2. Energy Efficiency in textile industry - Moda-ML

Factory management optimisation for energy
efficiency:
the ARTISAN project perspective
Innovation for resource efficiency
in the European Textile and Clothing Industry
22nd November 2012, Brussels
Piero De Sabbata
Bruxelles,
resource efficiency
22 Nov 2012
1
Summary
1. Artisan project in a nutshell
2. Energy Efficiency in textile
industry
3. Artisan approach
Bruxelles,
resource efficiency
22 Nov 2012
2
2
The project
ARTISAN
FP7 EU research project (STREP)
Challenge 6 - ICT for a low carbon
economy
Call ICT-2011.6.2 ICT systems for energy
efficiency
November 2011 – April 2014
OBJECTIVE reducing energy
consumption and carbon emission by at
least 10% in textile industry through:
Bruxelles,
resource efficiency
22 Nov 2012
Data capture technologies integration
Process based energy monitoring
Short time scale optimisation of
operations
Supply chain and energy market
3
perspectives in the decision processes
Summary
1. Artisan project in a nutshell
2. Energy Efficiency in textile
industry
3. Artisan approach
Bruxelles,
resource efficiency
22 Nov 2012
4
4
Scenario for textile industry
External factors:
Increasing energy costs
Carbon emissions regulations
Future energy market(s)
Sectorial trends
High competitivity and reduced
margins
More flexibility and timeliness are
required
Bruxelles,
resource efficiency
22 Nov 2012
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Challenge 2:
energy efficiency and carbon
emissions in day by day
operations and decisions
Challenge 3:
poor information about energy
costs in textile industry
Challenge 4:
From single machine efficiency
to supply chain efficiency
5
Scenario for textile industry
External factors:
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Increasing
energy
costs * :
Some figures
from literature
Carbon
emissions
Challenge
Thermal
energy regulations
required per meter of cloth
is 4,500-2:
energy efficiency and carbon
5,500
KCal market(s)
Future
energy
emissions
Electrical energy required per meter of cloth
is 0.45-in day by day
operations and decisions
0.55 KWh
Sectorial trends
Challenge 3:
poor information about energy
costs in textile industry
High competitivity and reduced
margins
More flexibility and timeliness are
Challenge
* “Improving profits with energy-efficiency enhancements”, December 2008,
Journal for Asia 4:
required
on Textile and Apparel
From single machine efficiency
to supply chain efficiency
Bruxelles,
resource efficiency
22 Nov 2012
6
Scenario for textile industry
External factors:
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Increasing
energy
costs * :
Some figures
from literature
Carbon
emissions
Challenge
Thermal
energy regulations
required per meter of cloth
is 4,500-2:
energy efficiency and carbon
5,500
KCal market(s)
Future
energy
Somerequired
observed
emissions
Electrical energy
perfigures
meter: of cloth
is 0.45-in day by day
operations
andfabric
decisions
to finished
total
0.55 KWh Case of wool mill: from yarn
Sectorial trends
2 of fabric
energy (thermal+electric)
0,002
TOE/
m
Challenge 3:
2)
(that
is
24
KWh/m
High competitivity and reduced
poor information about energy
margins
costs in textile industry
More flexibility…but…
and timeliness are
Challenge
* “Improving profits with energy-efficiency enhancements”, December 2008,
Journal for Asia 4:
required
are
we
aware
of
such
figures?
on Textile and Apparel
From
single
machine efficiency
are we sure these data apply
to our
plants?
to supply chain efficiency
Bruxelles,
resource efficiency
22 Nov 2012
7
Samples
Applying best practices and best available technologies to the concrete textile process
Action
Heat recovering from 8
ton/h steam generator
Cost
[€]
38K
New switching on policies 290K
and revamping of 1 MW
(steam)
co-generators
Steam generators, load
peak reduction
-
ROI /
10 years VAN
2 years / 120K
€
Energy saving
-5% total plant consumption
(finishing department)
2,5 years/ 635K -138.000 m3 methane,
€
equal to -7,5% total energy
consumption (finishing
department)
-
+5% efficiency (dyeing plant)
" and many other being discovered
Bruxelles,
resource efficiency
22 Nov 2012
8
the problem(s)
Monitor real current use
and consumption
Increase single process
efficiency
Flatten load peaks
Assume a supply chain
and societal perspective
Bruxelles,
resource efficiency
22 Nov 2012
9
the problem(s)
Monitor real current use
and consumption
Increase single process
efficiency
Flatten load peaks
Assume a supply chain and
societal perspective
Bruxelles,
resource efficiency
22 Nov 2012
10
the problem(s)
Monitor real current use
and consumption
Increase single process
efficiency
Flatten load peaks
Assume a supply chain and
societal perspective
Bruxelles,
resource efficiency
22 Nov 2012
11
the problem(s)
Monitor real current use
and consumption
Increase single process
efficiency
Flatten load peaks
Assume a supply chain and
societal perspective
Bruxelles,
resource efficiency
22 Nov 2012
12
Summary
1. Artisan project in a nutshell
2. Energy Efficiency in textile
industry
3. Artisan approach
Bruxelles,
resource efficiency
22 Nov 2012
13
13
A more global perspective
Direct consumption
Energy consumed by the production machines for
the production of an article
Indirect consumption
Energy consumed by non-process machine to
produce service fluids (compressed air, steam,..)
Energy consumed by the other building facilities:
HVAC (heating, ventilation, air-conditioning),
lighting
ARTISAN provides tools
allowing the decision
makers to tackle them in
a co-ordinated and non
separated way.
Efficiency in energy supplying (energy grids)
Efficiency in supplying (electric) energy
Bruxelles,
resource efficiency
22 Nov 2012
14
ARTISAN Services
Energy data capturing
Energy monitoring
Operations optimization
Energy Forecasting
Energy
Trading
Bruxelles,
resource efficiency
22 Nov 2012
Carbon
Trading
15
The ARTISAN approach in a nutshell
Supply chain
Energy & carbon permits trading
Energy
market and
suppliers
EMS:
- actual energy costs
- consumption Alarms
- consumption forecast
Production
order
Materials
Productive
capacity
DSS:
- Scheduler
- SCM
Floor
Bruxelles,
resource efficiency
22 Nov 2012
Monitoring
- faults
- performance
- energy consumpt.
Maintenance
Green
Products and
certifications
Efficiency
projects
Finished
Product
16
Expected results
Informative infrastructure to collect, store and communicate data on energy
consumption at machine level;
Energy performance indicators for textile industry, supported by services to
analyze such indicators over the actual productive processes;
Real time optimization algorithms for production planning and scheduling,
address both cost reduction and energy saving;
Energy forecasting on a daily base
Energy and emission trading among partners of a supply chain or with external
(Smart) Energy Grids;
GUIDE for energy saving in textile industry to allow a first approach to energy
efficiency and compare own company indexes with sectorial benchmarks
A number of energy audits and two representative Field tests from the European
Textile industry that demonstrate the results in real industry settings.
Bruxelles,
resource efficiency
22 Nov 2012
17
Opportunities for textile industry to
collaborate
registration at www.artisan-project.eu to get access to information, be
informed about workshops and results, social net initiatives…
participation to the Industry Interest Group, co-ordinated by EURATEX, to
validate the foreseen scenarios and receive first hand information
use “GUIDE for energy saving in textile industry” for free
Bruxelles,
resource efficiency
22 Nov 2012
18
Thanks
Contact: Piero De Sabbata,
[email protected]
More information and registration to the mailing list
www.artisan-project.eu
Bruxelles,
resource efficiency
22 Nov 2012
19