ISO 50001: More need for energy-efficient lab-equipment

Energy Management based on ISO 50001

You have heard of “energy management”? Or are you one of the companies that successfully lives an energy management system? Do you treat the topic of climate and resource conservation with open eyes and ears?

Then the ISO 50001, which is designed to help organizations and companies build a systematic energy management system, is well known to you. The International Organization for Standardization (ISO) published the ISO 50001 in June 2011, which since December 2011 has completely replaced DIN EN 16001.

Introduction of a ISO 50001 energy management system in your company

You decide, whether you introduce an energy management system according to ISO 50001. That means there is no certification requirement. However, certification according to ISO 50001 – at least in Germany – is a prerequisite for partial exemption of the EEG surcharge.

In the future, a practiced energy management system will be the basis for relieving you, as a manufacturing industry, of the electricity and energy tax.

A systematic energy management requires that you evaluate the following as a company:

• your energy consumers
• your energy sources
• and energy use.

To optimize your energy consumption, you need to measure it and systematically improve it through organizational and technical measures.

Do you know your energy flows in the company?

Do you know your departments and business units with the highest energy consumption share in the business?

What does NETZSCH have to do with the ISO 50001?

At the headquarter of NETZSCH-Gerätebau GmbH in Selb, we have introduced an energy management system in recent years and make our contribution to climate protection. It was clear to us that we needed a large part of our energy in the production area. Since we measure our energy consumption, we also realize that the energy consumption in our laboratory is just as high. Also, the final-control, where we bring all our equipment after production, recorded similarly high energy demand.
However, if you look at the ISO 50001, you also realize that this energy awareness is met with increased interest in only Europe, Asia and the Middle East alone. Other regions with not to be despised economic performance are completely outside. So the global potential is still very big.

Main market segments, where our customers are working in, are carrying the flag!

A big number of certified companies are from fields, where our main customer segments are coming from:

1. metals and metal products
2. foods
3. Chemical products
4. Rubber and plastic products
5. Electrical and optical equipment
6. Electrical supply
7. construction
8. Transportation, storage and communication
9. Machines and equipment
10. Water Supply

ISO 50001-Certificates by segments
Fig. 1: ISO 50001 certificates issued by industrial sector (2016) – Source: ISO

Customers and potential customers in our core markets “Metals”, “Food”, “Chemicals”, “Rubber and Plastics” and the “Building Materials Industry” in our priority regions of Europe and Asia are pulling together with us and are working on the efficient one Use of our worldwide resources.

The “ECO-STA” – Energy-efficient simultaneous thermobalance for energy-conscious laboratory use!

Simultaneous thermal analysis is becoming increasingly popular. Combine the two best known methods of thermal analysis in a single device. As a combination between a highly sensitive thermobalance and a differential scanning calorimeter, this method (STA = Simultaneous Thermal Analysis) shows us when mass loss (TG = thermogravimetry) or energy conversion (DSC = differential calorimeter) take place in one material. These events provide us with information about the temperature at which and for how long, for example, a binder degrades in a ceramic material. Also, show us when a material melts and what energy a material absorbs until it is completely melted.

In general, a simultaneous thermal analyzer will help you in the combined study of:

• Material compositions
• Thermal stability
• Phase transitions
• binder removal.

Highest precision on highest temperatures!

In order to equip a instrument of this type with the required temperature stability in application temperatures of up to 2400 ° C, manufacturers resort to a thermostating by means of a water cycle. Temperature-stabilized water flows from a thermostat through the balance chamber and sections of the furnaces. This keeps the high-precision balance systems at a constant temperature. The constant cooling of the water to constant temperature requires a lot of energy and produces waste heat, which must be regulated by air conditioners.

Primary and secondary energy consumption

Thus, the energy consumption of a “STA” is composed of the primary energy demand for the operation of the system and the ovens as well as the operation of the thermostat. As a secondary energy we consider the energy, which is omitted for example for the air conditioning of the place of installation and the water consumption.
We took a closer look at this circumstance at NETZSCH and developed the ECO-STA on the basis of these findings. At the same time, it achieves very high performance without the need of a thermostatic water circulation system.

This reduces the proportion of primary energy required by the thermostat by up to 90%.

Incidentally, we also achieve another effect. Especially in clean rooms or areas where sensitive conditions prevail, we exclude germs and contamination sources by not using thermostats.

Savings of approximately € 80,000 over the entire life cycle!

The thermostating of a STA system with a water cycle costs about € 1,000 per year in electricity. In the ECO-STA, the temperature-sensitive areas are stabilized with resistance-heating foiling, which consumes around € 100 per year. For a period of use of 10 years you save ONLY at the thermostat about 9.000, – €. But the costs for cooling water, maintenance and repair are not included yet.

At NETZSCH, we run 9 STAs in our application lab at the same time. That means an energy saving of about 80.000, – € over the possible average duration of use.

The first customer for our new ECO-STA is thus already certain: Of course – our own NETZSCH laboratory.

Since the cost of air conditioning the laboratory depends on how many heat sources are in the room, the cost component is much more difficult to capture. A thermostat requires about 20-30% of the total energy required and causes a major portion of the waste heat of a STA system. So we can say that the waste heat of a single STA in a room is reduced by about 1/3 due to the alternative thermostats.

Number of certified companies increased by 69% between 2015 and 2016!

Our common global climate goals and the responsible use of our energy resources are calling for a rethink. This can also be expressed in figures: The number of ISO 50001 certified companies worldwide increased by 69% between 2015 and 2016. Of course, the ISO 50001 is a “young” standard, where the annual growth is greater than in an ISO 9001 certification.

More and more companies are turning to efficient energy use and monitoring energy consumption.

At NETZSCH we are known for understanding ourselves in processes and problems of our customers. We usually go a step further than we expected. So, if your organization already has an agenda to monitor energy needs, one of your next purchases from your lab is to consider the new ECO-STA.

Alexander Frenzl has been employed in the Development Department at
NETZSCH Analyzing & Testing since 2005. In 2008, he became Head of the
Mechanical Development Department and, as such, has been involved
in the development of all NETZSCH instruments. Since 2014, Alexander
Frenzl has been the Business Segment Manager for Glass, Ceramics and
Building Materials and serves as an interface between our Development,
Sales and Marketing Departments. One of his focal points is industrial
quality assurance for insulating materials as well as the process optimization
during processing ceramics, especially with respect to new and more
efficient technologies.

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