5.3.1 - THE CITY PROGRAMME PROJECTS
THE INDUSTRIAL SECTOR
t IND1 - Energy service companies in the industrial sector.
Objective: to improve the energy efficiency in the industrial sec-tor and stimulate a new market based on energy efficiency.
Description: to favour energy services outsourcing in the industrial sec-tor.
Many industries need energy assistance to take optimal advantage of their savings potential, along with helping them define future strate-gic lines of energy generation or of service outsourcing. In conjunction with the Zona Franca Consortium Services Platform, it is proposed to support companies with technical assistance, stimulating, at once, the entrepreneurial communication between energy supply companies and energy consumption companies.
t IND2 - Energy efficiency agreement with other entities in the in-dustrial sector.
Objective: to reach an agreement to integrate efforts in measures and incentives which will lead to energy efficiency in the indus-trial sector.
Description: establish an agreement with other entities on energy effi-ciency in the industrial sector to solve the following issues:
- Disseminating real energy saving experiences by means of energy efficiency or local generation in the sector.
- Promoting, from the Administration, the creation of an industrial energy efficiency promotional programme, with an “award” system, with real energy measure and specific reduction objectives. A wide variety of consultations to industries on “how they would do it” is proposed for two reasons: to design something that “fulfils” needs, and to get commitment and motivation.
- Reinforcing and consolidating already existing industrial advising programmes (for example, the ICAEN PAGE programme) to optimise communication with the industry and to capture the needs of each one of them, while adapting the Administration programmes and acts to the industries’ reality.
- Focusing efforts (promotion, incentives, information, subsidies…) on the installation of energy measuring devices and on the con-nection to the control panel that industries normally have, and on
recording the data regularly. What is measured can be reduced. This way, the energy efficiency measures evaluation would be evident to industries.
- Consolidating the Administration’s “energy manager” figure, offe-ring management tools and tools for “normalising” procedures to those responsible for the energy part of industry, as well as trying to “convince” top management on the importance of this figure and the need to have resources available as well as decision making power.
- Promoting the coordination between the different agents and im-prove the Administration’s role as a contact with the industries, to have one single spokesperson. This would prevent the risk of “ti-ring” the industry from happening, and would maintain its availabi-lity to cooperate.
t IND3 – Industrial sector energy efficiency management systems.
Objective: promoting energy efficiency to the industrial sector.
Description: the implementation of energy management systems in the industrial sector generates energy savings and process improvements.
It is proposed to develop a project that promotes these management systems as long as they are associated with specific energy reducti-on objectives and linked to the company’s strategy plan. Additireducti-onally, the management system should include the necessary measuring ele-ments to be able to energetically characterise the processes by diffe-rent zones.
It is proposed to increase the energy efficiency in the industrial sector in conjunction with the ICAEN and the Zona Franca Consortium Ser-vices Platform, by designing strategies to support these industries in becoming more energy efficient and therefore more competitive.
The implementation of EN 16001 can be encouraged as a support tool.
t IND4 - Increasing energy efficiency in production processes.
Objective: to improve the industrial sector production processes to reach lower levels of energy consumption and emissions with the same production.
Description: the overall analysed industries in the PECQ have an energy saving capability when improving the quality of the raw material that enters the production process and when applying process improve-ments. It is proposed, in conjunction with the ICAEN and the Zona Franca Consortium Services Platform, to design support strategies for the industries to become more energy efficient and therefore more competitive.
Some methods or methodologies to work on according to process type:
- Heat recovery from combustion fumes generated by certain equip-ment in some plants.
- PINCH Analysis: industrial plants have multiple needs concerning heat and cold. The use of process integration strategies can genera-te important improvements in the energy efficiency of these proces-ses. The Pinch Analysis, also known as process design Pinch method or Pinch technology, is a methodology to optimise energy recupe-ration in industrial processes by minimising the local investment.
This methodology includes optimising the thermodynamic linkage between the cold and heat flows in industrial processes.
The use of Pinch Analysis allows for greater energy savings than those obtained from conventional methods such as the heat recovery from gases escaping from furnaces, insulation and the steam trap manage-ment system.
t IND5 - Promoting cogeneration in the industrial sector.
Objective: to improve the energy efficiency in the industrial sec-tor and to increase the distributed energy generation.
Description: to promote the installation of cogeneration plants that give out useful heat, mainly to the different processes in the industry.
This type of project is technically and economically viable and is pre-sented as company investment.
Eventually, other modalities to develop the project, such as the Energy Service Company (ESC) model, could be evaluated.
t IND6 – Sludge drying for energy rationalisation
Objective: to make the most of a sub-product such as sludge to generate energy.
Description: certain industries with small wastewater treatment plants generate tonnes of sludge which could be used energetically as bio-mass or municipal solid waste if we had a drying system available. The analysis for real possibilities to implement drying systems in certain industries is brought up.
The proper management of such waste has the following advantages:
- Reduction of waste and savings when managing them.
- Production from a non-fossil fuel source.
Additionally, there are various options to make use of this biomass:
1. Biomass for self-consumption.
2. Biomass for sale.
SCENARIOS AND STRATEGIES FOR ACTION - BLOCK 5: STRATEGIES FOR ACTION - THE PROJECTS
t IND7 - Photovoltaic (PV) solar energy in industrial roofing.
Objective: to take advantage of available space with great solar absorption capability such as industrial roofing to produce energy.
Description: It is proposed to revitalise the potential of some solar roofs by using the administrative advice and support to facilitate the installa-tion of photovoltaic energy in certain industrial roofs, whether the roof is owned or rented, hence bringing about solutions to possible barriers such as the industrial land rental temporality and the PV system amor-tisation period.
Not only does this project offer energy generation and CO2 emissions reduction, but it also carries an important corporate image aspect to it. In addition, it can be integrated at the electric car recharging si-tes, quite a current issue. Some companies have already evaluated the available roofs, estimating a very high average installable total power.
This project is also related to other PECQ projects in which it is propo-sed to reduce photovoltaic solar installation implementation formali-ties.
t IND8 - Separation of coloured and clear bottles to improve septic performance
Objective: to improve the performance of companies which melt bottles to make glass.
Description: it is proposed to install, in the bottle recycling process, a machine that separates clear from coloured bottles and, this way, reach an energy efficiency increase in the process of melting glass for recycling purposes.
In glass manufacturing, raw material is melted and said material reacts to form glass. The introduction of recycled material in the raw material lowers the specific glass production energy.
t IND9 - The energy savings in painting booths in small/medium size auto body shops.
Objective: to encourage energy efficiency in auto body shops and car paint shops by using a new technological system adaptable to conventional booths.
Description: Energy efficiency in auto body shops and car paint shops can be improved by using a new technology applicable to the car paint booths. This new system is adaptable to any conventional or newly built paint booth and consists of equipment that brings additional air in perpendicular direction to the cabin’s main circulation, in such a way that it modifies the conditions of the vertical flow, accelerating notice-ably the evaporation of the applied paint water, and therefore conside-rably reducing energy consumption and CO2 emissions.
According to a study commissioned by the ICAEN, there is a new technology (created in the UK and with ample experience in the lea-ding EU countries on the promotion of energy savings) applicable to the car paint booths and which can be adapted to any conventional or new construction paint booth. This technology consists of equipment that brings additional air perpendicular to the main booth circulation, such that it modifies the conditions of the vertical flow, noticeably ac-celerating the evaporation of the applied paint water, and considerably reducing energy consumption and CO2 emissions. For example, with said ICAEN’s study system, hot air drying time is reduced from 96 minu-tes in a conventional booth to only 60 minuminu-tes. Also, during the drying process that calls for auxiliary lateral air circulation, a greater quantity of caloric energy available in the air is taken advantage of, leading to time savings in the hardening process and substantially improving the energy performance.