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I N T E R N A T I O N A L E N E R G Y A G E N C Y Tracking Industrial Energy Efficiency and CO2 Emissions In support of the G8 Plan of Action Please note that this PDF is subject to specific restrictions that limit its use and distribution. The terms and conditions are available online at www.iea.org/w/bookshop/pricing.html ENERGY INDICATORS INTERNATIONAL ENERGY AGENCY The International Energy Agency (IEA) is an autonomous body which was established in November 1974 within the framework of the Organisation for Economic Co-operation and Development (OECD) to implement an international energy programme. It carries out a comprehensive programme of energy co-operation among twenty-six of the OECD thirty member countries. The basic aims of the IEA are: T To maintain and improve systems for coping with oil supply disruptions. T To promote rational energy policies in a global context through co-operative relations with non-member countries, industry and international organisations. T To operate a permanent information system on the international oil market. T To improve the world’s energy supply and demand structure by developing alternative energy sources and increasing the efficiency of energy use. T To assist in the integration of environmental and energy policies. The IEA member countries are: Australia, Austria, Belgium, Canada, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Japan, Republic of Korea, Luxembourg, Netherlands, New Zealand, Norway, Portugal, Spain, Sweden, Switzerland, Turkey, United Kingdom and United States. The Slovak Republic and Poland are likely to become member countries in 2007/2008. The European Commission also participates in the work of the IEA. ORGANISATION FOR ECONOMIC CO-OPERATION AND DEVELOPMENT The OECD is a unique forum where the governments of thirty democracies work together to address the economic, social and environmental challenges of globalisation. The OECD is also at the forefront of efforts to understand and to help governments respond to new developments and concerns, such as corporate governance, the information economy and the challenges of an ageing population. The Organisation provides a setting where governments can compare policy experiences, seek answers to common problems, identify good practice and work to co-ordinate domestic and international policies. The OECD member countries are: Australia, Austria, Belgium, Canada, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Japan, Republic of Korea, Luxembourg, Mexico, Netherlands, New Zealand, Norway, Poland, Portugal, Slovak Republic, Spain, Sweden, Switzerland, Turkey, United Kingdom and United States. The European Commission takes part in the work of the OECD. © OECD/IEA, 2007 International Energy Agency (IEA), Head of Communication and Information Office, 9 rue de la Fédération, 75739 Paris Cedex 15, France. Please note that this publication is subject to specific restrictions that limit its use and distribution. The terms and conditions are available online at http://www.iea.org/Textbase/about/copyright.asp FOREWORD FOREWORD Improving energy efficiency is the single most important first step toward achieving the three goals of energy policy: security of supply, environmental protection and economic growth. Nearly a third of global energy demand and CO2 emissions are attributable to manufacturing, especially the big primary materials industries such as chemicals and petrochemicals, iron and steel, cement, paper and aluminium. Understanding how this energy is used, the national and international trends and the potential for efficiency gains, is crucial. This book shows that, while impressive efficiency gains have already been achieved in the past two decades, energy use and CO2 emissions in manufacturing industries could be reduced by a further quarter to a third, if best available technology were to be applied worldwide. Some of these additional reductions may not be economic in the short- and medium-term, but the sheer extent of the potential suggests that striving for significant improvements is a worthwhile and realistic effort. A systems approach is needed that transcends process or sector boundaries and that offers significant potential to save energy and cut CO2 emissions. The growth of industrial energy use in China has recently dwarfed the combined growth of all other countries. This structural change has had notable consequences for industrial energy use worldwide. It illustrates the importance of more international co-operation. The IEA has undertaken an extensive programme to assess industrial energy efficiencies worldwide. This study of industrial energy use represents important methodological progress. It pioneers powerful new statistical tools, or “indicators” that will provide the basis for future analysis at the IEA. At the same time it contains a wealth of recent data that provide a good overview of energy use for manufacturing worldwide. It also identifies areas where further analysis of industrial energy efficiency is warranted. Industry has provided significant input and support for this analysis and its publication is intended as a basis for further discussion. I am encouraged by the strong commitment that industry is demonstrating to address energy challenges and welcome the valuable contributions from the Industrial Energy-Related Technologies and Systems Implementing Agreement of the IEA collaborative network. This book is part of the IEA work in support of the G8 Gleneagles Plan of Action that mandated the Agency in 2005 to chart the path to a “clean, clever and competitive energy future”. It is my hope that this study will provide another step toward the realisation of a sustainable energy future. This study is published under my authority as Executive Director of the IEA and does not necessarily reflect the views of the IEA Member countries. Claude Mandil Executive Director 3 ACKNOWLEDGEMENTS ACKNOWLEDGEMENTS This publication was prepared by the International Energy Agency. The work was coordinated by the Energy Technology and R&D Office (ETO). Neil Hirst, Director of the ETO, provided invaluable leadership and inspiration throughout the project. Robert Dixon, Head of the Energy Technology Policy Division, offered essential guidance and input. This work was done in close co-operation with the Long-Term Co-operation and Policy Office (LTO) under the direction of Noé van Hulst. In particular, the Energy Efficiency and Climate Change Division, headed by Rick Bradley, took part in this analysis. Also the Energy Statistics Division and the Office of Global Energy Dialogue provided valuable contributions. Dolf Gielen was the co-ordinator of the project and had overall responsibility for the design and development of the study. The other main authors were Kamel Bennaceur, Tom Kerr, Cecilia Tam, Kanako Tanaka, Michael Taylor and Peter Taylor. Other important contributions came from Richard Baron, Nigel Jollands, Julia Reinaud and Debra Justus. Many other IEA colleagues have provided comments and suggestions, particularly Jean-Yves Garnier, Elena Merle-Beral, Michel Francoeur, Dagmar Graczyk, Jung-Ah Kang, Ghislaine Kieffer, Olivier Lavagne d’Ortigue, Audrey Lee, Isabel Murray and Jonathan Sinton. Production assistance was provided by the IEA Communication and Information Office: Rebecca Gaghen, Muriel Custodio, Corinne Hayworth, Loretta Ravera and Bertrand Sadin added significantly to the material presented. Simone Luft helped in the preparation and correction of the manuscript. Marek Sturc prepared the tables and graphics. We thank the Industrial Energy-Related Technology Systems Implementing Agreement (IETS); notably Thore Berntsson (Chalmers University of Technology, Chair of the IETS Executive Committee) for its valuable contributions to a number of chapters in this report. A number of consultants have contributed to this publication: Sérgio Valdir Bajay (State University of Campinas, Brazil); Yuan-sheng Cui (Institute of Technical Information for the Building Materials Industry, China); Gilberto De Martino Jannuzzi (International Energy Initiative, Brazil); Aimee McKane (Lawrence Berkeley National Laboratory, United States); Yanjia Wang (Tsinghua University, China) and Ernst Worrell (Ecofys, Netherlands). We thank the IEA Member country government representatives, in particular the Committee on Energy Research and Technology, the End-Use Working Party and the Energy Efficiency Working Party and others that provided valuable comments and suggestions. In particular, we thank Isabel Cabrita (National Institute of Industrial Engineering and Technology, Portugal); Takehiko Matsuo (Ministry of Foreign Affairs, Japan); Hamid Mohamed (National Resources Canada) and Yuichiro Yamaguchi (Ministry of Economy, Trade and Industry, Japan). Our appreciation to the participants in the joint CEFIC – IEA Workshop on Feedstock Substitutes, Energy Efficient Technology and CO2 Reduction for Petrochemical Products, 12-13 December 2006 who have provided information and comments, in particular Giuseppe Astarita (Federchimica); Peter Botschek (European Chemical Industry Council); Russell Heinen (SRI Consulting); Hisao Ida (Plastic Waste Management Institute, Japan); Rick Meidel (ExxonMobil); Nobuaki Mita (Japan Petrochemical Industry Association); Hi Chun Park (Inha University, Korea); Martin Patel (Utrecht University); Vianney Schyns (SABIC) and Dennis Stanley (ExxonMobil). 5 6 TRACKING INDUSTRIAL ENERGY EFFICIENCY AND CO2 EMISSIONS Also we would like to thank the members of the International Fertilizer Association (IFA) Technical Committee that participated in the joint IFA – IEA Workshop on Energy Efficiency and CO2 Reduction Prospects in Ammonia Production, 13 March 2007 that have provided information and comments, in particular Luc Maene and Ben Muirhead (International Fertilizer Industry Association, France). We appreciate the information and comments from the International Iron and Steel Institute (IISI) and the members of its Committee on Environmental Affairs, in particular Nobuhiko Takamatsu, Andrew Purvis and Hironori Ueno (IISI, Belgium); Karl Buttiens (Mittal-Arcelor, France); Jean-Pierre Debruxelles (Eurofer, Belgium); Yoshitsugu Iino (JFE Steel Corporation and Japan Iron and Steel Federation, Japan); Nakoazu Nakano (Sumitomo Metals, Japan); Teruo Okazaki (Nippon Steel, Japan); Toru Ono (Nippon Steel, Japan); Larry Kavanagh and Jim Schulz (American Iron and Steel Institute, United States); Verena Schulz (VoestAlpine, Germany) and Gunnar Still (ThyssenKrupp, Germany). Participants in the joint WBCSD – IEA Workshop on Energy Efficiency and CO2 Emission Reduction Potentials and Policies in the Cement Industry, 4 – 5 September 2006 and other experts provided useful information and comments, in particular Andy O’Hare (Portland Cement Association, United States); Toshio Hosoya (Japan Cement Association); Yoshito Izumi (Taiheyo Cement Corporation, Japan and Asia-Pacific Partnership on Clean Development and Climate); Howard Klee (World Business Council for Sustainable Development, Switzerland); Claude Lorea (Cembureau, Belgium); Lynn Price (Lawrence Berkeley National Laboratory, United States); Yuan-sheng Cui and Steve Wang (Institute of Technical Information for Building Materials, China). In addition, we appreciate the participants in the joint World Business Council for Sustainable Development – IEA Workshop on Energy Efficient Technologies and CO2 Reduction Potentials in the Pulp and Paper Industry, 9 October 2006 and other experts that have provided information and comments, in particular Tom Browne (Paprican); James Griffiths (World Business Council for Sustainable Development, Switzerland); Mikael Hannus (Stora Enso, Sweden); Yoshihiro Hayakawa (Oji Paper, Japan;, Mitsuru Kaihori (Japan Paper Association); Wulf Killman (UN-FAO); Marco Mensink (Confederation of European Paper Industries, Brussels); Tom Rosser (Forest Products Association of Canada); Stefan Sundman (Finnish Forest Industries Federation) and Li Zhoudan (China Cleaner Production Centre of Light Industry). Chris Bayliss and Robert Chase (International Aluminium Institute, United Kingdom) are thanked for their comments and suggestions. We thank the participants in the IEA Workshop on Industrial Electric Motor Systems Efficiency, 15 – 16 May 2006 and other experts that have provided inputs on systems and combined hear and power, in particular Pekka Loesoenen, European Commission (Eurostat); Simon Minett (Delta Energy and Environment); Paul Sheaffer (Resource Dynamics Corporation, United States); Loren Starcher (ExxonMobil, United States) and Satoshi Yoshida (Japan Gas Association). Also, we thank the experts that provided data for and comments on the life cycle chapter, in particular Reid Lifset (Yale University), Maarten Neelis, Martin Patel and Martin Weiss (Utrecht University, Netherlands). This work was made possible through funds provided by the Governments of the G7 countries, which are most appreciated. We are grateful to the UK Government for its contribution to the China analysis through its Global Opportunities Fund. Introduction 1 Manufacturing Industry Energy Use and CO2 Emissions 2 General Industry Indicators Issues 3 Chemical and Petrochemical Industry 4 Iron and Steel Industry 5 Non-Metallic Minerals 6 Pulp, Paper and Printing Industry 7 Non-Ferrous Metals 8 Systems Optimisation 9 Life Cycle Improvements Options 10 Table of Contents Annexes 8 TRACKING INDUSTRIAL ENERGY EFFICIENCY AND CO2 EMISSIONS Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 List of Figures 13 List of Tables 15 Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Chapter 1  INTRODUCTION 31 Scope of Indicator Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Energy and CO2 Saving Potentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Next Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Chapter 2  MANUFACTURING INDUSTRY ENERGY USE AND CO2 EMISSIONS Chapter 3  GENERAL INDUSTRY INDICATORS ISSUES 39 45 Energy Indicators Based on Economic and Physical Ratios . . . . . . . . . . . . . . . . . 45 Methodological Issues 46 Definition of Best Available Technique and Best Practice 48 Data Issues 49 Practical Application of Energy and CO2 Emission Indicators. . . . . . . . . . . . . . . 51 Pulp, Paper and Printing 51 Iron and Steel 52 Cement 52 Chemicals and Petrochemicals 53 Other Sectors / Technologies 53 International Initiatives: Sectoral Approaches to Developing Indicators . . . . . 54 Intergovernmental Panel on Climate Change Reference Approach 54 Pulp and Paper Initiatives 55 Cement Sustainability Initiative 55 Asia-Pacific Partnership on Clean Development and Climate 56 Benchmarking in the Petrochemical Industry 56 Chapter 4  CHEMICAL AND PETROCHEMICAL INDUSTRY 59 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Global Importance and Energy Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Petrochemicals Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Steam Cracking: Olefins and Aromatics Production 66 TABLE OF CONTENTS Propylene Recovery in Refineries and Olefins Conversion Aromatics Extraction Methanol Olefins and Aromatics Processing 71 71 72 74 Inorganic Chemicals Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Chlorine and Sodium Hydroxide 76 Carbon Black 77 Soda Ash 78 Industrial Gases 80 Ammonia Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Combined Heat and Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Plastics Recovery Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Energy and CO2 Emission Indicators for the Chemical and Petrochemical Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Energy Efficiency Index Methodology 88 91 CO2 Emissions Index Life Cycle Index 93 Energy Efficiency Potential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Chapter 5  IRON AND STEEL INDUSTRY 95 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Global Importance and Energy Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Indicator Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 System Boundaries 99 Product and Process Differentiation 99 Allocation Issues 99 Feedstock Quality Issues 101 Energy Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Energy Intensity Indicators and Benchmarks 102 Energy Intensity Analysis 103 Efficiency Improvements 106 Coke Ovens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Coke Oven Gas Use 111 Coke Dry Quenching 111 Iron Ore Agglomeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Ore Quality 115 Blast Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Coal and Coke Quality 119 Coal Injection 120 9 10 TRACKING INDUSTRIAL ENERGY EFFICIENCY AND CO2 EMISSIONS Plastic Waste Use Charcoal Use Top-Pressure Recovery Turbines Blast Furnace Gas Use Blast Furnace Slag Use Hot Stoves 121 121 123 123 124 126 Basic Oxygen Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Basic Oxygen Furnace Gas Recovery 127 Steel Slag Use 127 Electric Arc Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Cast Iron Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Direct Reduced Iron Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Steel Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Energy Efficiency and CO2 Reduction Potentials . . . . . . . . . . . . . . . . . . . . . . . . 136 Chapter 6  NON-METALLIC MINERALS 139 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Global Importance and Energy Use 140 Cement Production Process 140 Energy and CO2 Emission Indicators for the Cement Industry 162 Lime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Overview 163 Lime Production Process 164 166 Energy Consumption and CO2 Emissions from Lime Production Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Overview 166 Glass Production Process 167 168 Energy Consumption and CO2 Emissions from Glass Production Ceramic Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Overview 169 Ceramics Production Process 172 173 Energy Consumption and CO2 Emissions from Ceramics Production Indicators for Lime, Glass and Ceramics Industries . . . . . . . . . . . . . . . . . . . . . . 174 Chapter 7  PULP, PAPER AND PRINTING INDUSTRY 175 Global Importance and Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Methodological and Data Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176