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Division BAT 19 In order to use energy efficiently, BAT is to use techniques (a) and (b) and an appropriate combination of the techniques (c) to (h) given below.

United Kingdom

Original text. Later amendments are not shown.

TechniqueDescriptionApplicability
Management techniques
(a)Energy efficiency planAn energy efficiency plan is part of the EMS (see BAT 1) and entails defining and calculating the specific energy consumption of the activity, setting key performance indicators on an annual basis (e.g. MWh/tonne of product) and planning the periodic improvement targets and related actions. The plan is adapted to the specificities of the plant in terms of process(es) carried out, materials, products, etc.The level of detail and nature of the energy efficiency plan and of the energy balance record will generally be related to the nature, scale and complexity of the installation and the types of energy sources used. It may not be applicable if the STS activity is carried out within a larger installation, provided that the energy efficiency plan and the energy balance record of the larger installation sufficiently cover the STS activity.
(b)Energy balance record

The drawing up once every year of an energy balance record which provides a breakdown of the energy consumption and generation (including energy export) by the type of source (e.g. electricity, fossil fuels, renewable energy, imported heat and/or cooling). This includes:

  1. (i)

    defining the energy boundary of the STS activity;

  2. (ii)

    information on energy consumption in terms of delivered energy;

  3. (iii)

    information on energy exported from the plant;

  4. (iv)

    energy flow information (e.g. Sankey diagrams or energy balances) showing how the energy is used throughout the process.

The energy balance record is adapted to the specificities of the plant in terms of process(es) carried out, materials, etc.

Process-related techniques
(c)Thermal insulation of tanks and vats containing cooled or heated liquids, and of combustion and steam systems

This may be achieved for example by:

  • using double-skinned tanks;

  • using pre-insulated tanks;

  • applying insulation to combustion equipment, steam pipes and pipes containing cooled or heated liquids.

Generally applicable.
(d)Heat recovery by cogeneration – CHP (combined heat and power) or CCHP (combined cooling, heat and power)Recovery of heat (mainly from the steam system) for producing hot water/steam to be used in industrial processes/activities. CCHP (also called tri-generation) is a cogeneration system with an absorption chiller that uses low-grade heat to produce chilled water.Applicability may be restricted by the plant layout, the characteristics of the hot gas streams (e.g. flow rate, temperature) or the lack of a suitable heat demand.
(e)Heat recovery from hot gas streamsEnergy recovery from hot gas streams (e.g. from dryers or cooling zones), e.g. by their recirculation as process air, through the use of heat exchangers, in processes, or externally.
(f)Flow adjustment of process air and off-gasesAdjustment of the flow of process air and off-gases according to the need. This includes reduction of air ventilation during idle operation or maintenance.Generally applicable.
(g)Spray booth off-gas recirculationCapture and recirculation of the off-gas from the spray booth in combination with efficient paint overspray separation. Energy consumption is less than in the case of fresh air use.Applicability may be restricted by health and safety considerations.
(h)Optimised circulation of warm air in a large-volume curing booth using an air turbulatorAir is blown into a single part of the curing booth and distributed using an air turbulator which turns the laminar airflow into the desired turbulent flow.Only applicable to spray coating sectors.

Table 3

BAT-associated environmental performance levels (BAT-AEPLs) for specific energy consumption

The BAT-AEPL may not apply where the coil coating line is part of a larger manufacturing installation (e.g. steelworks) or for combilines.

SectorProduct typeUnitBAT-AEPL(Yearly average)
Coating of vehiclesPassenger carsMWh/vehicle coated0,5–1,3
Vans0,8–2
Truck cabins1–2
Trucks0,3–0,5
Coil coatingSteel and/or aluminium coilkWh/m2 of coated coil0,2–2,5f1
Coating of textiles, foils and paperCoating of textiles with polyurethane and/or polyvinyl chloridekWh/m2 of coated surface1–5
Manufacturing of winding wiresWires with an average diameter > 0,1 mmkWh/kg of coated wire< 5
Coating and printing of metal packagingAll product typeskWh/m2 of coated surface0,3–1,5
Heatset web offset printingAll product typesWh/m2 of printed area4–14
Flexography and non-publication rotogravure printingAll product typesWh/m2 of printed area50–350
Publication rotogravure printingAll product typesWh/m2 of printed area10–30

The associated monitoring is given in BAT 19 (b).

Annotations

Footnotes

f1

The BAT-AEPL may not apply where the coil coating line is part of a larger manufacturing installation (e.g. steelworks) or for combilines.