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Copyright Siemens Siemens LTDA AG 2010. 2010.All All rights rightsreserved. reserved
Fonte: ABRACE
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Maio-10
Industrial Technologies
Fonte: ANEEL
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Maio-10
Industrial Technologies
4,7% a.a.
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Maio-10
Industrial Technologies
Potencial de Economia
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Maio-10
Industrial Technologies
AT Kearney 2007 *total costs incl. duties and taxes excl. VAT
Legal obligation for the reduction of CO2 (greenhouse gases) Participation to C02 trading Monitoring and reporting with regards to greenhouse gas emissions pursuant to regulation 2003/87/EG (Monitoring und Reporting)
New laws and general agreements for industrial power station operators (Renewable Energy Act, etc.) Increase the share of renewable energy about 12.5% till 2010 in Germany
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Maio-10
Industrial Technologies
Como economizar?
Potenciais de economia devem ser explorados no s atravs de aes TCNICAS, mas tambm Comportamentais e Organizacionais.
Preo
Tcnica
Comportamental
Consumo
Organizacional
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Maio-10
Industrial Technologies
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Descrio Entrevista com pessoas chave no cliente (3h) Utilizao de software especialista dedicado Anlise rpida do grau de desenvolvimento da empresa
Benefcios Base slida para estimativa das metas Principais pontos de melhoria Benchmarking internacional por segmento (base de dados com mais de 2000
empresas no mundo)
Produtos e Solues
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Maio-10
Industrial Technologies
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Produtos e Solues
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Maio-10
Industrial Technologies
Fases
Orientao
Anlise
Viabilidade
Conceito de implementao, ROI e viabilidade
Energy Optimization Services (EOS)
Energy Improvement
Produtos e Solues
Implementao
Technical Realization Validao
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Maio-10
Industrial Technologies
UTILIDADES
ETA / ETE
Energia Eltrica
FOX
Motores
Gases
LAMINAO
ACABAMENTO Coqueria Sinterizao Etc..
Energia Trmica
Subestaes Vapor
Etc..
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Maio-10
Industrial Technologies
Auxiliary plants
COREX FINEX
Coking Coal Coke oven gas Coke Sinter BFG
Scrap
Oxygen, etc.
Molten steel
Hot rolled products
Coke oven
Ore Hot metal
Ladle Furnace
Sintering plant Hot stove Blowers VVVF Automation Waste gas recycling Waste heat recovery Blast furnace
Continuous Caster
Reheating furnace
Hot rolling
Cold rolling
Processing Lines
Balanced drive operation Dry dedusting Waste heat recovery BOF gas recovery Process Optimization
ESP
ISP/ESP1 Demand-driven utilization of ancillary unit
Efficient Energy Supply, Net Optimization Energy Management & Control Systems, Cross Process Optimization
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Maio-10
Industrial Technologies
Blast Furnace
Power Plant
Gas-mixing Station
Steel Plant
Oxygen Plant
supply
Other Consumers
Coke Oven Gas Mixed Gas Converter Gas Blast Furnace Gas Natural Gas Steam Electrical Power
I IS IN OLM MS
Copyright notice
Measure
Preventive maintenance (equip., measurements, cond. monitoring) Coking process management system Low emission wet cooling (CWQ) or dry cooling (CDQ) Blowers VVVF (variable voltage variable frequency) Sinter expert system (Sinter Vairon) Waste gas recycling and waste heat recovery (process heat) XPS Vairon hot stoves incl. stove combustion controls Top gas pressure recovery turbine to produce power Stoves heat exchanger BF Expert system (BF Vairon) DDS "dry process" instead of wet dedusting process CO-gas recovery Zero waste concept (ZEWA, CONTOP) Preheating of feed material (use of off-gas) Modern, efficient furnace (EAF Ultimate) Online Tools Slag Manager Online Tools Laser Off-gas Analyzer for Shaft Furnace Online Tools EAF: Contact less temperature measurement Drive efficiency (main drives) Hot/direct charging, online implementation Drive efficiency (main and auxiliary drives) Roll gap lubrication Drive efficiency (main drives) Various E&A Furnace
10
2
2 2
EU-15
Eastern Europe
CIS
India
China
NAFTA
1. Investment values do not vary significantly across regions, since mainly engineering costs 2. All regions payback > 10 years Source: Team Page 14 analysis
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Industrial Technologies
Top performers
Coking Sintering Iron-making (BF) Steel-making (BOF) Casting
(CC)
Current situation
Local competitor
~7.7
~3.5
~1.5
~14.8 ~0.2 ~0.1 ~1.6 ~0.3 ~1.1
~3.3
Hot rolling
(HSM)
?
Siemens Energy Optimization
~22.2 ~0.7 ~0.3 ~3.6 ~0.6 ~2.4 Additional energy usage for low performers
Cold rolling
Finishing
Top performers
Different plant preconditions (size, input materials etc.) to be taken into account when comparing different sites
1. Not accounting for outdated technology, such as open hearth and ingot casting Source: SVAI, BCG
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22 September 2011
I IS IN OLM MS
Copyright notice
Fases
Orientao
Anlise
Viabilidade
Conceito de implementao, ROI e viabilidade
Energy Optimization Services (EOS)
Energy Improvement
Produtos e Solues
Implementao
Technical Realization Validao
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Maio-10
Industrial Technologies
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Produtos e Solues
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Maio-10
Industrial Technologies
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Descrio Priorizao das medidas para estudo detalhado Detalhamento e ajuste fino dos potenciais de economia e respectivos investimentos (detalhamento do ROI). Anlise da viabilidade tcnica em conjunto com os fornecedores Planejamento e programao coordenada com a produo e manuteno
Benefcios Estudo detalhado de viabilidade tcnica e econmica Clculo detalhado do ROI Visualizao das oportunidades reais de economias de energia Propostas reais para implementao das solues (Siemens / outros fornecedores) Metodologia Experincia em Gerenciamento de Projetos (PM@Siemens) Network global de especialistas
Industrial Technologies
Produtos e Solues
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Maio-10
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Estimativa de incio dos ganhos como input para melhoria dos contratos de fornecimento de energia
Plano Global para Economia de Energia
Forecast of the evolution of the energy savings
EUR 100.000,00 EUR 700.000,00 EUR 80.000,00 EUR 600.000,00 EUR 500.000,00 EUR 60.000,00 EUR 400.000,00 EUR 40.000,00 EUR 300.000,00 EUR 200.000,00 EUR 20.000,00 EUR 100.000,00 EUR 0,00 EUR 0,00
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17 .0 3 24 .04 .0 3 31 .04 .0 3 07 .04 .0 4 14 .04 .0 4 21 .04 .0 4 28 .04 .0 4 05 .04 .0 5 12 .04 .0 5 19 .04 .0 5 26 .04 .0 5 02 .04 .0 6 09 .04 .0 6 16 .04 .0 6 23 .04 .0 6 30 .04 .0 6 07 .04 .0 7 14 .04 .0 7 21 .04 .0 7 28 .04 .0 7 04 .04 .0 8 11 .04 .0 8 18 .04 .0 8. 04
Date
Cumul projects
Cumul pre-projects
Industrial Technologies
Produtos e Solues
EUR 120.000,00
Fases
Orientao
Anlise
Viabilidade
Energy Improvement
Descrio Implementao tcnica dos projetos de acordo com planejamento conjunto (Siemens
x Empresa x Outros Fornecedores)
Benefcios Transformao dos potenciais em economias reais Reduo das contas de energia e custos de produo
Produtos e Solues
Eficincia Energtica em
Motores Eltricos
2% 2% 13%
7% 4%
Industrial Sector
10%
48%
59%
20%
35%
Motors Heating Furnace Electrochemistry Lighting
Others
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Industrial Technologies
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Maio-10
Industrial Technologies
Quatro aes principais para economia Alternativas mais comuns e com ROI mais atrativo: 1. Controle de Velocidade. 2. Transmisso Mecnica. 3. Qualidade de Energia. 4. Carregamento do Motor.
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Industrial Technologies
~
H M
~
H
Vlvula de Controle
Slide 26 Maio-10
Controle de Velocidade
Industrial Technologies
PConsumida 44 % inferior
281% 265%
~ ~
158% 152% M
160% X 100%
Vlvula de Controle hV = 63 %
h1 = 38 %
142%
100%
Potncia til
Potncia til
hGlobal = 35 %
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hGlobal= 63 %
Industrial Technologies
Acoplamento Direto
Mtodo de maior eficincia (100%) Nem sempre podem ser utilizados!
Redutores
Eficincia reduzida Aplicaes especficas
Slide 28 Maio-10
Alternativa 3 Qualidade de Energia A qualidade de energia pode interferir na eficincia do motor de duas formas: 1. Desbalanceamento de Tenso.
VMAX = Tenso mxima entre fases VMIN = Tenso mnima entre fases
d% = VMAX VMIN 100 VMED
S
T
d% = 2,7%
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Maio-10
Industrial Technologies
Alternativa 3 Qualidade de Energia A qualidade de energia pode interferir na eficincia do motor de duas formas: 2. Distoro Harmnica.
Tenses e Correntes distorcidos Originada pelo chaveamento
THD =
V1
THD% = 8%
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Industrial Technologies
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Industrial Technologies
Ponto Crtico
90%
80%
70%
60%
50%
40%
30%
20%
10%
0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Carregamento
Industrial Technologies
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Industrial Technologies
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Maio-10
Industrial Technologies
Copyright Copyright Siemens Siemens LTDA Ltda 2006. 2010.All All rights rightsreserved. reserved
Controle de Velocidade
(Inversores de Freqncia)
30%
Carregamento do Motor
(% da carga nominal)
6%
Qualidade de Energia
5%
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Maio-10
Industrial Technologies
Analise as duas variveis da equao que define a PConsumida. Esta reduo pode ser obtida de duas formas distintas:
PConsumida =
Ptil
A instalao de Motores de Alto Rendimento contribui apenas para o aumento da eficincia. Diversas outras alternativas podem ser utilizadas para conseguir ganhos muito maiores.
Slide 37 Maio-10 Industrial Technologies
Temperatura do Ambiente#
3. 4.
Slide 38
Controle de Velocidade
(Inversores de Freqncia)
30%
Carregamento do Motor
(% da carga nominal)
6%
5%
Qualidade de Energia
5%
3%
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Maio-10
Industrial Technologies
Servios Tcnicos
Produtos
+
Servios Tcnicos:
=
Motores Energy-saving e inversores de freqncia:
Seus benefcios:
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Industrial Technologies
Fase 1
Maio-10
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Industrial Technologies
Cases
NLMK Metinvest Chia Far VOESTALPINE Arcelor Mittal Norddeutsche Affinerie AG Pasminco Budel Zink B.V. Aluminium Norf GmbH Schller Werke Thyssen Krupp Nirosta VOESTALPINE STAHL
Russia Ukraine Taiwan Austria Belgium Germany Netherlands Germany Germany Germany Austria
Energy study Energy check Energy management assessment Blast furnace energy system
2010 2009 2008 2008 2008 2007 2007 2006 2006 2006
Genk
Hamburg Budel Neuss Hellenthal Krefeld Donawitz
Energy study
Energieanalyse Energieanalyse Grobanalyse zur Energie- Einsparung Grobanalyse zur Energie- Einsparung Grobanalyse zur Energie- Einsparung
Metallurgical plant structure investigation (revamping 1996 study,energy balance) various heat & power systems in dependence on different steel production technologies (BF/BOF - vs. EAF)
OSTRAVSKO K. E.
Olomouc
Czech Rep.
Heat and power revamping study 32 MW power generation 327 MW heat generation machines and auxiliaries
1993
VOESTALPINE STAHL
Donawitz
Austria
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Industrial Technologies
NLMK Metinvest Chia Far VOESTALPINE Arcelor Mittal Norddeutsche Affinerie AG Pasminco Budel Zink B.V. Aluminium Norf GmbH Schller Werke Thyssen Krupp Nirosta
Russia Ukraine Taiwan Austria Belgium Germany Netherlands Germany Germany Germany
Energy study
2011 2009 2008 2008 2008 2007 2007 2006 2006 2006
Genk
Hamburg Budel Neuss Hellenthal Krefeld
Energy study
Energieanalyse Energieanalyse Grobanalyse zur Energie- Einsparung Grobanalyse zur Energie- Einsparung Grobanalyse zur Energie- Einsparung
Bindal
###
India
###
2011
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Industrial Technologies
Challenge
Siemens and the customer started a sustainability partnership program starting with combined energy and water audits and ending up with implementation projects
Solution
Integrated Approach to Integrate Water & Energy Solutions Solutions to meet current & future sustainability / operational needs Access Water & Energy Sector Best Available Technology Standardized Tools to Identify & Select Best Practices Global Capabilities Local Execution Energy savings: 1494 EUR/yr with a payback period of 3,9 years for all energy efficiency projects (48% of the saving potential have a payback 1 year) Water savings: 0760 Mio. EUR/yr with a payback period of 3,2 years for all energy efficiency projects (37% of the saving potential have a payback 1 year)
Environmental benefit
The customer want to reduce fossil fuel emissions by 50% per hl of beer by 2020, through improving Energy and water efficiency and increasing use of renewable energy.
Customer benefit
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Industrial Technologies
Challenge
BAT aims to reduce CO2 emissions by 50% until 2030 and 80% until 2050 compared with the 2000 value Reduce energy consumption by 6.7% to a max. of 11.03 GJ per million cigarettes equivalent until 2012 compared with the 2007 baseline Creating a higher energy awareness To define & realize energy saving projects Evaluation of energy efficiency and saving potential by means of an Energy Health Check conducted in Singapore; Germany; Russia Development of a corporate roadmap for internal energy assessments Piloting of the self assessment tool in two pilot plants in South Africa and Germany including a comprehensive Energy Analysis with an estimation of savings potential and necessary investments Energy saving potential identified in the EHCs between 5% and 15% Identified energy saving potential proved by technical measures Increased awareness regarding the of energy organizations improvement potential Development of a standard corporate energy assessment program to achieve synergies and communicate best practices within the plants
Solution
Environmental benefit
Reduced energy consumption and CO2 emissions through better utilization of the energy used and by creating awareness about energy issues
Customer benefit
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Industrial Technologies
The task
Leader in Latin America for thermoplastic resins and their related raw materials (ethylene, propylene, chlorine) Project developed at PVC plant.
Estimation of saving potential among 54 drive systems Measurements of operational parameters (Power Consumption, Power Quality) Evaluation of process requirements and design of solutions to reduce the overall energy consumption
The Solution
The Result
Identification of improvements for 34 systems Selection of concrete measures for improvements Overall Energy Saving Potential: 34%
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Industrial Technologies
The task
Quattor has 4 sites, 10 industrial plants and 13 production lines located in 3 Brazilian states, producing thermoplastic resins and their related materials (ethylene, propylene)
Agreement for optimization of drive systems, initially at 2 pilot plants
Initial estimation of saving potential for 2.430 drive systems from 7 plants Measurements and detailed analysis of 134 systems from 2 plants Recommendation of improvements and Calculation of Internal Return Rate for each measure
The Solution
The Result
Report with detailed evaluation and specific measures of improvement for implementation Overall Saving Potential of 17% and 23% on the selected plants
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Industrial Technologies
Potencial inicial de 15% de reduo no consumo de energia US$ 1.850.000,00 de reduo nos custos Payback da soluo de 2 anos Previso de economia at o final do perodo de explorao da mina: US$ 65 milhes
Desafio:
Altos custos de energia (230 USD / MWh) Sistema de gerao prprio (Geradores Diesel) Dificuldades logsticas para transporte de combustvel
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Industrial Technologies
Soluo
EHC Energy Health Check realizado em 3 sites para deteco dos aspectos crticos na matriz de gerenciamento de energia e benchmarking internacional
EPS Energy Potential Scan em 4 sites para anlise das alternativas para reduo do consumo de energia e reduo de custos
Benefcios
Potencial mdio de 35% de reduo nos custos de energia R$ 1.387.000,00 de reduo nos custos em 4 sites Realizao de Benchmarking Internacional para gerenciamento de energia
Desafio:
Detectar potenciais de reduo dos custos de energia Melhoria do Sistema de Gerenciamento de Energia Conscientizao de Usurios
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Industrial Technologies
Soluo
EHC Energy Health Check na fbrica de foges (So Paulo) para mapeamento dos aspectos crticos e benchmarking
Anlise de campo para identificao dos potenciais de reduo do consumo de energia e custos. Otimizao do sistema de combusto dos fornos Melhoria na eficincia dos sistemas de ar comprimido e motores eltricos
Benefcios
Potencial mdio de 12% de reduo dos custos e 13% de reduo do consumo de energia nas duas fbricas Reduo total no consumo de energia de 7.024 MWh / ano Realizao de Benchmarking Internacional para gerenciamento de energia na fbrica de foges
Desafio:
Alto consumo de energia eltrica e gs natural Inexistncia de estratgias para economia de energia de forma sustentvel Parque fabril com instalaes antigas e pouco eficientes Maio-10 Slide 53
Industrial Technologies
Soluo
Anlise detalhada de campo para identificao dos potenciais de reduo do consumo de energia e custos.
Otimizao do sistema de combusto dos fornos Melhoria na eficincia dos sistemas de ar comprimido e motores eltricos Eficincia dos sistemas de refrigerao
Benefcios
Potencial detectado de 9,2% no consumo de energia na fbrica do Rio de Janeiro e 3,8% de reduo dos custos para a fbrica de Recife. Reduo total no consumo de energia de 5.699 MWh / ano Entendimento de novas alternativas para economia
Desafio:
Reduzir o consumo de energia em duas unidades de produo de latas de alumnio e uma unidade de produo de tampas. Alto consumo de energia e gs natural em um processo de produo contnuo (24 x 7) (100.000 MWh/ano) Maio-10 Slide 54
Industrial Technologies
93
80% pela equipe internacional 4% Consultores
97
54% Engenheiros
7,1%
9,1% Unidades Industriais 35% - Prdios Comerciais
21,7%
8 % - Unidades Industriais
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Maio-10
Industrial Technologies