Martin Beck from ETA – Solutions GmbH presented “Energy system planning – On the way to climate neutrality” at the “New Technology Forum” at Hall 16, Booth F11 on the 19-09-2023.
The EMO Hannover 2023 “New Technology Forum” series features a diverse panel of speakers representing various companies and organizations. They share pioneering technologies and advancements to keep you informed about the most critical industry trends and developments.
Subscribe and learn more every week!
Welcome to my talk on Energy Systems planning towards climate neutrality so climate neutrality is Talk of the Town as we all know and it’s a big challenge to meet this objective within a short period of time but uh uh embarking on that way towards them obviously is uh an ambition
So you’re going go from zero to one let’s start with 0.5 until we really achieve full climate neutrality in the long term so these are the four agenda items that I’m going to cover today clim neutral neutrality has to be achieved across all Scopes and I’m going to tell
You what Scopes are that’s a central element of my presentation of the day and secondly it’s the technical system and not only a single machine of which we so see so many on Hana will tip the scales in terms of savings and you know always bearing in mind efficiencies and
What efficiencies can be tapped we’re going to look at um at what factors can be influencing Energy Efficiency not many customers are taking the holistic view we want to change that and then finally we’re going to talk about the business model of climate climate neutrality not everyone is really uh uh
Comprehensively addressing that we need to address uh the notion that a business model of climate neutrality is not only a challenge for us as energy Consultants but also for suppliers those who are selling machines systems uh production systems are always Energy Systems when you come to look at that and um that
Also means that your business model has to be efficient rather than inefficient so maybe you want to keep those agenda items on the top of your mind as you as we present you the entire talk here now just to give you a general idea about our company let me tell you where we’re
Coming from we uh are related to the ET ETA Factory at the University of dad this has been mentioned before the ITA Factory was uh set up as a concept in 2010 no one really believed in it it was our brainchild and then in between 2010
And 2012 um I’m sure you will notice that all of the industry shows were green everyone was talking about Energy Efficiency so that was the time when we started our project as well and this is when people have developed the general concept of the ETA Factory and then 2013 saw the beginning
Of a of a of a standalone project um Energy Efficiency in production was uh a showcase model that we developed at the campus of the Technical University Technical University of Dad and uh in many ways this is also about efficiency efficient connectivity of individual production items or elements um just
Earlier we had a presentation on energy networks and efficiency networks in the ETA Factory we heard about that but we also developed the eter transfer project and that was created because the Federal Ministry of economic Affairs had uh funding available but no company that were claiming those funds now we wanted
To match those so government subsidies efficiency programs and an implementation arm of it now uh thanks to the successful work of the eer factory we’ve been in a position to make that a reality and because it worked so well we created um ETA Solutions gmbh which is a corporate consultancy that is
Now 5 years old and on we go until this very day we work in the context um of the uh industry and commerce research Network we are working together with the Federal Ministry of economic Affairs provide consultancy for funding schemes to make sure we dovetail the available funding
To the needs of our customers and the demands and needs of the customers obviously are also changing that’s clear but it’s not only about Energy Efficiency where we’re coming from but also a couple years ago still um there were not too many people that were interested in Energy Efficiency and CO2
But now transformation Concepts have become mainstream literally in the last two to 5 years where people are focusing more now on co2 neutrality so you have a carbon footprint today not necessarily the product carbon footprint but a factory carbon footprint as a total operation facility how can you shape that towards
Achieving neutrality in the carbon process now that is something that is currently preoccupying us a lot not only in research projects but also in real life applications now what would an energy consultancy look like I’m just touching on those Topline aspects here but what is important Energy Systems must be
Understood so beginning from the individual com energy consumption of a component of a machine all the way to the system so a pump a tool uh machine um Chiller a control um cabinet coolant system as we’ve heard before this is where you start we’re not going to replace a machine a complete machine
Because no one would do that just to buy new machine tool just because uh it is more energy efficient but if you do that you can actually calculate your individual savings both in the procurement process but also in the existing machine Fleet and then you can actually have an impact on what your
Machine Fleet will look like implementing those savings is the second element here it’s what we help our customers with so not only do you create transparency to understand what is happening but you put it into reality with the network of partners that we’ve developed over the years and whenever we
Are at an industry show obviously it makes uh a lot of sense to add more spices to the whole dish of energy systems the next one is shaping the transformation well I said that before this is not only about working on individual projects but helping a company to support them to be climate
Neutral and here comes the final aspect we want to set off innov Innovation that’s because of the history of our company um what we offer can be really focused to what people need to do so you have your own uh energy needs energy reduction needs well we help you and
That to make sure that they’re compatible for the energy systems of the future and can be integrated in them as as well into them as well so uh I told you before that we are 5 years old we have a team of eight people working in the company and supporting customers towards climate
Neutrality and uh with all these other aspects here on the slide I think I’ve talked about them and can skip them and what I’d really want to do is to talk about Energy Systems planning which is the central aspect now that’s an animation that should uh start right
Now in a system like a factory energy uh is absorbed but it also results in exhaust heat actually you see that on the up level there on the higher level but it happens inside a machine as well so everything that’s happening in a Machine Tool uh is converted to heat so
All inefficiencies in other words uh would lead to additional power consumption so that also leads to inefficient use of waste heat even when you have a productive process there’s always a certain built-in waste in the system it happens on a machine level and a component level and one of our
Questions is well how can we use waste heat from machines in order to be reused in an energy process like cleaning fluids cleaning baths for instance can be heated using exhaust heat from a machine for those of you who uh were following the earlier presentation from MAAC well this is exactly what they’re
Doing and what we’ve been doing with them so you can put your focus also on the entire Factory but in a factory there’s too much waste heat now if you were not using air conditioning in this Factory or in this exhibition Hall here you would notice it’s actually very hot
A machine emits 200 watts of heat per square meter a floor heating only 80 wats so imagine a factory Hall is just as hot as a floor heating system working on full power you cannot use it in the production machine of course but you could use it
Elsewhere so what we do we create transparency as we’ve said before and what we also do we’re trying to Market those objectives so um we believe this is important for all of our customers in the sense you not only do meaningful things but you talk about it uh you
Spill the beans use it as a marketing instrument uh for their own customers as well and uh that brings us back full circle to the earlier business model that we talked about now this again is the core aspect of energy systems planning in a nutshell if you will a conventional machine that loses
Uses a lot of energy and produces a lot of waste heat uh becomes more efficient and as you move over the efficiency increases so that’s aspect number one we want to bring energy consumption down reduce waste heat so if you avoid waste heat you don’t need to cool it down
Again with a chiller or an air conditioning system like in this this exibition Hall it’s is almost as you put a hot air blower into your fridge so if you go back with your air blower from Level 3 to two you still will not adversely impact the effectiveness or
The efficiency of a machine so the same effect if you will but your refrigerator wouldn’t need much more energy so you use the waste heat of your hot AO within the refrigerator to stay with that same picture now in our case we connect it to a cleaning uh bath we
Heard about that before in an earlier presentation of the day and then finally you have excess heat in a factory well what you do with that if you’re efficient you can either uh dissipate it to the environment you don’t need any compressed Refrigeration anymore but you do that with outdoor or
Free cooling or imagine you have a residential building uh or a commercial building um right next to your factory premises well maybe you want to use the was he to heat those building there in order to conserve energy next to your factory now all of that works not only
In an academic context but also with our with our partners and customers that uh we have worked with in those past year and it works not only in the uh Machining industry or metal cutting industry but also in the Plastics in Industry mer is a partner of us that
Produces Pharmaceuticals but then we have a customer that also produces bitchin based roof covering so the methodology of energy systems planning works for everyone really because it doesn’t really matter where you consume energy what industry whether it’s metal cutting or process industry um it really isn’t that crucial
Because the general approaches should be similar so what are the results as we’ve talked about that now this is taken from a very specific example from Trump and we were allowed to disclose the name of that partner where we went through different aspects of energy in this project we uh or
The it not relate it doesn’t relate to the entire Manufacturing of that company but for that project we save about 20,000 Mega hours of uh so that’s the total Savings of all projects I should say because otherwise for one project 20,000 mega mega hours would be quite a
Lot but for the overall project scope we are saving 10,000 tons of CO2 per year always compared to a reference building I mean you can never always build up two factories and use one for a good and the other one for a bad example it’s always a reference value which is related to
The current state of play that we have to submit to the baa before we get approval for the investment funding investment is larger than 20 million EUR so far so what that means these are good these are relevant projects in terms of their relative size for our partners so
High energy cost savings related to the project work so a total factory will save you 10 to 20% of energy that is very feasible and practicable especially for electricity it’s slightly lower but when you talk about talk about gas by using waste heat and recuperating it
Um we can save much more because use that low temperature for building heating or for the cleaning uh machines the cleaning baths that we heard before all of that can be recuperated from waste heat from machines and processes which gives us a relatively High share of energy savings
With a good Roi now rois are always calculated to the time of when funding was applied for we know that energy costs will develop usually going up rather than down so those RIS can get even better because of the increase in Energy prices I also told you that I’m going to
Talk about Scopes and I think uh um what are scope emissions and uh what is it really mean in terms of climate neutrality well let me start with that climate neutrality is the zero net emissions of all processes in the factory and the real net output so it’s a bit of a
Mouthful no emissions within your own manufacturing process but also within your own products when you’re building uh fridges they must not have emissions and all precursor product shouldn’t emit anything either so that would be full uh poster boy climate neutrality if you will but uh it wouldn’t really work like that
If you do the calculation of the original element so let’s talk about the Scopes scope one emissions are the direct emissions within your factory premises or company premises so anything that is emitted out of the company by way of emissions then there indirect emissions that come from utilities or
Electricity purchases for instance and scope three emissions are the ones referring to upstream or Downstream products or the consumption and the use of your own product now what exactly that means I’ll show you in a second our aspect that we’re focusing focusing is improve the energy impact thanks to your
Energy optimization within your organization that’s what we’re focusing on what you could also do is work with companies to who who became climate neutral overnight uh that was a carbon compensation compensation works well no doubt about it but the question is is that really a one toone compensation de facto or not
So it’s more honest if you will to optimize your system with an energetic approach but you know Carbon compensation is certainly not a mistake at all what I haven’t said yet is that um companies that achieve climate neutrality today just focus on scope one and two and they
Carve out scope three from this calculation now let’s make it more specific and tell you what it means what happens within scope one in your internal organization it’s refrigerant losses for instance so refrigerants have a global warming potential gwp for short for those of you have heard it before so how do you
Account for those now what about aspects of production machines uh compressor compressed air uh process fluids Etc these are not really found in scope one emissions but this is something that the company has a big handle on and those are also depending on scope two elements so so energy and utility uh
Elements that you purchase so this is the distinction of scope one and scope two and your energy consultant needs to delineate one and the other now already at this and let me say again if you wanted to achieve climate neutrality today you would focus on the gray area I.E compensation measures and
There companies uh that became climate neutral overnight and they did that thanks to um compensation or green power purchasing so green power certainly is in a position to do that and um energy eff efficiency or renewable energies in your own production or energy flexibility have been playing a minor
Role although well they they are relative contributor to that as well but be it as it may climate neutrality of Tomorrow needs to focus on more aspects whereas Energy Efficiency has not been fully utilized has not been tapped well not by our customers they do that but others who are not
Yet um the still some pent of demand I think and they can uh move a mountain by being more energy efficient now how much can be done has been shown to us in the natural gas crisis so imagine how much people have been able to minimize their gas consumption thanks to optimizing
Your energy output and um we haven’t hit a wall there yet there’s still potential to go from there renewable energies no I mean that that’s a common place and it works really well and it also works quickly and then finally energy flexibility in the sense that you need
To decide when you you use your Renewables in your production process when do we have an excess when is your CO2 Factor low in the electricity grid and then use that energy and that is going to happen in the coming years almost definitely yeah now I’d like to refer
You to our earlier project with the trumph Trum is a metal cutting competence Center and number of measures that we implemented with them about 45% of carbon emissions were achieved or reduction was achieved about 800 tons per year in one single project now you would say that one person one human
Emits 10 tons of CO2 per year 800 tons would be 80 people and their equivalent of carbon emissions now how that done well I’m happy to talk about that we replaced decentral ized machine chillers by highly efficient Central chillers or refrigerators machine chillers really are the friends of energy consultants
And you can uh roam the Hanover exhibition here and hold your hand over the chillers and see how much hot air comes out there that’s that hot air blower sitting in your fridge that I mentioned before and uh it’s one of the exhaust pipes of um of energy chillers
So it’s very important actually to feel that don’t just look at machines try and listen it’s usually where something is noisy and where it’s hot this is where energy is happening I mean obviously it makes sense but not many people do that and take a look and take a listen so
These chillers it can be uh can be organized inefficiently bypass chillers are still very inefficient or organize it centrally R is a player that can do such centralized solution they have a good Booth here across from here or you use a centralized system where you use the waste hair of your machine
Not to dissipate it to the air but use it turn it to into a fluid into a water and use it from there if you’re looking at 20° of temperature in a centralized Chiller system or 15 or 12 we’re always uh above what geothermal energy or air to air
Heat pump would give you now imagine how much is going on at the moment here in this country on heat pumps and rightly so but if you have a 12° cooling water throughout the year that would be an excellent energy source would it not also to use for other purposes now what
Else can we do we could do um free cooling or um passive cooling especially at night and we have dry air you can evaporate water and make a lot of cooling capacity available through cooling towers but there also hybrid coolers that are used as closed cooling towers and this passive or free cooling
Uh could be these dried cooling tower like shown in this picture but they’re depending on the external temperature ambient temperature of well and you can use those to use this 12 or 15° cooling water virtually without carbon emissions if they’re operated meaningfully they have a factor of 30 to 5050 of energ
That you input into the system versus the output that can then be used as refrigerant energy or Refrigeration output and the third aspect is the use of waste heat as we said before so heat recuperation thanks to the 12 or 15° temperature levels for your internal purposes within your Energy System you
See a larger picture of how it all works together it’s it’s a schematic that is very complex we cannot avoid complexity in the system but conversely you could always say thanks to technology that’s always the Hope thanks to the ongoing development of Technology we can make a major contribution towards More Energy
Efficiency there other aspects as well as you see there in the list on the right is you can replace inefficient auxiliary systems like machine uh cooling systems control cabinet coolers as we’ve heard before hydraulic application that’s an aspect as well Hydraulics are always the noisy components so if you stand next to a
Machine well this is where you hear where Hydraulics is at work and there are many things and I’m not going to read them out now for you because we’ll be running out of time if I did so what’s uh the upshot with our RI of three and a half years and the
Investment grants we’ve received those grants mind you are not only available for smus but also small uh larger larger companies um so um we you see the indicators there in the slide and I said before transformation concepts are one aspect so can we achieve the 2030 Target of the
Energy transition with the measures we have in place today well the answer is straightforward the objectives are achievable already today with the measures that are in place uh in one step of iteration so that’s the entire project with trumph that I before so if we don’t just stop with one project but
Use the entire transformation Horizon but with all the measures that exist today we could already achieve the 2030 um climate targets and we didn’t even mention the replacement of Machinery uh or revamping so integration in terms of integration you could do even more so I am confident in other
Words that we can achieve the 2030 targets with the existing tools we have available today and with that I hope I was able to tell you that climate neutrality has to be embraced across all the different Scopes not only scope one or scope two because theoretically if
You want to be integrated you have to look at your precursors your upstream and downstream products because once you Market them throughing their life cycle they consume energy as well so they want to be efficient secondly the technical system decides not only an individual machine it’s not about your hair dryer
Or your air blower that’s sitting in the fridge somewhere that should be more efficient but at the end of the day the fridge itself as well so it’s a systems integrated view or an air conditioning system like in this exhibition Hall here today you need to know what your levers
And influences are it’s important for all industry players to know what they can to do themselves what their energy uh consumption is you have to be flexible to know what you’re doing to of course know what you can be doing going forward and if you’re flexible enough
You can invite external expert who will help you to find another solution and finally something I’d like to invite all of you to uh to work shoulder Tosh shoulder and understand how your business model of climate neutrality would look like how can you set a distinct profile for
Yourselves to compete with others in order to drive climate neutrality forward it is not only a business model for energy consultants in other words what would that business look like in the future in this word cloud you see quite a few things that will be on the agenda going
Forward and we believe where we are coming from Energy Efficiency and CO2 emissions something that has been Talk of the Town for many years now CO2 I think uh will uh uh diminish in relevance by 2030 because we already will be having 80% of renewable energies in electricity production by that time
So CO2 will not be uh on the agenda so much but you need to understand how much energy you consume how many more Renewables you need uh I mean if you reduce uh your energy consumption by 50% you don’t need much more renewable energy going forward and when do you
Need that renewable energy at what time at what place that is something that we will need to address after 2030 more so than today is assuming that the legislator plays along and as far as transformation Concepts maybe not only think about your roof mounted solar energy panels but think Energy Efficiency instead and
Here’s my final slide to give you an Outlook and quote from an existing study what are the current drivers for energy efficiencies and that’s a questionnaire that was sent to Industry players but also um energy consultancy for residential areas where everyone is saying that um the political uh conditions will matter the political
Environment the political environment is actually quite clear it has been defined it’s very statically defined for the residential business but they’re also evolving um as far as Energy prices are concerned with the war on Ukraine we’ve seen quite a few challenges during gas the gas crisis we didn’t need any
Additional funding because there was a lot of subsidies available and we do not necessarily claim subsidies for all of our projects but then there’s also more awareness of more sustainability across the board by people of all walks of life we need more technological innovation that is certainly true as well despite
The fact that we’re in a good shape today already a lot of tools are available and finally we need to reach out to the customer demands of the future if only only when the expectation by customers for efficient systems can be uh satisfied will we be making
Progress even if you leave out L leave out 2022 you can still say on the right of the slide that energy prices will be going going up anywhere between 21 and 2023 this number will still go up and um I think we are safe to assume that uh
That’s not uh the end of the story yet Energy prices will continue to increase therefore we need Energy Efficiency to achieve finally our 2040 targets thank you very much for your attention and I’m happy to