Energy Efficiency in Serbian Industry –
Implementation of Cleaner Production
Cleaner Production Centre of Serbia
Faculty of Technology and Metallurgy,
University of Belgrade
Cleaner Production in Serbia
•Cleaner Production Centre established in 2007 as UNIDO Project
•funded by Federal Government of Austria and Government of the Republic of
Slovenia
•Part of the Faculty of Technology and Metallurgy, University of Belgrade
•external consultants, Advisory Bord
• support of Ministry of Environment and Serbian Chamber of Commerce
Inauguration of the Serbian Cleaner Production Centre
on the
6th Ministerial Conference “Environment for Europe”
October 11, 2007 , Belgrade
Cleaner Production Definition
“The continuous application of an integrated
preventive environmental strategy applied to
processes, products, and services to increase
overall efficiency and reduce risks to humans
and the environment.”
(United Nations Environment Programme)
Workshops for the industry on cleaner
production
Around 300 people from 60 participating companies attended workshops
CP in companies - visits
- Informational meetings
- Quick scan audits by NE
- Energy audits by EE
- CP detailed assessments by IE and NE
- Consulting on collecting data and defining CP options
Agrosava
CP Assessment
Bambi – Banat
CP Assessment
Stark – meeting of CP
team and experts
Detailed CP and energy assessments were carried out in 60 companies
CP in companies – evaluation and implementation
- List of CP options and Action plan for implementation of proposed options
- Submission of Report and its evaluation
- CP award
- Monitoring and continuation
CP Award Ceremony in Serbian Chember of Commerce
In total 57 companies from different sectors were awarded
Resource Efficiency and Cleaner Production (RECP)
Project in EPS (Power Company of Serbia) – part I
In total, seventy-six RECP options were
identified and preliminary results (50 %
of options evaluated) show that with
investment of 164,000,000 € folowing
consumption reductions could be
reached:
Lignite: 330,000 t/year,
Water for 700,000 m3/year,
Electricity for 20 GWh/year,
CO2 emission for 200,000 t/year
Ash (waste) for 2,000,000 t/year
Cooperation with Municipalities
Local authorities in Pancevo and Cacak signed an agreement with the Cleaner
Production Center of Serbia on the introduction of cleaner production
City of Pancevo:
10 companies – petrochemical company, waste electrical and electronic equipment
recycling and 8 Public Utility companies
11 local consultants
City of Cacak:
7 companies, the building of the municipality and two schools
City of Pancevo – second phase:
5 private companies
Cleaner Production practices
1. Good housekeeping
take appropriate managerial and
operational actions to prevent:
- leaks
- spills
- to enforce existing
operational
instructions
Example
Example
25% of total length of pipes for hot water distribution were not well insulated
Reduction of coal by 6,000
tons and CO2 by 11,200 tons
Investment: 155,000 EUR
Savings: 125,000 EUR
Payback period: 1.2 years
Cleaner Production practices
2. Input substitution
substitute input materials
- by less toxic
- or by renewable materials
- or by adjunct materials which
have a longer service life-time in
production
Example
RB
1
Description
of the
problem
Large
expenses
and air
emissions
due to usage
of the heavy
oil for firing
of the boiler
as well as for
support in
lignite
combustion
Proposed
option of the
cleaner
production
Replacement of
heavy oil with
the light fuel or
gas
Potential for the
reduction
- Demi water
35,000 m3/y x 2 units =
70,000 m3/year
- 10,000 tons of coal x 2
unit = 20,000 tons of
coal/year
- 950 MWh/per year (2
motors for HO pumps
and 2 for demi water each 30 kw)
-Reduced quantity of
sulphur in flue gases
Reduction of 14600 t of
CO2 /per year
Estimated
expenses
[€]
Estimated savings
[€/g]
Increasing
costs of fuel
prices
1.15 million
€ / year
Savings on the
production of
demineralised water for
heating fuel oil 280,000
EUR
- Savings in electricity
consumption 38,000
EUR
- Savings on coal
240,000 EUR
- Savings
due to increase the total
unit of 0.5%, due to the
lack of contamination of
the boiler 4.8 million EUR
x 2 units
Cleaner Production practices
3. Better process control
modify:
- operational procedures
- equipment instructions
and process record keeping in order
to run the processes more efficiently
and at lower waste and emission
generation rates
Example
Installation of gas and electricity meters/ Installation of computerbased monitoring program
By continuous monitoring and recording of consumption of the main water and
energy consumers (boiler, makeup water for chillers, hot water generation,
slaughterhouses, meat processing, trucks cleaning, temporary houses), monitoring
production related specific indicators, and training of operators, it is assessed the
company could reduce energy and water consumption by 5 - 10%.
Comparing to current consumption of 500.000 m3 of water, 4,317,598 m3 of gas and
27,879 MWh of electricity it could bring savings up to 50,000 m3/year of water,
215,000 m3 of gas and 1.35 GWh of electricity.
This leads to reduction of CO2 by 920 t.
Investment: 60,000 EUR (total cost)
Savings: 236,000 EUR (188,000 for energy and 48,000 for water)
Payback period: 3 months
Cleaner Production practices
4. Equipment modification
modify the existing production
equipment and utilities in order:
- run the processes at higher
efficiency
- lower waste and emission
generation rates
Example
Even while the project was still ongoing, the company started to
implement some of the cleaner production options:
 exhausted capacitor batteries were replaced, the return of investment of
5,400 EUR was 9 months
 the process of purchasing an industrial suction dust remover in order to
replace the current practice of cleaning with compressed air was
initiated, 9,000 kWh electricity was reduced
 One of the cleaner production options is installation of the system for
automatic boiler desludging. It is estimated that annual consumption of
steam amounts to 5,700 tons. Losses in steam consumption caused by
manual desludging stand at around 15%, while automatic desludging
would reduce these losses to 3-5%. This would lead to gas savings of
12,000 m3 per year. Investment 12,000 EUR; estimated savings 4,300
EUR
Example
Condensate from the two heating substations has been discharged into the
sewer system. Measurements of the discharged condensate quantities have
shown that resulting heat loss, expressed in terms of fuel consumed, is
equivalent to heavy oil consumption of 21 t over the heating period. A carried out
reconstruction has provided for a condensate, which has been discharged from
the system for years, to be returned into the process (collector and a pump for
condensate transport).
Apart from the expected financial benefits
resulting from reduced heavy oil
consumption of 21 t/a, described measure
has also contributed to environmental
improvements observed through annual
reduction of CO2 emission equal to 68 t/a.
Cleaner Production practices
5. Technology change
replacement of:
- the technology
- processing sequence
- synthesis pathway
in order to minimise waste
and emission generation
during production
Case Study - Petrohemija
Since the beginning of the cleaner production project in 2010 till today, the
company HIP Petrohemija has invested more than 9 million € in various
cleaner production options, which resulted in reduction of consumption of
gas by around 520,000 m3 per year, of water by 30,000 m3 per year, and of
chemicals in substantial amounts. Some of the implemented measures are
primarily related to pollution prevention, and they considerably contribute to
the reduction of negative impact on the environment and human health.
For instance, in the Ethylene Factory,
by investing only 1,000 € and
changing the type of steam used for
flushing of pyrolytic furnaces, the
savings of around 120,000 € were
achieved, i.e. the consumption of
feeding boiler water was reduced by
around 30.000 t per year, and the
c o n s u m p t i o n o f c h e m i c a l s wa s
reduced by around 20-30 t per year.
Case Study - Petrohemija
There are several pumps in the Ethylene Factory that use water steam, but that can
use electricity as their energy source (one pump has a turbine, the other has an
electric engine). These pumps switched to the use of electricity, which is not only
cheaper than water steam, but it also reduces the consumption of fossil fuels, thus
reducing pollution.
The largest investment, of around 7.5 million €, was completed last year, with the
reconstruction of the HDPE Factory. This has a multiple environmental impact, by
reducing emissions, reducing the consumption of isobutene by about 100 t per year,
reducing the generation of waste catalyst in the amount of 1,500 kg per year, and
reducing the consumption of gas for activation furnace by around 30%.
Good housekeeping measures such as insulation of pipelines, valves and flanges,
replacement of malfunctioning condensate separators, condensate return, or repairs
of water steam leakage have resulted in savings of around 180,000 € with a return
period of around 4 months.
Case Study – Bambi - Banat
CP option
Investment
€
Saving €/y
Option 1: Optimization of burners
on furnaces for baking biscuits
(setting relations fuel-air)
1,200
15,000
OPTION 2: Elimination of
technological steam on lines
for baking biscuits replacement of furnace on line
B2 / 1
OPTION 3.
Optimizing the parameters of
steam and hot water boilers of
working unit Vrsac
1,100,000
-
280,000
13,800
Returns of
Investment
Impact on the Environment
1 month
Reducing consumption of LPG by 30 t / yr, or
reducing CO2 emissions to 78.6 tons /
year
4 years
Reducing consumption of LPG for 530 t / yr,
or reducing CO2 emissions by 1390 tons
/ year, increasing the energy efficiency of
the process of burning, reducing
irreversible resources
immediately
Reducing consumption of natural gas for
320,000 m3/year and reduce CO2
emissions to 640 tons / year
OPTION 4.
Shortening the time of mixing in
production of soup fill , without
changing the quality.
-
1,900
immediately
Reducing electricity consumption by 40 MWh
/ year, or reducing CO2 emissions to
41.6 tons / year
OPTION 5.
Installation of systems for heating
sanitary water waste heat
recovery from flue gases from
tunnel kiln on line B1 / 2
36,400
9,000
4 years
Reducing consumption of LPG by 17 t / yr, or
reducing CO2 emissions to 44.6 tons /
year, reduced emissions of waste heat
Case Study – Bambi - Banat
CP option
Investment
€
Saving
€/year
Returns of
Investment
Impact on the Environment
OPTION 6.
Installation of systems for heating
sanitary water by recuperation of waste
heat recovery line B2 / 4
29,000
7,100
4 years
Reduction of electricity consumption to 151.2
MWh / year, or reducing CO2 emissions by
157.2 tons / year, reduced emissions of waste
heat
OPTION 7.
Installation of facilities for reactive energy
compensation in TS2 of working unit
Pozarevac
18,000
6,200
3 years
Reduction of reactive power for the year 1150
kVArh/ year
immediately
Reducing electricity consumption by 50 MWh /
year, or reducing CO2 emissions to 52 tons /
year
3 months
Reducing consumption of LPG and electricity,
15% reduction of energy consumption,
reducing CO2 emissions by up to 60 t / year
just on the line B2 / 4
OPTION 8.
Turning off lighting in the production
plant during certain periods of the day
OPTION 9.
Introduction of energy management in
the company
-
-
2,500
19,400
Cleaner Production Results
RESULTS:
•So far, (2006-2012) total of 60 companies participated
•Average savings per company: 100,000 EUR/year
•Average decrease of water consumption: 50,000 m3/year
•Average decrease in electrical power consumption: 500
MWh/year
•Average decrease in CO2 emission: 500 t/year