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

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

Scenario for textile industry

External factors:
Increasing energy costs Carbon emissions regulations Future energy market(s)
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

Sectorial trends
High competitivity and reduced margins More flexibility and timeliness are required

Bruxelles, resource efficiency 22 Nov 2012

Scenario for textile industry

External factors:
Challenge 1: overcome opposition Efficiency vs Flexibility

Increasing energy costs * : Some figures from literature Carbon emissions Challenge 2: Thermal energy regulations required per meter of cloth is 4,500energy efficiency and carbon 5,500 KCal market(s) Future energy

Sectorial trends

emissions in day by day Electrical energy required per meter of cloth is 0.45operations and decisions 0.55 KWh Challenge 3: poor information about energy costs in textile industry From single machine efficiency to supply chain efficiency
6

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
Bruxelles, resource efficiency 22 Nov 2012

Scenario for textile industry

External factors:
Challenge 1: overcome opposition Efficiency vs Flexibility

Increasing energy costs * : Some figures from literature Carbon emissions Challenge 2: Thermal energy regulations required per meter of cloth is 4,500energy efficiency and carbon 5,500 KCal market(s) Future energy
Some observed figures emissions in day by day Electrical energy required per meter: of cloth is 0.45operations andfabric decisions Case of wool mill: from yarn to finished total 0.55 KWh 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 flexibilitybut 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 ROI / 10 years VAN 2 years / 120K Energy saving -5% total plant consumption (finishing department)

New switching on policies 290K and revamping of 1 MW (steam) co-generators Steam generators, load peak reduction -

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

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

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 Carbon Trading

Bruxelles, resource efficiency 22 Nov 2012

15

The ARTISAN approach in a nutshell

Supply chain
Energy & carbon permits trading EMS:
Production order Materials Productive capacity Energy market and suppliers

- actual energy costs - consumption Alarms - consumption forecast

DSS:
- Scheduler - SCM

Monitoring
- faults - performance - energy consumpt.

Maintenance
Efficiency projects

Green Products and certifications

Floor

Finished Product

Bruxelles, resource efficiency 22 Nov 2012

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, piero.desabbata@enea.it More information and registration to the mailing list www.artisan-project.eu

Bruxelles, resource efficiency 22 Nov 2012

19