Industrial energy management

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Energy management process

The use of energy management systems in industry is becoming increasingly important –  on the one hand due to increasing energy costs and ever stricter environmental regulations, and on the other hand due to companies’ efforts to achieve certification under the ISO 50001 Energy Management Standard. Industrial energy management helps companies improve their energy efficiency and increase productivity in their plants, which in turn improves their competitiveness – in all verticals. Energy efficiency in production, in

Systematic energy management

We offer you a unique portfolio of products for industrial energy management, using an energy management system that helps to optimally define your energy needs. We divide our industrial energy management into three phases – identification, evaluation, and realisation – and we support you with the appropriate hardware and software solutions in every process phase.

Making energy flows transparent, company-wide

A major factor in optimising production processes is the effective use of production resources. Systematic collection of consumption data for electricity, thermal energy, compressed air, or water is the way to achieve successful industrial energy management over the long term. This enables meaningful comparisons to be made – not only for existing plants but already during the planning phase, and to define effective and realistic optimisation measures.

Precise calculation of potential savings

The second phase of industrial energy management is evaluation. Once the energy flows have been collected, evaluated, and visualised, and the largest energy consumers identified, the specific energy-saving potential must be evaluated at all factory automation levels. The cost effectiveness of potential measures for the specific application can be derived from this result.

Realizing measures – increasing energy efficiency

After defining suitable measures, based on the cost-effectiveness analysis, the next step is to harness the identified energy-saving potential as effectively as possible by applying specific measures. A special focal point of industrial energy management is drive technology: Drives represent about two-thirds of the power consumed by industry. A savings potential of up to 70 percent is absolutely realistic with individual drive solutions. This applies to new plants and systems as well as to retrofit concepts.

Higher energy efficiency: expert consulting for industry

In order to calculate the energy-saving potential in production, we can offer you expert consulting services covering all aspects of industrial energy management – for all verticals. For instance, we can assist you in determining the cost-saving potential of individual applications as well as in optimizing the energy consumption of complete plants – for example with our EOA service package. Initially, EOA only analyzes the drive systems where optimisation of energy consumption has a maximum payback time of two years. This allows energy costs to be reduced specifically and with low investment costs. EOA is part of our energy optimisation service EOS, which examines all of the relevant energy processes and types to identify the energy-saving potential.

Standards and legislation

With the growing importance of energy efficiency, this topic is finding its way with increasing frequency into standards, directives, and legislation at the national and international level. These must be implemented in the design of products as well as in the daily operation of industrial plants.

Energy-efficiency legislation for drive technology

Just how important energy-efficiency legislation is for equipment and plants is described, for example, in Directive 2005/32/EEC of the European Parliament and the Council from July 6, 2005. It creates a framework for defining the requirements placed on environmentally compatible design of products that use energy. Article 11 formulates the following requirements for the lifecycle assessment:

  • Environmentally compatible design of products that use energy in order to comply with the increasing demand for energy

  • Information for operators about the environmental aspects and properties of the components

  • Inclusion of all phases of the product lifecycle according to the methods of the lifecycle assessment per ISO 14041

New efficiency classes for motors

Extensive legislation covering energy efficiency has been passed in the European Union. In order to reduce energy consumption in the industrial sector, new efficiency classes have been defined for induction motors in IEC 60034-30 (IE = International Efficiency).

Die Effizienzklassen Motoren sind:

  • IE1 (Standard Efficiency)

  • IE2 (High Efficiency)

  • IE3 (Premium Efficiency)

When do the new regulations go into effect?

Since June, 16, 2011, it is no longer permissible to market IE1 standard motors in the European economic arena. It is now a legal requirement that all standard motors that are marketed must comply, at a minimum, with the IE2 classification.

Future dates are:

  • from January 1, 2015: The legally specified minimum efficiency IE3 will be mandatory for power ratings from 7.5 kW up to 375 kW – or as an alternative, an IE2 motor plus converter

  • from January 1, 2017: The legally specified minimum efficiency IE3 will be mandatory for power ratings from 0.75 kW up to 375 kW – or as an alternative, an IE2 motor plus converter

Social responsibility

Implementing energy efficiency in industry is more than just a technological challenge. It also means accepting economic, environmental, and social responsibility. Sustainability is an important concept in this context. For Siemens, it means acting responsibly in the interests of future generations, and this includes the economical use of resources. However, demand for energy is growing and this means that energy suppliers, industry, and consumers are faced with the challenge of using energy as efficiently and as ecologically as possible.

Utilising energy-saving potential

There is already enormous potential for saving energy with the technology available today, true to the motto that the best electricity is the electricity that is not consumed. In particular, there is considerable potential for saving energy in industry. Electric motors today account for nearly two-thirds of electric power consumption in industry, for example for drives or pumps. Their power consumption could be slashed by up to 60 percent with energy-saving motors and smart controls from Siemens, an investment that can pay for itself in less than two years through the energy savings alone.