Energy efficiency potential in Thailand`s iron foundries

Transcription

Exportinitiative Energieeffizienz
Energy efficiency potential in
Thailand's iron foundries
Report on the experiences from the project “Capacity Development
for Increasing of Energy-Efficiency in Medium Sized Enterprises”
Focus: Energy Efficiency and Best Available Techniques
Konrad Mair, Dipl.-Ing.
Government of Upper Bavaria, Munich
Head of Department “Environmental Protection,
Public Health and Consumer Protection”
www.efficiency-from-germany.info
giz
Energy Efficiency in SMEs
PSortner für Perspektiven,
Weltweit.
The Programme
•
The International Climate Initiative of the German Federal Ministry for
the Environment, Nature Conservation and Nuclear Safety (BMU)
•
In 2008/09 the German-Thai Climate Initiative has started
•
GIZ implemented 3 projects
1.
Development and Implementation of Climate Protection Policy in Thailand;
Partner: Ministry of Natural Resources an Environment (MoNRE), Office of
Natural Resources and Environmental Policy and Planning (ONEP)
2.
Capacity Development for Increasing of Energy-Efficiency in
Medium-Sized Enterprises;
Partner: Ministry of Industry (MoI), Department of Industrial Works
(DIW)
3.
Dissemination of Experiences in the Implementation of Climate Protection Policy
in the Nature-Oriented Tourism;
Partner: Designated Areas for Sustainable Tourism Administration (DASTA).
Workshop: Energy Efficiency in Thailand‘s Industry - Statement Mair
Frankfurt, 26th June 2012
2
1
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Weltweit.
Goal of the project
Reduction of climate affecting emission through the
improvement of energy efficiency in medium-sized
enterprises. (Industrial enterprises in production and
manufacturing)
Target groups
• Thai Administrative Offices
• Thai Industrial Associations
• Unit operators of Medium-Sized Enterprises
• Consulting firms in the energy and environment sector
• Education and training institutes and universities
giz
3
Weltweit.
Project’s Objectives and Services
•
Elaboration of a Guideline on Best Available Techniques for 5 industrial
sectors
Ferrous Metal Casting Industry
Glass Manufacturing Industry
Textile Industry: Dyeing and Finishing
Secondary Aluminium Industry
Canned Food Industry
•
Ad hoc advice and recommendations during On-Site Visits
•
Pilot installation
•
Consultations with stakeholders on the side of the operators and
administrations on Best Available Techniques for Environment and Energy
Efficiency
•
Curriculum for Trainers
•
Train the Trainers; Train the SMEs
4
2
giz
Weltweit.
Expected Results/Effects
•
New forms of organisation and sponsor structures of the facility
(Centre of Energy and Environment for Thai Industry)
•
Improvement of the consultation service for the medium-sized
enterprises
•
Improvement of economic relation between Thai and German
•
Reduction of greenhouse gas emission through the
implementation of energy efficient measures and Best Available
Techniques (BAT) in medium-sized enterprises
•
Recommendations for improvement of administrative processes
and procedures (permitting, monitoring, inspection)
giz
5
Weltweit.
Guideline Ferrous Metal Casting Industry
Table of Contents – Main Chapters
1.
Introduction
2.
Basic Processes – Ferrous Metal Casting
3.
Resources
4.
Energy Efficiency
5.
Environmental Impacts and Measures
6.
Safety
7.
Annexes
6
3
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Weltweit.
Training: Ferrous Metal Casting Industry
1. Introduction
2. Basic Processes – Ferrous Metal Casting
3. Resources
4. Energy efficiency
4.1 Energy Management
4.2 Process specific measures
4.3 General measures – cross-sectional technologies
5. Environmental Impacts and Measures
6. Safety
7. Annexes
giz
7
Weltweit.
Energy consumption in German ferrous metal foundries
- kWh/to good casting -
others
compressed air
process
heating
Energy consumption total
2637.46 kWh/to good casting
8
4
giz
Weltweit.
General Impression
•
Production procedures in Thai foundries are similar to German
foundries
•
Great interest and understanding of the operators as well as of the
civil servants and consultants to modern technology
•
Energy efficiency is becoming increasingly important – great
interest in forward-looking technology
•
Main interest is currently focused to casting quality and competitive
costs
•
Automation is not yet in focus
•
Environmental performance depends on the company's philosophy
giz
9
Weltweit.
Potential – Energy Efficiency
• Energy Audit
o No results of audits were reported
• Energy Management System (EnMS)
o Hardly respectively not implemented
(EN 16001, ISO 50001)
• Energy consumption
o Generally no separate department gathering
Good chance for Consultants
•
implementation of the results regularly brings of cost saving and
•
benefits for environment protection
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5
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Weltweit.
Potential – Energy Efficiency – production units 1
• Main consumer:
Melting Process (50 – 60 %)
• Predominantly use of induction furnaces
• Production of GG and GGG
• Energy consumption
o Theoretically:
390 kWh/t casting
o High performance induction furnace:
600 kWh/t casting
o Examples:
780, 980 – 1130, 500 – 530 kWh/t
Great potential for improvement
giz
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Weltweit.
Potential – Energy Efficiency – production units 2
• Induction furnaces
o Great chance for modern medium frequency technology
combined with process control technology
connected with
o BAT technology:
cover extraction (or swing aside hood) plus fabric filter
• Ladle management (10 – 15 % energy consumption)
o Till now hardly focused
12
6
giz
Weltweit.
Potential – Energy Efficiency – cross sectional technology
• Compressed air systems
• Electric motors and motor systems
• Illumination
• Air conditioning
• Air ventilation systems
Potential for improvement:
Electric motors
giz
13
Weltweit.
Summary
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The Ferrous Metal Casting Industry produces in a wide range
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Knowledge on production procedures is very high
•
To be in compliance with national emission limit values is of course
•
Basics how to improve energy efficiency should be known
•
Improvement of energy efficiency and environmental performance
always is hand in hand
•
The demand for consulting and investment to improve the energy
efficiency and to keep BAT in the Ferrous Metal Casting Industry is
estimated to be high
•
Even if the industry was invited to all of our project workshops, the
guideline should be presented once more to the Ferrous Metal
Casting Industry
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Energy efficiency potential in Thailand`s iron foundries

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