# Presentation: 714905

**Energy Analysis Department**
**Environmental Energy Technologies Division**
**Lawrence Berkeley National Laboratory**
**美国劳伦斯伯克利国家实验室**
**环境能源技术处**
**能源分析室**

**Cement Industry Energy Efficiency **
**and Benchmarking**
- Presentation for the
- China Building Materials Academy Delegation Visit to
- Lawrence Berkeley National Laboratory
- October 1, 2007
- Berkeley • California** **
** **

## 美国EPA工业能源之星 U.S. EPA Energy Star for Industry

- 美国政府部门的自愿项目,旨在通过提高能效,帮助生产商保护环境
- 	Voluntary U.S. government program that helps manufacturers protect the environment through superior energy efficiency
- 超过450合作公司,涉及工业各个领域
- 	Over 450 partner companies in a wide range of industries
- 为能源管理者提供能源管理信息
- 	Provides energy management resources for energy managers** **
- 促进信息共享、网络和共识
- 	Promotes sharing of ideas, networking & recognition
- 能源指南-为企业和能源管理者提供技术评价报告
- 	Energy Guidebooks - technical opportunities assessment report for plant and energy managers
- 企业能源性能指标,以同能效进行对标
- 	Energy performance indicator for enterprises to “benchmark” energy efficiency

## 美国EPA工业能源之星-能源指南 U.S. EPA Energy Star for Industry - Energy Guides

- 工业概况 Industry overview
- 工艺描述 Process description
- 能耗概要 Energy use summary
- 提高能效机会 Energy efficiency opportunities
- 技术或实践的简要概述
- 	Brief overview of technology or practice
- 应用的局限性(如果有)
- 	Limitations on applicability (if any)
- 典型的节能量
- 	Typical energy savings
- 典型的简单回收期
- 	Typical simple payback period
- 工业实际应用的案例数据
- 	Case study data from real-world industrial applications
- 出版物未来信息的参考
- 	References to further information in the public domain
-  http://www.energystar.gov/index.cfm?c=industry.bus_industry

## China-US Bilateral Cooperation on Persistent Organic Pollutants

- China ratified Stockholm Convention on Persistent Organic Pollutants (POPs) in 2004
- EPA signed Memorandum of Understanding with SEPA December 2003
- Comprehensive management of dioxins/furans from cement kilns
- Goal: Reduce emissions of dioxins/furans from cement kilns
- Accurate emissions factors for rotary and vertical shaft kilns
- Source inventory of dioxins/furans from cement kilns in pilot provinces
- China's National Implementation Plan (NIP) for reducing dioxins/furans emissions from cement production
- Financing mechanisms and incentives for private sector investment to improve combustion efficiency and control particulate emissions from cement kilns
- Dioxin/furan sampling from 8 Chinese cement kilns in 2006

## China-US Bilateral Cooperation on Persistent Organic Pollutants

- 1Polychlorinated dibenzodioxins and polychlorinated dibenzofurans, in nanogram toxic equivalence (TEQ).
- 2Based on industry-wide emissions from the national emissions inventory.
- 3This is based on the regulatory limit.  It is assumed all kilns are below this limit.

***Preliminary Results***

***Sampling Sites***

## China-US Bilateral Cooperation on Persistent Organic Pollutants

- Energy audit of 2 cement kilns in Shandong Province, September 2007
- US EPA/SEPA organized
- LBNL and DOE energy expert participated
- Significant technical assistance from CBMA
- Goal is to improve kiln combustion efficiency in order to reduce formation of dioxins and furans
- Energy efficiency recommendations will be provided to each cement plant
- Emissions testing repeated following energy efficiency retrofits

## Significant Technical Assistance from CBMA

## 提高水泥窑能效的投资机遇Investment Opportunities for Improving Cement Kiln Energy Efficiency          

- LBNL受美国环保署和亚洲发展银行委托作的报告
- 	Report prepared by LBNL at request of U.S. EPA and the Asian Development Bank
- 基于国际和国内的案例资料
- 	Relied on both international and China-specific case study information
- 得到中国建材工业技术情报研究所的大力帮助
- 	Significant assistance from the Institute of Technical Information for Building Materials Industry of China
- 报告正在评审中—中国建材研究院的汪澜教授提供了帮助
- 	Report now being reviewed – assistance provided by Prof. Wang Lan of China Building Materials Academy

## 提高水泥窑能效的投资机遇Investment Opportunities for Improving Cement Kiln Energy Efficiency

- 大量的文献调查
- 	Extensive literature search
- 技术文献:报告,杂志文章
- 	Technical literature: reports, journal articles
- 贸易杂志 Trade journals
- 工厂-特定数据 Plant-specific data
- 案例研究 Case studies
- 调查 Surveys
- 每样技术都有以下信息
- 	For each technology, the following information is provided:
- 成本 ($/t) 		Capital costs ($/t)
- 运行和维修成本	Operations and maintenance costs ($/t)
- 投资回收期 (年) 	Simple payback period (years)
- 节约燃料量	Fuel savings (GJ/t)
- 节电量		Electricity savings (kWh/t)
- 二氧化碳减排量	CO2 savings (kgC/t)
- 措施年数(年)  	Lifetime of measure (years)

## 提高水泥窑能效的投资机遇Investment Opportunities for Improving Cement Kiln Energy Efficiency 

- 22 options evaluated评估过的选项:

| Improved refractories 
改良的耐火材料 | Low temperature heat recovery for power
低温废热发电 |
| --- | --- |
| Energy management & process control
能源管理和过程控制 | High temperature heat recovery for power
高温废热发电 |
| Convert VSK to NS preheater/precalciner
把VSK 改成 NS 型预热器/预分解炉 | Low pressure drop cyclones
低压降旋流器 |
| Long dry kiln upgrade to preheater/precalciner
长干窑改良为预热器/预分解炉 | Efficient kiln drives
更高效的窑驱动器 |
| Preheater kiln upgrade to precalciner
预热器改良为预分解炉 | Kiln shell heat loss reduction
减少窑壁热损失 |
| Old dry kiln upgrade to multi-stage preheater
旧干窑改良为多级预热器 | Adjustable speed drive for kiln fan
窑鼓风机可变速驱动器 |
| Convert to reciprocating grate cooler
改良为往复炉篦冷却器 | Blended cements
混合水泥 |
| Kiln combustion system improvements 改进窑燃烧系统 | Use of waste-derived fuels         废料利用 |
| Indirect firing  间接烧窑 | Limestone cement            石灰石水泥 |
| Optimize heat recovery/upgrade clinker cooler
优化废热利用/改良熟料冷却器 | Low alkali cement            
 低碱水泥 |
| Seal replacement  密封体替换 | Use of steel slag       钢渣利用         |

## 提高水泥窑能效的投资机遇Investment Opportunities for Improving Cement Kiln Energy Efficiency 

-  初期结果 Preliminary findings:
- 在22种能用来改造和更新旧的能效低的水泥窑的措施和技术中
- 	Of the 22 technologies or measures that can be used to retrofit or to replace old, inefficient cement kilns to improve their energy efficiency:
- 大部分技术和措施能减少燃料消费或电力消费,其他的可以同时减少燃料和电力消费
- 	Most of the technologies and measures reduce fuel consumption, while some reduce electricity consumption and others reduce both
- 14种技术和措施能在三年或更少的时间能回收投资
- 	14 of the evaluated technologies and measures have simple payback periods of three years or less
- 报告还在审查阶段
- 	Report is still in review process

## 对标Benchmarking

**对标是用于评估设备或企业绩效****(****资金、生产、能源****)****的一种普遍性方法**
-        Benchmarking is a common way to evaluate facility or company performance: financial, production, energy, etc.
**全球已经开发了一定数量的工业节能项目的节能对标工具**
-        Energy efficiency benchmarking tools have been developed for use in a number of industrial energy efficiency programs around the world
**节能对标的不同类型** Various types of energy efficiency benchmarking:
**与同行对比**
- 	Peer to peer
**定期自我对比**
- 	Self performance over time
**与国家或地区平均或最佳实践对比**
- 	Self performance to national or regional average and best practice
**与国际最佳实践对比**
- 		Self performance to international best practice
**不同类型的优缺点** Advantages and disadvantages to all types

## 美国EPA工业能源之星 U.S. EPA Energy Star for Industry

**	****Energy Performance Indicator (EPI) ****能效指标**
**在美国同等企业规模范围内,就企业的能效情况进行排队**
**	**Ranks an enterprise’s energy performance within the US industry normalized to the enterprise’s configuration
**将企业与美国平均和“高效”(即所有工厂中****75****%节能的)的工厂进行对标,美国所有工厂的能效**
- 	Benchmarks the enterprise to the average and “efficient” plants in the U.S., where efficiency is defined as the 75th percentile of all plants
**工厂经理输入工厂的运行数据,即得出一个能效等级**
- 	Plant managers input key plant operating data to receive an energy efficiency rating

## 美国EPA工业能源之星 U.S. EPA Energy Star for Industry

**基于美国的普查数据**
**	**Based on US Census data
**同时也基于产品产量或基于企业管理者不可控制的其他因素,**
**	****例如:**
**	**Also based on product outputs or other factors beyond control of plant manager, for example:
**产品具体类型或结构**
- 	Specific type or mixture of products
**同能耗相关联的其他因素,例如:工时,气候**
- 	Other factors that correlate with energy use, e.g. labor hours, weather
**为改进和监督进度设定目标**
- 	Used to set goals for improvement and monitor progress
**成为为企业授“能源之星”标识的依据**
** ****	**Basis for awarding the ENERGY STAR label for a plant** **
**已经提出了水泥、谷物磨制、汽车制造业的能效指标**
- 	EPIs have been developed for the cement, corn milling, and automobile manufacturing industries

## 对标和节能工具 (BEST)  BEST: Benchmarking and Energy Savings Tool

- BEST**为每个设备提供了对标的核心,以表明在能效方面同国际最佳实践的距离**
- 	BEST provides a benchmark score for each facility indicating its distance from international best practice in terms of energy
**只比对能源情况,其他变量不变**
- Compares only energy to best practices, keeping other variables the same.
**例如:最佳实践的水泥企业生产量同等,同样标号的水泥,使用同样的原材料,但使用高效技术。**
-        For example for cement, the best practice enterprise produces the same amount of cement, the same grades of cement and uses the same input raw materials but it (or they) uses the most efficient energy technologies to do so
- BEST**制定提高能效计划和目标制定**
-      BEST allows for development of an efficiency
- 	improvement plan and target-setting

-   BEST

## 的能效指数Energy Intensity Index (EII)

- 	EII	= energy intensity index 能效指数
- 	n	= number of products to be aggregated累计产品数量
- 	EIi	= actual energy intensity for product I 产品l实际能耗
- 	EIi,BP	= best practice energy intensity for product i产品i最佳能耗
- 	Pi	= production quantity for product i.产品i质量
- 	Etot	= total actual energy consumption for all products
-                                 所有产品的实践总能耗

## Slide 17

## 水泥行业实例:设定边界Cement Industry Example: Defining Boundaries 

**水泥行业实例:设定边界****Cement Industry Example: Defining Boundaries **

*水泥业分析边界实例*
*Example boundary of analysis for cement*

## 水泥行业实例:输入表格Cement Industry Example: Input Sheet     

- 生产数据 Production Data
- 原材料的投入Raw materials input (t/year)
- 石灰石Limestone
- 添加剂种类Additives by type
- 窑型 Kiln Type
- 熟料产量 Clinker output  (t/year)
- 水泥产量 Cement output by type (t/year)
- 水泥型号 Grades of cement

## 水泥行业实例:输入表格Cement Industry Example: Input Sheet     

- 能源数据 Energy Data
- 年燃料消耗 Fuel consumed per year (tce/year or kWh/year)
- 煤、焦炭、生物质 Coal, coke, biomass (tce/year)
- 电力 Electricity (kWh/year)
- 其他 Other
- 工序用能 By process step
- 原料准备Raw material preparation (quarrying, conveying, prehomogenization, proportioning, limestone preparation, additives preparation, additive drying, fuel preparation, homogenization)
- 熟料烧成 Clinker making (preheaters, precalciners, kiln, cooler)
- 水泥磨 Finish grinding
- 其他(运输、辅助、包装、非生产用能)
-     Other (other conveying, auxiliaries, packaging, non-production energy use)
- 年燃料成本 Cost of fuel per year (yuan/kWh or yuan/tce)

## 水泥行业实例:假设的对标 Cement Industry Example: Hypothetical Benchmarking

- BEST PRACTICE = 100

**离最佳实践的距离**
**Distance from best practice**

## 假设的对标结果Hypothetical Benchmarking Results

**假设的对标结果****Hypothetical Benchmarking Results**

## 对标和节能工具 (BEST) BEST: Benchmarking and Energy Savings Tool

- 不仅提供对标的核心为目标的制定和能源管理提供进一步的能效菜单Provides not only benchmarking score BUT ALSO provides additional energy efficiency menu for target setting and energy management
- 低成本和易评价的潜力
- 	Allows low-cost and easy evaluation of potential
- BEST制定提高能效计划和目标制定
- 	In this way, BEST allows for development of an efficiency improvement plan and target-setting

-   BEST

## 节能机会Energy Efficiency Opportunities

- 可实施的能效或减排措施清单
- 	Extensive menu of energy-efficiency or carbon emission reduction measures that could be implemented
- 跨行业:电机系统、风机、空压机、照明
- 	Cross-cutting: motor systems, fans, compressed air, lighting
- 同工艺相关:所有主要的工艺(窑炉升级,混磨)
-       Process-related: all major process technologies (kiln upgrades, blending)
- 措施 Each measure
- 产品单耗(熟料或水泥)
- 	Typical energy savings per ton product (clinker or cement)
- 实施成本
- 	Cost of implementation
- 投资回收期
- 	Typical payback period
- 一旦实施方案选定,BEST计算企业新的潜力
- 	Once options for implementation are selected, BEST calculates new, potential EII for plant

## 水泥行业能效措施初步清单Preliminary List of Energy Efficiency Options for the Cement Industry

## 假设对标结果Hypothetical Benchmarking Results

**假设对标结果****Hypothetical Benchmarking Results**

## 假设对标结果Hypothetical Benchmarking Results

**假设对标结果****Hypothetical Benchmarking Results**

## Next Steps

- 发布中文的水泥行业能效指南
- 	Publication of Energy Efficiency Guide for Cement in Chinese
- 完成提高水泥窑的能效的投资机会报告
- 	Completion of Investment Opportunities for Improving Cement Kiln Energy Efficiency
- 为中国水泥能效技术和措施增加投资成本和绩效等信息
- 	Incorporation of cost and performance information for Chinese cement energy efficiency technologies and measures
- 完成中国最佳水泥工具的开发
- 	Completion of BEST-Cement for China

## 联系信息 For further information

- Lynn Price (_[LKPrice@lbl.gov](mailto:LKPrice@lbl.gov)_)
- Christina Galitsky (_[CGalitsky@lbl.gov](mailto:CGalitsky@lbl.gov)_)

- LBNL Industrial End Use Analysis Website:
- _[http://industrial-energy.lbl.gov/](http://industrial-energy.lbl.gov/)_
- LBNL China Group Website:
- _[http://china.lbl.gov](http://china.lbl.gov/)_
- BEST Website:
- _[http://industrial-energy.lbl.gov/node/100](http://industrial-energy.lbl.gov/node/100)_
- Publications:
- _[http://industrial-energy.lbl.gov/publications](http://industrial-energy.lbl.gov/publications)_