Energy Solutions - Meeting the Energy Efficiency Challenge Sebastian Ferecu ş General Manager South East Europe
About Emerson slide 2
Emerson at a Glance 2015 US $22.3 Billion in Sales Headquarters in Diversified global manufacturer Approximately 110,000 St. Louis, Missouri USA and technology provider employees worldwide Manufacturing Founded 205 manufacturing No. 120 on 2015 and/or sales presence in 1890 FORTUNE 500 list locations around in more than of America’s largest NYSE: EMR the world 150 countries corporations slide 3
Emerson Process Management The largest Emerson business segment… representing 36% 36% of the total Emerson business. Industrial Automation Climate Technologies Network Power Commercial & Residential Solutions slide 4
Emerson Process Management Core Offerings Taking on the industry’s toughest challenges, and bringing predictable success any time, any place. Final Control & Operate & Manage Solve & Measure & Analyze Regulate Support The systems and tools that The broadest range of Highly reliable final control Expertise and global provide the decision measurement and technologies to help you resources to help you integrity to run your analytical technologies for regulate and isolate your dependably define, operation at its full process clarity and insight. process with certainty. execute and support a potential. strategy throughout the lifecycle of your operation. Rosemount Daniel DeltaV AMS Suite Fisher Micro Motion Roxar Ovation Bettis slide 5
Industries We Serve Oil & Gas Power Refining Chemical Life Sciences Industrial Energy Marine Metals & Mining Food & Beverage Pulp & Paper Alternative Energy Water & Wastewater slide 6
European Legislation Driving Energy Efficiency European Climate Change Policy (ECCP) Emissions Efficiency Renewable EU CO2 20% 20% 20% Reduction Targets 20% by 2020 EED ETS 40% by 2030 Energy Efficiency Phase III (2013-20) Directive 80-95% by 2050 Emissions Trading Scheme Legally binding energy efficiency measures. Covers energy transformation, Cap & Trade System distribution & consumption. 1.74%/yr Cap reduction over Req energy audit every 4 yrs average total quantity of allowances issued annually in Implementation of y-o-y energy saving 2008-2012 projects Source: JRC, Axens, Europia, Envir Agency slide 7
EU Directive Encourage Implementation of Energy Management System (EMS) Implement an Energy Management System Energy Management Energy Management Processes and System Procedures Energy Management Energy Policy Energy Improvement System Team Determine Opportunities headed by Energy Plan & Goals Programs & Projects Manager Energy Monitoring and Reporting Energy Management Information System www.emersonprocess.com/EEDUserGuide slide 8
What is Energy Management? Energy Management Energy Improvement Opportunities. Energy Monitoring, & Reporting Energy Saving projects. Energy Management Best Available Technologies Information System Energy Savings Reporting Implement Best Practices Energy Saving opportunities Energy Flow Measurements e.g. Process Optimisation Energy Accounting and Performance Monitoring Billing (cost allocation) e.g. EAM, GPA, APM Visibility Control Energy Loss Measurement & Standard Operating Detection Procedure Amendment Delivering Sustainable Energy Efficiency slide 9
What is Energy Management: Reporting Energy Management Energy Improvement Opportunities. Energy Monitoring, & Reporting Energy Saving projects. Energy Management Best Available Technologies Information System Energy Savings Reporting Implement Best Practices Energy Saving opportunities Energy Flow Measurements Asset Optimisation etc Energy Accounting and Billing Performance Monitoring (Cost Allocation) EAM, GPA, APM etc Control Energy Loss Standard Operating Procedure Measurement and Detection Amendment slide 10
Get the Full Energy Picture - Real Time Energy Advisor Detect abnormal changes in energy performance to trigger corrective action real time Identify opportunities to understand periods of best performance and make actions repeatable Move from reactive to proactive energy management 1 Choose the level 2 Report type 3 Time-frame 4 Generate Understand WHY energy consumption is Generate Powerful Analytic Role based KPI’s to drive not as expected using Dynamic Energy Reports Identify and monitor Targets: 1 st Principle Models, Regression decision making & culture Energy Saving Projects Analysis slide 11
Energy Measurement Best Practices Energy Flow Measurements and Losses Energy Fluids Measurment Best practice measurement technology for Energy Stream Minimize Permanent pressure loss and installation cost WirelessHart enabled Energy flow measurement acquisition Energy Loss Measurement Electrical Energy Measurment Energy Content Measurement Primary Fuel Energy Energy consumption Stack Heat Loss Content Analysis monitoring kWh, kVAh Measurement Final Product Heat Monitor Unit Health Fiscal Accounting Measurement Accreditation Improved Quality Full range of CT Air and Water coolers DIN EN 17025 Finished Product Emerson Climate Technologies sensors Losses slide 12
Energy Measurement Surveys Mass & Energy Balances Mass & Energy Balances Balance Model Offline/Online monitoring tool Identify actual energy consumption vs design Causes for discrepancy Actions (cures) leading to energy savings Missing Measurements Energy Measurements in place providing cost effective energy management insight Project Management Documentation Review Operating Data Review Current Instrumentation Review Additional Instrumentation Recommendation Additional Instrumentation Costing Survey Report Methodology to determine effective energy measurement for Real time monitoring is essential slide 13
What is Energy Management: Energy Savings Energy Management Energy Improvement Opportunities. Energy Monitoring & Reporting Energy Saving projects. Energy Management Best Available Technologies Information System Energy Flow Measurements Implement Best Practices Energy Saving opportunities Energy Savings Reporting e.g. Process Optimisation Performance Monitoring Emissions Monitoring e.g. EAM, GPA, APM Standard Operating Procedure Visibility Energy Loss Detection Amendment slide 14
How Do Energy Saving Projects Deliver Results? Automate Operation MAN AUTO Value & Benefits Process Stabilization Improved Regulatory Control Best Practice Less Energy Consumed Reduce Variability Economical Operation Increased Throughput Control Audits, Loop Tuning Best Practice Improved Product Operate at Economical Best Point Quality Best Available Model Predictive Control Technology slide 15
Energy Performance Improvement - Powerhouse Power House Energy (Producer) Combustion Control Multi-fuel, Combustion Overall Utility Optimised Power & Energy Management Economic Dispatch Steam & Electricity Optimisation, Boiler, Header, Boiler Optimal Performance Soot Blowing Governor Control & Increase Use of Cost Effective Optimisation Alternative Fuels BMS Automatic Header Control, Responsive steam delivery, >MW CEMS Water Treatment Reliable Burner Management Eliminate False Trips Boiler Efficiency Steam Leaks slide 16
Our Customers Have Improved Powerhouse Response, Stability and Performance Improved Boiler Cascade trips Boiler stability improved Efficiency eliminated Natural Gas eliminated EUR Packaging Plant NA Pulp Mill EUR Steel Mill • HRSG boiler part of Cogen (2 x • (2) multi-fuel wood boilers and coal • (7) multi-fuel boilers, (8) steam GT’s) supplies steam to boiler turbines, (5) steam headers manufacturing plant • Unit interaction made powerhouse • Gas, COG, and BFG • Standalone operation NG only, unstable and difficult to run • Constant reliability issues and performance variability and poor • Coal used to manage demand frequent unplanned shutdowns efficiency. swings • Emerson established full • Emerson established full automatic • Emerson greatly improved boiler automatic control, trips virtually control, improved steam stability, turndown and overall stability while eliminated, and negated use of and increased boiler efficiency reducing coal use by 5 tons/day Natural Gas (pilots only) to by 2.7% balance the boilers Annual CO2 Reduction circa 5,763 t Annual CO2 Reduction circa 5220 t Annual CO2 Reduction circa 250K t slide 17
Energy Performance Improvement - Process Process Energy (Consumer) Optimisation Distillation etc Model Predictive Control Improved Product Quality Regulatory Control and Energy Audit Steady state control Improved Reliability Adaptive tuning Control Strategy Design Reduced Process Fluctuations Inferential Measurement Optimised Energy Efficiency Load management Load Balancing Increased Product Throughput Steam Leaks slide 18
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