Industrial Insulation: Energy and CO2 savings potential in EU27

25.04.2013

EiiF Presentation

European Industrial Insulation Foundation

www.eiif.org

25.04.2013

EiiF presentation for

European Industrial Insulation Foundation www.eiif.org

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EiiF European Industrial Insulation Foundation

Who is EiiF? Independent and non-profit Foundation Registered in Emmen (Luzern) with offices in Gland (near Geneva), Switzerland

Article 2 Purpose of the foundation

The Foundation engages itself throughout Europe, exclusively and irrevocably, on a non-profit basis for the deployment of sustainable insulation systems in industrial plants and in the industrial environment with the aim of saving energy, reducing CO2 emissions and realizing the best possible noise and fire control systems.

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We Power Sustainability

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Sour

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EiiF strategy to stop energy losses

Proof (facts & figures) • EU-Study • Best practise examples

Building Awareness (awareness & knowledge) • Communication • Coordination & networking

TIPCHECK Programme • TIPCHECK engineers • TIPCHECK audits

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Split responsibilities between: Project manager, Maintenance manager

Maintenance budget

Additional investment in insulation

Energy Costs

Energy budget

Invest only once

Save every year!

Split responsibilities & budgets

Energy Manager CEO & CFO

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EU-Study: Climate protection with rapid payback

Current (A) Cost-effective (B) Energy-efficient (C)

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Result: 620 PJ Energy Savings Potential

The annual cost-effective savings potential is 620 PJ

= Energy consumption of the entire Dutch industry.

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The annual cost-effective savings potential is 620 PJ

= The Energy consumption of

10 million households

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In return 15 coal-fired power plants of 500 MW could be switched off

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Result: 49 Mt CO2 Reduction Potential

The annual CO2 reductions potential is equivalent to the emissions of 18 million middle class cars (running 12 500 kilometres per year)

18 million cars

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No Limits

The savings potential exists across all: • Regions • Sectors • Equipment • operating temperatures.

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Attractive payback times

Uninsulated and damaged parts offer attractive payback times: Payback times are typically less than one year (life time = 15 years)

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One-time Investments offer high annual Savings

3.5 billion euro 900 million euro

Insulating bare surfaces to cost-effective levels and repairing damaged insulation would save about 460 PJ = about 75% of the entire Savings Potential One time investment: High annual Savings:

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Quick Calculation of typically un-insulated parts

Size Heatloss

Bare pipe 25 mm 80 mm ∆ bare, 80mm ∆ 25 mm, 80 mm ∆ bare, 80mm / ∆ 25 mm, 80 mm

[inch] [W/m] [W/m] [W/m] [W/m] [W/m] [-] 8 2657 220 92 2565 128 20 10 3197 281 111 3086 170 18 12 3664 297 127 3537 170 21

Savings potential of insulating un-insulated vs. improving existing insulation (25mm)

approx. 20 times higher

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Quick Calculation of typically un-insulated parts Achievable savings

Size Insulation Thickness

specified

Energy saving

CO2-emission reduction

Total saving

[inch] [mm] [W/m] [kg/m/a] €/a 8 80 2565 5133 700 10 80 3086 6140 825 12 80 3537 7078 950

Calculation for Singapore average weather conditions (Source: NEA Meteorological Services) Temperature medium: 200 °C Ambient temperature (annual average): 27.2 °C Wind velocity: 2 m/s Steam generation efficiency: 75 % Price of energy: 8 €/GJ Trading value CO2-emissions: 7 €/tonne

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Quick Calculation of typically un-insulated parts How many un-insulated parts do you have on your plants?

Nr. of items X 800,- € = large savings 500 X 800,- € = 400’000,- €

Size Insulation Thickness

specified

Energy saving

CO2-emission reduction

Total saving

[inch] [mm] [W/m] [kg/m/a] €/a 8 80 2565 5133 700 10 80 3086 6140 825 12 80 3537 7078 950

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TIPCHECK Standard

TIPCHECK = Technical Insulation Performance Checks A. Standardised energy auditing tool to evaluate

industrial insulation systems with the aim to improve the energy efficiency of industrial processes -> standardized TIPCHECK audits

B. Qualification programme for Insulation engineers -> certified TIPCHECK engineers (Minimum Requirements: 4 years experience, university degree in engineering, ability to calculate & design industrial insulation systems, EiiF member, participate in one week training course, pass test, refresh certificate every 3 years)

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Missing insulation to protect cold processes

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Proof Best Practice examples Cold

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Typical situation onsite

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TIPCHECK examples

Chemical Plant in France

Key facts: • 1 employee equiped with a thermografic camera • 2 weeks on-site • 400 pictures taken and used for the audit report

Key findings:

• Safety: Burn risk due to missing insulation • Financial: Money savings due to reduced energy loss • Energy Efficiency: Energy/heat loss

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TIPCHECK example: Chemical Plant, France

Non-insulated parts of equipment: Detected burn danger: Surface temperatures above 280°C bare a great risk of severe burn injuries for staff Proposed insulation solution: Installment of mattress insulation to assure surface temperatures below 50°C Action: About 30 similar valves were identified and insulated

Key findings - Safety

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Key findings – Energy Efficiency

1. Storage tanks 35 Storage tanks with uninsulated roof tops Surface approx. 28m2

Temperature of stored liquids: 150˚C Unnecessary energy loss per year approx. 12.000 MWh 2. Valves 30 Uninsulated valves (see Safety): Internal temperature: approx. 300 °C Unnecessary energy loss per year approx. 600 MWh

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Savings potential: Total unnecessary annual energy loss (valves+tanks): approx. 12.600 MWh Total annual financial saving potential (4ct/kWh): approx. 505.000 EUR Investment: TIPCHECK: approx. 10.000 EUR Insulation instalment and material costs: approx. 90.000 EUR Total investment: approx. 100.000 EUR Payback time: approx. 2,4 months

Key findings – Financial

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TIPCHECK example: Refinery, Italy

Refinery in Italy Doubling the insulation thickness and using better material cut the heat losses in half. Energy Savings: 1.021.958 kWh/a Financial Savings: 75.000,00 EUR Payback time: 1-3 years* *The new insulation system had to improve the fire protection, which lead to more expensive materials than those that would have been used for energy efficiency only. This higher investement extended the payback in this example from 1 to 3 years.

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TIPCHECK example: Processing plant, Germany

• Tube, ferritic steel, thickness: 5 mm • Width 1,70 m • Depth 0,760 m • Hight 26 m • Surface 127,92 m2

• Average heatprice 0,033 €/kWh • Operating hours: 1‘500

• Insulation investment 12.792 EUR • Energy savings 1.450 MWh/a • Financial savings 47.800 EUR/a • Payback time < 3 months

Insulation of an asphalt boiler in Germany

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TIPCHECK

Your Savings Potential

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How does a TIPCHECK contribute to our Sustainability programme?

FAQ

– Insulation is the first step of initiating measures to reduce energy loss, CO2 emissions and contribute to a cleaner environment

– Besides energy savings potentials insulation offers significant life-cycle cost reduction potentials

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FAQ

Why should we start to insulate un-insulated fittings, valves, flanges, etc.?

– EiiF study has proven that by insulating bare surfaces we can reduce up to 95 % of our energy losses and significantly reduce CO2 emissions.

– We all care about the environment; this is an important step to tap into the energy savings potential of industrial insulation.

– Insulation investments usually have a payback period of less than one year.

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How do we approach this energy efficiency programme?

FAQ

– Our certified TIPCHECK engineers will analyse the present situation and come up with a road map to energy savings.

What steps need to be taken in order to implement the road map to energy savings?

– Our certified TIPCHECK engineers will work closely with all stakeholders including production, plan/asset integrity, site maintenance, mechanical, energy management, etc. to define the correct implementation and execution strategy for your facility.

How long will it take? – The duration of the project depends very much on the size and scope.

Therefore a detailed project plan will be set up according to client’s needs.

FAQ

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What is the impact on daily operations?

FAQ

– By working in close conjunction with all relevant stakeholders we will mitigate disruption.

– The work is non-intrusive and all measurements or changes can be done on fully operational units and therefore will not interfere with on-going production.

What are the technical and operational challenges we’ll have to deal with? – How to detect and control leaks from valves and flanges? – How to insure mechanical integrity (e.g. bolts tensioning, mechanical design

temperature limits) of newly insulated parts? – How to avoid water ingress? – How to insure mechanical rigidity of insulation covers?

These topics will be addressed in close conjunction with the maintenance and operations department by the TIPCHECK engineer and his company.

FAQ

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What is expected from everyone working on site?

FAQ

– A careful and professional handling of insulated systems in order to ensure energy savings

What are the advantages for associates?

– An even safer working environment by substantial reduction of cold or hot hazardous surfaces

– Better working conditions due to reduced heat radiation

– Personal contribution to a cleaner environment

FAQ

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Summary

The Savings Potential of Industrial Insulation is

This Savings Potential is highly

The Savings Potential can be

large

cost-attractive tapped today

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European Industrial Insulation Foundation Avenue du Mont-Blanc 33 1196 Gland (Geneva) Switzerland Andreas Gürtler Foundation Director t: +41 22 99 500 - 70 f: +41 22 99 500 - 71 m: +41 78 69 63 662 e: [email protected]

www.eiif.org

EiiF Contact

Technology

Industrial Insulation: Energy and CO2 savings potential in EU27