Kein Folientitel - Umweltbundesamt

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Transcript Kein Folientitel - Umweltbundesamt

Reduction of energy consumption by the
Austrian sugar factories in the period 1990 – 2002
T / TL / Merkl
Josef Merkl
AGRANA Zucker GmbH
A-3430 Tulln, Reitherstraße 21-23
Reduction of energy consumption by the
Austrian sugar factories in the period 1990 – 2002
 Introduction
 Manufacturing process for sugar production
 Energy consumption of Austrian sugar factories
 Measures to reduce energy consumption (1990 – 2002)
 Evaluation of energy requirements
T / TL / Merkl
 Evaluation of future savings potentials
Folie 2
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T / TL / Merkl
Manufacturing process for sugar production
Folie 3
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Process sections and energy consumptions

Section for sugar production
– Beet intake, beet storage, beet processing, juice extraction,
pulp pressing, juice purification including lime kiln, evaporation and
crystallization, sugar storage and shipping, boiler system for
steam production, turbines, water and waste water networks

Section for production of dried pulp
– Pulp drying station, pellet station and storage of animal feed

Energy consumption for sugar prodction
– Including power station
T / TL / Merkl

Energy consumption for pulp drying
Folie 4
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T / TL / Merkl
Heat distribution – Material separation system
Folie 5
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Energy consumption 1990 - 2002
Energy for sugar production
Energy for pulp drying
Logarithmisch (Energy for sugar production)
Logarithmisch (Energy for pulp drying)
100
[%]
90
80
73 %
70
T / TL / Merkl
Energy for sugar production: 100% = 912 MJ / t beets
Energy for pulp drying: 100% = 399 MJ / t beets
60
1990
1991
1992
1993
1994
1995
67 %
1996
[Year]
Folie 6
1997
1998
1999
2000
2001
2002
21.07.2015
CO2 – Emissions (Campaign)
CO2 - Emissions (Campaign)
Logarithmisch (CO2 - Emissions (Campaign))
110
100
[%]
90
80
69 %
70
T / TL / Merkl
CO 2-Emissions: 100% = 79.2 kg / t beets
60
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
[Year]
Folie 7
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CO2 – Emissions (Year)
CO2 - Emissions
Logarithmisch (CO2 - Emissions)
120
[%]
110
100
86 %
90
T / TL / Merkl
CO2-Emissions: 100% = 213,000 t / a
80
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
[Year]
Folie 8
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Electrical power consumption 1990 - 2002
Electrical power consumption
Logarithmisch (Electrical power consumption)
110
[%]
100
90
80
77 %
T / TL / Merkl
Electrical power consumption: 100% = 29.6 kWh / t beets
70
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
[Year]
Folie 9
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Survey AGRANA factories 1990 – 2002
Survey AGRANA factories 1990 to 2002
Denotation
Unit
Beet processed
[t/a]
Sugar content in beets
[% on beets]
Deviation
[2002]
2.508.525
3.043.398
21 %
18,5
16,5
-11 %
Sugar
[t/a]
414.579
432.871
4%
Dried pulp
[t/a]
165.172
178.309
8%
Average daily slice rate
[t/d]
25.569
36.768
44 %
98,1
82,8
-16 %
85.931
76.138
-11 %
4.746
0
-100 %
Campaign days
Natural gas
Heavy oil
[d]
[1000 Nm³/a]
[t/a]
Electrical power production
[MWh/a]
79.028
76.580
-3 %
Electrical power consumption
[MWh/a]
74.303
69.660
-6 %
Lime stone
[t/a]
87.171
63.759
-27 %
Coke
[t/a]
6.198
5.066
-18 %
[kg/100kg]
112,9
103,3
-8 %
[MJ/t beets]
912
610
-33 %
[MJ/t sugar]
5.520
4.289
-22 %
[kWh/t beets]
29,6
22,9
-23 %
Lime stone
[kg/t beets]
34,8
21,0
-40 %
Coke
[kg/t beets]
2,4
1,7
-31 %
[% DS]
27,6
31,4
14 %
[MJ/t beets]
399
291
-27 %
6.064
4.971
-18 %
198.747
165.606
-17 %
79,2
54,4
-31 %
[t/a]
212.905
183.514
-14 %
[kg/t beets]
Folie84,9
10
60,3
-29 %
Raw juice draught
Energy to sugar production
Electrical power consumption
Pressed pulp
Energy to pulp drier
[MJ/t DP]
CO2 - Emissions
T / TL / Merkl
Year
[1990]
(Campaign)
CO2 - Emissions
(whole year)
[t/a]
[kg/t beets]
21.07.2015
T / TL / Merkl
Sugar factory Hohenau
Folie 11
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Measures Hohenau factory 1990 - 2002
 Steam boiler and pulp drying converted to
natural gas operation (1990)
 New extraction tower (1991)
 Evaporation station renewed to a 6-stage operation
(1997)
 Waste heat utilization (1998 – 2000)
 New pulp presses
 Modernization of vacuum pans
T / TL / Merkl
 Modernization of juice purification (2001 – 2002)
Folie 12
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Sugar factory Leopoldsdorf
Folie 13
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Measures Leopoldsdorf factory 1990 - 2002
 Steam boiler and pulp drying converted to
natural gas operation (1990)
 Beet washing house (1991)
 Modernization of Evaporation station (1993)
 Optimization of juice purification (1994)
 Lengthening of an extraction tower (1996)
T / TL / Merkl
 New pulp presses (1997)
Folie 14
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Sugar factory Tulln
Folie 15
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Measures Tulln factory 1990 - 2002
 Steam boiler and pulp drying converted to natural gas
(before 1990)
 Optimization of slicing machines
 Evaporation station renewed to a 5-stage operation
(before 1990)
 Optimization sugar end and heat exchangers
 Reduction of lime utilization
T / TL / Merkl
 New pulp presses
Folie 16
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Benchmarking: Energy consumption for
sugar production (Südzucker-AGRANA-Group)
300
250
Energy for sugar production: 100% = 181 kWh / t beets
[%]
200
150
100
50
T / TL / Merkl
0
AT
DE
BE
FR
HU
CZ
SK
RO
PL
MD
[Country]
Folie 17
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Benchmarking values (by IPRO Industrieprojekte GmbH)
Energy for sugar production of the 15 top-factories in Western Europe 2001/2002
6.000
5.000
[MJ / t S]
4.000
3.000
2.000
1.000
5
N
r.
1
4
N
r.
1
3
N
r.
1
TU
1
N
r.
1
LE
O
N
r.
9
N
r.
8
N
r.
7
N
r.
6
N
r.
5
H
O
N
r.
3
N
r.
2
N
r.
1
ic
e
pr
ac
t
ar
ki
ng
Be
st
Be
nc
hm
T / TL / Merkl
0
[Factories]
Folie 18
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Benchmarking values (by IPRO Industrieprojekte GmbH)
Energy for pulp drying of the 20 top-factories in Western Europe 2001
6.000
5.000
[MJ / t DP]
4.000
3.000
2.000
1.000
Nr
.2
0
Nr
.1
9
LE
O
TU
Nr
.1
6
HO
Nr
.1
4
Nr
.1
3
Nr
.1
2
Nr
.1
1
Nr
.1
0
Nr
.9
Nr
.8
Nr
.7
Nr
.6
Nr
.5
Nr
.4
Nr
.3
Nr
.2
Nr
.1
Be
nc
hm
pr
ac
ar
tic
k
e
DS
33
%
[Factories]
Be
st
T / TL / Merkl
0
Folie 19
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T / TL / Merkl
Benchmarking of electrical power consumption
2002 (21 factories in 7 European countries)
Folie 20
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Benchmarking of electrical power consumption
2002
AGRANA
Benchmarking best
Benchmarking worst
Benchmarking average
15
[kWh / t beets]
10
T / TL / Merkl
5
0
Sugar production
Quelle: Zuckerindustrie 129 (2004) Nr. 6
Pulp drying
Environment
[Factory area]
Folie 21
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Evaluation of the future savings potentials
and their efficiency
 Hohenau
– Further modernization of the pulp press station
(33% DS) – investment costs recouped after 62 years
 Leopoldsdorf
– Increase of the evaporation station –
investment costs recouped after 38 years
 Tulln
T / TL / Merkl
– Enlarge extraction tower –
investment costs recouped after 23 years
Folie 22
21.07.2015