Efficiency booster retrofit: Reducing energy costs through modernization

With the elimination of nuclear power from the German energy mix, possible bottlenecks, for example in the coming winter, will have to be offset primarily by fossil fuels. This is because the expansion of renewables in Germany is still comparatively sluggish. But there is an additional problem with natural gas: Russia has turned it into a weapon in the war against Ukraine. Instead, the government is relying on LNG, which, however, remains comparatively expensive despite fixed-price contracts and gas price brakes. 

The price of electricity also remains at record levels. In a recent statement, Tanja Gönner, CEO of the Federation of German Industries (BDI), criticized the fact that the energy price brakes are not being implemented by many companies. The stock exchange prices for electricity are still more than three times higher than the average for the years 2010-2019. The DIHK also emphasizes: "Although the price level for electricity and gas has fallen slightly recently, it continues to weigh on international competitiveness. 

Reducing operating costs through energy savings

For companies in the metallurgical plant engineering sector, the trend towards retrofits is opening up new growth potential. This is because they play a key role in the topic of modernization: "Saving or replacing gas in industrial processes is only possible with the help of technologies from mechanical and plant engineering," explains Matthias Zelinger, Head of Climate and Energy at VDMA. "That's why gas burners in industrial furnaces and heating processes are currently being modified, control systems are being reprogrammed and gas mixing equipment is being installed throughout the country." 

In particular, he said, converting processes to alternative energy sources - including oil, propane-butane gas, biogas and electricity - is in demand in the short term to reduce dependence on natural gas. "This applies to energy-intensive customer groups, but also to mechanical engineering itself," Zelinger explains. On average, he says, mechanical engineering is not a large consumer. "But gas is used in crucial production steps, so the willingness to invest is also high."

30% less energy consumption thanks to modernization

Like every crisis, the energy crisis also holds opportunities: it accelerates the switch to other energy sources, especially renewable energies. More and more plant engineers are examining which processes can be converted from gas to electric heating. Often, a long overdue modernization of the plant park also helps to reduce energy consumption by up to 30 percent, explains Jörn Ludewig, Managing Director of Jasper GmbH.  

Successful example: Aichelin modernizes at SKF

SKF GmbH produces various rolling bearing products in Lüchow, Lower Saxony. Aichelin equipment and services have been used for decades in the heat treatment of these products. SKF commissioned Aichelin Service to comprehensively modernize five of these plants in the course of 2022. SKF declares that it will have fully achieved its project goals with their recommissioning at the end of 2022. Production reliability has been ensured during ongoing operation, while productivity has been increased in the long term. 

To increase part throughput in the heat treatment facilities, Aichelin designed a new stacking gantry with the SKF project team and an external partner. It is being used for the first time at SKF and now enables rolling bearings to pass through two to a maximum of three layers in a single heat treatment process instead of the previous single-layer process. In addition to expanding production capacity, this now allows SKF to respond more flexibly to additional demand. And most importantly, the plants can be utilized in a much more energy-efficient manner. FOCOS 4.0, Aichelin's Industry 4.0 application for monitoring and quality verification of process values, has also been newly integrated.

Investment inhibited by planning uncertainty

Two factors are still limiting project business for modernization and retrofit: First, numerous plant operators are uncertain and are waiting to see how the situation on the markets will develop. They are holding back on investments for fear of stranded assets. A second limiting factor is the capacity utilization of the plant manufacturers responsible for retrofits. As the current situation entails an enormous need for advice, the number of inquiries is skyrocketing. Plant engineers cannot process this in a short time. There is a lack of time, components and personnel resources - a brake on comprehensive modernization.

But in the long term, the political goal is clearly defined. In 2045, industrial process heat must be generated in a CO2-neutral manner. "With the goal of climate neutrality, industries are probably facing the biggest transformation in their history," says Friedrich-Georg Kehrer, Global Portfolio Director at Messe Düsseldorf GmbH. And operators and plant engineers must implement this transformation together - albeit under increased pressure.