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Efficient Use of Energy in the Industrial Sector: an Analysis of Options for Selected Escwa Member States

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Efficient Use of Energy in the Industrial Sector: an Analysis of Options for Selected Escwa Member States ECONOMIC AND SOCIAL COMMISSION FOR WESTERN ASIA EFFICIENT USE OF ENERGY IN THE INDUSTRIAL SECTOR: AN ANALYSIS OF OPTIONS FOR SELECTED ESCWA MEMBER STATES United Nations D i s t r . G E N E R A L E / E S C W A / E N R / 2 0 0 1 / 1 4 3 0 O c t o b e r 2 0 0 1 O R I G I N A L : E N G L I S H ECONOMIC AND SOCIAL COMMISSION FOR WESTERN ASIA EFFICIENT USE OF ENERGY IN THE INDUSTRIAL SECTOR: AN ANALYSIS OF OPTIONS FOR SELECTED ESCWA MEMBER STATES United Nations New York, 2001 ii The designations employed and the presentation of the material in this publication do not imply the expression of any opinion whatsoever on the part of the Secretariat of the United Nations concerning the legal status of any country, territory, city or area, or of its authorities, or concerning the delineation of its frontiers or boundaries. Mention of firm names and commercial products does not imply the endorsement of the United Nations. 01-0934 CONTENTS Page Abbreviations and explanatory notes ................................................................................................... vii Introduction .......................................................................................................................................... 1 Chapter I. THE ESCWA INDUSTRIAL SECTOR, MAIN FEATURES AND ENERGY CONSUMPTION PATTERNS .................................................................................................. 3 A. The total energy consumption patterns.................................................................................. 3 B. The manufacturing industries, classification and main features ............................................ 7 C. The industrial sector’s energy consumption patterns, and the need for efficiency improvement ......................................................................................................................... 9 II. PRIORITY OPTIONS FOR EFFICIENT USE OF ENERGY IN THE ESCWA INDUSTRIAL SECTOR ............................................................................................................ 11 A. Potential energy efficiency and conservation technologies................................................... 11 B. The procedure and criteria for ranking and selecting the priority energy efficiency and conservation options...................................................................................... 14 C. The selected case studies ...................................................................................................... 18 III. EVALUATION OF THE SELECTED PRIORITY OPTIONS FOR EFFICIENT USE OF ENERGY IN THE ESCWA INDUSTRIAL SECTOR.............................................. 20 A. Evaluation requirements and limitations .............................................................................. 20 B. The evaluation approaches for the selected priority options ................................................. 20 IV. EFFICIENT USE OF ENERGY IN THE INDUSTRIAL SECTOR: THE CASE OF EGYPT ............................................................................................................. 27 A. The industrial sector of Egypt: Classification and main features .......................................... 27 B. The situation of energy and industry in Egypt....................................................................... 27 C. Status of activities for improving industrial energy efficiency.............................................. 31 D. Combined heat and power systems, status assessment and evaluation.................................. 36 E. Waste heat recovery systems, status assessment and evaluation ........................................... 39 F. Tune-up of boilers and furnaces, status assessment and evaluation ...................................... 43 G. Constraints and recommendations ......................................................................................... 45 V. EFFICIENT USE OF ENERGY IN THE INDUSTRIAL SECTOR: THE CASE OF LEBANON ....................................................................................................... 47 A. The industrial sector in Lebanon: classification and main features ....................................... 47 B. The situation of energy and industry in Lebanon .................................................................. 48 C. Status of activities for improving industrial energy efficiency.............................................. 51 D. Combined heat and power systems, status assessment and evaluation.................................. 53 E. Waste heat recovery systems, status assessment and evaluation ........................................... 56 F. Tune-up of boilers and furnaces, status assessment and evaluation ...................................... 56 G. Constraints and recommendations ......................................................................................... 57 iii CONTENTS (continued) Page VI. EFFICIENT USE OF ENERGY IN THE INDUSTRIAL SECTOR: THE CASE OF THE SYRIAN ARAB REPUBLIC ................................................................. 58 A. The industrial sector of the Syrian Arab Republic: classification and main features............. 58 B. The situation of energy and industry in the Syrian Arab Republic ....................................... 59 C. Status of activities for improving industrial energy efficiency ............................................. 64 D. Combined heat and power systems, status assessment and evaluation ................................. 65 E. Waste heat recovery (WHR) systems, status assessment and evaluation.............................. 67 F. Tune-up of boilers and furnaces, status assessment and evaluation...................................... 68 G. Constraints and recommendations ........................................................................................ 68 VII. SUMMARY, CONCLUSIONS AND RECOMMENDATIONS ............................................ 70 A. Summary and main conclusions ............................................................................................ 70 B. Recommendations ................................................................................................................. 76 References ............................................................................................................................................... 78 LIST OF TABLES 1. Primary energy consumption in the ESCWA region in 1999 ....................................................... 4 2. Final energy consumption in the ESCWA region by type of fossil fuels and electricity.............. 6 3. Main features and economic indicators of the manufacturing industries in selected ESCWA member countries (1999) ............................................................................................... 8 4. ....................................................................................................................................Electricity consumpti 5. Estimated final energy consumption in the industrial sector ................................. 10 6. Industrial energy intensity development for 1995-1998 ........................................ 10 7. Examples of the identified measures and the potential energy efficiency improvement in selected industries ......................................................................................................................... 15 8. General characteristics of the well-proven energy conservation measures............ 16 9. Matrix for the selection of high priority energy conservation measures................ 19 10. Comparison of the characteristics of the CHP technologies.......................................... 22 11. Typical examples of CHP system capital cost estimates ............................................... 23 12. Primary energy consumption in Egypt .......................................................................... 28 13. Development of industrial energy consumption and energy intensity in Egypt ............ 29 14. ECEP/DSM, energy audit results................................................................................... 33 15. Installed and estimated potential capacities of CHP in Egyptian industry .................... 37 16. The set of proposed CHP options modules for application in the Egyptian industry ................................................................................................................................38 17. Evaluation results of the selected CHP modules for energy efficiency application in Egyptian industry .......................................................................................................................... 39 18. A Summary of major audited and implemented WHR options in Egyptian industry................... 40 iv 19. Priority ranking of the selected WHR systems for Egyptian industry .......................................... 41 CONTENTS (continued) Page 20. Evaluation summary of waste heat recovery options .................................................... 42 21. Fuel savings and emissions reduction by industrial sectors (Tune-up programme)...................... 44 22. Anticipated fuel savings of fuel oil, gas oil and natural gas for the nationwide tune-up programme of boilers and furnaces............................................................................................... 45 23. Summary of the analysis of nationwide tune-up programme using portable gas analyzers.......... 45 24. Main indicators of the Lebanese industrial sub-sectors ...............................................................
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