ENERGY AUDITING
tool to increase
ENERGY EFFICIENCY
Ing. Bronislava Herdová, PhD.
energy auditor
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Why energy efficiency?
Overal EU policy objective:
20% GHG emissions – 20% RES – 20% Energy savings (until 2020)
Directive No. 2006/32/ES on on energy end-use efficiency and energy services
New Directive 2012/27/EU of the European Parliament and of the Council of 25
October 2012 on energy efficiency
Tools to increase EE? => energy auditing, energy services
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Why energy efficiency?

cheapest energy is that which is not necessary to produce

EE is in the center of economy and political attention

EE contributes to fulfilment of main three targets of EU energy policy sustainability, security and competitivness

EE decreases dependance of economy on non-stabile prices of oil and gas

EE is part of healthy energy and economy policy of state

It supports local economy and its growth based on innovations

It increase lifetime of objects and technology equipment

Decreases operational costs, environmental impact

Saves money and time
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
WHAT IS AN ENERGY AUDIT (EA)?
 pool of activities (systematic procedure) focused on analysis of current energy need
and consumption going out of valid technical standards,
 analysis of problems (weaknesses and deficiencies),
 EA identifies and in detail quantifies effective possibilities of energy savings tailored
to the object being analyzed,
 „field-work“, economy tool having dynamic character, often basis for grant financing
of projects.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
WHAT IS THE AIM OF EA?
 to minimize costs for energy
 to minimize operational costs
 to minimize costs for repairs and reconstruction
 increase quality of environment that contributes to increased work productivity
In case of EA as duty (Industrial consumers with annual energy consumption over 5,5
GWh/year) the procedure of EA as well as content of the report is determined by
Regulation No. 429/2009.
In case of voluntary EA is the content and focus as well as target given by customers
requirement.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
MAIN TOPICS/AREAS OF EA
Subject of energy consumption analysis are energy resources consumed in the industrial
area, i.e.:






Electricity
Natural gas
Steam
Coal
Wood, wood chips/pellets
Fuels (petrol, oil, propane-butane).....
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
MAIN TOPICS/AREAS OF EA
• thermal-technical protection of buildings,
• heating systems
• hot water preparation,
• ventilation systems and air-conditioning (buildings and technology)
• electric appliances (administrative and technological incl. electrical connection,
transformation, distribution network, el. switchboards, el. compensation)
• gas or other energy resources consuming appliances (furnaces, cleaning devices,..)
• Indoor/outdoor lighting,
• measurement and regulation.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
WHAT OFFERS EA TO THE CUSTOMER?
 identifies highest achievable potential of energy and costs savings and its effort,
 points out on often visible as well as hidden technical/hygienic/safety deficiencies
of buildings and building and production technology equipment,...
 recommends technical parameters of measures,
 calculates investment needs of measures, their asset - economical, technical,
environmental,
 proposes procedure for realisation of measures,
 it is very effective technical, economical and management tool for investment
decision processes going out of economical modelling,
 it is solid basement for effective control of energy consumption and herewith also
operational costs
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
ENERGY AUDIT - PRACTICE
1.
Identification of subject of EA
2.
Data collection, analysis and evaluation of current status
3.
Proposal of EE and RES measures
4.
Economy and environmental evaluation of measures
5.
Proposal of at least two variants for implementation of measures and
recommendation of optimal variant
6.
Drafting of written report from EA
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
CASE STUDY – chemical industry
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Step 1: Identification – EA subject
a) Collection of main data about the customer and basic description:
Name of company:
Legal status:
Address:
Responsible person:
Contact:
Sector:
Subject of EA:
OSPRA Invest, Ltd.
Ltd
Rovinka, BA (Istrochem)
Chemical industry
-buildings (administrative and
production hall) and their
technical equipment
-production technology
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Step 1: Identification – EA subject
Identification of activities
Type of activitiesi (NACE2)
Number of heated buildings:
2222
4 (PH – administrative part, administrative building,
portable container housing units, building for
security)
Site plan:
Purpose of production
Number of employees
Operation regime (days a week)
Buidings
Main building- production hall
Administrative building and Dressing
rooms
Container housing units
Security building
Production of PE and PP folies (Rovinka)
Production of re-granulate (BA)
100 (Rovinka) + 30 (BA, Istrochem)
24 hours/ 7 days
Shape factor of building
Heated volume V [m3]
A/V [1/m]
26 890,0
0,37
1 179,36
0,77
164,16
246,9
1,55
1,13
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
1 STEP: Identification of subject of EA – site plan
b) Description of main activities of EA
c) Site plan
d) List of all buildings and theirs use, description of all
energy consumers
4
6
3 – new storage hall
5 – storage hall – tent
8
3
2 – AB, dressing rooms, showers
4 – main production hall (offices,
social spaces, production hall
Bielloni, production hall A, B,
welding hall)
5
7
1 – security
2
6 – crusher of waste follies recycling
1
Vstup do areálu
7 – container housing units
8 – transformer station - TS 1, TS 2
TS3 – out of the area of the company
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
1 STEP:
Identification of subject of EA – site plan (ISTROCHEM)
Production of re-granulate
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on energy inputs
Input – fuels and energy
Unit
Amount
Purchase – electricity
Purchase - heat
Natural gas
Brown coal
Black coal
Coke
Other solif fossil fuels
Heavy heating oil
Biomass
Light heating oil
Diesel
Petrol
MWe
GJ
m3
t
t
t
t
t
t
t
t
t
12 147,15
3,19
5,73
-
Energy
content
in MWh
12 147
-
11, 66
12,22
37
70
Annual costs
EUR excl.
VAT
1 405 588
4 250
9 300
t
16,03
12,78
205
16 000
Secondary energy devided into
not used heat and others
-
-
-
-
RES devided into solar, wind,
geothermal and others
-
-
-
-
Other fuels
-
-
-
-
12 459
1 435 139
460
53 302
11 999
1 381 836
Other energy gases (Propane)
caloric
value
Total fuel and energy input
External customers
Total consumption of fuels and energy OSPRA INVEST, s.r.o.
- Collection of monthly energy
and water consumption of at
least of 3 last years!
- Collect data on costs coupled
with purchase of energy for
relevant 3 years
- Most of the data from
INVOICES
- If possible – readings from
meters or data collected
through e-manager application
if available
- Energy consumption that is
given by climate conditions
should be re-calculated with
decree-days!!!
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on energy inputs
Priemerné mes. spotreby a ceny elektrickej energie po mesiacoch za roky 2009-2010 v areále Rovinka
700 000
90 000
spotreba
cena
650 000
80 000
600 000
kWh
550 000
70 000
€
500 000
60 000
450 000
400 000
50 000
OSPRA Invest, Ltd. (Rovinka+BA):
- 97,4% of all energy consumed is
ELECTRICITY (57% Rovinka, 43%
BA)
- No Natural gas consumption
- 2,6% - fuels
350 000
december
november
október
september
august
júl
jún
máj
apríl
január
marec
40 000
február
300 000
Priemerné mes. spotreby a ceny el. energie po mesiacoch za roky 2008-2010 v areále Istrochem
700 000
90 000
spotreba
cena
650 000
80 000
600 000
70 000
€
500 000
60 000
450 000
400 000
50 000
350 000
december
november
október
september
august
júl
jún
máj
apríl
marec
40 000
február
300 000
január
kWh
550 000
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on transformation and el. distribution
- Who is power supplier (ZSE, a.s.),
measurement on NN or VN side
- Power supply through 3 TS, 3 x 22 kV line,
transformation from 22 to 420/230
- Data about transformers (type, year of
construction, output, connection, cooling?...
- Data about VN and NN distribution lines
(dimensions and lengths of distribution lines,
used materials, transmission power, scheme of
el. connection, technical state, technical state,
equipment with measurement and regulation,
control of el. review reports (duty))
- Data about switchboxes in the VN/NN
- Control of power factor correction
- Control of invoices on technical supply
conditions and tariffs
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection about main energy consumers
Main energy consumers:
A. Buildings
B. Production technology
A. In case of buildings (thermal protection, heating, ventilation, air-conditioning):
- Purpose and operation
- Thermal-technical parameters of buildings
- Building technical equipment (HVAC)
- Thermal losses
- Consumption of energy for operation of buildings
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- Thermal-technical parameters of heated buildings,
- check project documentation
- check building materials and parameters of all building
envelope components,
- measure indoor temperature in heating period (ideally also
in summer)
- Heating/hot water system:
- check for type of heating (steam, hot water, electricity),
common system for heating and hot water?
- type, characteristics and technical parameters of heat
sources (el. boiler, gas boiler, coal boiler, biomass…)
- types of heating bodies (el. convectors, infra-red heaters,
radiators (hot water/steam)...)
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- heat distribution network length and thermal insulation, materials and
thickness
- check if consumption of electricity for heating/hot water is measured,
- make on site measurement of internal temperature 22oC,
- how is the measurement and regulation (equithermic, hydraulic regulation,
thermostatic valves...)
- check all relevant documentation – project documentation, revisions, and etc.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- Heating: OSPRA INVEST (Rovinka, BA not analyzed)
- electric heating – el. infra-red heaters in production hall, el. convectors, el. oil
radiators
- indoor temperature: 22oC
- regulation (according to indoor temperature)
- Hot water: OSPRA INVEST (Rovinka, BA not analyzed)
- prepared for dressing rooms (showers) and toilets
- el. heaters
Number
El. heaters FAICO
El. convectors Technotherm
E. convectors Technotherm
El. heater Heler
Oil el. radiators
8
19
2
2
2
Output
kW
9-14
2,0
0,5
0,7
2,0
Počet
DHW el. heater 150l
DHW el. heater 200l Tatramat
DHW flow el. heater 5l
5
1
3
Príkon
kW
2
2,2
2
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- Cooling and ventilation
- Check and collect same data as in case of heating...
characteristic and technical data of source,
distribution, measurement&regulation…
- OSPRA INVEST (Rovinka, BA not analysed) - ventilation
- No central ventilation system, only ventilators placed in the roof ( 6 x 750 W)
and by ventilation windows
- these consumers are not important consumers
- However the ventilation – fresh air intake and extraction of waste air was not
satisfacory!
- OSPRA INVEST (Rovinka, BA not analysed) – cooling/air-conditioning system
- No central cooling system, only 2 adiabatic evaporative chillers installed on the
roof
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- OSPRA INVEST (Rovinka, BA not analysed) – coolling
- No central cooling system, only 2 adiabatic evaporative chillers installed on
the roof for 2 production halls
Number of adiabatic evaporative chillers:
Type:
Parameters of chiller:
2
evaporative chillers JH 30
Qvzd. = 30 000 m3/hod. x 2
= 60 000 m3/hod.
El. input power:
3,0 x 2= 6,0 kW, 3 x 380V, 50Hz.
Coolling output (tout 30 °C and relative humidity 45%): Qch = 100 kW.
Assumed average water consumption:
0,16 m3/hod / pH 5-7 /
Regulation:
according to indoor temperature
Measurement:
no separate measurement
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- Indoor lighting
- Check for lighting system characteristics and parameters – type of lamps,
lighting sources, input power, type of ballast/driver and etc.
- Check way of operation and regulation
- Check consumption if measured, otherwise check all necessary inputs to
calculate lighting electricity consumption
- Check if lighting-technical conditions are observed
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on main en. consumers - buildings
- Indoor lighting – OSPRA Invest (Rovinka)
- Administrative spaces – associated lighting combined with daylight inbuilt lamps with linear fluoresenc lighting sources type T8 (1 x 18W, 2 x
36W) with conventional ballast, in some technical places are conventional
incandescent lamps 60W
- Production hall – ceilling lamps with IP65, hang down in high of 4,5 m,
linear fluorescent lighting sources type T8 with input power 3x36W,
conventional ballast.......
Main object
Administrative
spaces
Toilet
Wellding hall
Toilet
number
Num
ber of
functi
onal
Power
input
(W)
14
14
86
Pinšt(W)
1 204
Preal (W)
1 204
t
(h/year
)
W
(kWh/year)
1 560
1 878,24
W
(kWh/rok)
1 878,24
3
3
60
180
180
520
93,60
93,60
176
176
139
24 464
24 464
8 640
211 368,96
211 368,96
4
4
60
240
240
1 620
388,80
388,80
Office
2
2
86
172
172
8 640
1 486,08
1 486,08
Hall B
134
134
139
18 626
18 626
8 640
160 928,64
160 928,64
Hall B
135
135
139
18 765
18 765
8 640
162 129,60
162 129,60
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection on en.
consumers – production processes
In case of technology consumption
- collection of technical data on electric
appliances/devices from documentation and
/or from labels (input power, voltage, output)
- operating mode and time of processes/devices
operation during year,
- check for technological schemes
- control of technical documentation
- notes from operation
- measured energy consumption of individual
devices or production sections (if measured
and processed)
- level of control of energy consumption and
regulation
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection electricity consumers - production
Name
Input power
kW
Output
kW
Number
-
Voltage
V
Year of
construction
M19
18
n.a.
1
230/400
n.a.
BSM 1300
28
1
230/400
2009
Production of bags –
welding of bags
ROLO 3
16
n.a.
1
230/400
n.a.
Production of bags –
welding of bags
ROLO2
n.a.
n.a.
28
n.a.
n.a.
28
n.a.
n.a.
n.a.
n.a.
1
1
1
1
230/400
Production of bags
COEMTER BETA 1
COEMTER BETA 2
COEMTER BETA 3
STIEGLER - 1
230/400
n.a.
n.a.
n.a.
n.a.
Production of bags
STIEGLER - 2
28
n.a.
1
230/400
n.a.
Dehumidification
MAHLA
3
n.a.
1
230/400
new
Production of bags
GUNTER
28
n.a.
1
230/400
n.a.
ROLLOMAT - 2
20
n.a.
1
230/400
n.a.
Production of bags
ROLLOMAT - 850-1
15
n.a.
1
230/400
n.a.
Packing – heating of shrink
foil
BRUCHER
18
n.a.
1
230/400
n.a.
Wellding hall
Production of PP and PE
bags
Production of PE bags
n.a.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection electricity consumers - production
Except directly technology consumers, it is necessary to focus also on energy carriers
that are input for the production processes – OFTEN BIGGEST POTENTIAL FOR
PROPOSAL OF MEASURES:
- Compressed air
- Heat / Hot water / steam for technology purposes
- Cooling of technology devices
- Water treatment
- Waste water treatment
- and etc....
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - production
Compressed air – OSPRA Invest (Rovinka) – pneumatic driver
Is the most expensive energy carrier!!!!!
- 3 compressed air production stations – delivery to 2 central
compressed air distribution networks
- Type of compressors – screw compressors
- mater/slave – switch every 24 hours, regulation – according to
pressure in the network 7/8,5 atm.
- no continuous control of compressors (by inverter)
- no regular measurement of pressure decrease in the distribution
network
- no heat recovery
Hall A
Screw compressor
Hala Bielloni
BELT 55-8
Zvarovňa
Kaeser AS 35
number
8
m3/min
power
output
5,9
2
Year of
production
n.a.
60
n.a.
n.a.
1
2011
22
7,5
n.a.
1
1986
kW
bar
power input
Pe
37
ks
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection – main el. consumers production
Cooling – technology purposes – OSPRA INVEST (Rovinka)
- FRIGOSYSTEM – placed in hall B – producing of cooling water for
extruder (16oC)
- Hall Bielony – chiller - cool for central distribution system – only
production purposes
- Welding hall – chiller - cool for central distribution system – only
production purposes
- Cooling tower – cooling of recycling device REMA only (already ordered
new cooling device)
- Regulation – operation according to needed temperature in the cooling
system
- use of excess heat – in winter for heating, in summer – is exhausted out
of the building
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - production
Cooling – technology purposes – OSPRA INVEST (Rovinka)
kW
Cooling
output
kW
1
10
28
400
2009
FRIGOSYSTEM RACA2
1
47
140
400
2009
Water treatment EUROWATER
1
2
n.a.
n.a.
2000
Cooling device ERS SC64V,
1
22
230/400
2003
Water treatment EUROWATER
1
2
n.a.
n.a.
2000
New coolling device EVK 324/09 Cofely
1
3
n.a.
400
2011
New water treatment - EUROWATER
1
n.a.
n.a.
n.a.
n.a.
Device
Number
Output
Voltage
V
Year of
production
Hall B
Coolling device RACA AIR 80 - R1
Hall Bielloni
Welding hall
74
(pri 15°C)
Coolling for regranulation device REMA
Old coolling tower – out of operation
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - production
Cooling – technology purposes – OSPRA INVEST
At least for the purpose of preparing energy balance, it is necessary to check also small
electric appliances – as their are not significant consumers further analysis were not
necessary
Administrative appliances
Name
PC
Printer
electric kettle
Copy maschines
Mikrovawe owen
Fax maschine
Input
power
Number
kW
0,3
0,2
2
0,5
1,2
0,1
9
3
1
2
1
1
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
STEP 2: analysis and evaluation of current state
OSPRA INVEST - compiling basic energy balance (Rovinka+BA)
Row
1
2
3
4
5
6
7
Indicator
Input of fuels and energy
Change in stocks of fuel
Consumption of fuels and energy
Sale of energy to other customer
Final consumption of fuels and energy
(row 3 – row 4) – according to need
devide other types of fuels and energy
MWh/r
12 459
11 999
460
tisíc eur/r
1 435 139
1 381 836
53 302
11 687
1 352 286
Diesel
Petrol
Propane
37
70
205
4 250
9 300
16 000
Losses in own sources and distribution
(from value given in row 5) – according
needs devide into other types of fuels and
energy
Electricity
12
1 389
Heat
-
-
Others
-
-
Energy consumption for heating and DHW
(from value given in row 5) – according
needs devide into other types of fuels and
energy
Electricity
Heating
Electricity
DHW
366
42 349
34
3 934
11 275
1 304 614
-
-
-
-
Electricity
Heat
Others
8
Energy consumption for technology
purposes and other processes
(from value given in row 5) – according
needs devide into other types of fuels
and energy
Electricity
Heat
Others
Rovinka
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
2 STEP: analysis and evaluation of current state
OSPRA INVEST – analysis of electricity consumption
Analysis and evaluation of supply tarrifs
3 delivery points with reserved and max. reserved capacity (Rovinka)
Red – overrunning od ¼ max.
Blue - overrunning of reserved capacity
- Delivery point 3108116420 is
overrunning these values (winter el. heating, external consumer)
- Delivery point 3108132200 –
possible measure – lowering of
reserved cap. to 660 kW event.
max. res. cap. to 700 kW
- Electric distribution network and
main electric devices are according
to measurements and revisions in
good technical state
- el. distribution lines are currently
over dimensioned – reason: reserve
for connection of new devices/
retain variability for shifting of
existing technology devices
Rok
Number of
delivery point:
Reserved
capacity [kW]
Max. reserved
capacity [kW]
Month
January
February
March
April
May
June
July
August
September
October
November
December
2009
2010
3106043653
3108116420
3108132200
3106043653
3108116420
3108132200
250
340
700
250
340
700
300
360*
880
300
360
880
1/4h max.
kW
1/4h max.
kW
1/4h max.
kW
1/4h max.
kW
1/4h max.
kW
1/4h max.
kW
226
231
230
223
219
225
225
217
207
218
204
207
351
359
348
277
267
266
249
268
263
321
319
336
593
603
609
571
565
572
558
568
574
591
579
652
227
219
225
229
206
234
219
207
201
241
226
236
376
371
354
294
282
273
260
273
308
313
321
393
631
619
588
574
589
592
559
564
510
418
581
623
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
2 STEP: analysis and evaluation of current state
OSPRA INVEST – analysis of electricity consumption – production technology (Rovinka)
Total installed power input and el.
consumption
-
Assessment of energy consumption going out from
operational hours, power input and load factors,
Division of consumption according technological areas
Technical state – satisfactory even most of the production
devices are old and energy intensive
Motors with input power up to 100 kW are replaced by
asynchrony motors with inverter, large motors – larger
investments – up to 50% of savings per device
Hall A – input power and assumed consumption.
A7
13%
A7
7%
A1
23%
A1
28%
A5
14%
Suma Hala
A
14%
Regranulač
ná linka
13%
Regranulač
ná linka
9%
Zvarovňa
4%
Stl. vzduch
1%
Zvarovňa
10%
Chladenie
2%
Stl. vzduch
3%
Chladenie
4%
Suma Hala
B + Bialloni
56%
Suma Hala
B + Bialloni
67%
Hall B – input power and assumed consumption.
Bialloni
3%
B8
23%
B2 B3
2% 2% B4
2%
Bialloni
2%
B8
9%
B5
14%
B2
2%
B3
1%
B4
2%
B7
10%
B5
24%
A5
17%
A4
14%
A2
18%
A4
17%
B6
27%
A3
14%
A3
12%
A2
23%
B7
27%
B6
50%
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Suma Hala
A
17%
STEP 2: analysis and evaluation of current state
OSPRA INVEST – analysis of electricity consumption – production technology
Measurement and regulation - Production technology:
- Full automatic regime of most of the devices
- Way of operation is putted manually by employees
- Measurement is not provided for large consumers!
- Operation is given by order and type of foils ordered – in case of
Rovinka is not evaluated specific energy consumption of electricity
given by amount of produced foils (too many different processes –
individual processes are not monitored)
- In operation in BA – specific energy consumption has been
evaluated
Compressed air and cooling:
- Consumption of el. for compressed air and cooling presents from
total electricity for production only 3%
- Evaluated as effective – new investments already planned
- No measurement, only regulation – T/p
- No use of heat recovery
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
2 STEP: analysis and evaluation of current state
OSPRA INVEST – heating and hot water
Evaluation of thermal-technical properties of
heated buildings (no measurement):
- Calculation of heat need for heated buildings
(720540-2)
- Estimation of heat gains
- Estimation of consumption of electricity for
heating
- Technical state – satisfactory, regulation
according internal temperature
- Hot water – only teoretical calculation (no
measurement) – going out of normative
calculation
BUDOVA
Production hall A,B
Administrative
building and dressing
rooms
Container buildings
Security building
Total
°C
22
kWh/rok
908 360
kWh/rok
630 465
Consumptio
n of
electricty for
heating
kWh/rok
277 895
20
52 320
-
52 848
20
20
18 173
16 464
995 317
630 465
18 356
16 630
365 729
Spotreba leto - zima
3 900 000
3 800 000
3 700 000
334 272
3 600 000
kWh
Uni mo bunky;
18 173 kWh/r;
2%
Heat need for
heating
Thermal
gains from
technology
4 000 000
Výpočtová potreba tepla na vykurovanie
Budova
a dmi ni s tra tívy
a š a tne;
52 320 kWh/r;
5%
Internal
temperatur
e
Vrá tni ca ;
16 464 kWh/r;
2%
3 500 000
397 185
3 400 000
El. energia vykurovanie
277 895
kWh/r; 31%
Tepelný zisk
z techn.;
630 465
kWh/r; 69%
3 300 000
3 200 000
3 100 000
3 000 000
Výrobná ha l a
A,B; 908 360
kWh/r; 91%
apr - sept
okt - mar
apr - sept
okt - mar
leto 2009
zima 2009 - 2010
leto 2010
zima 2010 - 2011
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
2 STEP: analysis and evaluation of current state
OSPRA INVEST – indoor lighting
Calculation of consumption (no measurement) – Rovinka:
- Calculation of electricity consumption going out of input power, operation hours and
efficiency of lighting sources and type of ballast – 638,32 MWh/year
- Lighting is under-dimensioned on places with permanent stay of persons
- No regulation of lighting system that would switch or dim according to need –
currently manual
- Partly obsolete lighting – low efficiency of optical system, missing covers of lamps,
used linear fluorescent lamps with low specific output with classical ballast (20%
consumption of power input of lighting source)
- In part of production hall was made reconstruction with appropriate lamps, but some
of new lamps have classical ballast...
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
Type of measures:
a)
-
According to size of investment
no cost measures (mostly organizational measures)
low cost measures (coupled with low investments and quick payback)
iinvestment measures (coupled with large investments and longer payback
b) According to achievable savings and economic return
- measuers with short payback period (up to 5 years)
- measures with long payback or without payback period
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
NON-COST Measures:
- Monitoring and evaluation of energy consumption on monthly basis
- Monitor and decrease internal temperature especially in administrative part were
was measured temperature higher by 2,2°C in comparison to normative requirements!
- Lower the reserved capacity to 660 kW eventually max. reserved capacity to 700 kW
in case of el. delivery point 3108116420
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
LOW-COST Measures:
- Connect heaters (DHW) through thermostats with timer in order to provide for
setback mode 3 hours before end of shift.
- Connect el. convectors (heating) through thermostats with timer in order to provide
setback mode of heating in administrative spaces (8 hours working time).
- Provide for monitoring and measurement of el. consumption of biggest el.
consumers
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
Investment measures – production technology
- Replacement of main driver of the production line line B5 with input power 160 kW
with new el. motor with with frequency speed control.
Investment costs
Total in EUR
Energy consumption per unit:
Average el. price
Energy savings:
Achievable electricity savings
Cost savings (electricity)
Simple payback period
EUR
36 500
EUR/kWh
0,11
MWh/year
EUR/year
year
150
16 474
2,2
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
Investment measures – production technology, i.e.:
- Replacement of main driver of the production line B6 with total input power 337 kW.
The main driver input power is 160 kW, replacement with new el. motor with
frequency speed control.
Investment costs
Total in EUR
Energy consumption per unit:
Average el. price
Energy savings:
Achievable electricity savings
Cost savings (electricity)
Simple payback period
EUR
24 000
EUR/kWh
0,11
MWh/year
EUR/year
year
80
8 750
2,8
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
Investment measures – buildings – thermal protection of buildings, i.e.:
- Building for administrative purposes with dressing rooms – thermal insulation,
replacement of windows, instalation of thermotat with timers on heating bodies
Measure
Investment costs
Thermal insulation
Roof – thermal insulation
Replacement of windows
Installation of thermotats with timers
Total costs in EUR
Unit price of energy:
Average price of electricity/heat
Energy savings:
Achievable electricity savings
Cost savings (electricity)
Simple payback period
EUR
EUR
EUR
EUR
EUR
8 496
3 297
4 665
291
16 749
EUR/kWh
0,11
MWh/rok
EUR/rok
rok
25,82
2 840
7,5
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of EE and RES measures
OSPRA Invest - Rovinka
Investment measures – buildings – indoor lighting, i.e.:
- Replacement of existing lamps with lamps with IP65, high efficient optical system –
reflector, linear fluorescent lamps type Master TL5 HE ECO 45W and electronic
ballast.
Investment costs
Total in EUR
Energy consumption per unit:
Average el. price
Energy savings:
Achievable electricity savings
Cost savings (electricity)
Simple payback period
EUR
47 000
EUR/kWh
0,11
MWh/year
EUR/year
year
208
22 880
2,1
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of at least 2 variants of EE measures
OSPRA Invest - Rovinka i.e. - proposal of 2 variants
Measure
Frequency speed control of main driver of
extruder A1+replacement of snail, gearbox
and extrusion head (Rovinka)
Frequency speed control of main driver of
extruder B5 (Rovinka)
Frequency speed control of main driver of
extruder B6 (Rovinka)
Frequency speed control of main driver of regranulation line (BA)
Frequency speed control of main driver of
automatic mill KUNG (BA)
Main production hall in Rovinka – replacement of
gates, thermal barriers, copilits and thermotats
Administrative and dressing building – thermal
insulation, replacement of windows, thermostats Rovinka
Indoor lighting reconstruction - Rovinka
Total
Energy
savings
MWh/rok
Costs savings
(energy)
EUR/rok
EUR
Simple
payback
rok
150
16 517
160 000
16,7
150
16 474
36 500
2,2
80
8 752
24 000
2,8
210
23 123
48 000
2,1
58
6 412
25 000
4,3
66
7 216
14 280
2,0
26
2 840
16 749
7,5
208
947
22 880
104 213
47 000
371 529
2,1
3,9
Investment
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
3. STEP: Proposal of at least 2 variants of EE measures
OSPRA Invest - Rovinka i.e. – energy balance after realization for each variant
Before
R. Indicator
1
2
3
4
5
6
Inputs – fuels and energy
Changed state of resources
Consumption of fuels and energy
Sale of energy to external consumer
Final consumption of fuels and energy
Losses in el. distribution network
Losses in production and distribution of heat
7
from NG
Consumption of electricity for heating and
8
DHW
9 Consumption of NG for heating and DHW
10 Consumption of el. for technology purposes
After
12 459
11 999
460
11 999
12
thousand
EUR/year
1 435 138
1 381 836
53 302
1 381 836
1 389
-
-
-
-
400
11 275
46 283
1 304 614
309
10 419
36 227
1 210 457
GJ/year
GJ/year
EUR/year
11 512
11 052
460
11 052
12
1 330 925
1 277 623
53 302
1 277 623
1 389
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
4. STEP: Economy evaluation
- Simple payback period
IN = investment
CF – cash-flow
- Real payback period by considering discount rate TSD
CFt = annual savings (changes of cash flow after realisation of measures)
r – dsicount factor
(1 + r)-t – odúročiteľ
- Net present value
CFt - Cash - Flow of the project in year t
r - discount
t – evaluated timeframe (1 to n years)
Tž – lifetime of equipment
-
Internal Rate of Return
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
5. STEP: Environmental evaluation
Emisssions
Solid particles
SO2
NOx
CO
CO2
Electricity
kg/MWh
0,28
1,87
2,88
2,33
1084
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
5. STEP: Selection of variant
- Economy evaluation
Indicator
Total costs
Change of costs for energy (– decrease/+ increase)
Change of personal costs, i.e. slaries, insurance, ... (–/+)
Changes of other operational costs, i.e repairs and maintenance,
services,insurance of property, ... (–/+)
Change of other individually given costs, i.e emissions, waste and others (–
/+)
Change of sales, i.e. of heat, electricity, used wastes, ... (–/+)
Benefits from realisation total
Timeframe of evaluation
Discount factor
Simple payback (Ts)
Real payback (Tsd)
Net present value (NPV)
Internal rate of return (IRR)
Value
Unit
371 529
-104 213
0
EUR
EUR
0
0
0
0
0
0
-104 213
20
5
3,9
6,1
756 666
23,63
0
EUR
year
%
year
year
EUR
%
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
5. STEP: Selection of variant
- Environmental evaluation
Emissions
Before
t/year
after
t/year
Difference
t/year
3,0
5,6
30,9
25,0
11 641,7
0,3
0,5
2,7
2,2
1 027,0
Variant 2
Solid partcles
SO2
NOx
CO
CO2
3,3
6,1
33,7
27,2
12 668,7
Selection criterias:
- Economy and environmental benefits
- Technical – lifetime of variants
- Operational – costs/changes of costs on maintenance and operation
- Legislative – if variants can bring from legislative pouint of view any complications
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713
Thank you for your
attention!
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713