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Modelling Energy Saving Potential in Industry. Case of the Steel - - PowerPoint PPT Presentation

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Modelling Energy Saving Potential in Industry. Case of the Steel and Paper Industries 4-9 June Colle sur Loup EDF R&D / CMA, ECEEE Summer 1/31 A. Djemaa Study 2007 Study optic Modelling the Long range Energy needs and potential

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SLIDE 1

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 1/31

Modelling Energy Saving Potential in Industry.

Case of the Steel and Paper Industries

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SLIDE 2

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 2/25

…Study optic

  • TIMES Model tools

Oil Refining Industry Cement & Lime Industry Graphic Paper Paper board Industrial Paper Paper Processes Mchanical Pulp Chimical Pulp Recycled Pulp Biopulping Pulpr Process Pulp & Paper Industry Iron Processes Steel Processes Iron & Steel Industry Tiles & Briks Industry Ceramics Industry Glass Industry

Energy Intensive Industry

Industry

  • ther industries
  • Modelling the Long range Energy needs and potential energy savings in European industry
  • EDF R&D / CMA Program
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SLIDE 3

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 3/25

…TIMES Model

1: TIMES Documentation, R. Loulou et Al., 2005

The Integrated MARKAL-EFOM System Created by ETSAP members - 1997 Current users: CMA, IER, VTT, Italy…

MARKAL EFOM-ENV TIMES

services and products for demands : variables : d traded consumed, produced, s commoditie

  • f

amounts es, technologi

  • f

, activities , capacities s, investment : variables decision : x bounds

  • ptional

LB x UB s constraint technical and logical, financial, b Bx emissions

  • n

cap e Ex demands

  • f
  • n

satisfacti

  • .

. surplus net

  • f

NPV : function

  • bjective

) ( d Ax t s x c dq q p Max

t d d

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SLIDE 4

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 4/25

…TIMES Reference Energy System (RES)

Cost and emissions balance

GDP Process energy Heating area Population Light Communication Power Person kilometers Freight kilometers

Demand services Coal processing Refineries Power plants and Transportation CHP plants and district heat networks Gas network Industry Commercial and tertiary sector Households Transportation Final energy Primary energy Domestic sources Imports Demands Energy prices, Resource availability Energy flows Emissions Capacities Costs P r i c e s

Project Optic

Source: IER

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SLIDE 5

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 5/25

…RES Industry

Demand services Boiler Cogeneration Turbines Iron & Steel Pulp & Paper Ciment Final energy Primary energy Primary Resources Importations Demands Energy flows E m i s s i

  • n

s

Energy Prices Study Optic

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SLIDE 6

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 6/25

…RES

Existing Technologies New Technologies

Residual Capacity Installed Capacity Emissions Demand Energy/ Matter

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SLIDE 7

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 7/25

…RES Steel Industry

Coke oven Electricity N Gas Sintring Pelletisation Blast Furnace Coal Oxy Converter SC Metallurg EAFurnace Heat COG Coke Lime Minerai de Fer Sinter Pellet Nitr Oxyg BFG BFHM Scrap Oxyg BOFG Liquid Steel Nitro Oxyg SCM Liquid steel Oxyg DRI C Cast Cold Roll Hot Roll Others Opert° CRP Steel HRP Finished products

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SLIDE 8

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 8/25

…RES Paper Industry

COA WOO ELC HTH RCYPPR PLPIMP BLiquor ELC GASNAT FOL HTH

Boiler Plant Cogen Plant Turbine Plant Specials Paper Corrugated Paperboard Domestic & sanitary paper Mechanical Pulp Chimical Pulp

HYD

Demand Sc PRICE SC Recycled Pulp Mi-Chimical Pulp ThermoMecha- nical Pulp Graphic Paper Packaging Paper Corrugated Paper Paper Board

HTH BIO

VCFM Pulp

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SLIDE 9

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 9/25

RES

Existing Technologies New Technologies

Residual Capacity Installed Capacity Emissions Demand Energy/ Matter

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SLIDE 10

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 10/25

…Steel Routes Production

Ore Sinter/Pellet Coke oven Blast Furnace Pig Iron OH Furnace Oxyge n Oxygen Converter Steel Hot Rolling Cold Rolling Finition Scrap Electric Furnace Continuous Casting Lime Coal Direct Reduction DRI Smelting Reduction SR ELYSIS Products Iron Ore Pellet Iron Ore Alkaline Electrolysis Iron Ore PLYSIS Pyro electrolysis Iron Ore

BF Route EAF Route

DR Route SR Route A-Electrolysis P-Electrolysis Bases Futures

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SLIDE 11

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 11/25

… Steel Industry Available Technologies

Identified technologies

BF Route EAF Route New Routes Sintering Coke Oven Blast Furnace Comelt EAF Contiarc EAF Direct reduction Smelting Reduction A-Electrolysis Pyroelectrolysis Midrex HYL III Stm Ref Hydrogen Electroly Hydrogen Corex CCF HIsmelt Arex Finmet Dios AISI Romelt EOS Direct Coal Injection CO2 Sequestration & Storage Electric Blast Furnace CDQ Heat recovery

Continuous Casting

Thin Slab Casting Spray Casting Thin Strip Casting

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SLIDE 12

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 12/25

… Paper Industry Available Technologies

Identified Technologies in the Pulp & Paper Industry

Pulp production Paper Production Chimical Pulp Mecanical Pulp Airless Drying Dry Sheet Forming Press Drying Condebelt Drying Impulse Drying Optimised Chimicalpulp TMPulp CTMPulp BiOPulping Thermopulp Enzyme Aidded Refiner Air Impingement Drying Steam Impingement Drying Optimisation

  • f Drying

Ameliored Press Section Enclosing

  • f Hoods
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SLIDE 13

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 13/25

…Scenarios

Business as usual High Environmental Constraints

CO2 Prices

Industrial demand growth

Energy Prices

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SLIDE 14

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 14/25

In the Iron & Steel industry the demand scenario is a final steel product scenario, with stability until 2015 and a 1%/year growth up to 2030.

…Demand Scenario

CTP Demand Scenario by product (%) 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 2001 2004 2007 2010 2013 2016 2019 2022 2025 2028 Graphic Ppr Corrugated Ppr Special Ppr Packaging Ppr Ppr Board Corrugated Ppr Board Domistic & Sanitary Ppr

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SLIDE 15

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 15/25

…Scenarios

Business as usual (BAU) High Environmental Constraints

CO2 Prices

Industrial demand growth

Energy Prices

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SLIDE 16

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 16/25

…Price Scenario BAU

Demand scenario key indicators

0.5% 2.2% 1.7% 0.9% 2.9% 2.0% 1.3% 3.5% 2.2% 8.9 164 090 18 513 8.1 105 930 13 107 6.8 59 524 8 764 6.1 42 224 6 907 5.2 29 880 5 697 Population (Billions) GDP (MEURO) GDP per capita (EURO) 2030/5 2010/30 1990/10 Growth (%/an) 2050 2030 2010 2001 1990 Key Indicators Energy prices Trend SC (/MWh) 0.000 10.000 20.000 30.000 40.000 50.000 60.000 70.000 80.000 2001 2003 2006 2009 2012 2016 2020 2025 2030 Oil N Gas Coal Electricity Biomass

BAU CO2 Taxe in the Trend Scenario (Euro/t) 5 10 15 20 25 2003 2005 2007 2010 2013 2016 2020 2025 2030 BAU

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SLIDE 17

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 17/25

…Scenarios

Business as usual (BAU) High Environmental Constraints

CO2 Prices

Industrial demand growth

Energy Prices

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SLIDE 18

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 18/25

…Price Scenario High Env Const

Energy price evolution (/MWh) High SC 0.000 10.000 20.000 30.000 40.000 50.000 60.000 70.000 80.000 90.000 2 1 2 3 2 6 2 9 2 1 2 2 1 6 2 2 2 2 5 2 3 Fioul Gaz Naturel Charbon Electricité Biomasse

Demand scenario key indicators

0.5% 2.2% 1.7% 0.9% 2.9% 2.0% 1.3% 3.5% 2.2% 8.9 164 090 18 513 8.1 105 930 13 107 6.8 59 524 8 764 6.1 42 224 6 907 5.2 29 880 5 697 Population (Billions) GDP (MEURO) GDP per capita (EURO) 2030/5 2010/30 1990/10 Growth (%/an) 2050 2030 2010 2001 1990 Key Indicators

CO2 Taxe in the High Env Const scenario (Euro/t) 10 20 30 40 50 60 70 80 90 100 2003 2006 2009 2012 2016 2020 2025 2030

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SLIDE 19

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 19/25

…Paper production by technology in the BAU Sc

G raphic paper production profile by technology (Mt) 1 2 3 4 5 6 7 8 9 10 2001 2003 2006 2009 2012 2016 2020 2025 2030

Impulse Dryer Process Condensing Belt Dryer Process Conv entional Processes

Packaging paper production profile by technology (Mt) 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 2001 2003 2006 2009 2012 2016 2020 2025 2030

Press Drying Process Impulse Dryer Process Condensing Belt Dryer Process Airless Drying Process Conventional Processes

Pulp production profile by technology (Mt) 5 10 15 20 25 2001 2003 2006 2009 2012 2016 2020 2025 2030

Chimical pulp (New) Recycled pulp (New) Thermomechanical pulp (New) Enzym-Aidded Refiner Thermomechanical pulp (Base) Recycled pulp (Base) Mechanical pulp (Base) Chimical pulp (Base) Mi-Chimical pulp

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SLIDE 20

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 20/25

… Steel production by technology

Iron and Steel production profile in the high scenario (Mt) 5 10 15 20 25 30 2003 2005 2007 2010 2013 2016 2020 2025 2030

Blast Furnace Conventional EAF Contiarc EAF Hismelt Process

Iron and Steel production profile in the BAU scenario (Mt) 5 10 15 20 25 30 2003 2005 2007 2010 2013 2016 2020 2025 2030

Blast Furnace Conventional EAF Contiarc EAF Hismelt Process

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SLIDE 21

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 21/25

…Pulp & Paper Energy Consumption

Energy Consumption ratio in the pulp production 20 40 60 80 100 120 2001 2003 2006 2009 2012 2016 2020 2025 2030 Electricity Heat Energy Consumption ratio in the paper production 20 40 60 80 100 120 140 2001 2003 2006 2009 2012 2016 2020 2025 2030 Electricity Heat

Biomass consumption (TWh)

5 10 15 20 2001 2003 2006 2009 2012 2016 2020 2025 2030 SC High SC Trend SC BAU

Hard Coal consumption (TWh)

5 10 15 20 2001 2003 2006 2009 2012 2016 2020 2025 2030 SC High SC Trend SC BAU

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SLIDE 22

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 22/25

… Iron & Steel Energy Consumption

Electrcity consumption by scenario (TWh)

10.5 11 11.5 12 12.5 13 13.5 2003 2005 2007 2010 2013 2016 2020 2025 2030 BAU scenario High Env Scenario

Energy consumption ratio in the electric steel route

20 40 60 80 100 120 2003 2005 2007 2010 2013 2016 2020 2025 2030 Electricity Natural Gas

Energy consumption ratio in the blast furnace route

20 40 60 80 100 120 2003 2005 2007 2010 2013 2016 2020 2025 2030 Electricity Coal

Hard Coal consumption by scenario (TWh)

38 40 42 44 46 48 50 52 54 2003 2005 2007 2010 2013 2016 2020 2025 2030 BAU scenario High Env Scenario

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SLIDE 23

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 23/25

…CO2 Emissions by Industry

Paper CO2 Emissions (Mt)

2 4 6 8 10 12 2001 2003 2006 2009 2012 2016 2020 2025 2030 BAU Scenario High Env Scenario

Iron and steel CO2 Emissions (Mt)

5 10 15 20 25 30 35 2003 2005 2007 2010 2013 2016 2020 2025 2030 SC Trend SC High

SC BAU

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SLIDE 24

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 24/25

…Conclusions

The energy savings remain exist in the industry.

The results show that:

  • The emergence of the Enzyme aided refining and the new thermo-mechanical pulp process; allow electricity saving in

the mechanical pulp production of about respectively 100kWh/t and 90kWh/t.

  • The appearance of some new drying processes like the impulse dryer process in the paper production permit an

increase of about 23% in the electricity consumption and 31% decrease in the heat consumption.

  • The upraise of the Contiarc EAF in iron and steel industry allowed less electricity consumption in the electric arc

furnace route of about 40%.

  • The HISmelt process reduces both the coal and the electricity consumption by about respectively 20 %, 10% and

permits less CO2 emissions in blast oxygen furnace route.

  • However, at 93 euro/tCO2 in 2030, the huge investments needed for Alkaline electrolysis or Pyroelectrolysis can not

be justified though such processes emit no CO2.

  • These two sectors do not react in the same manner in terms of this environmental constraint: the manufacturing

processes in the iron & steel industry are much more influenced.

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SLIDE 25

4-9 June Colle sur Loup

  • A. Djemaa

EDF R&D / CMA, ECEEE Summer Study 2007 25/25

Thanks for your attention