Final Report Task 3 Version: 16 December 2011
Study on Amended Working Plan under the Ecodesign Directive (remaining energy-using products and new energy-related products)
Prepared for the European Commission under DG ENTR Service Contract SI2.574204, by: Martijn van Elburg (coordinator), Maaike van der Voort, Roy van den Boorn, Rene Kemna and William Li
Van Holsteijn en Kemna B.V. (VHK) Elektronicaweg 14 2628 XG Delft The Netherlands www.vhk.nl
Disclaimer The sole responsibility for the content of this report lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein.
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) [page intentionally left blank]
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
TABLE OF CONTENTS EXECUTIVE SUMMARY ................................................................................................................ 16 3
Task 3 - Preliminary analysis ................................................................................................ 18 3.1 Introduction ........................................................................................................................... 18 3.1.1 3.1.2 3.1.3 3.1.4
3.2 3.3 3.3.1 3.3.2 3.3.3
4
Structure of Task 3 ........................................................................................................................... 18 Method for energy analysis ............................................................................................................. 18 For future consideration .................................................................................................................. 20 Scope ............................................................................................................................................... 20
Ranking of product groups by energy saving potential ......................................................... 22 Assessment of costs related to purchase and operation ....................................................... 25 Quantitative cost analysis ................................................................................................................ 25 Qualitative cost analysis .................................................................................................................. 29 Conclusion ....................................................................................................................................... 33
Preliminary energy analysis of product groups ..................................................................... 34 4.1 Mobile agricultural machinery............................................................................................... 34 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5
4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5
4.3 4.3.1 4.3.2 4.3.3 4.3.4
4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5
4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5
4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5
4.7 4.7.1 4.7.2
Product group .................................................................................................................................. 34 Market and stock data ..................................................................................................................... 35 Energy consumption ........................................................................................................................ 39 Improvement potential ................................................................................................................... 40 Discussion / Issues to consider for follow-up .................................................................................. 42
Mobile construction machinery ............................................................................................. 44 Product group .................................................................................................................................. 44 Market and stock data ..................................................................................................................... 44 Energy consumption ........................................................................................................................ 48 Improvement potential ................................................................................................................... 49 Discussion / Issues to consider for follow-up .................................................................................. 50
Handheld power tools ............................................................................................................ 51 Product group .................................................................................................................................. 51 Market data ..................................................................................................................................... 51 Improvement potential ................................................................................................................... 58 Discussion / Issues to consider for follow-up .................................................................................. 58
Stationary agricultural equipment......................................................................................... 59 Product group .................................................................................................................................. 59 Market and stock data ..................................................................................................................... 59 Energy consumption ........................................................................................................................ 60 Improvement potential ................................................................................................................... 62 Discussion / Issues to consider for follow-up .................................................................................. 63
Stationary construction equipment ....................................................................................... 64 Product group .................................................................................................................................. 64 Market and stock data ..................................................................................................................... 64 Energy consumption ........................................................................................................................ 65 Improvement potential ................................................................................................................... 66 Discussion / Issues to consider for follow-up .................................................................................. 67
Small fans (< 125 W) .............................................................................................................. 68 Product group .................................................................................................................................. 68 Market and stock data ..................................................................................................................... 68 Energy consumption ........................................................................................................................ 69 Improvement potential ................................................................................................................... 70 Discussion / Issues to consider for follow-up .................................................................................. 71
Blowers .................................................................................................................................. 72 Product group .................................................................................................................................. 72 Market and stock data ..................................................................................................................... 73
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.7.3 4.7.4 4.7.5
4.8
Energy consumption ........................................................................................................................ 73 Improvement potential ................................................................................................................... 74 Discussion / Issues to consider for follow-up .................................................................................. 75
High temperature ventilation equipment .............................................................................. 76
4.8.1 4.8.2 4.8.3 4.8.4 4.8.5
4.9
Product group .................................................................................................................................. 76 Market and stock data ..................................................................................................................... 76 Energy consumption ........................................................................................................................ 77 Improvement potential ................................................................................................................... 78 Discussion / Issues to consider for follow-up .................................................................................. 79
Positive displacement pumps................................................................................................. 80
4.9.1 4.9.2 4.9.3 4.9.4 4.9.5
4.10
Product group .................................................................................................................................. 80 Market and stock data ..................................................................................................................... 80 Energy consumption ........................................................................................................................ 83 Improvement potential ................................................................................................................... 83 Discussion / Issues to consider for follow-up .................................................................................. 84
Mobile power generators ...................................................................................................... 86
4.10.1 4.10.2 4.10.3 4.10.4 4.10.5
4.11
Thermal insulation products for buildings ............................................................................. 92
4.11.1 4.11.2 4.11.3 4.11.4 4.11.5
4.12
Product group............................................................................................................................ 114 Market and stock data .............................................................................................................. 114 Energy consumption.................................................................................................................. 115 Improvement potential ............................................................................................................. 115 Discussion / issues to consider for follow-up ............................................................................ 117
Home audio products........................................................................................................... 118
4.15.1 4.15.2 4.15.3 4.15.4 4.15.5
4.16
Product group............................................................................................................................ 111 Market and stock data .............................................................................................................. 111 Energy consumption.................................................................................................................. 111 Improvement potential ............................................................................................................. 112 Discussion / issues to consider for follow-up ............................................................................ 113
Detergents ........................................................................................................................... 114
4.14.1 4.14.2 4.14.3 4.14.4 4.14.5
4.15
Product group............................................................................................................................ 102 Market and stock data .............................................................................................................. 103 Energy consumption.................................................................................................................. 105 Improvement potential. ............................................................................................................ 106 Discussion / issues to consider for follow-up ............................................................................ 109
Clothes ironing products ...................................................................................................... 111
4.13.1 4.13.2 4.13.3 4.13.4 4.13.5
4.14
Product group.............................................................................................................................. 92 Market and stock data ................................................................................................................ 92 Energy consumption.................................................................................................................... 94 Improvement potential ............................................................................................................... 96 Discussion / issues to consider for follow-up ............................................................................ 100
Window products for buildings ............................................................................................ 102
4.12.1 4.12.2 4.12.3 4.12.4 4.12.5
4.13
Product group.............................................................................................................................. 86 Market and stock data ................................................................................................................ 86 Energy consumption.................................................................................................................... 88 Improvement potential ............................................................................................................... 89 Discussion / Issues to consider for follow-up .............................................................................. 91
Product group............................................................................................................................ 118 Market and stock data .............................................................................................................. 118 Energy consumption.................................................................................................................. 120 Improvement potential ............................................................................................................. 123 Discussion / issues to consider for follow-up ............................................................................ 124
Kitchen appliances ............................................................................................................... 125
4.16.1 4.16.2
Product group............................................................................................................................ 125 Market and stock data .............................................................................................................. 125
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.16.3 4.16.4 4.16.5
4.17
Lawn and riding mowers...................................................................................................... 127
4.17.1 4.17.2 4.17.3 4.17.4 4.17.5
4.18
Product group............................................................................................................................ 155 Market and stock data .............................................................................................................. 155 Energy consumption.................................................................................................................. 156 Improvement potential ............................................................................................................. 157 Discussion / issues to consider for follow-up ............................................................................ 158
Steam boilers ....................................................................................................................... 159
4.24.1 4.24.2 4.24.3 4.24.4 4.24.5
4.25
Product group description......................................................................................................... 153 Market and stock data .............................................................................................................. 153 Energy consumption.................................................................................................................. 153 Improvement potential ............................................................................................................. 154 Discussion / issues to consider for follow-up ............................................................................ 154
Point-of-sale and cash dispenser equipment ....................................................................... 155
4.23.1 4.23.2 4.23.3 4.23.4 4.23.5
4.24
Product group............................................................................................................................ 150 Market and stock data .............................................................................................................. 150 Energy consumption.................................................................................................................. 150 Improvement potential ............................................................................................................. 151 Discussion / issues to consider for follow-up ............................................................................ 152
Electric kettles / water cookers ............................................................................................ 153
4.22.1 4.22.2 4.22.3 4.22.4 4.22.5
4.23
Product group............................................................................................................................ 145 Market and stock....................................................................................................................... 145 Energy consumption.................................................................................................................. 146 Improvement potential ............................................................................................................. 147 Discussion / issues to consider for follow-up ............................................................................ 149
Toilets................................................................................................................................... 150
4.21.1 4.21.2 4.21.3 4.21.4 4.21.5
4.22
Product group description......................................................................................................... 139 Market and stock....................................................................................................................... 139 Energy Consumption ................................................................................................................. 140 Improvement potential ............................................................................................................. 142 Discussion / issues to consider for follow-up ............................................................................ 144
Taps and showerheads ........................................................................................................ 145
4.20.1 4.20.2 4.20.3 4.20.4 4.20.5
4.21
Product group............................................................................................................................ 131 Market and stock data .............................................................................................................. 134 Energy consumption.................................................................................................................. 135 Improvement potential ............................................................................................................. 137 Discussion / issues to consider for follow-up ............................................................................ 138
Servers and data storage equipment................................................................................... 139
4.19.1 4.19.2 4.19.3 4.19.4 4.19.5
4.20
Product group............................................................................................................................ 127 Market and stock data .............................................................................................................. 127 Energy consumption.................................................................................................................. 129 Improvement potential ............................................................................................................. 129 Discussion / issues to consider for follow-up ............................................................................ 130
Base station subsystems ...................................................................................................... 131
4.18.1 4.18.2 4.18.3 4.18.4 4.18.5
4.19
Energy consumption.................................................................................................................. 125 Improvement potential ............................................................................................................. 126 Discussion / issues to consider for follow-up ............................................................................ 126
Product group............................................................................................................................ 159 Market and stock....................................................................................................................... 162 Energy consumption.................................................................................................................. 166 Improvement potential ............................................................................................................. 166 Discussion / issues to consider for follow-up ............................................................................ 168
Hot tub / Spa / Whirlpool..................................................................................................... 169
4.25.1 4.25.2
Product group............................................................................................................................ 169 Market and stock....................................................................................................................... 169
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.25.3 4.25.4 4.25.5
4.26
Sauna's ................................................................................................................................. 172
4.26.1 4.26.2 4.26.3 4.26.4 4.26.5
4.27
Product group............................................................................................................................ 198 Market and stock....................................................................................................................... 198 Energy consumption.................................................................................................................. 199 Improvement potential ............................................................................................................. 199 Discussion / issues to consider for follow-up ............................................................................ 200
Medical equipment .............................................................................................................. 201
4.33.1 4.33.2 4.33.3 4.33.4 4.33.5
4.34
Product group............................................................................................................................ 192 Market and stock....................................................................................................................... 192 Energy consumption.................................................................................................................. 193 Improvement potential ............................................................................................................. 193 Discussion / issues to consider for follow-up ............................................................................ 197
Lighting Controls .................................................................................................................. 198
4.32.1 4.32.2 4.32.3 4.32.4 4.32.5
4.33
Product group............................................................................................................................ 189 Market and stock....................................................................................................................... 189 Energy consumption.................................................................................................................. 190 Improvement potential ............................................................................................................. 190 Discussion / issues to consider for follow-up ............................................................................ 191
Heating controls................................................................................................................... 192
4.31.1 4.31.2 4.31.3 4.31.4 4.31.5
4.32
Product group............................................................................................................................ 186 Market and stock....................................................................................................................... 186 Energy consumption.................................................................................................................. 187 Improvement potential ............................................................................................................. 187 Discussion / issues to consider for follow-up ............................................................................ 188
Logistic systems ................................................................................................................... 189
4.30.1 4.30.2 4.30.3 4.30.4 4.30.5
4.31
Product group description......................................................................................................... 181 Market and stock data .............................................................................................................. 181 Energy consumption.................................................................................................................. 183 Improvement potential ............................................................................................................. 184 Discussion / issues to consider for follow-up ............................................................................ 185
Traffic lights ......................................................................................................................... 186
4.29.1 4.29.2 4.29.3 4.29.4 4.29.5
4.30
Product group............................................................................................................................ 176 Market and stock data .............................................................................................................. 176 Energy consumption.................................................................................................................. 178 Improvement potential ............................................................................................................. 178 Discussion / issues to consider for follow-up ............................................................................ 180
Non-domestic hot beverage equipment .............................................................................. 181
4.28.1 4.28.2 4.28.3 4.28.4 4.28.5
4.29
Product group............................................................................................................................ 172 Market and stock data .............................................................................................................. 173 Energy consumption.................................................................................................................. 174 Improvement potential ............................................................................................................. 175 Discussion / issues to consider for follow-up ............................................................................ 175
Elevators, escalators and moving walkways ....................................................................... 176
4.27.1 4.27.2 4.27.3 4.27.4 4.27.5
4.28
Energy consumption.................................................................................................................. 170 Improvement potential ............................................................................................................. 170 Discussion / issues to consider for follow-up ............................................................................ 171
Product group............................................................................................................................ 201 Market and stock....................................................................................................................... 201 Energy consumption.................................................................................................................. 202 Improvement potential ............................................................................................................. 207 Discussion / issues to consider for follow-up ............................................................................ 208
Mobile phones ..................................................................................................................... 209
4.34.1 4.34.2
Product group............................................................................................................................ 209 Market and stock....................................................................................................................... 209
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.34.3 4.34.4 4.34.5
4.35
Fractional horsepower motors............................................................................................. 214
4.35.1 4.35.2 4.35.3 4.35.4 4.35.5
4.36
Product group............................................................................................................................ 214 Market and stock....................................................................................................................... 215 Energy consumption.................................................................................................................. 215 Improvement potential ............................................................................................................. 216 Discussion / issues to consider for follow-up ............................................................................ 217
Power cables ........................................................................................................................ 219
4.36.1 4.36.2 4.36.3 4.36.4 4.36.5
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Energy consumption.................................................................................................................. 211 Improvement potential ............................................................................................................. 212 Discussion / issues to consider for follow-up ............................................................................ 213
Product group............................................................................................................................ 219 Market and stock....................................................................................................................... 219 Energy consumption.................................................................................................................. 220 Improvement potential ............................................................................................................. 221 Discussion / issues to consider for follow-up ............................................................................ 223
For future consideration .................................................................................................... 224 5.1 Air filters............................................................................................................................... 224 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5
5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5
5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5
5.4 5.4.1 5.4.2 5.4.3 5.4.4
5.5 5.6 5.7 5.8 5.9
Product group ................................................................................................................................ 224 Market and stock ........................................................................................................................... 224 Energy consumption ...................................................................................................................... 224 Improvement potential ................................................................................................................. 224 Discussion/ issues to consider for follow-up ................................................................................. 225
Ducts and duct systems ....................................................................................................... 225 Product group ................................................................................................................................ 225 Market and stock ........................................................................................................................... 225 Energy consumption ...................................................................................................................... 225 Improvement potential ................................................................................................................. 226 Discussion/ issues to consider ....................................................................................................... 226
Humidifiers ........................................................................................................................... 226 Product group ................................................................................................................................ 226 Market and stock ........................................................................................................................... 227 Energy consumption ...................................................................................................................... 228 Improvement potential ................................................................................................................. 229 Discussion / issues to consider for follow-up ................................................................................ 230
Swimming pool equipment .................................................................................................. 230 Product group ................................................................................................................................ 230 Market and stock ........................................................................................................................... 230 Energy consumption ...................................................................................................................... 231 Improvement potential ................................................................................................................. 232
Solar shading devices ........................................................................................................... 234 Personal Care ....................................................................................................................... 234 Commercial kitchen equipment ........................................................................................... 238 Low-voltage switchgear and control gear ........................................................................... 238 Other product groups .......................................................................................................... 239
Annex I - Indication of overlap of savings by Motor Regulation 640/2009................................... 240 Annex II - Overview table of quantitative cost analysis .............................................................. 245
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Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) List of Tables Table 1 Saving potential and preliminary ranking (executive summary) .............................................. 17 Table 2 List of product groups, ranked by indicative energy saving potential for year 2030 ............... 22 Table 3 Assessment of costs related to purchase and energy .............................................................. 28 Table 4 Qualitative cost analysis............................................................................................................ 30 Table 5 Apparent consumption of mobile agricultural/forestry equipment......................................... 35 Table 6 Sales of agricultural equipment ................................................................................................ 37 Table 7 Agricultural equipment - input for calculation ......................................................................... 38 Table 8 Mobile agricultural equipment energy consumption ............................................................... 39 Table 9 Agricultural equipment - energy saving options ....................................................................... 41 Table 10 Calculation mobile agricultural machinery ............................................................................. 41 Table 11 Apparent consumption of mobile construction machinery.................................................... 44 Table 12 Sales of construction machinery ............................................................................................. 46 Table 13 Mobile construction machinery - input data .......................................................................... 47 Table 14 Mobile construction machinery energy consumption............................................................ 48 Table 15 Mobile construction machinery - energy savings ................................................................... 49 Table 16 Apparent consumption power tools ....................................................................................... 51 Table 17 Sales data power tools ............................................................................................................ 53 Table 18 Input data power tools ........................................................................................................... 54 Table 19 Sales and energy consumption power tools ........................................................................... 55 Table 20 Assumptions power tools ....................................................................................................... 56 Table 21 Market chainsaws ................................................................................................................... 57 Table 22 Calculation chain saws ............................................................................................................ 57 Table 23 Input data chain saws ............................................................................................................. 57 Table 24 Energy consumption chain saws ............................................................................................. 58 Table 25 Improvement potential chain saws ........................................................................................ 58 Table 26 Apparent consumption of such stationary agricultural equipment ....................................... 59 Table 27 Improvement potential stationary agricultural equipment ................................................... 62 Table 28 Production stationary mining equipment ............................................................................... 64 Table 29 Saving potential mining equipment ........................................................................................ 66 Table 30 Input data small fans ............................................................................................................... 69 Table 31 Stock and energy small fans.................................................................................................... 70 Table 32 Improvement potential small fans .......................................................................................... 71 Table 33 Input data blowers .................................................................................................................. 74 Table 34 Improvement potential blowers ............................................................................................. 74 Table 35 Input data high temperature fans........................................................................................... 77 8
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 36 Improvement potential high temperature fans...................................................................... 78 Table 37 Volume of sales of pumps ....................................................................................................... 82 Table 38 Apparent consumption of generating sets ............................................................................. 86 Table 39 Input data generating sets ...................................................................................................... 87 Table 40 Stock of mobile power generation equipment ....................................................................... 88 Table 41 Energy consumption gensets .................................................................................................. 88 Table 42 Improvement potential gensets ............................................................................................. 90 Table 43 Market insulation products..................................................................................................... 93 Table 44 Insulation product families ..................................................................................................... 94 Table 45 Share of insulation products ................................................................................................... 94 Table 46 Biomass based insulation products ........................................................................................ 94 Table 47 Improvement options insulation (IMPRO) .............................................................................. 97 Table 48 Improvement potential insulation products ........................................................................... 99 Table 49 Market data for window products ........................................................................................ 103 Table 50 Market of windows (and external doors) for the EU27, source: Eurowindoor .................... 104 Table 51 Distribution of glazing in the EU building stock .................................................................... 105 Table 52 Two scenario's savings by TNO/Glass for Europe ................................................................. 107 Table 53 Improvement potential window products ............................................................................ 108 Table 54 Reference and Improvement scenario for window products ............................................... 108 Table 55 Market smoothing irons........................................................................................................ 111 Table 56 Projections for market of irons ............................................................................................. 111 Table 57 Energy consumption irons .................................................................................................... 112 Table 58 Improvement potential irons ................................................................................................ 112 Table 59 Detergent market.................................................................................................................. 114 Table 60 Apparent consumption of home audio products ................................................................. 118 Table 61 Input data home audio ......................................................................................................... 119 Table 62 Power consumption of home cinema sets (NL Consumentenbond) .................................... 120 Table 63 Power consumption of various home audio equipment (1) ................................................. 120 Table 64 Power consumption of various home audio equipment (2) ................................................. 121 Table 65 Power consumption home audio .......................................................................................... 122 Table 66 Energy consumption home audio ......................................................................................... 122 Table 67 Assumed power consumption for improvement scenario home audio ............................... 123 Table 68 Improvement potential home audio .................................................................................... 123 Table 69 Apparent consumption kitchen appliances .......................................................................... 125 Table 70 Power consumption kitchen appliances ............................................................................... 125 Table 71 Improvement potential kitchen appliances .......................................................................... 126 9
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 72 Market of lawn mowers ........................................................................................................ 127 Table 73 Sales of mowers .................................................................................................................... 128 Table 74 Stock of mowers.................................................................................................................... 128 Table 75 Specific energy consumption of mowers(per unit)............................................................... 129 Table 76 Energy consumption mowers(for stock) ............................................................................... 129 Table 77 Improvement potential mowers ........................................................................................... 129 Table 78 Improvement potential mowers output data per type mower ............................................ 130 Table 79 Base station market according Prodcom .............................................................................. 134 Table 80 BTS specific energy consumption per type ........................................................................... 136 Table 81 Base station energy consumption......................................................................................... 137 Table 82 Calculation of improvement potential Base stations ........................................................... 137 Table 83 Data centre Market ............................................................................................................... 139 Table 84 Summary of energy savings potential................................................................................... 143 Table 85 Improvement potential server / storage / power conversion equipment ........................... 143 Table 86 Market taps and showerheads ............................................................................................. 145 Table 87 Ecotapware market taps and showerheads ......................................................................... 145 Table 88 Ecotapware stock taps and showerheads............................................................................. 146 Table 89 Stock of taps and showerheads ............................................................................................ 146 Table 90 Ecotapware product life taps and showerheads .................................................................. 146 Table 91 Taps and showerheads usage taps and showerheads .......................................................... 147 Table 92 Improvement potential taps and showerheads ................................................................... 148 Table 93 Calculation of toilet flushed volume, sales and stock characteristics .................................. 150 Table 94 Improvement potential of toilets by flushed volume, .......................................................... 151 Table 95 Market of water heaters (may include electric kettles) ....................................................... 153 Table 96 Improvement potential electric kettles ................................................................................ 154 Table 97 Apparent consumption and production POS and ATM equipment...................................... 155 Table 98 Sales and stock of point-of-sale equipment (POS)................................................................ 155 Table 99 Sales and stock of automatic teller equipment (ATM) ......................................................... 156 Table 100 Energy input data for POS equipment ................................................................................ 156 Table 101 Energy input data for ATM equipment ............................................................................... 157 Table 102 Usage input data for ATM equipment ................................................................................ 157 Table 103 Overview of energy calculation POS and ATM equipment ................................................. 157 Table 104 Steam boiler fossil fuel energy conversion technologies ................................................... 159 Table 105 Prodcom data for steam boiler equipment (production only) ........................................... 163 Table 106 Overview of US inventory of steam boilers per capacity and sector.................................. 164 Table 107 Energy consumption of steam production in several industries ........................................ 166 10
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 108 Energy saving for steam boiler equipment per sector........................................................ 167 Table 109 Sales and stock of hot tubs etc. .......................................................................................... 170 Table 110 Different types of sauna's ................................................................................................... 172 Table 111 Sauna stock Finland ............................................................................................................ 173 Table 112 Sauna stock - Finland and Germany.................................................................................... 174 Table 113 Energy consumption of electric sauna's ............................................................................. 174 Table 114 Power consumption electric sauna's ................................................................................. 175 Table 115 Overview of energy calculation sauna's ............................................................................. 175 Table 116 Prodcom data for escalators and moving walkways (app. consumption) .......................... 176 Table 117 Elevator market statistics.................................................................................................... 177 Table 118 Sales of escalators 2008 ...................................................................................................... 177 Table 119 Sales and stock of escalators and elevators........................................................................ 178 Table 120 Overview of energy consumption of elevators and escalators .......................................... 179 Table 121 Prodcom data for production of non-domestic hot beverage equipment ......................... 182 Table 122 Stock of non-domestic hot beverage equipment[source: Eurostat] .................................. 182 Table 123 Sales and stock of non-domestic hot beverage equipment ............................................... 182 Table 124 Stock data non-domestic beverage .................................................................................... 183 Table 125 Average electricity consumption of non-domestic beverage equipment .......................... 184 Table 126 Overview energy consumption of non-domestic hot beverage equipment ...................... 184 Table 127 Estimation of traffic lights based on UK figures .................................................................. 186 Table 128 Energy consumption of traffic lights in the UK ................................................................... 187 Table 129 Energy consumption of traffic lights extrapolated to the EU27 ......................................... 187 Table 130 Prodcom data for various logistics equipment (app. consumption) .................................. 189 Table 131 Prodcom data for heating controls (app. consumption) .................................................... 192 Table 132 Energy input data for heating controls ............................................................................... 194 Table 133 Energy saving by heating controls ...................................................................................... 195 Table 134 Overview of heating control energy saving ........................................................................ 196 Table 135 Stock (and saving potential) of lighting control systems .................................................... 199 Table 136 Overview of lighting control system energy savings .......................................................... 199 Table 137 Prodcom data for various medical equipment (production only) ...................................... 201 Table 138 Prodcom data for various medical equipment (apparent consumption) ........................... 202 Table 139 Overview of 'medical' buildings .......................................................................................... 204 Table 140 Stock of MRI equipment in selected EU countries.............................................................. 205 Table 141 Overview of energy calculation of medical equipment ...................................................... 206 Table 142 Energy improvement potential of 'other' medical equipment ........................................... 208 Table 143 Market and stock of mobile phones ................................................................................... 209 11
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 144 Stock of mobile (smart) phones .......................................................................................... 209 Table 145 CO2 emissions and deducted energy consumption of mobile phones ............................... 211 Table 146 Split up of mobile phone stock ........................................................................................... 212 Table 147 Energy consumption per mobile phone type ..................................................................... 212 Table 148 Overview of mobile phone energy calculation ................................................................... 212 Table 149 Electricity consumption of fractional horsepower motors ................................................. 215 Table 150 Calculation of Reference and Improvement scenario energy consumption FHM ............. 217 Table 151 Sales of power cables (kTon Copper) .................................................................................. 219 Table 152 Stock of power cables (kTon of Copper) ............................................................................. 220 Table 153 Final affected energy demand, related to power cables .................................................... 220 Table 154 Improvement scenario power cables ................................................................................. 221 Table 155 CO2 balance of (Copper input to) improved power cables ................................................ 222 Table 156 Greenhouse gas emissions (CO2 equivalent) by improved power cables .......................... 223 Table 157 Technologies for humidifiers ............................................................................................. 227 Table 158 Prodcom data for humidifiers ............................................................................................. 227 Table 159 Calculation of humidifier energy demand based on two sectors ....................................... 228 Table 160 Energy data for selected humidifier technologies .............................................................. 229 Table 161 Swimming pool filter characteristics................................................................................... 232 Table 162 Prodcom descriptions of personal care products ............................................................... 234 Table 163 Prodcom data for hair dryers (app. consumption) ............................................................. 234 Table 164 Energy calculation of hair dryers ........................................................................................ 235 Table 165 Prodcom data for shavers ................................................................................................... 235 Table 166 Energy calculation of shavers ............................................................................................. 235 Table 167 Prodcom data for tooth brushes (assumed electric and non-electric) ............................... 236 Table 168 Stock data for electric tooth brushes.................................................................................. 236 Table 169 Energy calculation of electric tooth brushes ...................................................................... 236 Table 170 Prodcom data for electric blankets (app. consumption) .................................................... 236 Table 171 Energy calculation of electric blankets ............................................................................... 237 Table 172 Energy calculation of water beds ........................................................................................ 237 Table 173 Overview of personal care products ................................................................................... 237 Table 174 Overview of results quantitative cost analysis ................................................................... 245 Table 175 Energy prices used for cost assessment ............................................................................. 247
12
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) List of Figures Figure 1 Indicative saving potential per product group ........................................................................ 24 Figure 2 Sales of mobile agricultural equipment ................................................................................... 38 Figure 3 Stock of agricultural equipment (incl. tractors) ....................................................................... 39 Figure 4 Energy consumption of mobile agricultural equipment .......................................................... 40 Figure 5 Reference and improvement scenario mobile agricultural machinery ................................... 42 Figure 6 Hydrostatic drive mechanism ................................................................................................. 46 Figure 7 Sales of mobile construction equipment ................................................................................. 47 Figure 8 Stock of mobile construction machinery ................................................................................. 48 Figure 9 Energy consumption of mobile construction machinery ........................................................ 48 Figure 10 Reference and Improvement scenario of mobile construction machinery........................... 49 Figure 11 Sales of electric power tools .................................................................................................. 53 Figure 12 Reference and Improvement scenario of handheld power tools.......................................... 56 Figure 13 Farm holdings by size ............................................................................................................. 60 Figure 14 Dairy farm energy consumption per application ................................................................... 61 Figure 15 Energy consumption of US farms, by fuel and by application ............................................... 62 Figure 16 Reference and Improvement scenario of stationary agricultural equipment ....................... 63 Figure 17 Mining output per region, Euromines presentation ............................................................. 65 Figure 18 EU Mining output approximation .......................................................................................... 66 Figure 19 Reference and Improvement scenario of stationary construction equipment ..................... 67 Figure 20 Indication of stock of small fans per application ................................................................... 69 Figure 21 Indication of energy consumption of small fan applications................................................. 70 Figure 22 Reference and Improvement scenario energy consumption of small fans ........................... 71 Figure 23 Reference and Improvement scenario energy consumption of blowers .............................. 75 Figure 24 Indication of energy consumption of HT fans per application .............................................. 78 Figure 25 Reference and Improvement scenario of high temperature fans ......................................... 79 Figure 26 Positive displacement pump categorisation.......................................................................... 81 Figure 27 Industrial pump energy consumption per application .......................................................... 83 Figure 28 Overview of (positive displacement) pump technologies ..................................................... 85 Figure 29 Sales of mobile power generating sets .................................................................................. 87 Figure 30 Stock of mobile power generating sets ................................................................................. 88 Figure 31 Energy consumption of mobile power generating sets......................................................... 89 Figure 32 Reference and Improvement scenario of mobile power generators .................................... 91 Figure 33 Contribution to primary energy for various buildings and components ............................... 96 Figure 34 Relative environmental improvement potential per building type and measure ................. 98 Figure 35 Reference and Improvement scenario of thermal insulation products ................................ 99 13
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 36 Performance of glazing in windows ..................................................................................... 105 Figure 37 Overview of energy flows in typical building ....................................................................... 107 Figure 38 Reference and Improvement scenario energy consumption of window products ............. 109 Figure 39 Reference and Improvement scenario energy consumption of clothes irons .................... 113 Figure 40 Lawn mower (left) and riding mower (right) ....................................................................... 127 Figure 41 Reference and Improvement scenario energy consumption of mowers ............................ 130 Figure 42 Base transceiver station (BTS, left), base station controller (BSC, right)............................. 131 Figure 43 Overview base station from picocell to femtocell ............................................................... 132 Figure 44 Overview base stations, connected to wired network ........................................................ 133 Figure 45 Speed of various generations of mobile data traffic ........................................................... 133 Figure 46 GSM and UMTS stations in the Netherlands from 3rd Q. 2005 to 1st Q. 2011. .................... 134 Figure 47 Estimation of EU stock of base stations............................................................................... 135 Figure 48 Breakdown of energy consumption of cellular networks and base stations ...................... 135 Figure 49 Power consumption of cellular equipment, per element and per voice call ...................... 136 Figure 50 Reference and Improvement scenario of base station subsystems .................................... 138 Figure 51 Stock of servers .................................................................................................................... 140 Figure 52 Typical Data Centre layout................................................................................................... 140 Figure 53 Power consumption of data centres in 2006....................................................................... 141 Figure 54 Energy consumption of data centres ................................................................................... 142 Figure 55 Reference and Improvement scenario energy consumption of taps and showerheads .... 148 Figure 56 Energy consumption of Reference and Improvement scenario for toilets ......................... 152 Figure 57 Reference and Improvement scenario energy consumption of POS and ATM equipment 158 Figure 58 Examples of small steam boilers (electric) .......................................................................... 161 Figure 59 Examples of small steam boilers, fuel combustion and other types ................................... 161 Figure 60 Overview of steam boiler ancillary equipment ................................................................... 162 Figure 61 Share of smaller steam boilers in overall emissions ............................................................ 165 Figure 62 Distribution of steam boilers per capacity and number of installations ............................. 165 Figure 63 Position of sauna heaters in scope of local heaters in Lot 20/21 ........................................ 172 Figure 64 Reference and Improvement scenario of elevators, escalators etc. ................................... 179 Figure 65 Production of non-domestic hot beverage equipment ....................................................... 182 Figure 66 Japanese top runner values for hot beverage equipment .................................................. 183 Figure 67 Reference and Improvement scenario of non-domestic hot beverage equipment............ 185 Figure 68 Example of thermostat with built-in intelligent operation and multiple sensors ............... 195 Figure 69 Example of modern heating control system (zone control) ................................................ 196 Figure 70 Reference and Improvement scenario energy consumption of heating controls............... 197 Figure 71 Example of lighting control - daylight adaptive system....................................................... 199 14
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 72 Reference and Improvement scenario energy consumption of lighting controls ............... 200 Figure 73 Breakdown of hospital energy consumption per application ............................................. 203 Figure 74 Market penetration mobile phones .................................................................................... 210 Figure 75 Market penetration mobile 'smart' phones ........................................................................ 210 Figure 76 CO2 emissions Apple iPhone 4 (2010) (picture left)............................................................. 211 Figure 77 CO2 emissions 2008 conventional phone Sony Ericsson (2008) (picture right)................... 211 Figure 78 Reference and improvement scenario power cables .......................................................... 221 Figure 79 Primary energy consumption per m2 of (Dutch) tertiary buildings (offices and hospitals) 228 Figure 80 Stock of swimming pools ..................................................................................................... 231 Figure 81 Breakdown of public swimming pool energy consumption ................................................ 231 Figure 82 Energy consumption of domestic swimming pools ............................................................. 232 Figure 83 Swimming pool equipment.................................................................................................. 233 Figure 84 Energy loss swimming pools indoor and outdoor and type of pool covers ........................ 233 Figure 85 Energy consumption of farms, by fuel and application ....................................................... 244
15
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
EXECUTIVE SUMMARY The objective of this study is to provide the background information and analysis which will allow the Commission to establish an amended Working Plan under the Ecodesign Directive 2009/125/EC. This amended Ecodesign Working Plan will set out, for the years 2012-2014, a list of energy-related product groups which are considered priorities for the adoption of implementing measures under the Ecodesign Directive. The study contributes to this aim by identifying energy related product groups, ranked by environmental improvement potential. The final ranking is realised by completing four tasks. Task 1 In Task 1 the background and context of the study are described and the methodology for performing the study explained. The definition of energy-related products is provided and its implications are discussed. Another important element of this Task is the enabling of stakeholder participation. For this purpose a study website (www.ecodesign-wp2.eu) is launched through which stakeholders can indicate their interest in participation and through which they can download relevant documents. Task 2 In Task 2 a list of energy-related product groups is created. First, the overall list of economic activities in the European Community, the Prodcom 2009 list, is reduced from 3902 product categories to 1028 categories by excluding the non energy-related products. The remaining list of product categories is further reduced to 838 categories by removing those categories of products that are already (or shortly will be) dealt with by Ecodesign policies. The list of Prodcom categories however is not suited as a format for identifying product groups. Therefore, in a separate approach an assessment is made of energy flows in the EU, from energy carrier, through conversion process, to final product. This assessment shows that a limited number of archetypical product functions are responsible for the majority of energy consumption. It shows that a product function approach is well suited to structure a grouping of energy-related products, both actively energy using products as well as that only indirectly affect energy consumption. A third learning element is provided by the assessment of product group descriptions as applied in the first Working Plan study. This analysis shows that although a complete sectorial approach is suboptimal there still are good grounds to discern at least ‘primary/secondary’ and ‘tertiary/domestic’ applications for equipment. Using these lessons a suggestion for a final list of product groups is created. In this list the product groups already dealt with by the Ecodesign policy process are omitted. Task 3 In Task 3 a preliminary energy analysis is performed on 36 product groups resulting from Task 2. Not all product groups identified in Task 2 are analysed; in certain cases in anticipation of the Task 4 analysis, but mostly due to limited resources available for the study. The energy analysis focuses on the current and projected energy consumption of the product group and indicates the energy saving potential in coming years, assuming a feasible implementation of improved products. The product groups are ranked by saving potential (relating to year 2030, to allow for a full implementation of 'improved' products). The highest saving potential is identified for the indirect energy-related product group 'thermal insulation products for buildings' (set at 1500 PJ in 2030). Task 3 also entails a cost analysis to investigate whether excessive costs can be expected. The analysis follows a two-fold approach: A quantitative analysis focusing on payback periods and life cycle costs, and a qualitative analysis, focusing on cost-effects of directions of improvement. The quantitative cost analysis is hampered by limited availability of data, especially regarding costs of products and improvement options. It concludes for four product groups that excessive costs are 16
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) "unlikely", since the analysis shows the conclusions remain fairly robust. For the other product groups not enough data is available to confirm or exclude the occurrence of excessive costs. The qualitative analysis indicates that for certain product groups medium to high cost modifications to the products can be expected, but also this analysis could not provide sufficient backing for a conclusion to confirm or exclude the occurrence of excessive costs. The overall outcome of the cost analysis is that the study set-up and available resources did not allow for a full cost analysis and therefore no firm conclusion regarding occurrence of excessive costs can be drawn. Table 1 gives the preliminary ranking according energy saving potential (PJ primary, in 2030). Table 1 Saving potential and preliminary ranking (executive summary) Product group
Saving potential (PJ/year, 2030) 1500 885
Energy ranking 1 2
Window products for buildings Lighting controls Heating controls Positive displacement pumps Fractional HP motors Power cables Steam boilers / systems
785 610 319 270 258 182 177
3 4 5 6 7 8 9
Detergents Servers and data storage equipment Elevators, escalators etc. Logistic systems Medical equipment Blowers Stationary agricultural equipment Electric kettles
155 135 57 50 44 43 39 37
10 11 12 13 14 15 16 17
Mobile agricultural machinery Base station subsystems Mobile construction machinery Small fans 200W 4.36 Power cables Included: power cables of certain size and other characteristics (to define) Excluded: other power cables 4.24 Steam boilers / systems Included: (no restrictions in capacity, fuel, etc.) Excluded: none preliminary 4.14 Detergents Included: detergents for machine washing Excluded: other detergents 4.19 Server and data storage equipment Included: (enterprise) servers, data storage equipment and specific ancillary equipment (power conversion etc.) Excluded: data centre infrastructure (cooling, UPS, lighting, etc.) 4.27 Elevators, escalators and moving walkways Included: elevators, escalators and moving walkways (to add: telerefics) Excluded: (intra)logistic systems, such as conveyor belts for industrial applications 4.30 Logistic systems Included: self standing and configurations of equipment used for logistics (transport, storage, handling) of various material (bulk, unit shipment, etc.) Excluded: some logistic equipment is also covered by the product group 'mobile construction machinery' (industrial , service trucks etc.) 4.33 Medical equipment Included: energy-related medical equipment not already covered by Ecodesign Policy process Excluded: Equipment covered by Voluntary Agreement (if accepted) 4.7 Blowers
258
72
29
182
51
20
177
49
20
155
43
17
135
38
15
573
16
6
50
14
6
44
12
4,9
43
12
5
Rank
Product group
1.
2.
3.
4.
5.
8.
9.
10.
11.
12.
13.
14.
15.
3
Includes correction for overlap of savings with Regulation 640/2009
22
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
4
Including: blowers, sold separately or incorporated in products such as air knifes, hand dryers, etc. Excluding: (to discuss) 4.4 Stationary agricultural equipment Included: stationary equipment (milking machines to brooders) Excluded: mobile equipment 4.22 Electric kettles / water cookers Included: Equipment for boiling water, with the aim of consumption (assessment relates to domestic products only) Excluded: other boiling water equipment 4.1 Mobile agricultural machinery Including: mobile machinery for agricultural, horticultural and forestry applications Excluding: agricultural tractors 4.18 Base stations Included: GSM-, UMTS base stations Excluded: (to discuss) 4.2 Mobile construction machinery Including: cranes, dozers, excavators, for both construction and mining/quarrying applications Excluding: (to discuss) 4.6 Small fans < 125 W Including: small fans with electric input power < 125 W Excluding: fans covered by Lot 11 4.8 High temperature ventilation equipment Including: various high temperature fans in various applications Excluding: fans covered by Lot 11 4.23 Point-of-sale and cash dispenser equipment Including: Various point-of-sale and cash dispenser equipment Excluding: (to discuss) 4.34 Mobile phones Included: mobile phones Excluded: none / to discuss 4.13 Clothes ironing products Including: various domestic and non-domestic products (analysis limited to domestic style products) Excluding: industrial style ironing 4.10 Mobile power generation sets Included: mobile equipment Excluded: stationary equipment 4.28 Non-domestic hot beverage equipment Including: coffee / tea / hot chocolate machines, (instant) soup preparing machines Excluding: domestic equipment, like coffee makers, etc. 4.29 Traffic lighting Included: street signs, stoplights, traffic signalling Excluded: other purpose lighting 4.21 Toilets Included: normal flushing toilets Excluded: non-flushing toilets 4.17 Lawn and riding mowers Including: various motorised mowing equipment Excluding: (to discuss) 4.3 Handheld power tools Included: various power tools, both electric and with combustion engines (chain saws, jack hammers, hedge trimmers) Excluded: compressed air power tools 4.15 Home audio products Including: home theatre systems, alarm clock radio’s, table radio's Excluding: Sound and imaging products already covered by ENTR Lot 3 4.5 Stationary construction equipment Including: sifters, screeners, graders, grinders, crushers Excluding: equipment covered by Lot 11 (fans, motors incorporated)
No overlap of savings with Regulation 640/2009
23
39
11
4
37
10
4,1
33
9.1
3,7
30
8.3
3,3
22
6.1
2,4
21
5.8
2.3
17
4.7
1,9
16
4.4
1,8
13
3.6
1,4
11
3.1
1,2
84
2.2
0,9
7
1.9
0,8
7
1.9
0.8
5
1.4
0,6
5
1.4
0,6
5
1.4
0,6
4
1.1
0,4
2
0.7
0,3
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 34.
35.
36.
4.16 Kitchen appliances Included: juicers, electric toasters, blenders Excluded: kitchen equipment covered by existing Ecodesign policy process 4.25 Hot tubs / spa's / whirlpools Included: Excluded: swimming pools
2
0.6
0,2
0,75
0.2
>0.1
4.26 Sauna’s Included: various sauna types Excluded: (to discuss)
0,07
>0.02
>0.01
Note: This ranking is a based on a preliminary analysis only and conducted under restrictions in time and resources. This introduces limitations as regards the robustness/reliability of data. It is recommended to confirm savings and cost effects by further in-depth research.
The figure below gives an overview of the relative potential savings identified for the product groups. Figure 1 Indicative saving potential per product group
The preliminary analysis of each product group is presented in section 4 of this study. The following section presents the cost analysis which is also part of Task 3.
24
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
3.3
Assessment of costs related to purchase and operation
Article 15, item 2-c of the Directive 2009/31/EC requires amongst others that in order for a product to be eligible for setting ecodesign requirements the product shall present significant potential for improvement in terms of its environmental impact without entailing excessive costs. For this reason the products groups that have been ranked by saving potential have also been subject to a cost analysis to assess that no excessive costs are involved in achieving the indicated savings. Cost analysis in ecodesign preparatory studies entails a detailed technical analysis for identifying design options and their life cycle costs, being based on effects on purchase price and operating costs for each option. In many cases it is found that the more energy efficient product is more costly. Without trying to be comprehensive, there can be various reasons for this mark-up. 1. Costs of Research & Development and/or manufacturing are higher: Investments need to be recovered; 2. Costs of materials, parts and components may be higher: For example the use of a permanent magnet motor can improve energy efficiency, but is also more costly than a lowefficiency, low-cost standard motor; 3. The product is positioned in a 'premium' market segment: Product scarcity, image, recent introduction ('new to the market') may drive prices upwards; 4. The product-market combination lacks competition, allowing higher prices to exist. It is therefore not always clear upfront what drives the purchase prices of more efficient equipment upwards: Stakeholders have commented that a certain share of the savings potential may be realised against very low or even at no extra costs. This may very well be the case for specific options, but generally speaking the more efficient product is often sold at a premium. In time however, most mass-produced products also decrease in price due to optimised production, recuperation of investments, transfer of production to low-wage countries, etc. which can explain that a A-class refrigerator of today may costs as much as a C-class refrigerator in 1995. A full cost analysis that considers all the elements above (and more) is however not feasible in this background study due to the large number of product groups considered and the limited resources available. Therefore the cost effects were examined as follows: First, on the basis of publicly available economic data (provided by analysis of PRODCOM data) an quantitative assessment of product purchase costs is made. This is combined with the expected savings from the energy analysis of task 3 (see section 4 of this report) to allow an indicative life cycle cost analysis. Secondly, a qualitative cost analysis was performed based on a valuation of the relevance of several basic design options for achieving the savings potential established. Both approaches are explained in the following sections. 3.3.1
Quantitative cost analysis
The quantitative analysis aims to 1) quantify the life cycle costs of the reference product and a more energy efficient ('improved') product and 2) establish the payback period (how many years are needed before the lower energy costs have recovered the extra purchase price). 25
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
The purchase costs of the Reference product have been approximated by taking from Prodcom datasets the average 'unit value' of relevant product categories5. This value is multiplied by a factor three to take into account mark-up factors for manufacturing, wholesale and retail. The result is labelled 'purchase costs'. Divided by the average product life, as applied in the energy calculations, the annual average purchase price for the average product in the product group for the Reference scenario per year is calculated. The purchase costs of the Improved (more energy efficient product) have been established by four scenario's. The first scenario assumes that the purchase price increases with the same rate as the savings potential (as in: 'a 10% saving potential would result in a 10% purchase price increase'. This approach was however heavily contested by certain stakeholders who claimed that energy efficient products do not always need to be so much more expensive than their reference prices6. To address this issue, three other scenario's have been added in which the energy saving remains as in the first scenario, but the purchase price increases with pre-set intervals of 5%, 10% and 20%. This way the effect of a modest purchase price increase (5%) and a relatively steep purchase price (10% or even 20%) increase can be assessed7. The energy costs are calculated on the basis of the energy consumption in the 'Reference' and 'Improvement' scenario (see section 4 for details), while taking into account the type of energy (electricity, fuel for stationary applications (mainly gas, some oil) and fuel for mobile machinery (mainly diesel, some gasoline) and the type of end-user (to take into account the different electricity rates for domestic and non-domestic end-users). Divided by the stock8, this gives the energy costs per year for the average product in the product group. The analysis allows an assessment of payback years, whereby a payback period of more than the economical / technical product life is undesirable. Even payback periods of over three years are considered unattractive by certain investors in technologies. The calculation of life cycle costs shows that if the life cycle costs of the improvement option exceed that of the reference option, the improved option is unattractive. The difference in life cycle costs can also be expressed in a savings percentage.. The initial assessment is included in Annex II. The calculation did not prove feasible or meaningful for all product groups due to lack of data or incompatible metrics. For certain product groups no price calculation was possible due to absence of PRODCOM unit values for price information. This was the case for: - lighting control (systems); - datacentre servers and data storage equipment; - blowers; - high temperature ventilation equipment; - traffic lighting; - hot tubes, etc.; - sauna's; - toilets;
5
Only one stakeholder provided the authors with an estimate of the average purchase price of the products See minutes of 2nd stakeholder meeting in the Feedback Log or the project website www.ecodesign-wp2.eu . 7 The comment also led to the inclusion of the qualitative assessment - see following section. 8 'Stock' means the total installed base of products currently in use.. 6
26
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) For several other product groups the calculated purchase price resulted in awkward values, that could not be related to expected selling prices. This was the case for: - Steam boilers systems: the calculated purchase price is 277 euro, which can not be correct. Apparently the PRODCOM data leads to erroneous conclusions which blocks further analysis; - Logistic equipment: the calculated purchase price is 5952 euro, which is probably not correct for most of the equipment and machinery covered by the product group. An explanation could be that the value applies to various types of logistic equipment at once and should be broken down further in order to become meaningful. However, there is no estimate of possible energy savings at this more detailed product level, which blocks further analysis; - Electric kettles / water cookers: the calculated purchase price of 328 euro appears relatively high for a product believed to be mainly sales of table-top electric kettles. Since neither data on actual stock is available, the calculation of purchase price could not be concluded; - Mobile agricultural machinery: the calculated purchase price is 1016 euro , which is probably not correct for most of the equipment and machinery covered by the product group. An explanation could be that the value applies to various types of agricultural equipment at once and should be broken down further in order to become meaningful. However, there is no estimate of possible energy savings at this more detailed product level, which blocks further analysis; - Other medical equipment: the average calculated purchase price is 25 euro, which is difficult to relate to the intended scope of energy-related medical equipment. The calculation had to be abandoned. For other product groups the analysis could not be completed due to other data lacking (no stock data). This was the case for: - Thermal insulation products; - Window products; - Positive displacement pumps; - Detergents; For all the above mentioned product groups the quantitative analysis had to be abandoned. The remaining products for which the quantitative analysis could be followed through (with limitations as indicated above) are: - Taps and showerheads; - Heating controls; - Mobile power generation sets; - Stationary agricultural equipment; - Elevators, escalators, etc.; - Non-domestic hot beverage equipment; - Base station subsystems; - Mobile construction machinery; - Home audio products; - POS and ATM equipment; - Small fans9; - Clothes ironing products; - Lawn and riding mowers; - Stationary construction equipment; - Handheld power tools;
9
For 'small fans' a stakeholder provided an average purchase price, which has been used instead of the PRODCOM derived value.
27
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) The calculated payback period and life cycle costs (expressed as percentage saved compared to reference) are indicated in the table below for each of the four scenario's. Table 3 Assessment of costs related to purchase and energy Product group
cost aspect
Taps and showerheads
payback period (yrs) LCC reduction (% of Ref.) payback (yrs) LCC reduction (% of Ref.)
Heating controls
Mobile genset
Purchase price increase impr. potential 5% 10% 20% 0,8 0,2 0,4 0,9 -16% -17% -17% -16% 0,0 0,0 0,1 0,1 -8% -8% -8% -8%
payback (yrs)
5,1
10,1
20,2
40,4
LCC reduction (% of Ref.)
-1%
-1%
1%
3%
payback (yrs)
31,9
14,2
28,3
56,6
3%
10%
Stat. agr. equipment
LCC reduction (% of Ref.)
4%
0%
Elevators, escalators, etc.
payback (yrs) LCC reduction (% of Ref.)
194,6 18%
38,9 1%
payback (yrs)
28,6
5,7
LCC reduction (% of Ref.) payback (yrs) LCC reduction (% of Ref.) payback (yrs)
12% -3% 1,1 0,2 -23% -26% 5,8 5,8
Non-domestic hot beverage Base station subsystems Mobile constr. machinery
LCC reduction (% of Ref.) payback (yrs)
-2%
-2%
185,9 108,1
77,9 155,7 5% 14% 11,4
22,8
1% 8% 0,4 0,7 -25% -24% 11,7 23,4 0%
3%
216,2 432,4
Home audio products
LCC reduction (% of Ref.) payback (yrs)
8% 52,6
4% 5,3
9% 10,5
19% 21,0
POS/ATM equipment
LCC reduction (% of Ref.) payback (yrs)
34% 52,7
-4% 10,3
0% 20,6
9% 41,2
Small fans
LCC reduction (% of Ref.) payback (yrs)
21% 13,6
2% 6,8
7% 13,6
16% 27,1
Clothes ironing Lawn / riding mowers
LCC reduction (% of Ref.) payback (yrs) LCC reduction (% of Ref.)
3% 75,0 22%
0% 12,7 1%
3% 25,5 5%
9% 51,0 14%
Stat. constr. equipment Handheld power tools / chainsaws
payback (yrs) LCC reduction (% of Ref.) payback (yrs) LCC reduction (% of Ref.)
41,1 26,7 4% 2% 6,4 0,9 7% -11%
mobile phones
payback (yrs) LCC reduction (% of Ref.)
155,2 29%
25,5 4%
53,5 107,0 5% 13% 1,8 3,6 -8% -2% 51,0 102,0 9% 19%
Remarks payback acceptable higher PP of little influence on LCC payback acceptable higher PP of little influence payback exceeds product life when over 5% PP increase PP increase over 5% results in higher than reference LCC payback exceeds product life when over 5% PP increase PP increase over 5% results in higher than reference LCC payback exceeds product life overall - inputs not fit for assessment PP increase results in higher than reference LCC payback exceeds product life when over 5% PP increase PP increase over 10% results in higher than reference LCC payback acceptable higher PP of little influence payback too high for over 5% PP increase PP increase over 10% results in higher than reference LCC payback exceeds product life overall - inputs not fit for assessment PP increase over 5% results in higher than reference LCC payback too high for over 5% PP increase PP increase over 10% results in higher than reference LCC payback exceeds product life overall - inputs flawed PP increase over 5% results in higher than reference LCC payback unrealistically high PP increase over 5% results in higher than reference LCC payback unrealistically high PP increase results in higher than reference LCC payback exceeds product life overall - inputs not fit for assessment PP increase results in higher than reference LCC payback acceptable PP increase at 20% still lower than reference LCC payback exceeds product life overall - inputs not fit for assessment PP increase results in higher than reference LCC
3.3.1.1 Discussion An indication of the possibility of 'excessive costs' occurs if: - The payback period exceeds the technical/economical life; - The LCC of the 'Improvement' option are higher than the 'Reference'. In the table above these situations are indicated in 'red' text for each product group. 'Green' text indicates acceptable payback periods or effects on LCC.
28
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) On the basis of the assumptions given (regarding purchase price, its increase, the energy savings and costs) the analysis above indicates that for the following product groups excessive costs are unlikely to occur, since both payback and LCC reduction appear fairly robust against differences in purchase price increase: - Taps and showerheads; - Heating controls; - Base station subsystems; - Handheld power tools (chainsaws only); Note: the analysis for this product group does indicate higher than reference LCC for the improvement option occur if the price increase matches the saving potential! For all the other product groups the analysis can not confirm or exclude that excessive costs will occur. This does not mean that energy saving in these product groups will always result in higher life cycle costs or very high payback periods. Such conclusions can only be drawn after a full technical, economical and environmental analysis, taking into account all cost aspects and ecodesign improvement options. 3.3.2
Qualitative cost analysis
During the second stakeholder meeting a qualitative cost analysis was suggested to overcome limitations of the quantitative assessment10. In this qualitative analysis, the improvement potential identified in task 3 is related to four different product modifications or other market transformations with different impacts on product purchase costs: 1. low-cost modifications: for instance by software instructions, low-cost sensors (implemented as auto-power down, presence sensing) and application of thermal insulation in industrial products; 2. medium cost modifications: for instance use of improved parts or components (more efficient motor, fan); 3. high cost modifications: for instance the complete redesign of product (different working principle, new product platform); 4. changes in user involvement: this can be a low-cost modification option based on a different involvement of actors (by changes in user interaction such as set-up menu's, eco-programs, but also the realisation of a higher renewal/refurbishment/retrofit rate). In this context, the term 'user' also refers to those responsible for specification and purchase of equipment. For each of the product groups for which a saving potential is established, the main areas of modification/transformation have been suggested in the table below. The relevance of the options in the establishing the saving potential is indicated (valued) by one, two or three stars (*, ** and ***), whereby a higher star count translates to a higher relevance in establishing the savings potential. The valuation is based on general knowledge of product groups and, where possible, takes into account relevant stakeholder comments. It is not to be perceived as an exhaustive overview of cost implications of improvement options. For this a more thorough approach, involving a detailed technical, economical and environmental analysis (as applied in ecodesign preparatory studies), is needed.
10
Suggested by Eduoard Toulouse, ECOS (Minutes 2nd stakeholder meeting 16-9-2011)
29
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 4 Qualitative cost analysis Product group
Options
Thermal insulation products
low-cost medium-cost high cost
Valuat ion * * *
user low-cost medium-cost high cost user low-cost medium-cost high cost
*** *** * * ** ** * ***
user
**
Taps and showerheads
Steam boilers / systems
Lighting control (systems)
low-cost
***
medium-cost high cost user
* * **
Window products for buildings
low-cost medium-cost high cost user
* ** * ***
Heating controls
low-cost
**
medium-cost high cost user
** * ***
Positive displacement and reciprocating pumps
low-cost
*
medium-cost high cost user
*** * ***
Detergents
low-cost medium-cost high cost
* *** *
user low-cost medium-cost high cost user low-cost medium-cost high cost
*** * *** * *** * * ***
Stationary agricultural equipment
user low-cost medium-cost high cost user
*** ** ** * ***
Elevators, escalators and moving walkways
low-cost medium-cost
** **
high cost
*
Data centre server, storage and ancillary equipment Mobile power generation sets
Comments Most of the savings potential is not linked to technical modifications of the products, but to a different use of products, whereby an increased refurbishment rate and product selection in favour of more efficient products is assumed to be most relevant. Estimated is that most of the of savings can be achieved by relatively minor changes to product design (low-cost modifications). Another relevant share of the savings is assumed to be achieved by different user behaviour as regards purchase and operating of products. Large steam boilers are very complex systems and made on a one-off basis. This analysis applies to only series fabricated products, for which better controls are assumed to relate to a relevant share of the potential (better temperature sensors and load following controls). A minor share is believed to be related to medium-cost modifications related to components such as heat exchangers and auxiliary equipment (note that steam boilers often operate at designated temperatures which reduce the possibilities for higher thermal efficiencies). Better user control may is also considered relevant for total savings, leaving a significant share to be to be realised by high cost modifications (very innovative solutions like for instance molten carbonate fuel cells in CHP operation). For lighting control / systems it is assumed that a large percentage of savings is due to use of sensors and control options. Another relative large share in savings is assumed to lie in better user control of available options and a higher refurbishment rate. Medium cost and high cost options are assumed less relevant (these are mainly related to bulb and armature design). Most of the savings can be achieved by applying existing products, which requires more user incentives to boost refurbishment rates. Medium-cost modifications (double glazing, with E-coating, triple glazing for new builds only) are thought to apply to most of the savings potential. High-cost options as in advanced window designs (vacuumated glass, glass combined with advanced solar control) are believed to be less relevant for the saving potential as are relatively low-cost modifications (solar control film/coating). Here as well, most of the savings can be achieved by applying existing products, which requires more user incentives to boost refurbishment rates (three stars). Relatively low/medium cost modifications (thermostatic valves, better room thermostats) are thought to apply to most of the remaining cost savings potential. High cost modifications are believed to be of lesser importance to the savings potential identified. For positive displacement pumps most of the savings will likely involve medium cost modifications (more efficient motor, improved impeller design, etc.). Also application of variable speed drives is assumed to be a medium cost modification. Also important in achieving the savings potential is the user involvement who should select the right pump for the right application. For detergents most of the savings can be achieved by: low-temperature detergents, more compact detergents and preventing overdosing. The first two are assumed to be medium cost modifications, the latter is mainly related to user involvement. Improvement options can be related to 'virtualization' (considered under user involvement) and use of more efficient components (considered under medium cost modifications). The savings potential is assumed to be related to user involvement (selection of products, renewal rate) and to high-cost modifications (to engine and generator). Savings to be achieved by medium and low cost modifications are considered to be limited. Overlapping legislation (as regards emissions and noise) exists The savings potential is established at a very high level of aggregation (very heterogeneous product group) which makes it difficult to value concrete options. It is assumed that user involvement may unlock a relatively large saving potential. Other savings are most likely relate to use of better controls (operating temperatures, presence control) and components (more efficient motors, fans, etc.). The savings potential is largely related to the renewal rate (user involvement), use of more efficient components (motors, lighting) and controls (in equal amounts - for instance regeneration of power requires adapted motors and control strategies).
30
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) user low-cost medium-cost high cost user low-cost
*** ** ** * ** **
medium-cost high cost user low-cost medium-cost high cost user
** ** *** * * ** ***
Non-domestic hot beverage equipment
low-cost medium-cost high cost user
** ** ** *
Base station subsystems
low-cost medium-cost high cost user low-cost medium-cost high cost
** ** ** * * * ***
user
***
Blowers
low-cost medium-cost high cost user
* *** * ***
Home audio products
low-cost medium-cost high cost
** ** *
user
**
High temperature ventilation equipment
low-cost medium-cost high cost user
* *** * ***
Point-of-sale and cash dispenser equipment
low-cost medium-cost
*** **
high cost user
* **
Medical equipment
low-cost medium-cost high cost user
** ** *** **
Traffic lighting
low-cost medium-cost
* ***
high cost
*
Logistic equipment
Electric kettles / water cookers
Mobile agricultural machinery
Mobile construction machinery
Logistic equipment is also a very heterogeneous product groups which comprises stationary logistic systems (which rely heavily on control/sensing options to achieve improved efficiency) and mobile equipment (which may rely on use of improved components like motors).User involvement is also believed to enable savings. The savings potential is to a large degree related to user involvement (by preventing overdosing) but also technical modifications, from low-cost (improved temperature sensors) to medium-cost and high-cost (complete redesign of kettle) can be relevant. The savings potential is established at a very high level of aggregation (very heterogeneous product group) which makes it difficult to value concrete options. Comments from stakeholders point towards an integral sectorial approach to achieve costeffective savings, since many savings can be achieved by non-technical means (no-tillage options). Only for the product group of very large motorised equipment technical savings options are thought to be feasible, although overlapping legislation (as regards emissions and noise) exists. Therefore the most relevant saving option is considered to be user involvement followed by high-cost modifications. The savings potential is to a large degree, assumed to be related to technical modifications, from low-cost (improved temperature sensors, applying insulation) to medium-cost and high-cost (complete redesign of equipment). User involvement is assumed to be less relevant in achieving savings. The savings potential is assumed to be related to technical modifications but the cost-level has been difficult to assess. Therefore two stars are valued for each category. User involvement is assumed to be less relevant in achieving savings. The savings potential is established at a very high level of aggregation (very heterogeneous product group) which makes it difficult to value concrete options. Comments from stakeholders point towards overlapping legislation (as regards emissions and noise). The savings potential is assumed to be related primarily to user involvement (selection of products, renewal rate) and to high-cost modifications (to engine and other equipment). Savings to be achieved by medium and low cost modifications are considered to be limited. For blowers most of the savings will likely involve medium cost modifications (more efficient motor, improved rotor design, etc.). Application of variable speed drives is assumed to be a medium cost modification and considered very relevant for achieving savings. Also important in achieving the savings potential is the user involvement in selecting the right blower for the right application. For 'Home audio' relevant savings can be achieved by power management (auto power down) which is considered a low-cost modification. An exception to this is 'Hi-End' audio/video equipment for which stakeholders have indicated their issues with such modifications. More costly modifications are the application of improved components such as power supplies and electronics (class D instead of A amplifier sections). High cost options are considered not so relevant for generic home audio/video (but may apply to HiEnd audio/video). For HT ventilation fans most of the savings will likely involve medium cost modifications (more efficient motor, improved rotor design, etc.). Application of variable speed drives is assumed to be a medium cost modification and considered very relevant for achieving savings. Also important in achieving the savings potential is the user involvement in selecting the right fan for the right application. For cash registers and ATM equipment the savings will most likely relate to power management and are considered relatively low-cost. Other savings can be achieved by replacing parts and components by more efficient designs (power supplies, processors, etc.) which is considered a medium-cost option. Other options (high-cost, user involvement) are assumed to be less relevant. Medical equipment is also a very heterogeneous product group, which ranges from large medical imaging equipment to relatively simple patient monitoring and support systems. Special care need to be given to avoiding any negative impacts on the primary purpose of the equipment. Therefore low/medium-cost measures (like power management) are assumed to be moderately relevant for the identified savings. And most savings will be related to relatively high cost modifications. User involvement is also considered less relevant for the identified savings. For traffic lighting most of the savings identified relate to the use of different components (e.g. LEDs instead of filament bulbs). The other options are deemed less relevant for achieving the savings.
31
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) user low-cost medium-cost high cost user
* * *** * ***
Clothes ironing products
low-cost medium-cost high cost user
** ** * **
Lawn and riding mowers
low-cost medium-cost high cost
* ** **
user
***
Stationary construction equipment
low-cost medium-cost high cost user
** ** * ***
Handheld power tools
low-cost
*
medium-cost high cost user
** ** **
Power cables
low-cost medium-cost high cost user low-cost medium-cost high cost user
* *** * * * *** ** *
For power cables the most important modification is the amount of copper used (to reduce electric losses) which is considered a modification of a part of the product and therefore a medium cost option. Other options are considered less relevant.
Mobile phones
low-cost medium-cost high cost user
* *** * ***
The savings potential identified for mobile phones is assumed to be largely related to use of more efficient components (chargers). Low-cost options as power management offer less potential, since phones are already optimised for longer battery life. High-cost options are difficult to value, due to the very high innovation rate in this sector. An unknown share of savings can be related to 'spill-over' effects created by use of phones displacing use of more powerful larger equipment (considered as user involvement).
Hot tubs / spa's/ whirlpools
low-cost medium-cost high cost user
*** *** * **
The savings potential to a large degree will depend on relatively low-cost modifications (pool covers, insulation, temperature control, power management) and medium-cost modifications (different components such as heaters, pumps, etc.). High-cost modifications may involve a fuel switch (heater using primary fuels) and are considered not relevant for the identified savings. User involvement is relevant insofar differences in efficiencies of product can be valued.
Sauna’s
low-cost medium-cost high cost user low-cost medium-cost high cost
* * * *** *** * *
Most of the savings identified are related to user involvement since it mainly addresses the type of sauna. Other improvement options (within subgroups of sauna's) have not been presented and are difficult to value.
user
***
low-cost medium-cost high cost user
** *** * **
Small fans < 125 W
Fractional horse power motors
Toilets
Kitchen appliances
For small fans most of the savings will likely involve medium cost modifications (more efficient motor, improved rotor design, etc.). Application of variable speed drives is in this fan market segment assumed to be a high cost modification and considered less relevant for achieving savings. Also important in achieving the savings potential is the user involvement in selecting the right fan for the right application. The savings potential is to a large degree related to technical modifications, from low-cost (improved temperature sensors) controls) to medium-cost (advanced control options, 'smart' settings) to high-cost (redesign, using primary energy instead of secondary energy such as electricity). The latter option is considered not very relevant for the identified savings. User involvement is considered moderately relevant (use of correct settings). The savings potential is assumed to be related to user involvement (selection of products, renewal rate) and to medium/high-cost modifications (different components e.g. efficient electric motor or engine modification). Savings to be achieved by low cost modifications are considered to be limited. Overlapping legislation (as regards emissions and noise) exists The savings potential is established at a very high level of aggregation (very heterogeneous product group) which makes it difficult to value concrete options. It is assumed that user involvement may unlock a relatively large saving potential. Other savings are most likely relate to use of better controls (operating temperatures, presence control) and components (more efficient motors, fans, etc.). The savings potential is limited to use of better motors and (for cordless equipment) batteries and their charging regimes. These options are considered to be medium- to highcost given the relatively low-cost opt the products themselves. Other options (low-cost, user involvement) are assumed to be less relevant in achieving savings identified. For engine-driven equipment overlapping legislation (as regards emissions and noise) may exist.
For fractional horsepower motors most savings are assumed to relate to use of mediumcost options such as different parts and components (different motor design, copper package, steel types). Variable speed drives are considered a high-cost option. Other options (low-cost, user involvement) are assumed to be less relevant.
the saving options for toilets relate primarily to the flush volume, modification of which is considered a low-cost option. User involvement is also a relevant option (especially for dual flush of flush control toilets, and also as regards the refurbishment rate). The actual savings to be achieved is limited by the drainage system which may require a minimal flush volume. For kitchen appliances most savings are assumed to relate to use of medium-cost options such as different parts and components (different motor design). Other options (low-cost sensor controls, user involvement) are assumed to be relevant. as well.
32
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 3.3.2.1 Discussion The valuation of improvement options (modifications) indicates that for certain product groups medium to high-cost modifications are expected. Note that the analysis is characterised by a high degree of subjectivity. 3.3.3
Conclusion
The quantitative and qualitative analysis indicate that there are product groups for which a very high return on investment is calculated (quantitative assessment) or for which the establishment of even a part of the savings is expected to require medium and high cost modifications to the product (qualitative assessment). The analysis therefore can not confirm or exclude that excessive costs apply to the realisation of the savings potential identified, but the conclusions from the previous analyses indicates that higher costs are expected for at least some of the product groups. In order to arrive at a conclusion regarding the occurrence of excessive costs, a dedicated follow-up study is recommended that provides the necessary depth of investigation and detail, that could not be accommodated in this background study due to its sheer volume and range in product groups and limited available resources.
Reading guidance: The assessment of cost concludes Task 3. The following sections 4 (and 5) present the preliminary energy analysis of the product groups.
33
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
4
PRELIMINARY ENERGY ANALYSIS OF PRODUCT GROUPS
4.1 4.1.1
Mobile agricultural machinery Product group
"Mobile agricultural machinery" means mobile machinery intended for use in agricultural, horticultural and/or forestry applications. The group intends to cover all equipment used in agricultural and/or forestry settings, that is selfpropelled, intended to be towed by self-propelled equipment or incorporated in such equipment. Agricultural, horticultural and forestry machinery that is intended to be installed permanently11 is covered by another product group. Mobile agricultural and horticultural equipment covered by this group may be used for (but is not limited to) soil cultivation, planting, fertilizing and pest control, produce sorting, harvesting/postharvesting, hay making and various other purposes that can be indicated as agricultural or horticultural applications. Examples are: 2-wheel tractors, harvesters / combines, sprayers, manure distributors, agriculture mowers, nalers, tillers, swatchers, etc.). Mobile forestry equipment covered by this group may be used for (but is not limited to) felling, logging, tree/timber harvesting and processing, etc. (harvesters, skidders, tree trimmers and processors, haulers, forestry cultivators, fellers/bunchers, shredders, log loaders, pilling machines, etc.). The group comprises both self-propelled machinery (like harvesters) and the combination of tractors plus implements (equipment powered/moved by tractors). This latter group of implements is extremely diverse (stakeholders indicate that some 450 different products may be applicable), but they are included because they may affect the energy consumption of tractors through which they are powered. The tractors are the 'affected energy system'. An option is to limit this product group to 'self-powered' products only. This would exclude indirect energy-related products ('implements' such as ploughs towed behind a tractor) from the scope. The energy analysis indicates that some 85% of the total energy consumption can be attributed to tractors. This implies that if the product group would be reduced to direct ErP agricultural machinery (only self-powered products, excluding implements) the energy consumption and also the energy saving potential (assuming the same improvement potential applies) would be some 15% of what is calculated for the total group. Excluded Excluded from the scope of the Ecodesign Directive are 'agricultural tractors', since these are considered 'means of transport, primarily intended for persons or goods' (in line with Machinery Directive). However, many pieces of equipment receive power from tractors (for operation and mobility) which means that in this energy assessment the energy use of tractors must be included. Excluded from this product group is stationary equipment (installed 'permanently' in one place) like milking machines, stationary sorters and other (often material handling) equipment. These will be handled in a separate product group. Excluded is 'handheld' equipment for which a separate product group applies. 11
In this study, 'permanently' is meant to apply to products who spend their technical or economical product life (whichever is shortest) on a single site
34
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Excluded from this product group are riding and lawn mowers, these products have a large domestic end-user base, whereas the other products have not. The actual sales figures of motorised mowers are also much higher. Therefore a separate product group has been created for such mowers. Stakeholders Major stakeholders relevant for this group are represented on European level by: 4.1.2
Euromot12: European Association of Internal Combustion Engine Manufacturers (engines for power plants, pumps, power carriers, non-road mobile machinery, lawn and garden equipment, locomotives, marine and commercial vessels and recreational equipment) CECE13: European Construction Equipment Industry; CEMA14: Agricultural Machinery Industry in Europe. Market and stock data
The apparent consumption of mobile agricultural/forestry equipment according Prodcom is shown below. Table 5 Apparent consumption of mobile agricultural/forestry equipment App.cons.
(units)
Prodcom #
Description
28303140
Ploughs
"p/st"
28303150
"p/st"
22147
1458
49893
15913
10079
-37930
#VALUE!
28303210
Ploughs (excluding mouldboard ploughs) Scarifiers and cultivators
"p/st"
153433
214023
128148
123343
181998
583365
627355
28303220
Disc harrows
"p/st"
14211
-11362
10536
17870
21272
4796
15766
28303230
"p/st"
18169
35230
28799
3391
5974
28631
17823
28303250
Harrows (excluding disc harrows) Rotovators
"p/st"
154606
125556
148867
163961
278920
227176
253295
28303270
Weeders and hoes
"p/st"
30456
85691
2910
46585
78542
77791
129642
28303333
Central driven precision spacing seeders for agricultural or horticultural use
"p/st"
13779
9961
20155
31904
431135
816959
558707
28303335
Seeders for agricultural or horticultural use (excluding central driven precision spacing seeders) Planters and transplanters
"p/st"
31331
45128
115254
37663
122432
45228
58526
"p/st"
18190
41855
-31215
21298
25525
-21836
15842
"p/st"
216020
190310
196961
243017
222566
-112253
170111
28303450
Distributors for mineral or chemical fertilizer for soil preparation Manure spreaders and fertilizer distributors (excluding for mineral or chemical fertilizers)
"p/st"
30202
305863
318
-1421
148373
145646
177821
28305200
Hay-making machinery
"p/st"
6059
28718
-1795
64788
54997
132978
81691
28305330
Pick-up balers
"p/st"
23367
14636
27900
-59954
42669
28969
14022
28305350
Straw or fodder balers (excluding pick-up balers)
"p/st"
9193
1524
-4551
2379
104404
69765
5605
28305420
Potato-diggers and potato
"p/st"
6091
5540
5730
6447
4999
5663
5379
28303350 28303430
2003
2004
2005
2006
2007
2008
2009 86812
12
http://www.euromot.org/about%20euromot/what%20is%20euromot http://www.cece-eu.org/ 14 http://www.cema-agri.org/ 13
35
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) harvesters 28305450
Beet-topping machines and beet harvesters Root or tuber harvesting machines (excluding potatodiggers and potato harvesters, beet-topping machines and beet harvesters) Forage harvesters (excluding self-propelled) Forage harvesters, self propelled Harvesting machines (excluding combine harvester threshers, root or tuber harvesting machines, forage harvesters) Harvesting machines (excluding combine harvester threshers, root or tuber harvesting machines, forage harvesters, grape harvesters)
"p/st"
485
485
285
1675
-1638
291
279
"p/st"
1369
1318
1421
-5145
1685
32904
75829
"p/st"
6433
-7273
6169
21814
-676
-3097
1091
"p/st"
-9688
1048
327
21632
358
1167
890
"p/st"
88318
11404
13096
53374
59708
77679
#VALUE!
28305915
Combine harvester-threshers
"p/st"
8346
7159
-7208
-8213
8670
8979
6714
28305930
Agricultural threshing machinery (excluding combine harvester-threshers)
"p/st"
2815
1903
4551
2304
12506
5024
3130
28306030
Portable mechanical appliances with or without a motor, for projecting, dispersing or spraying liquids or powders, for agricultural or horticultural use (excluding watering appliances) Sprayers and powder distributors designed to be mounted on or drawn by agricultural tractors (excluding watering appliances) Other appliances, agricultural or horticultural
"p/st"
846119 3
860917 3
809575 8
560571 9
660694 8
699068 2
7149818
"p/st"
500988
144581
90698
107635
96620
253933
25379
"p/st"
195289 1
183730 8
591938
376878 8
-346250
736867 4
-982930
Self-loading or self-unloading trailers for agricultural purposes Agricultural or horticultural watering appliances
"p/st"
88829
90295
86828
91639
92864
100619
80344
"p/st"
837166 3
560000 0
459536 3
941992 9
924141 4
829091 2
1175062 5
28305480
28305945 28305960 28305970
28305990
28306050
28306090
28307040
28306010
"p/st"
362
Characteristics Most equipment in this group is powered by built-in compression ignited engines (diesel or light fuel oil) or indirectly powered by tractors (by mechanical or hydraulic power supplied from tractor to other equipment).
36
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) For the purpose of this assessment the market and stock data is described according subgroups as identified in the main source of information, the NRMM Review15 by IES: -
small agricultural equipment: any small equipment not in other categories; agricultural tractors: all agricultural and forestry tractors (affected energy system); agricultural harvesters: combine, forage and other self-powered harvesters.
These groups and therefore this section does not include sales of agricultural/forestry equipment without engines (ie. towed or incorporated and driven by an engine of another piece of equipment) these are essentially passive energy-related products and any improved of energy efficiency of these products, results in a reduced demand for energy from the self-powered products. This is then reflected in the energy analysis below by a reduction of energy consumption of these self-powered equipment. Market The NRMM review describes the sales of agricultural equipment with an engine for EU15 only. Assuming that the EU15 represents 85% of total EU27 sales16 the EU27 sales have been approximated by adding the missing 15% of sales in EU10+2: Table 6 Sales of agricultural equipment SALES EU27 (units)
2005
power range (kW)
< 19 kW
19-37 kW
37-56 kW
56-75 kW
75-130 kW
130-560 kW
> 560 kW
total
Small equipment
22.353
0
0
0
0
0
0
22.353
Agricultural tractors
17.259
3.835
38.353
57.529
57.529
17.259
0
191.765
Agricultural harvesters
0
0
0
0
904
10.165
226
11.294
TOTAL
39.612
3.835
38.353
57.529
58.433
27.424
226
225.412
tractors as % of total
44%
100%
100%
100%
98%
63%
0%
85%
Total sales of mobile agricultural equipment (including forestry, excluding tractors) is some 33.6 thousand pieces in 2005. If tractors are included the sales are about six times larger and amount to 225 thousand units. No split-up between agricultural and forestry equipment could be given. Sales of towed and mounted agricultural equipment without an engine were not identified. Future and historic sales are approximated using a binominal trend line, based on fuel consumption estimates.
15
Krasenbrink, A. et al, 2007 Technical Review of the NRMM Directive 1997/68/EC as amended by Directives 2002/88/EC and 2004/26/EC, DG JRC - IES, (Final), September 2008 16 Based upon NRMM review table 2.7 to 2.12.
37
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 2 Sales of mobile agricultural equipment
Stock The NRMM Review calculated the stock of agricultural equipment, based on the following assumptions: -
relatively stable market conditions in the EU15; product life of equipment with engines > 37 kW: 16 years or 10.000 hrs. (whichever comes first); product life of equipment with engines < 37 kW: 10 years or 6250 hours (whichever comes first); machinery population follows normal distribution with a mean of 1 and a standard deviation of 0.25.
For agricultural harvesters a smaller product life was assumed to correct for increasing sales in recent years. Table 7 Agricultural equipment - input for calculation STOCK EU27 (units)
2005
power range (kW)
< 19 kW
19-37 kW
37-56 kW
56-75 kW
Small equipment
223.529
0
0
Agricultural tractors
172.588
38.353
Agricultural harvesters
0 396.118 44%
% tractors in total
130-560 kW 0
> 560 kW
total
0
75-130 kW 0
0
223.529
613.647
920.471
920.471
276.141
0
2.941.671
0
0
0
14.455
162.635
3.613
180.704
38.353
613.647
920.471
934.926
438.776
3.613
3.345.904
100%
100%
100%
98%
63%
0%
88%
Based on the NRMM calculation of the EU15 stock (see assumptions above) and the ratio between EU15 and EU10+2 sales and stock, the underlying study assumes a total stock (including tractors) of some 3.3 million pieces of machinery equipped with an engine, including tractors. If tractors are removed some 400.000 pieces (12% of total agricultural) of machinery remain within the scope of the assessment. The historic and future stock is based upon the NRMM estimates for future fuel consumption (NRMM table 2.10-2.11)
38
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 3 Stock of agricultural equipment (incl. tractors)
4.1.3
Energy consumption
The energy consumption of various mobile agricultural equipment (incl. tractors) is estimated to be some 641 PJ/year for year 2005, slightly growing towards 671 PJ/year (table 2.11-2.12 of NRMM review). This estimate takes into account the effects of Directive 2004/26/EC, tier IIIB and IV. Table 8 Mobile agricultural equipment energy consumption EU27 (PJ/year)
2005
2010
2015
2020
Agricultural mob. eq.
641
659
667
671
The share in total energy consumption by tractors is approximately 85% of the total (based on NRMM data for NOx and PM emissions). This growth is primarily caused by an increase of fuel consumption of such equipment in especially the 'new' EU Member States as shown in the figure below. The trend line shows a small gradual increase indicating the effects of opposing trends of a sales increase (in EU10+2) and reduced fuel consumption / improved fuel efficiency (in the EU15, most likely related to tighter emission limits).
39
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 4 Energy consumption of mobile agricultural equipment
4.1.4
Improvement potential
The trend line above represents the reference scenario on which the energy improvement potential is projected. A complicating factor is that a certain share of the total energy improvement potential is realised by the current NRMM Directives. The remaining potential is therefore based on an estimate, taking into account the expected reductions in emissions and fuel consumption and reductions for the overall sector as identified in various literature sources. An overview of saving potential within agricultural sector as established for the US sector is provided below.17 Note that these savings potential include both technology improvements as well as practice improvement (e.g. transition to no-till agriculture serves).
17
Brown, Elizabeth, Neal Elliot, R., Potential Energy Efficiency Savings in the Agricultural Sector, report nr. IE053, ACEEE, April 2005
40
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 9 Agricultural equipment - energy saving options
For tractors this source indicates '0.70' savings potential, whereas forage harvesters and other machinery have a savings potential of '0.05'. Assumed is that the tractor potential includes mostly practice improvement (reduced use of tractors: no-tillage crop production, etc.) whereas for harvesters the improvement is likely to be more technology related. Therefore an overall technology related savings potential of 0.05 is probably applicable given the Ecodesign context. The savings potential is applied to overall energy consumption of mobile agricultural machinery, which includes tractors (as affected energy system of implements etc.). It is assumed that the overall savings of 5% is realised by changes to the self-propelled equipment (like harvesters, excluding tractors) and implements (which affects tractor energy consumption as 'affected energy system').Assuming one third of sales have a product life of 10 years and two thirds have a product life of 16 years, the average product life is 14 years. This means that (assuming stable markets) 5/14 or 36% is replaced in 2020, 10/14 or 71% is replaced in 2025 and the whole population has established the saving potential in 2030. Table 10 Calculation mobile agricultural machinery 2005
2010
2015
2020
2025
2030
BAU
641
659
667
671
666
655
population remaining for saving potential % saving potential (PY/year)
100%
100%
100%
64%
29%
0%
32
33
33
21
10
0
EU27 incl. savings (PY/year)
641
659
667
659
642
622
actual savings (PY/year)
0
0
0
12
24
33
41
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 5 Reference and improvement scenario mobile agricultural machinery
The assessment indicates a saving potential of 12 PJ in 2020, increasing compared to BAU to 24 PJ in 2025 and 33 PJ in 2030.
4.1.5
Discussion / Issues to consider for follow-up
-
Stakeholders have indicated that some 450 different types of products can be identified within this product group. It is therefore essential that if a follow-up study were to take place, the product scope should be made more specific. Among harvesters, there is more homogeneity in the market environment and there is a potential for improvement; however their sales volume makes up only 5% of the total sales of mobile agricultural equipment. Also it is a highly competitive industry with mainly big players, with limited differentiation of environmental/energy impacts.
-
The savings identified above include savings by agriculture tractors. These products are not within the scope of the current Ecodesign Directive. No source indicating the allocation of energy (and therefore saving potential) to use of the tractor itself or to the use of other agricultural equipment ('implements') was found. This issue should be addressed in follow-up studies (if appropriate).
-
The effects of the NRMM Directive (regarding noise, NOX and PM10 emissions) were not integrated in this assessment and should be addressed in follow-up studies (if applicable / appropriate) .
-
The sector itself indicates that the greatest potential for energy saving is in the ‘use’ phase. In this case, energy saving and CO2 reduction are directly related (proportional). Existing discussions are already taking place between the non-road mobile machine industry and DG Enterprise of the European Commission (unit G4) on identifying the most appropriate measures for energy/CO2 reduction by the sector. It is inappropriate to have separate parallel evaluations on the same topic under multiple regulatory instruments. Consequently, consideration should not be given to the inclusion of Agricultural & Construction Equipment in the scope of the ErP directive whilst the work on this topic by DG Enterprise G4 is still taking place.
-
No stakeholder comments regarding the costs for improvement were received.
42
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) -
A sector approach would probably indicate that certain environmental impacts (like GHG) of the agriculture sector are much more determined by other emissions sources than the equipment used.
-
Stakeholders have argued that a legislative product-centred approach such as envisaged by the Ecodesign Directive does not address the complete agricultural value chain (tractors, selfpropelled, and implements) and does not offer the right framework to get the highest gain in energy efficiency from implements. They expect that such measures would be counterproductive and increase administrative costs for manufacturers significantly. A good example of legislation that enables the whole chain to be involved is the ‘thematic strategy for the sustainable use of pesticides’ where manufactures, users, member states and testing stations each have their own obligations. The procedures inside the Ecodesign Directive do not allow for such an approach. It is the market itself (not the products) that need to be changed in order for industry to deliver the right equipment and achieve the lowest energy footprint given a certain situation in the field.
-
The energy savings in this sector come from the combination/interaction of improvements in process efficiency, operations efficiency and machine (product) efficiency, together with use of alternative energy sources. Any regulation of only one item from this list will likely result in a sub-optimal solution and therefore should be avoided. The investigation of improvements of the 4 areas should be integrated in one consolidated approach/study.
43
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.2
Mobile construction machinery
4.2.1
Product group
"Mobile construction machinery" means mobile machinery used for construction, but also mining and quarrying applications, and that is self-propelled, intended to be towed by self-propelled equipment or incorporated in such equipment. Equipment that is intended to be installed permanently in one place is covered by another product group. Mobile construction machinery covered by this group may be used for (but is not limited to) building construction (mobile elevating platforms, cranes, dozers, pavers, etc.), tunnel construction, road and other infrastructure construction (excavators, asphalt plant, etc.). The group also comprises equipment for mining and quarrying applications and certain 'light industrial applications' including airport services and other service equipment (sweepers/cleaners, snow ploughing/levelling, towing, and lifting). Mobile elevating platforms can be considered to be included in this product groups, as well as various industrial trucks. However, most industrial trucks should be handled separately in a subcategory of "logistic systems" since most 'industrial trucks' have no link to construction purposes at all. Excluded Excluded from this product group is stationary equipment (permanently installed) like sorters, conveyors and other equipped installed permanently on a production site. These will be handled in a separate product group. Excluded is 'handheld' equipment for which a separate product group applies. Major stakeholders relevant for this group are represented on European level by: 4.2.2
Euromot18: European Association of Internal Combustion Engine Manufacturers (engines for power plants, pumps, power carriers, non-road mobile machinery, lawn and garden equipment, locomotives, marine and commercial vessels and recreational equipment) CECE19: European Construction Equipment Industry; CEMA20: Agricultural Machinery Industry in Europe. FEM, industrial trucks, mobile elevating platforms, etc. Market and stock data
The apparent consumption of mobile construction machinery according Prodcom is shown below. Table 11 Apparent consumption of mobile construction machinery App. cons. (units)
2003
2004
2005
2006
2007
2008
2009
28922130 Crawler dozers (excluding wheeled) 28922150 Wheeled dozers (excluding track-laying)
12143
1232
2802
4857
3193
298
-224
-361
-3653
-5690
3037
468
88953
-12291
28922200 Motor graders and levellers
-18150
58830
521
1488
1486
7425
-80953
28922300 Motor scrapers
5199
4677
21346
2733
12296
8067
-2657
28922400 Ride-on compaction equipment
30037
5598
43835
49249
-29470
19820
-13008
18
http://www.euromot.org/about%20euromot/what%20is%20euromot http://www.cece-eu.org/ 20 http://www.cema-agri.org/ 19
44
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) and the like 28922530 Loaders specially designed for underground use 28922550 Wheeled loaders, crawler shovel loaders, front-end loaders 28922600 Self-propelled bulldozers... with a 360° revolving superstructure 28922730 Self-propelled bulldozers, excavators..., n.e.c. 28922750 Self-propelled earth moving, excavating... machinery, n.e.c. 28922900 Dumpers for off-highway use
-10535
-140
-29040
-598
-2032
-288
-861
72107
32287
32348
20497
26618
38491
-56128
77701
78380
88563
7146
-30034
13693
99899491 44472
53865
-49950
409959 10575
177315
208947
541826
19435
20527
18181
18038
16826
-16
28923010 Pile-drivers and pile-extractors
-9080
-52508
-2773
-7528
13066
-76053
12793
28925000 (Crawler tractors) Track-laying tractors
-5286
4414
10964
4616
-3352
6381
3927
28921233 Self-propelled coal or rock cutters and tunnelling machinery 28921253 Self-propelled boring or sinking machinery 28922750 Self-propelled earth moving, excavating... machinery, n.e.c. 28923070 Scrapers earth moving, excavating, extracting... machinery, not self-propelled 28923090 Machinery for public works, building..., having individual functions 28924030 Sorting, screening, separating, washing machines; crushing, grinding, mixing, kneading machines excluding concrete/mortar mixers, machines for mixing mineral substances with bitumen
40000
4376
5534
6829
3135
60000
2598
76070
66261
71616
54027
50283
88244
70632
3313
3474
7395
9664
10737
9283
6237
21178
25183
67210
74169
51481
37779
19079
187280
124676
121370
230451
315802
374251
326267
138917
121182
142130
187101
122906
152591
700000
The Prodcom category descriptions are however not conclusive whether the equipment is mobile or not (although all 'self propelled' equipment can be considered to be 'mobile'). Characteristics Most equipment in this group is powered by compression ignited engines (diesel or light fuel oil). Some pieces of equipment may be indirectly powered by tractors (by mechanical or hydraulic power supplied from tractor to this equipment). Most construction machinery applies a hydrostatic drive, with a combustion engine driving a hydraulic compressor, which then drives the propulsion and other mechanics.
45
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 6 Hydrostatic drive mechanism 21
Certain industrial trucks or service equipment may be electrically powered (using batteries, such as airport service trucks and industrial trucks). Market For the purpose of this assessment the market and stock data is described according subgroups as identified in the main source of information (NRMM Review).: -
small construction equipment: any small equipment not in other categories; light construction equipment (< 75 kW motor output); heavy construction equipment (> 75 kW motor output);
This source does not cover the market or energy aspects of the electrically driven machinery in this product groups. No other source providing information regarding these aspects was found. The NRMM review describes the sales of construction machinery with an engine for EU15 only. Assuming that the EU15 represents 85% of total EU27 sales22 the total sales have been approximated by adding the missing 15% of sales in EU10+2: Table 12 Sales of construction machinery SALES EU27 (units)
2005
power range (kW)
< 19 kW
Small equipment Light construction equipment heavy construction equipment TOTAL
21 22
37-56 kW 0
56-75 kW 0
75-130 kW 0
130560 kW 0
> 560 kW 0
total
39.136
19-37 kW 16.773
33.545
33.545
28.514
72.123
0
0
0
167.727
0
0
0
0
20.295
15.867
738
36.900
72.682
50.318
28.514
72.123
20.295
15.867
738
260.536
http://www.merlo.com/Tre_Emme/prodotti/idrostatica_e.htm Based upon NRMM review table 2.7 to 2.12.
46
55.909
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Total sales of mobile construction equipment (including various 'light equipment') is some 260 thousand pieces in 2005. Sales of towed and mounted constructional equipment without an engine could not be identified. Future sales are based on fuel consumption estimates, historic sales are approximated using a binominal trend line. Figure 7 Sales of mobile construction equipment
Stock The NRMM Review calculated the stock of construction machinery, based on the following assumptions: -
relatively stable market conditions in the EU15; product life of equipment with engines > 37 kW: 16 years or 10.000 hrs. (whichever comes first); product life of equipment with engines < 37 kW: 10 years or 6250 hours (whichever comes first); machinery population follows normal distribution with a mean of 1 and a standard deviation of 0.25.
For large construction equipment a smaller product life was assumed to correct for increasing sales in recent years. Table 13 Mobile construction machinery - input data STOCK EU27 (units)
2005
power range (kW)
< 19 kW
37-56 kW 0
56-75 kW
391.364
19-37 kW 167.727
Small equipment Light construction equipment heavy construction equipment TOTAL
130-560 kW 0
> 560 kW 0
total
0
75-130 kW 0
335.455
335.455
456.218
1.153.964
0
0
0
2.281.091
0
0
0
0
243.540
158.670
7.380
409.590
726.818
503.182
456.218
1.153.964
243.540
158.670
7.380
3.249.772
559.091
Based on the NRMM calculation of the EU15 stock (see assumptions above) and the ratio between EU15 and EU10+2 sales and stock, the underlying study assumes a total stock (including tractors) of some 3.2 million pieces of mobile construction machinery (equipped with a combustion engine). 47
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) The historic and future stock is again approximated using the estimates for future fuel consumption (NRMM table 2.10-2.11). Figure 8 Stock of mobile construction machinery
4.2.3
Energy consumption
The energy consumption of various mobile construction machinery is estimated to be some 369 PJ/year for year 2005, growing towards 428 PJ/year (table 2.11-2.12 of NRMM review). This estimate takes into account the effects of Directive 2004/26/EC, tier IIIB and IV. Table 14 Mobile construction machinery energy consumption EU27 (PJ/year)
2005
2010
2015
2020
Mobile constr. machinery
369
394
414
428
This growth is primarily caused by an increase of fuel consumption of such equipment in especially the 'new' EU Member States as shown in the figure below. The trend line shows a small gradual increase indicating the effects of opposing trends of a sales increase (in EU10+2) and reduced fuel consumption / improved fuel efficiency (in the EU15, most likely related to tighter emission limits). Figure 9 Energy consumption of mobile construction machinery
48
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.2.4
Improvement potential
The trend line above represents the baseline scenario to which the energy improvement potential is assessed. The saving potential for construction equipment is assumed to be comparable to that of mobile agricultural equipment, ie. 5% 23 (see also 'Mobile agricultural equipment'). The savings and saving potential is then calculated as follows. Assuming half of the sales have a product life of 10 years, some 8% of sales have a life of 12 years and almost 39% of sales have a life of 16 years, the average product life is 12.5 years. This means that (assuming stable markets) 5/12.5 or 40% is replaced in 2020, 10/12.5 or 80% is replaced in 2025 and in 2030 the whole population has put in practice the saving potential. Table 15 Mobile construction machinery - energy savings BAU population remaining for saving potential % saving potential (PY/year) EU27 incl. savings (PY/year) actual savings (PY/year)
2005
2010
2015
2020
2025
2030
369
394
414
428
437
440
100%
100%
100%
60%
20%
0%
18
20
21
13
4
0
369
394
414
419
419
418
0
0
0
9
17
22
The scenario-analysis indicates a potential saving of 9 PJ in 2020, increasing to 17 PJ in 2025 and 22 PJ in 2030. Figure 10 Reference and Improvement scenario of mobile construction machinery
23
Brown, Elizabeth, Neal Elliot, R., Potential Energy Efficiency Savings in the Agricultural Sector, report nr. IE053, ACEEE, April 2005
49
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.2.5
Discussion / Issues to consider for follow-up
-
The effects of the NRMM Directive (noise, NOX and PM10 emissions) were only partially integrated in this assessment and can be addressed in follow-up studies (if appropriate) .
-
The estimate of average 5% savings for new products (on top of savings due to existing measures) needs to be firmed up by cross-checking with relevant stakeholders and the effects on (excessive) costs need further investigation.
50
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.3
Handheld power tools
4.3.1
Product group
"Handheld power tools" means tools intended to be carried by hand or carried on the human body, with a self-contained motor (connected to an on-board or separate power source) and used for (but not limited to) various applications in a construction, agricultural, horticultural, industrial and domestic context. Examples of such products are demolition jack hammers, electric power tools (e.g. in construction and building / DIY), chainsaws (in agricultural and forestry) and hedge trimmers, cutters possibly with combustion engines (in garden sector). Also leaf or lawn blowers can be regarded to be included in this product group. For the assessment the product group is split up into electric power tools (both corded and cordless) and tools with combustion engines (represented by chainsaws). Of course the product group is more diverse than these two subgroups, but the level of detail should be enough to provide an estimate for the ranking. Only the market data based on Prodcom and the overall combined savings potential is indicated for both groups combined. 4.3.2
Market data
This overview gives the apparent consumption according Prodcom for electric and other power tools. Table 16 Apparent consumption power tools App. cons. (units) Prodcom #
Description
28241113
Electromechanical hand drills operated without an external source of power Electro pneumatic hand drills (including drilling, tapping or reeming machines, boring machines and rock drills) Electromechanical hand drills of all kinds (excluding those operated without an external source of power, electro pneumatic) Electromechanical chainsaws Electromechanical circular saws
28241115
28241117
28241123
28241125
28241127
Electromechanical handsaws (excluding
2003
2004
2005
2006
2007
2008
2009
12.015.815
13.324.222
12.346.425
12.511.369
12.176.250
10.730.189
8.922.357
3.099.492
3.548.592
3.096.496
3.973.354
4.148.928
2.978.534
1.907.258
13.867.262
14.498.384
11.539.075
11.264.794
11.212.184
9.585.793
6.256.563
1.394.309
1.056.831
1.279.744
1.640.270
2.134.991
1.502.110
1.273.689
3.232.360
3.370.250
2.936.407
3.496.755
3.013.449
2.442.932
2.274.289
7.371.645
8.146.670
7.690.861
7.538.349
7.521.931
5.516.817
4.314.129
51
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
28241133
28241135
28241150
28241180
28241190 28241240
28241260
28241280
chainsaws, circular saws) Electromechanical hand tools used for working textile materials (excluding drills, saws) Electromechanical hand tools operated without an external source of power (excluding drills, saws, those used for working textile materials) Grinders, sanders and planers, for working in the hand, with selfcontained electric motor, operating with an external source of power Electromechanical hedge trimmers and lawn edge cutters Other electric tools Tools for working in the hand, pneumatic, rotary type, including combined rotarypercussion Chainsaws with a self-contained non-electric motor Hand tools, hydraulic or with a self-contained non-electric motor (excluding chainsaws)
10533
10490
10029
0
0
0
0
3.531.924
4.540.405
6.138.961
8.212.744
9.749.884
7.469.348
4.721.583
9.977.389.546
23.894.289
22.201.755
21.756.158
27.189.872
22.542.525
13.261.736
5.397.798
5.940.589
7.517.465
5.655.449
7.252.761
8.032.152
6.756.940
12.133.868
13.321.089
11.445.398
10.290.418
9.787.509
7.911.585
6.105.723
1.045.371
1.097.157
1.498.336
1.048.675
1.146.888
1.044.823
648.707
3.684.356
3.463.370
4.557.661
4.507.126
5.159.010
5.016.253
4.305.317
752.151
2.500.000
2.578.697
2.818.595
2.792.466
1.770.553
1.603.696
Stock data is presented for each subgroup. The next subsections focus on two handheld products, electric power tools and chainsaws, to describe market, stock, energy consumption and improvement potential. 4.3.2.1 Electric power tools Market of electric power tools Electric power tools are used for working with wood, metal and mineral products such as stone and concrete by professionals, skilled tradesmen and “do it yourself” (DIY) consumers. There are four categories of power tools. Corded power tools both for pro’s and for DIY consumers and cordless power tools for both groups. The context of use is most often home or construction sites. Do It Yourself products are typically used intermittently and are purchased for home projects or gifts. With the typical motor life and average operating pattern the typical product life is estimated to be 52
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) five years. Professional products are used more frequently and purchased by tradesmen or professionals for their work. The designed lifespan of professional tools is two years. The market for electric power tools is between 3 to 4 billion euro in size (source: EPTA communication). Table 17 Sales data power tools Sales ( EPTA ) Sales in € Billion
2000 2,7
2002 2,8
2004 2,9
2006 3,2
2008 4,0
2009 2,9
Forecast 2010 2011 3,0 3,2
2012 3,4
2013 3,6
Figure 11 Sales of electric power tools
Recovery in 2010 is thought to have been positive and the forecast for the coming three years show an increase at the rate of 3 to 5 %. Professional sales are influenced by residential and industrial construction trends. DIY sales influenced by the economy and disposable income trends. Sales data on unit level are available for year 2009. A split up is applied into professional and DIY products and corded/cordless products. The sales and lifespan data are used to calculate the stock. Every year one fifth of the DIY stock is replaced and half of the stock for professional products. Energy consumption of electric power tools Corded DIY products use universal motors rated between 250 and 750 watts. Corded professional products are powered between 500 and 2500 watts. The universal motors operate at typically 60% efficiency. Cordless DIY products use batteries mainly in the range 7,2 to 12 volts usually with a low amp hour rating. Cordless professional products apply a range of 12 to 36 volt, usually with a higher amp hour rating. The three batteries chemistries in use are NiCad, NiMH and LI-Ion. Cordless products use predominantly permanent magnet motors. Data regarding average product life, annual operating hours, typical power consumption is provided by EPTA. The resulting annual energy consumption per product type is shown in table below.
53
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 18 Input data power tools Realistic
Average
Average
Average
Average
Average
Average
Motor
Design
Design
Input
Lifetime
Annual
Efficiency
Life
Life
Power
Energy
Energy
Use phase
Use phase
%
Hours
Years
KW
KWh
KWh
Corded
60
80
2
1,0
80
40
Cordless
80
100
2
n/a
41
21
Corded
60
20
5
0,5
10
2
Cordless
80
20
5
n/a
97
19
Professional
DIY
Total
Design life: The motor lasts for approximately 80-100 hours for professional products and approximately 20 hours for DIY products. Note that this is an average and that depending on the specific type of product motor life may vary significantly. Input power: For cordless tools the energy consumption in the use phase is determined by the battery charging equipment and how it is handled. Power tools stock: For professional products the stock is calculated assuming a design life of 2 years (meaning the average stock is replaced every two years) and the annual sales. For DIY products a different approach is needed, since it is known that many products are given as presents and do not fully end-up in the 'active' stock. Calculation stock on the basis of annual sales and a design life of 5 years would lead to an exaggeration of stock. Therefore EPTA assumed that the active stock is about twice as big as the annual sales. Combining professional and DIY figures leads to an overall stock of 28.6 million tools. The total electric power consumption of the stock is approximately 1 TWh per year (in 2009). Improvement potential of electric power tools The main improvement area for corded power tools relates to the motor. Efficiency can be improved by using permanent magnet motors which need additional electronics to provide control. Thus far this technology has not been commercially viable due to the on-cost for the consumer in relation to the overall product price. Nevertheless, efficiency improvements of around 15% could be achieved. The efficiency improvements of professional cordless products is zero, since these already use advanced battery loading controls. For cordless DIY products some saving is possible as regards the energy loss from battery loading (33% of average annual electricity consumption). The industry association EPTA indicates that although savings may be technically possible, the product on-cost (purchase price increase) will outweigh the economic savings from lower electricity consumption. Therefore these savings are not cost-effective according industry opinions. Furthermore, the increased use of electronics and efficient motors will lead to a higher resource use of rare-earth materials.
54
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 19 Sales and energy consumption power tools Sales professional DIY
2005
2010
2015
2020
2025
2030
corded
6,4
6,3
7,8
8,5
9,2
10,0
million
cordless
3,4
3,3
4,2
4,5
4,9
5,3
million
corded
13,0
12,8
16,0
17,5
18,9
20,4
million
cordless
6,3
6,2
7,7
8,4
9,1
9,8
million
29,1
28,6
35,8
39,0
42,3
45,5
million
total product life DIY
years
2
professional
years
5
Stock professional DIY
2005
2010
2015
2020
2025
2030
corded
32
31
39
43
46
50
million
cordless
17
17
21
23
25
27
million
corded
26
26
32
35
38
41
million
cordless
13
12
15
17
18
20
million
total
87,4
86,0
107,5
117,2
127,0
136,8
million
Energy consumption professional
standard
improved
corded
40,0
34,0
kWh/year
cordless
20,5
20,5
kWh/year
corded
2,0
1,7
kWh/year
cordless
19,5
13,1
kWh/year
DIY
Energy consumption Reference scenario professional DIY
corded
1,3
1,3
1,6
1,7
1,8
2,0
TWh/year
cordless
0,3
0,3
0,4
0,5
0,5
0,5
TWh/year
corded
0,1
0,1
0,1
0,1
0,1
0,1
TWh/year
cordless
0,2
0,2
0,3
0,3
0,4
0,4
TWh/year
TOTAL
1,9
1,9
2,4
2,6
2,8
3,0
TWh/year
corded
50%
cordless
50%
corded
20%
cordless
20%
replacement rate professional DIY
Replaced by improved product
2005
2010
2015
2020
2025
2030
professional
corded
0%
0%
0%
100%
100%
100%
cordless
0%
0%
0%
100%
100%
100%
corded
0%
0%
0%
100%
100%
100%
cordless
0%
0%
0%
100%
100%
100%
DIY
Energy consumption improved scenario professional DIY
corded
1,3
1,3
1,6
1,5
1,6
1,7
TWh/year
cordless
0,3
0,3
0,4
0,5
0,5
0,5
TWh/year
corded
0,1
0,1
0,1
0,1
0,1
0,1
TWh/year
cordless
0,2
0,2
0,3
0,2
0,2
0,3
TWh/year
TOTAL
1,9
1,9
2,4
2,2
2,4
2,6
TWh/year
Saved
0,0
0,0
0,0
0,4
0,4
0,4
TWh/year
Saved
0
0
0,0
3,4
3,7
3,9
PJ primary
55
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) For the electric power tools the scenario analysis calculated a possible savings of some 4PJ in 2020. Figure 12 Reference and Improvement scenario of handheld power tools
Table 20 Assumptions power tools Notes and assumptions Sales volumes derived from EPTA industry data for EU27 Data relates to power tools only and not products such as household and hand held vacuum devices The "Power Tools in use" numbers are derived using the design life for Professional tools and 40% of the design life for DIY as it is known that DIY tools are little used Energy consumption data derived from aggregated member company input as shown in the detailed workings sheet and relates to use phase only Energy improvement figures derived from aggregated member company input as shown in the detailed workings sheet For the savings potential on cordless DIY products, it has been assumed that savings can only be made on products using simple transformer chargers without controls. It has been assumed that these comprise 3m of the total 6.2m DIY cordless products Energy improvements can only be delivered with additional manufacturing phase energy resulting in increased energy use overall Additional manufacturing phase energy data is derived from the LCA performed for EPTA and Recharge by PE International in 2009 on a corded and cordless power tool Additional "Critical Raw Materials" as detailed in the EU Communication dated 2nd February 2011 would also be needed to achieve these energy improvements
4.3.2.2 Chainsaws A chainsaw (or chain saw) is a portable mechanical saw, powered by electricity, compressed air, hydraulic power, or most commonly a two-stroke engine. It is used in activities such as tree felling, limbing, bucking, pruning, by tree surgeons to fell trees and remove branches and foliage, to fell snags and assist in cutting firebreaks in wildland fire suppression, and to harvest firewood. Chainsaws with specially designed bar and chain combinations have been developed as tools for use in chainsaw art. Specialist chainsaws are used for cutting concrete24
24
http://en.wikipedia.org/wiki/Chainsaw
56
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Market and stock data Total sales of chainsaws in Europe are some 1.5 million units in 2020, based on NRMM Review sales data 25. Most chain saws (> 95%) belong to the 'hobby' category. Table 21 Market chainsaws split up
2000
2005
2010
2015
2020
2025
2030
Sales
1.501.376
1.279.744
1.546.417
1.792.721
2.078.255
2.409.267
2.793.001
units
Stock Total
9.808.448
9.586.816
9.853.489
10.099.793
10.385.327
10.716.339
11.100.073
units
hobby
95%
9.292.214
9.082.247
9.334.884
9.568.225
9.838.731
10.152.321
10.515.859
units
professional
5%
516.234
504.569
518.605
531.568
546.596
564.018
584.214
units
The product life of chain saws ranges from 8 years for hobby products to just 2 years for professional users. The difference can partly be explained by the intensity of use. Based on the data provided by the NRMM Review the stock has been estimated to grow from almost 10 million products in 2010 to almost 11 million in 2030. Table 22 Calculation chain saws Sales Chain saws
2000
2005
2010
2015
2020
2025
2030
hobby
1,43
1,22
1,47
1,70
1,97
2,29
2,36
million
professional
0,08
0,06
0,08
0,09
0,10
0,12
0,12
million
total
1,5
1,3
1,5
1,8
2,1
2,4
2,5
million
2000
2005
2010
2015
2020
2025
2030
hobby
9,3
9,1
9,3
9,6
9,8
10,2
10,2
million
professional
0,5
0,5
0,5
0,5
0,5
0,6
0,6
million
total
9,8
9,6
9,9
10,1
10,4
10,7
10,8
million
Stock Chain saws
Energy consumption The NRMM provided characteristics for chain saws which can be used for an energy assessment. Table 23 Input data chain saws Engine type Chainsaws hobby chainsaws professional
Engines numbers per year 1.022.220
Market population 8.177.760
average power [kW] 1,8
engine class
EDP [h]
SH 2
50
Average run time per year (hrs/year) 6,25
227.160
454.320,
3
SH 3
300
150
(EDP means 'Engine Durability Period' or the product life expressed in hours) Professional chain saws require 22 MJ fuel input for each kWh output (efficiency 16%), hobby chain saws require 28 MJ/kWh (efficiency 13%) 26. Combined with a load factor of 0.6 and 0.3 respectively and the above data the primary energy consumption of the stock is as shown below.
25
Non-road mobile machinery directive, http://ec.europa.eu/enterprise/sectors/mechanical/files/nrmm/final_report_nrmm_review_part_i_en.pdf 26 http://lipasto.vtt.fi/yksikkopaastot/muute/tyokoneete/bens_s_te.htm
57
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Table 24 Energy consumption chain saws Chain saws
hobby
6,6
6,5
6,7
6,8
7,0
7,2
7,3
PJ
professional
6,1
6,0
6,2
6,3
6,5
6,7
6,7
PJ
TOTAL
12,8
12,5
12,8
13,1
13,5
13,9
14,0
PJ
Improvement potential No sources were found regarding the improvement potential for (gasoline) chain saws. Assuming that energy efficiency has never been a real design issue before, and the general efficiency is one of the worst identified for moveable equipment27, the indicative improvement potential was set at 50%. Assuming a renewal of stock based on average product life, the savings are as shown below. Table 25 Improvement potential chain saws replacement rate Chain saws
hobby
13%/year
professional
50%/year
Replaced by improved product
2005
2005
2010
2015
2020
2025
2030
Chain saws
hobby
0%
0%
0%
0%
63%
100%
100%
professional
0%
0%
0%
0%
100%
100%
100%
Energy consumption improved scenario
2005
2005
2010
2015
2020
2025
2030
Chain saws
hobby
6,6
6,5
6,7
6,8
5,6
4,8
4,9
PJ
professional
6,1
6,0
6,2
6,3
4,3
4,5
4,5
PJ
TOTAL
12,8
12,5
12,8
13,1
9,9
9,3
9,4
PJ
Saved
0,0
0,0
0,0
0,0
3,6
4,6
4,7
PJ
The indicative energy improvement scenario calculates an energy saving of almost 5 PJ of primary energy in 2030. 4.3.3
Improvement potential
The energy saving potential of electric power tools is some 4 PJ/year but is not cost-effective and should therefore be discarded. The energy saving potential of chainsaws (and other handheld equipment with combustion engines) is some 5 PJ/year in 2030 and will be used for the relative ranking of this product group. 4.3.4 -
27
Discussion / Issues to consider for follow-up Regarding electric power tools, the relevant industry association has indicated that the savings in this product group will not be cost-effective (will not be recouped by lower electricity bills). The estimate of 50% savings potential for chain saws needs to be firmed up by cross-checking with relevant stakeholders and a consideration of costs.
http://lipasto.vtt.fi/yksikkopaastot/muute/tyokoneete/bens_s_te.htm
58
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
4.4
Stationary agricultural equipment
4.4.1
Product group
"Stationary agricultural equipment" means non-mobile energy-related equipment that is intended to be used in agricultural, horticultural and forestry applications. Examples for the agricultural sector are milking machines/robots, cattle equipment (automated gates, fences, sluices), incubators/brooding equipment, equipment for transport / distribution of fodder, equipment for handling manure/excrements, etc. Examples for the horticultural / forestry sector may be stationary shredders, compactors for plant waste, etc. Excluded Excluded are 'generic' products used in these sectors: Heating, lighting, ventilation products have been dealt with or are being dealt with by the Ecodesign policy process (respectively Lot 20/21 on local heating and air heating, Lot 8/9/19 on lighting and Lot 10 on Fans > 125 W). Cleaning products such as power washers are indirectly dealt with by positive displacement pumps, material handling equipment such as conveyor belts are treated under "logistic systems". 4.4.2
Market and stock data
Energy-related agricultural equipment is mainly limited to intensive farming as extensive farming does not rely so much on automated equipment. The apparent consumption of such stationary agricultural equipment according Prodcom is shown below. Table 26 Apparent consumption of such stationary agricultural equipment App.cons. (units)
2003
2004
2005
2006
2007
2008
2009
28308100
28000
15000
15000
11124
13176
12385
12340
8583
610449 4 74024
14521
28308200
Machines for cleaning, sorting or grading eggs, fruit or other agricultural produce Milking machines
82302
16143
10279
28308300
Machinery for preparing animal feedstuffs
40713
41669
77262
86263
189976
96446
11573 1
28308400
Poultry incubators and brooders
90711
77356
137306
199242
122187
90715
28308500
Poultry-keeping machinery (excluding poultry incubators and brooders) Automatic drinking troughs for farm animals
180000 0 139077 7
175959
276539
312869
141216
157661
135372 4
134032 4
199151 5
152002 8
183916 1
12807 6 30421 8 n.a.
28308640
The average 'apparent consumption' between 2003 and 2008 is some 3.3 million units. Assuming an average product life of 15 years (often applicable to installed equipment) and stable market conditions, the average stock is estimated to be some 50 million units. The market data shows large deviations (between 1.7 million in 2004 to 8.8 million in 2006). Therefore, as a conservative estimate the stock of equipment is assumed to remain constant (only following increase of intensive farming). The total number of farms (agricultural holdings) in EU27 is close to 7.3 million in 2007, but this includes also small (extensive) farms28.
28
Agricultural Statistics - Main results 2008-09, by Eurostat, 2010 edition
59
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 13 Farm holdings by size
The Eurostat study expects a continued increase of larger farming enterprises. 4.4.3
Energy consumption
A desk research study has been undertaken to identify the energy consumption of the various agricultural stationary equipment, but no usable data could be retrieved within the budgetary constraints of this study. Therefore, in order to provide an indicative assessment of the agricultural energy consumption a top-down approach is used. Total consumption of energy in agriculture in 2007 was 27826 kton oil equivalent or 1165 PJ29. Considering this includes the approximately 650 PJ for mobile agricultural equipment30, this leaves some 515 PJ (44% of total) for other agricultural energy consumption31, most of which is assumed to be related to stationary equipment. For forecasts to 2030 the energy consumption of non-mobile agricultural equipment is assumed to stay constant at 515 PJ/year , because even if the total number of agricultural holdings is decreasing, this will be mainly at the cost of small holdings. The larger holdings are in general more intensive holdings. It can be expected however that a significant share of this consumption is related to use of equipment already dealt with by measures. Across all farming businesses, the major areas of energy consumption are lighting, heating, ventilation, air circulation and refrigeration. Specific agricultural equipment is not identified as major area of interest for energy savings. The main areas of energy consumption by broad agricultural activity are32: • • • •
horticulture - heating typically accounts for 90 per cent of the energy used in a greenhouse; pig farming - energy is used in a number of pig farming processes, including welfare and feeding systems, building services and environmental protection, waste management and emissions control; poultry farming - most energy is used for maintaining good environmental conditions for housing the flock (ventilation, lighting, heating); dairy - cooling milk and heating water account for as much as 65 per cent of the energy used, with lighting and pumping identified as other significant consumers;
29
Agricultural Statistics - Main results 2008-09, by Eurostat, 2010 edition See product group "mobile agricultural machinery' 31 One kg oil equivalent (OE) equals 41.868 kJ energy (net calorific value). Therefore 1 Mtoe (1000 kg) equals 41.9 PJ and 28.000 ktoe equals 1165 PJ. 32 Carbon Trust, UK 30
60
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) • •
crop stores - the amount of energy required by a crop store is closely linked to the thickness of the insulation and the difference between the storage temperature and the temperature outside (cooling, heating); combinable crops - energy is often wasted in storing and drying these crops;
When looking at dairy farms in particular, some 27-35% of total energy consumption may be related to equipment already dealt with (lighting 13%, air circulation (fans) 10%, compressed air (ENER Lot 31) 4% and water systems (mainly pumps/circulators) 8%). This leaves 65-73% of energy consumption not yet covered. Figure 14 Dairy farm energy consumption per application33
At a higher aggregate level ,according a study by ACEEE 34 - see picture below- , some 2/3 of farm energy consumption (of US farms) could not be categorised, the remaining 31% being related to motor systems (18%), lighting (1%), onsite transport (3%) and machinery (9%). It must be assumed that a large share of this 'un-categorised' energy consumption is related to mobile machinery. When looking at fuel type, the picture repeats the split-up in stationary (47%) and mobile machinery (53%) identified by the sources mentioned in the previous section, if it is assumed that diesel and gasoline are primarily used for mobile machinery. Of the 47% energy consumption of stationary equipment, 18% is electricity, 10% is by natural gas and 21% is 'other'. If it is assumed that at least half of the electricity use is already dealt with (concerns pumps and other electric motor systems, lighting and ventilation) and also half of the natural gas consumption is dealt with (most likely linked to water heating, which is dealt with by Lot 2 primarily, and space heating as dealt with in ENER Lot 20/21) only 34% of the total consumption remains within scope, or again some 2/3 of stationary energy use only.
33 34
http://www.dairyfarmenergy.com/page1.html Brown, E. and Elliot, R.N., On-farm energy use characterizations, March 2005, Report number IE052, http://www.aceee.org/node/3078?id=28
61
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 15 Energy consumption of US farms, by fuel and by application
Therefore this study will assume that the energy consumption within scope (and not yet dealt with) is 2/3 of the total energy consumption of stationary agricultural equipment, or (0.67*515 is) 345 PJ. 4.4.4
Improvement potential
Agricultural and forestry/horticultural businesses carry out a wide range of different activities but there are several low and no-cost measures, as well as those requiring investment, that farming businesses can put in place to lower energy consumption and save money. These relate to the energy consuming activities shown above (previous section). According studies by the UK Carbon Trust 35 average savings are in the area of 50% for intensive livestock (pig farming) and 10% for crop production. It can be expected however that most of these savings are achieved by products already dealt with (air heating, lighting, ventilation, etc.), which will reduce the remaining saving potential. In order to provide an indicative estimate of the saving potential it is assumed that a remaining saving potential of 15% is unlocked, through an implementation rate of 5% per year (a renewal rate of 20 years). Note: this assumption for the remaining saving potential is not based on independent sources or research material. However, no stakeholders comments have been received during the course of the study that contradict these initial findings. The table below shows the estimated saving potential of 39 PJ in 2030. Table 27 Improvement potential stationary agricultural equipment 1990
1995
2000
2005
2010
2015
2020
2025
2030
345
345
345
345
345
345
345
345
345
PJ
Savings implemented Unchanged stock
0%
0%
0%
0%
0%
0%
25%
50%
75%
100%
100%
100%
100%
100%
100%
75%
50%
25%
Improvement scenario Savings
345
345
345
345
345
345
332
319
306
% of stock % of stock PJ
0,0
0,0
0,0
0,0
0,0
0,0
12,9
25,9
38,8
PJ
Reference scenario Saving potential
35
-15%
http://www.carbontrust.co.uk/Publications/pages/publicationdetail.aspx?id=CTV009&respos=0&q=agriculture&o=Rank&od= asc&pn=0&ps=10
62
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 16 Reference and Improvement scenario of stationary agricultural equipment
The scenario analysis concludes an indicative saving of 60 PJ/year by 2030, assuming the 15% saving for 5% of stock per year can be achieved. Correction on savings due to Electric Motor Regulation 640/2009 A part of the savings identified for stationary agricultural equipment may be realised by the Electric Motor Regulation as well - these savings overlap. In Annex I a quantification of this overlap of some 2 PJ is calculated. Therefore the corrected savings for stationary agricultural equipment, without overlap, are estimated to be 60 PJ - 2 PJ is 58 PJ.
4.4.5 -
Discussion / Issues to consider for follow-up The European average agricultural energy intensity is heavily distorted by the large amount of crop production in greenhouses in the Netherlands, the most energy-intensive form of agricultural production. While the Netherlands employs only 1 % of EU27 Utilised Agricultural Area (UAA, in ha), the country uses 6.7% of the European final energy consumption associated with agricultural use. The discussion whether 'greenhouses' are/can be covered under the Ecodesign Directive cannot be answered in this report. The effects of a less energy intensive greenhouse sector could not be investigated in this study. The saving potential indicated is assumed to apply to generic farming equipment and not buildings.
-
Agriculture also uses energy indirectly, for the production of agrochemicals, farm machinery and buildings. Considerable amounts of natural gas are used for the production of inorganic nitrogen fertilisers. This indirect energy consumption is outside the scope of this study.
63
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.5 4.5.1
Stationary construction equipment Product group
"Stationary construction equipment" means stationary36 energy-related equipment that is intended to be used in construction, mining and quarrying applications. Most construction equipment is mobile and construction sites are usually only temporary. Mining and quarrying are in essence also mobile sites (the mines/quarries shall be depleted at some time), but here the duration of the activities may be such that the equipment used on the site can be considered stationary. Therefore the only 'stationary' construction equipment is likely to be mining and quarrying equipment. Of the various equipment used in the mining/quarrying industry, most is also mobile equipment (drills, dozers. loaders, shovels, draglines, long wall and continuous miners, borers, trucks, graders, etc. - see also "mobile construction machinery"). The stationary equipment may be found in equipment for handling and processing the final products like graders, crushers, grinders, centrifuges, flotation equipment, dryers, screens and other separators, filters, washers, thickeners, compactors, cyclones, furnace, roasters, smelter, refiners, calcining equipment, etc. although some of this equipment may also be mobile. Other stationary equipment will be the auxiliary equipment like fans, pumps, compressors, motor systems for transport/material handling, lighting, etc. 37 4.5.2
Market and stock data
It is estimated 38there are some 114 mines in Europe (not counting Turkey) of which a certain share is already dormant/closed. The amount of quarries will be in the number of thousands. The production (not 'apparent consumption') of stationary mining equipment (excluding selfpropelled equipment) as identified in Prodcom are indicated below: Table 28 Production stationary mining equipment Production (units) 289211 00 289212 55 289212 35
Continuous-action elevators and conveyors, for underground use Boring or sinking machinery (including fixed platforms used for oil or natural gas exploration) (excluding self-propelled) Coal or rock cutters and tunnelling machinery (excluding self-propelled)
2003
2004
2005
2006
2007
2008
2009
Producti on Producti on
62241, 00 25136, 00
18000, 00 25677, 00
28793, 00 32035, 00
37357, 00 19183, 00
27897, 00 20619, 00
42848, 00 13849, 00
27089, 00 7887,0 0
Producti on
2717
5700
6000
2101
1850
1020
1000
Total annual production is well below the indicative threshold of 200.000 units. Production trends are diverging for the specific types of equipment, with conveyor sales rising and boring / cutting machines following a predominantly downward trend. Based on these production data, a market (excluding import/export activities) of some 60.000 units is identified (average of 2003-2009). Assuming a product life of at least 15 years (often applied to installed equipment) this would indicate a stock of some 900 thousand units. No other sources have been identified which could confirm or oppose these conclusions.
36
"stationary" means: intended to be used on the same site within the technical or economical product life of the equipment - whichever is shortest 37 Product examples taken from the overview from US Department of Commerce, data quality and methodology for calculating energy consumption estimates, based on SHERPA Mine Cost Estimating Model from Western Mine Engineering Inc. 38 http://www.tailings.info/ minesineurope.htm
64
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.5.3
Energy consumption
A desk research study has been undertaken to identify the energy consumption of the various stationary construction equipment, but no usable data could be retrieved. Therefore, in order to provide an indicative assessment of the stationary construction energy consumption a top-down approach is applied. The energy consumption of mining in the USA is according to a study by LBNL/Oak Ridge39 some 44 TWh, of which some 90% is consumed by motor driven systems, the majority being underground fan systems (12 TWh annually or 27% of the total, applicable to year 1997, 1998). The rest is consumed mainly by compressed air and pumps and other equipment such as lighting, furnaces, other motor systems. Figure 17 Mining output per region, Euromines presentation40
Assuming that the EU mining industry output is around 50% of that of the US (year 1990), the total energy consumption of the EU mining industry could therefore be close to some 22 TWh (assuming comparable energy intensity) or 80 PJ. The energy consumption by fans (27%) should be subtracted from this overall consumption (dealt with by Fan Regulation or covered under a separate product group 'High Temperature Fans'). Also the consumption by compressed air and lighting should be subtracted since these are also already dealt with. The exact share of this equipment in the total is unknown, but it is known that compressed air is a major end-use application in mines. If it is assumed that lighting, compressed air and other motor/pump applications already covered represent some 1/3 of remaining consumption, the total energy consumption of equipment within scope is probably close to 40 PJ. Note that the actual total EU energy consumption of the products covered in this group is probably more influenced by economic trends (closure of mines etc.) than by possible legislation on product energy efficiency of mining equipment. Future energy consumption is estimated to decrease (in spite of a resurgence of activities expected by Euromines after 2010). In order to have an indication of the future energy consumption of the product group an exponential trend line is created on the basis of historical EU mining output (see
39
Riyaz Papar, P.E. et al, "Increasing Energy Efficiency of Mine Ventilation Systems", Lawrence Berkely National Laboratory, together with Oak Ridge National Laboratory, Flowcare engineering and ABC Industries.Year unknown. 40 Presentation by Euromines
65
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) above). For the years 2010-2030 this trend line indicates - on average - a gradual decrease of activities by 5% per 5 years. The energy consumption is assumed to follow this trend. Figure 18 EU Mining output approximation
4.5.4
Improvement potential
Most end-use equipment within the scope of this group is already dealt with (lighting, pumps, fans, furnaces) or will be dealt with by coming studies (ie. DG ENTR Lot 28-31, 'other' pumps, compressors). The remaining categories of stationary construction products (crushers, grinders, screens, other separators, etc.) are predominantly 'motor systems' of which the motors are also already dealt with by the Electric Motor Regulation. Nonetheless, it is possible that despite motor efficiency improvements, some energy saving potential remains in most equipment. In order to provide an indicative estimate of the saving potential it is assumed that a remaining saving potential of 15% is unlocked, through an implementation rate of 12.5% per 5 year (a renewal rate of 40 years). This scenario would lead to savings of some 2.4 PJ in 2030. Note: this assumption for the remaining saving potential is not based on independent sources or research material. However, no stakeholders comments have been received during the course of the study that contradict these initial findings. Table 29 Saving potential mining equipment Reference scenario
1990
1995
2000
2005
2010
2015
2020
2025
2030
49
46
44
42
40
38
36
34
33
PJ
Saving potential Savings implemented
Improvement scenario
-15% 0%
0%
0%
0%
0%
0%
13%
25%
50%
100%
100%
100%
100%
100%
100%
88%
75%
50%
49
46
44
42
40
38
35
33
30
% of stock % of stock PJ
0,0
0,0
0,0
0,0
0,0
0,0
0,7
1,3
2,4
PJ
66
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Figure 19 Reference and Improvement scenario of stationary construction equipment
The scenario analysis concludes an indicative saving of 2.4 PJ/year by 2030, assuming the 15% saving for 2.5% of stock per year can be achieved.
4.5.5
Discussion / Issues to consider for follow-up
-
The savings potential used in the above analysis is an indicative estimate, which needs to be confirmed by product specific studies or stakeholder comments;
-
It is assumed that the savings can be achieved without excessive costs to manufacturers or users - this needs to be confirmed by follow-up study and/or stakeholder consultation.
67
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) 4.6 4.6.1
Small fans (< 125 W) Product group
This product group comprises electrically powered fans with a power input below 125 W41 . These fans are currently excluded from the scope of the 'Fan regulation' 327/2011 and found in numerous applications ranging from cooling fans in PC's, combustion fans,' frost-free' fans in refrigerators, fan coil-units of HVAC systems, hairdryers, etc. 4.6.2
Market and stock data
The fan market, due to its ubiquitous properties, is notoriously difficult to quantify. Prodcom identified for 2009 an EU production of fans below 125 W (category 27511530 "Table, floor, wall, window, ceiling or roof fans, with a self-contained electric motor of an output 0.1 TWh or 8 PJ primary energy. Table 173 Overview of personal care products
227
http://www.energysavers.gov/your_home/appliances/index.cfm/mytopic=10040 http://www.daftlogic.com/information-appliance-power-consumption.htm 229 http://www.infotalia.com/nld/wonen/huishouden/slaapkamers/slaapkamer_detail.asp?id=1065 230 www.mileucentraal.nl 231 VHK: Elektrische apparatuur in Nederlandse Huishoudens 1980-2020 228
237
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Product
Unit
43600000
electric blanket 42.799.472 31318964
Power consumption
Watt
1000
1,5
120
Stand by use
Watt hrs./year
15
0,3 8760
420
total energy consumption
TWh/year
2,29
1,93
0,11
1,58
3,34
9,25
PJ PJ 10%
8,23 20,58 2,06
6,96 17,40 1,74
0,41 1,03 0,10
5,68 14,21 1,42
12,03 30,07 3,01
33,31 83,28 8,33
Sales 2009 Stock
Primary energy Improvement potential in PJ
5.7
Hair dryers 26.296.421 125.275.856
Electric Hair removing app 66.984.585 250.551.713
Electric Toothbrush
Waterbed
Total
4.175.861,88
Commercial kitchen equipment
Restaurants, or facilities with commercial kitchens, are one of the highest energy consumers of buildings — using approximately 250,000 Btu/sq.ft. This is roughly 2.5 times more energy per square foot than other commercial buildings. There are currently 6 ENERGY STAR criteria documents for Commercial Kitchen Equipment: 1. Commercial Dishwashers 2. Commercial Fryers 3. Commercial Griddles 4. Commercial Hot Food Holding Cabinets 5. Commercial Ice Machines 6. Commercial Ovens 7. Commercial Solid Door Refrigerators & Freezers 8. Commercial Steam Cookers Of these eight groups "fryers", "hot food holding cabinets" and "steam cookers" have not yet been subject to studies in the context of the Ecodesign policy process. Their uptake could be considered.
5.8
Low-voltage switchgear and control gear
In the application area "electric power", low-voltage switchgear such as electrical connectors, switches, fuses, circuit breakers are mentioned as direct ErPs. The function of these devices is to wire, control and to protect electric loads and also to protect humans against electric shock. While doing so, this 'switchgear' consumes a very small percentage of the energy that is used by the load: approximately 1 unit of energy on 10 000 units handled by the gear. Assuming a total EU load of 2800 TWh, then 'lost' in switchgear would be max. 0.28 TWh (or 2.5 PJ primary energy). Just for indicative reasons, if a 10% reduction in affected energy would appear feasible (to be confirmed by possible further analysis) then only 0.03 TWh (or some 0.2 PJ primary energy) would be saved (bottom places of current ranking). From another angle, relevant stakeholders have suggested that it is more efficient to focus on the management of the final loads and installing appropriate switches to control them, instead of improving the switchgear itself.
238
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
5.9
Other product groups
Other request for consideration of product groups have been received for the following product groups: -
Combined washer driers (excluded from washing machine and tumble drier scope),
-
Dry-cleaning equipment, proposed by the UmweltBundesAmt/BAM (Germany);
-
networked standby power consumption of professional equipment, proposed by the UmweltBundesAmt/BAM (Germany);
-
self-propelled (riding or hand guided) cleaning equipment (vacuuming, sweeping, wet cleaning), industrial vacuum machines, robotic vacuum machines,
[end of main text / begin of Annexes - the preliminary ranking on energy saving potential can be found in section 3.2]
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ANNEX I - INDICATION OF OVERLAP OF SAVINGS BY MOTOR REGULATION 640/2009.. Elevators, escalators and moving walkways Elevators According an LCA conducted by Schindler232 approximately 40% of the energy consumption of an elevator during the use phase is attributable to lighting (until 1998 it was customary to have the lighting turned 'on' all day). These values are confirmed by studies by KONE, who provided a split up of use phase energy consumption: 37% is cabin lighting, 27% is control equipment and 36% is motor energy (see picture below - in Dutch).
The energy consumption of the motor system is partly determined by the efficiency of the motor and its drive. Conventional elevators use a worm gear-drive, which results in a total efficiency of about 70-80% (SenterNovem233) . Assuming the elevator has a standard motor efficiency of 85%234 and a drive efficiency of 90%, this results in a combined efficiency of 76,5%. If, due to Ecodesign Regulation for electric motors (which only applies to single speed, three phase, asynchronous, induction / squirrel cage motors), the motor efficiency increases from 85% to 87% and 89% (two tiers) the total drive efficiency increases from 76.5% to 78.3% and 80.1%. This results in a savings for drive energy of 2,3 to 4,5%. The savings on the total energy consumption of the elevator (including lighting and control) is then 0,8 respectively 1,6% because the drive only represents some 36% of the total energy consumption.
232
Source: Egli, Norbert (BUWAL), Jordi, Beat: Okobilanzen: Vernetztes Denken Im Interesse Der Umwelt, Umwelt 4/01, p.47-49 http://www.senternovem.nl/mja/energie_efficiency/ketenefficiency/voorbeelden/ezp /machinekamerloze_lift.asp 234 Elevator motors are between 5,5 kW to 20 kW, Cijfers & Tabellen 2007. 233
240
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) A much larger saving is possible by proper standby mode for cabin lighting, application of a different kind of electric motor (not asynchronous squirrel cage, but permanent magnet etc.), possibly combined with regeneration (recuperation of energy). The most cited energy saving measures are: -
use standby-mode and more efficient lighting (fluorescent instead of halogen) -29%, use LEDs 34%;
-
replacement of motor -7.5%, add regeneration: -13%
-
improved control: -1,5%
-
combined, maximum -49%
Escalators / moving walkways As for elevators only a fraction of total energy consumption of escalators, some 50%, can be attributed to use of electric motors. The remainder is again lighting and controls For escalators usually an induction motor in the range of 4 tot 7,5 kW is applied 235, with 4 to 6 poles (more poles gives lower rpm). De final speed is reduced by a worm gear-transmission. An improvement of transmission drive gear (from worm gear to planetary drive) would improve the efficiency of the drive from average 87% to 96% and would save some 16% on the escalator energy consumption (Kone Eco-drive). Applying a star-delta wiring allows double speed settings and saves some 25% -30% (Schindler Ecoline competence, Kone star-delta option). Although this wiring affects speed, it is not a speed control as implied by the Electric Motor Regulation 640/2009. If by using an inverter also crawl-speed is possible, a saving 70% is possible (Schindler Ecoline Premium). Inverters may be applied more often as of 2015 (as of 7,5 kW) and 2017 if a less efficient I2 motor is applied. For escalators and their variable load, it makes less sense to apply an IE3 motor, so that more escalators will be equipped with VSD's. Nonetheless, the replacement of lighting by more efficient types (LEDs) saves about as much as can be achieved by drivetrain improvement. Regeneration of energy is only possible with the right combination of motors and controls but may lead to the highest savings. For escalators the same line-of-thought for overlapping savings apply, only slightly higher since the share of motor energy is larger for escalators (50% instead of 36%). Therefore a total savings of 1.4 * 1.6% is 2.2% is applied. The combined overlap in savings from the Regulation 640/2009 and the savings potential identified for escalators and elevators is therefore some 1.6% plus 2.2% is approximately 5%.
Mobile power generating sets For the savings identified for this product group no overlap with savings due to the Motor Regulation 640/2009 are expected.
Stationary agricultural equipment
235
Schindler 9300 advanced edition
241
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Stationary equipment may be used for the production, storage, processing or marketing of farm products. Stationary equipment is defined as any type of equipment that under ordinary operating conditions would remain in one location. It may be possible to move the equipment to another location but it would not be operated during the relocation process Various applications can be described: Crop Protection Propane cannons are used to scare birds and protect crops. A variety of other noise-making devices may also be used Feeding Equipment Feeding systems for livestock are often mechanized. Sometimes the feeding operation is tied to other operations such as milking dairy cows. Heating and Cooling Equipment Large buildings, greenhouses or buildings where drying or cooling of produce occurs often require large equipment such as boilers for heating and compressors for refrigeration. This equipment may run almost continuously day and night. Power Generators In remote locations, power generators may be used almost continuously. In some cases cogeneration plants may be used to provide electricity and the waste heat used in greenhouses. Standby generators are often used to supply emergency power during power outages. Sometimes tractors are used as the power source for the generator. Processing and Packaging Equipment A variety of processing and packaging is carried out on farms. Cleaning, size reduction, mixing, sorting, drying, cooling and packaging operations may occur. Conveyance and materials handling equipment are also used. Material Handling Cleaning – Cleaning can be accomplished by soaking, water sprays, rotary drums, brush washers or shaker washers or any combination thereof. Sorting – Fruits and vegetables are sorted according to colour, size and quality using screens, diverging belts, roller sorters and weight sorters. Grains, nuts and seeds are cleaned and sorted by size, shape, specific gravity and surface characteristics using screens, blowers, specific gravity separators, centrifuges, cyclones and other similar equipment. Separating – Cream separators, cyclone and gravity separators are used. Grading – Farm products may be graded according to colour, quality, shape and size. Packing – Farm products may be packaged individually, in groups, or in bulk. Conveying and transporting equipment - Conveyors, elevators, lift trucks and other methods are used to move goods. Size Reduction Cutting – Fruit and vegetables are cut in preparation for processing (freezing or canning). Chopping or shearing – Fodders such as corn and silage are sometimes chopped to reduce their size. Shredding – Some products are shredded to assist with drying or mixing. 242
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Crushing – Some produce is crushed to extract its juice or oil or to expedite drying. Grinding – Grain is ground to make livestock feed. Milling – Flour is milled. This term also applies to the separation of fibres such as flax. Mixing Feed – Batch and continuous mixers use augers or paddles. Fruits and vegetables – Drums, paddles in kettles and egg beaters are used. Fertilizers and soils – Batch or continuous mixing is done using augers, drums or paddles. Composting – Front end loaders, side mounted or self propelled windrow turners, and invessel compost turners are used. Drying Grain – Batch, bin, and continuous gravity flow dryers are used. Hay – Natural air or heated air may be used to dry hay. Fruits and vegetables and their wastes – Vacuum ovens, rotary, tray or tunnel dryers, and freeze dryers are used. Powders – Spray dryers are used. Heat Treatments Heat is used to pasteurize milk and juice, boil fruits and vegetables for vacuum or freeze packing, steam or thermal sterilize canning equipment, and can, fry and bake many products. Conduction, convection and radiation methods are used. Cold Treatments Many products are cooled to prolong their shelf life. Ice coolers, mechanical refrigeration units and freezing units including dairy coolers, cold storages, freezers and controlled atmosphere storage structures are used. Chemical Treatments Seed may be treated with fungicides and/or insecticides to improve its resistance. Various substances may be added to processed fruit, vegetable, meat and dairy products to improve their shelf life and appeal. Biological Treatments Aeration or oxygenation may be used. Fermentation may be used to produce the product for marketing. Retail Activities Ventilation Systems Ventilation is very important to provide the correct environment in buildings for live animals, stored horticultural produce and drying or cooling operations. Large fans are often used for summer cooling in poultry and swine barns. Drying onions and fall cooling of potatoes also require large amounts for ventilation. Water Systems Water is often conveyed with pumps in livestock watering, irrigation and drainage systems. Usually these are permanent installations using electric motors. In some situations, tractors may be used with pumping systems. 243
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Waste Management Equipment Pumps, augers, chains and other conveyance equipment may be used on livestock farms. Compost turners are used in compost operations. Wind Machines Wind machines may be used to protect orchards and vineyards from frost damage both in the spring and fall. Wind machines should be started prior to the temperature dropping to levels where the plants or fruit may be damaged. In the US 16% of total farm energy consumption is electricity (assumed the total is expressed in primary energy)236. Considering that approximately half of the farming energy consumption is consumed by mobile machinery (diesel and gasoline), this leaves 32% of energy consumption of stationary machinery as electricity. Assuming that only half of this electricity consumption is related to applications using asynchronous motors (the other half may be Joule-effect applications or lighting or controls) the electric motor consumption is again 16% of stationary equipment energy consumption. Assuming that the average motor efficiency is 85% and the average drive it is connected to is 90% efficient the overall efficiency is 76%. If the motor efficiency is increased to 87% and 89% (due to the Electric Motor Regulation 640/2009) the overall efficiency increases with only 2-3%. The 16% consumption by motors is then reduced to average 16%*0.975 = 15.6% consumption, a reduction by 0.4%. This translates roughly to 1.3 PJ savings when applied to the 345 PJ energy consumption of stationary agricultural machinery (section 4.4) - and applicable to the year 2030, when the majority of the stock has been replaced. Figure 85 Energy consumption of farms, by fuel and application237
236 237
No such data has been found for the EU Brown, E. and Elliot, R.N., On-farm energy use characterizations, March 2005, Report number IE052, http://www.aceee.org/node/3078?id=28
244
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011)
ANNEX II - OVERVIEW TABLE OF QUANTITATIVE COST ANALYSIS Table 174 Overview of results quantitative cost analysis Product group
Purchas e price Ref. (euro)
Purchas e Price Impr. (euro)
Differe nce Purcha se Price (Impr. Ref.) (euro)
Energy costs Ref. (euro per year, per unit)
Energy costs Impr. (euro per year per unit)
Thermal insulation products for buildings Taps and showerheads
2,04
2,30
0,27
No stock
No stock
48,17
57,49
9,31
58,25
46,99
Steam boilers / systems
277,52
311,89
34,37
No stock
No stock
Lighting control (systems)
No unit data, no sales
No unit data, no sales
No stock
No stock
Window products for buildings Heating controls
116,70
123,36
No unit data, no sales 6,66
No stock
No stock
21,39
23,10
1,71
473,20
435,35
Positive displacement and reciprocating pumps Detergents
35,02
43,77
8,75
No stock
No stock
2,77
2,77
0,00
No stock
No stock
could not be calculated due to lack of energy costs per unit of product
Data centre server, storage and ancillary equipment Mobile power generation sets
0,00
0,00
0,00
No stock
No stock
could not be calculated due to lack of PP and energy costs per unit of product
33725,7 6
40386,3 3
6660,5 7
6653,96
5339,86
1314,1 1
5,07
Stationary agricultural equipment Elevators, escalators and moving walkways Logistic equipment
11646,2 4 86507,6 4 5952,45
12957,8 5 108413, 01 6871,04
1311,6 2 21905, 37 918,59
365,24
324,10
41,13
31,89
438,79
327,68
No stock
No stock
Electric kettles / water cookers Mobile agricultural machinery
328,75
411,50
82,75
No stock
No stock
1016,64
1067,86
51,22
58065,75
55140,30
Non-domestic hot beverage equipment Base station subsystems
3524,87
4406,09
881,22
407,41
305,56
2972,45
3873,19
900,74
2750,00
1916,67
Mobile construction machinery
28498,9 3
29923,8 7
1424,9 5
4875,75
4631,96
Blowers
no unit value 411,33
no unit value 109,03
27,46
23,97
3,49
Home audio products
no unit value 302,30
1,98
1,27
0,72
could not be calculated since no unit price data could be established 152,39 322,14 424,02 101,87
High temperature ventilation equipment
no unit value
no unit value
no unit value
10191,32
9602,65
588,67
245
Differe nce annual energy costs (Ref.Impr.)
paybac k = diff. PP / diff. EC (year)
Total Total Diff. life life life cycle cycle cycle costs costs costs Ref. Impr. (euro, (euro, (euro, over over over produc produc produc t life) t life) t life) could not be calculated due to lack of energy costs per unit of product 11,26 0,83 630,68 527,40 -103,28 could not be calculated due to lack of energy costs per unit of product could not be calculated due to lack of energy costs per unit of product
could not be calculated due to lack of energy costs per unit of product 37,84 0,05 7119,3 6553,4 -565,91 2 1 could not be calculated due to lack of energy costs per unit of product
133535 ,23
120484 ,22
13051, 01 694,61
17124, 17819, 81 42 111,11 197,15 99671, 118243 18572, 48 ,52 03 could not be calculated due to lack of energy costs per unit of product could not be calculated due to lack of energy costs per unit of product 2925,4 0,02 872002 828172 5 ,89 ,36 43830, 53 101,85 8,65 7598,9 7461,6 -137,30 5 4 833,33 1,08 23597, 18248, 45 19 5349,2 6 243,79 5,85 89445, 87823, 80 41 1622,4 0
could not be calculated since no unit price data could be established
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) Product group
Purchas e price Ref. (euro)
Purchas e Price Impr. (euro)
Differe nce Purcha se Price (Impr. Ref.) (euro)
Energy costs Ref. (euro per year, per unit)
Energy costs Impr. (euro per year per unit)
Point-of-sale and cash dispenser equipment Other medical equipment Traffic lighting
2226,23
3339,34
42,33
21,16
25,40
27,94
1113,1 1 2,54
No stock
No stock
no unit value 35
no unit value 44
no unit value +8,95
No stock
No stock
0,66
Clothes ironing products Lawn and riding mowers Stationary construction equipment Handheld power tools
90,31
107,79
17,48
535,85
693,45
105367, 38 315,38
Kitchen appliances
77,73
Hot tubs / spa's/ whirlpools
could not be calculated - not enough data available
Sauna’s
could not be calculated - not enough data available
Toilets
could not be calculated - not enough data available
Swimming pool equipment
could not be calculated - not enough data available
Small fans < 125 W
Differe nce annual energy costs (Ref.Impr.)
paybac k = diff. PP / diff. EC (year)
0,49
Total Total Diff. life life life cycle cycle cycle costs costs costs Ref. Impr. (euro, (euro, (euro, over over over produc produc produc t life) t life) t life) 21,16 52,59 2649,5 3550,9 901,47 1 8 could not be calculated due to lack of energy costs per unit of product could not be calculated due to lack of energy costs per unit of product -0,17 53 38 46 +8,00
1,97
1,59
0,38
45,91
105,06
119,68
14,62
157,60
7,15
5,04
2,10
74,99
607,30
743,89
136,59
113472, 56 428,02
8105,1 8 112,64
2561,00
2364,00
197,00
41,14
49,64
31,91
17,73
6,35
143782 ,38 526,37
148932 ,56 563,65
5150,1 8 37,28
92,53
14,81
No stock
No stock
could not be calculated due to lack of energy costs per unit of product
Clarification of the cost assessment table above: - Purchase price Reference: An approximation of the product purchase price based upon the unit value as identified on the basis of Prodcom data, multiplied by a factor three to account for mark-ups related to wholesale, retail , etc.; - Purchase price Improvement: Same as above, however now corrected by a factor of the same magnitude as the energy savings potential (in %). For certain products groups this relation between purchase price and energy saving has been identified. For the preliminary analysis this assumption is applied to all product groups; - Difference purchase price: 'Purchase price Improvement' minus 'Purchase price Reference'; - Energy costs Reference: The energy costs of the stock of products as calculated in the Reference scenario. The energy costs take into account the type of energy (electric or fuel), the sector (domestic electricity or non-domestic electricity) and the type of fuel (gas/oil for most stationary applications, diesel/gasoline for most mobile applications); - Energy costs Improvement: Same as above, but now based on Improvement scenario; - Difference annual energy costs: 'Energy costs Reference' minus 'Energy costs Improvement'; - Payback: Is calculated as the 'Difference purchase price' divided by 'Difference annual energy costs' and provides an indication of how many years of energy saving are needed to recuperate the increase of the purchase price. Note that this is an indication only, based on a simplified approach; - Total life cycle costs Reference: This is the 'Purchase price Reference' to which the 'Energy costs Reference' over the product life (annual costs multiplied by average product life) are added. This is an approximation of the total life cycle costs (also known as 'costs of ownership'). 246
Study for the Amended Ecodesign Working Plan Final Report Task 3 (version 16 December 2011) -
Total life cycle costs Improvement: Same as above, but now based on Improvement scenario; Difference life cycle costs: This is calculated as the 'Life cycle costs Improvement' minus 'Life cycle costs Reference' . A negative value indicates that the life cycle costs of the Improvement scenario are lower than the Reference scenario costs, indicating that according this calculation the improvement will result in lower costs (expenditure);
The energy prices on which the running costs are based are presented below: Table 175 Energy prices used for cost assessment Fuel type
Sector (domestic/ non domestic)
Price (euro)
Unit
Electricity
Domestic
0,18
kWh
Non- Domestic
0,1
kWh
Domestic
14,54
GJ
Non-Domestic
8,44
GJ
Domestic
824
1000 litre
22,83
GJ
478
1000 litre
13
GJ
1280
1000 litre
35,46
GJ
Remark
Stationary applications Gas
Oil
Non-Domestic
Mobile applications Diesel
Non-Domestic
[end Task 3]
247
(NCV)
(NCV)
(NCV)
