Energy Management in copper industry using OSIsoft PI System Aurubis AG Hamburg Thorsten Stölcken Energy management Aurubis AG, Hamburg Atanas Rusev PlantSoft GmbH 20. Juni 2012 1 Agenda 1. Aurubis 2. Energy management at Aurubis Hamburg 3. The energy management system (EMS) 2 Aurubis has taken its first step outside of Europe with the acquisition of Luvata RPD Production sites Copper production Copper processing BU Primary Copper BU Copper Products » Hamburg D » Hamburg D Olen B » Pirdop BG » » Emmerich D » Olen B » Avellino I » Röthenbach D » Stolberg D » Buffalo USA BU Recycling / » Pori FIN Precious Metals » Finspång S » Zutphen NL » Lünen D » Mortara I » Olen B » Smethwick GB » Hamburg D » Dolný Kubín SK » Fehrbellin D Aurubis has a service and sales network in more than 20 countries (Europe, Asia and North America) 3 Aurubis main production works in Hamburg - a downtown copper smelter Continuous casting plant Secondary smelter / precious metals Primary smelter Tankhouse Rod plant 4 Aurubis, an integrated copper producer Integrated copper processor Mines and Processors and Copper production Copper processing recycling markets end users BU Primary Copper BU Copper Products SULFURIC Iron silicate SHAPES Pre-rolled strip and ACID strips CONCENTRATES BU Recycling / Precious Metals Shaped wires CATHODES WIRE ROD RECYCLING PRECIOUS Other MATERIALS METALS metals Special profiles 5 Around 2 million tonnes of copper concentrates are processed in the Group Discharging copper Storage and mixing of Casting of copper anodes concentrates in copper concentrate in the primary smelter Brunsbüttel for further transportation 6 Agenda 1. Aurubis 2. Energy management at Aurubis Hamburg 3. The energy management system (EMS) 7 Energy department 39 employees 8 white collar 31 blue collar 3 employees in energy management 8 Agenda 1. Aurubis 2. Energy management at Aurubis Hamburg 3. The Energy Management system (EMS) 9 Aspects considered for development of an EMS according to DIN EN ISO 50001 » An EMS is a Management system, similar to others, e.g. ISO 14001 » An EMS needs a strong support by Management » The Company has a commitment for efficient usage of energy and energy targets » Sufficient personel and money has to be planned » A responsible Energy Management commissioner has to be named, this person is reporting directly to Management » All production units have to be included » Processes should be transparent and documented » A Data Storage system has to be installed. All data have to be comprehensible; » Data validation is very important. » Energy flows have to be analysed, opportunities for energy optimization demonstrated » Internal audits for each production unit have to be done; annual Management Review fo the whole company. 10 EMS Aurubis Hamburg Costs and Benefits » Costs for Aurubis site Hamburg Costs 1 Mio.€, mostly for metering hardware; existing PI System for the production has been extended. Total metering units: app. 2.000 units » The EMS Hamburg is tested and certificated by the German TÜV. » This is a prerequisite for EEG (renewable energy law) tax exemption in Germany » Benefits for the site » Necessity because of EEG reduction » Database for CO2-Certificates trading 3.HP (ETS) » Energy optimization and energy saving » Transparency and Energy accounting on demand 11 Data Security, Analyses, Energy reports Display All meterings in PLC and via OPC on PC‘s (by using a buffer) to PI Server All metering data stored in PI Server; Specific calculations (PE, ACE, AF) Energy Reports Analyses The EMS-Server is used for Energy accounting, related to SAP cost accounting positions, and archived the results in a SQL-Database; SAP interface via XML No direct access from EMS to PLC/DCS SAP 12 Intelligent combination of PI and SQL-DB All data written in SQL-DB PI-data SAP-data Monthly data for • measurement Read out • cost center (water meter) • cost center group Oracle-DB (electr. counter) These data are essential for Manual input • Monthly calculations and balances • Energy optimazation projects The Importer • emission trading system (ETS) is the all-in-one Gateway, developed by PlantSoft 13 Example for SQL-templates Using Microsoft Excel 14 The SQL-Query Using Microsoft Excel and the add-in sql query, SQL-queries can be made easily, referring to cells in Excel. 15 Technical organisation of EMS Hamburg PI-Server power plant RWN cast plant Ethernet chemical plant Using existing infrastructure acid plant » installed measurements in the plant existing data path » rod plant » existing PI-Server smelter tankhouse » existing Software (ProcessBook) 16 All over 30 different energy types are in the EMS Start mask 17 Flow of nat.gas has to be monitored 18 Maximum consumption of nat.gas has to be checked 19 electricity – prognosis from SQL-DB vs. consumption monitored in PI 20 A typical user electricity grid 21 PI-NotifyMe In case of defined situations, PI-NotifyMe sends » E-Mails » SMS 22 Detailed presentations are necessary for energy optimization 23 Compression of measured energy data to total sum at Aurubis site in Hamburg example: nat.gas measurement converter (smelter) 10000 Plant Hamburg Nat.gas converter 1 Cost center KST-group Area-KST-group Division 12000 Nat.gas 661 12220 12200 (primary converter 2 (converters) (converters + (converters + copper) Nat.gas anode ovens) anode ovens) converter 3 More measurement more cost center More measurement 24 Compression of the Sites Costs to Total Company Costs in SAP (w/o third party companies) 25 The energy report (part 1) 26 The energy report (part 2) 27 Expansion of EMS to different sites (Pirdop Bulgaria, Stolberg, Lünen, Straß,…) The EMS is used companywide via Internet by using a keycode 28 Energy Management in copper industry using OSIsoft PI System Aurubis AG Hamburg Thorsten Stölcken Energy management Aurubis AG, Hamburg Atanas Rusev PlantSoft GmbH 20. 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