product for hot water or space heating
• Evaporating temperature between –20°C and 12°C
• Condensing temperature required up to 65°C (15 KW)
• Necessity of small size, low cost, no noise
• High potential of sales but high cost to access to the customers
• Return of investment more long
Opportunities : size of the system permit technological innovations
22
Experiences, Potential and global environmental benefits (1994) Experiences, Potential and global environmental benefits (1994)
ContextIndustrial Heat Pumps can provide a number of process-related benefitsDespite these potential benefits, the number of IHPs installed is low Why ? : lack of knowledge, lack of experience with IHP technology and with the
coupling with the process
Program (data of more than 100 industrial processes, 5 industrial sectors, 5 categories of IHPs studied)
Closed-cycle compression, Mechanical vapor recompression, Thermal vapor recompression, Absorption heat pump, Heat transformer or absorption heat pump
ConclusionsReduce total industrial process heat pump energy consumption : 2-4%Reduce process heat energy consumption for individual process : 66% (depending
on the industry and process)35 different industrial processesPotential increasing of refrigerant emissions by some 93-190 t/y
estimation of potential global environmental benefits of IHPsEach industrial site has to be analyzed case by case
23
2008 : to find new answers2008 : to find new answers
The energy cost increases and CO2 emissions have to bereduced
The solutions proposed in 1994 become more profitable
More constraints on refrigerantObjective : GWP < 150 New refrigerant and adapted compressors are required for high
temperature
New opportunities for Industrial Heat PumpTechnical investments become possibleNew sectors have to be involved
24
Integration of Heat PumpIntegration of Heat Pump
NecessityNecessity to analyse the to analyse the processprocess ((energyenergy and and exergyexergyintegrationintegration) to ) to integrateintegrate the the HeatHeat PumpPump and and modifymodify the cold the cold and and heatheat sources.sources.
ConsequencesConsequencesNecessityNecessity to to calculatecalculate the global the global energyenergy efficiencyefficiency of the of the processprocess and and not not onlyonly the COP of the the COP of the equipmentequipment
ThenThen genericgeneric applications for the applications for the HeatHeat PumpsPumps••
EveryEvery
wastewaste
withwith
a a
temperaturetemperature
more more
highhigh
thanthan
the the
environmentenvironment
cancan bebe
usedused
as cold source.as cold source.
••
EveryEvery
production of production of steamsteam
by combustion by combustion whichwhich
isis
usedused
underunder
9090°°C C cancan bebe
replace by a replace by a HeatHeat
PumpPump
••
EveryEvery
refrigerationrefrigeration
machine machine couldcould
bebe
a a ««
thermothermo‐‐frigofrigo‐‐heatheat‐‐pumppump
»»
25
Some technological challengesSome technological challenges
LubrificationLubrificationAdaptation of the Adaptation of the lubricicationlubricication oiloil for for temperaturetemperature more more highhigh ((fromfrom 60 to 10060 to 100°°C)C)CoolingCooling of the machine, of the machine, recoveryrecovery of the of the energyenergy, , developmentdevelopment of machines of machines withoutwithout oiloil, , ……
To select To select fluidsfluids withwith a GWP a GWP lowerlower ((underunder 150 ?)150 ?)StudyStudy of new of new fluidsfluids (mixed), adaptation of the system, (mixed), adaptation of the system, wastewaste fofo fluidsfluids, , ……
Variable speedVariable speedFew technologies Few technologies existexist
DifficultyDifficulty
to to adaptadapt
existingexisting
equipmentsequipments
NecessityNecessity to to developdevelop global system global system withwith variable speed of the variable speed of the compressorcompressor, , pumpspumps and and coolingcooling, new , new regulationregulation
HeatHeat transformer transformer withwith micro tubesmicro tubes