energy audit energy audit presentation
TRANSCRIPT
ENERGY AUDITINGtool to increase
ENERGY EFFICIENCY
Ing. Bronislava Herdová, PhD.
energy auditor
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], 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: [email protected], Tel.: 0904 220 713
WHAT IS AN ENERGY AUDIT (EA)?
pool of activities (systematic procedure) focused on analysis of current energy needand consumption going out of valid technical standards,
analysis of problems (weaknesses and deficiencies),
EA identifies and in detail quantifies effective possibilities of energy savings tailoredto the object being analyzed,
„field-work“, economy tool having dynamic character, often basis for grant financingof projects.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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 5,5GWh/year) the procedure of EA as well as content of the report is determined byRegulation No. 429/2009.
In case of voluntary EA is the content and focus as well as target given by customersrequirement.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], 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: [email protected], Tel.: 0904 220 713
WHAT OFFERS EA TO THE CUSTOMER?
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
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
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: [email protected], Tel.: 0904 220 713
CASE STUDY – chemical industry
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
Name of company: OSPRA Invest, Ltd.Legal status: LtdAddress: Rovinka, BA (Istrochem)Responsible person:Contact:Sector: Chemical industrySubject of EA: -buildings (administrative and
production hall) and theirtechnical equipment
-production technology
Step 1: Identification – EA subject
a) Collection of main data about the customer and basic description:
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
Identification of activitiesType of activitiesi (NACE2) 2222
Number of heated buildings:4 (PH – administrative part, administrative building, portable container housing units, building for security)
Site plan:
Purpose of productionProduction of PE and PP folies (Rovinka)
Production of re-granulate (BA)Number of employees 100 (Rovinka) + 30 (BA, Istrochem) Operation regime (days a week) 24 hours/ 7 days
Buidings Heated volume V [m3]Shape factor of building
A/V [1/m]Main building- production hall 26 890,0 0,37Administrative building and Dressing rooms
1 179,36 0,77
Container housing units 164,16 1,55Security building 246,9 1,13
Step 1: Identification – EA subject
1 STEP: Identification of subject of EA – site plan
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
Vstup do areálu
1
2 3
4
5
6 7
8
1 – security
2 – AB, dressing rooms, showers
3 – new storage hall
4 – main production hall (offices, social spaces, production hall Bielloni, production hall A, B, welding hall)
5 – storage hall – tent
6 – crusher of waste follies -recycling
7 – container housing units
8 – transformer station - TS 1, TS 2
TS3 – out of the area of the company
b) Description of main activities of EA
c) Site pland) List of all buildings and theirs use, description of allenergy consumers
1 STEP: Identification of subject of EA – site plan (ISTROCHEM)
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
Production of re-granulate
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
STEP 2: data collection on energy inputs
- 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!!!
Input – fuels and energy Unit Amountcaloric value
Energy content in MWh
Annual costs EUR excl.
VAT
Purchase – electricity MWe 12 147,15 - 12 147 1 405 588
Purchase - heat GJ - - - -
Natural gas m3 - - - -
Brown coal t - - - -
Black coal t - - - -
Coke t - - - -
Other solif fossil fuels t - - - -
Heavy heating oil t - - - -
Biomass t - - - -
Light heating oil t - - - -
Diesel t 3,19 11, 66 37 4 250
Petrol t 5,73 12,22 70 9 300
Other energy gases (Propane) 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 - - - -
Total fuel and energy input 12 459 1 435 139
External customers 460 53 302
Total consumption of fuels and energy OSPRA INVEST, s.r.o. 11 999 1 381 836
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
STEP 2: data collection on energy inputsPriemerné mes. spotreby a ceny elektrickej energie po mesiacoch za roky 2009-2010 v areále Rovinka
300 000
350 000
400 000
450 000
500 000
550 000
600 000
650 000
700 000
janu
ár
febr
uár
mar
ec
aprí
l
máj jún júl
augu
st
sept
embe
r
októ
ber
nove
mbe
r
dece
mbe
r
kWh
40 000
50 000
60 000
70 000
80 000
90 000
€
spotreba cena
Priemerné mes. spotreby a ceny el. energie po mesiacoch za roky 2008-2010 v areále Istrochem
300 000
350 000
400 000
450 000
500 000
550 000
600 000
650 000
700 000
janu
ár
febr
uár
mar
ec
apríl máj jún júl
augu
st
sept
embe
r
októ
ber
nove
mbe
r
dece
mbe
r
kWh
40 000
50 000
60 000
70 000
80 000
90 000
€
spotreba cena
OSPRA Invest, Ltd. (Rovinka+BA):- 97,4% of all energy consumed is
ELECTRICITY (57% Rovinka, 43% BA)
- No Natural gas consumption- 2,6% - fuels
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], 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: [email protected], 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)...)
STEP 2: data collection on main en. consumers - buildings
- heat distribution network length and thermal insulation, materials andthickness
- 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: [email protected], Tel.: 0904 220 713
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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
NumberOutput
kW
El. heaters FAICO 8 9-14
El. convectors Technotherm 19 2,0
E. convectors Technotherm 2 0,5
El. heater Heler 2 0,7
Oil el. radiators 2 2,0
PočetPríkon
kWDHW el. heater 150l 5 2DHW el. heater 200l Tatramat 1 2,2DHW flow el. heater 5l 3 2
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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®ulation…
- 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: [email protected], 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: 2 Type: evaporative chillers JH 30Parameters of chiller: 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 temperatureMeasurement: no separate measurement
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], 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 in-built lamps with linear fluoresenc lighting sources type T8 (1 x 18W, 2 x36W) with conventional ballast, in some technical places are conventionalincandescent 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.......
number
Number of functional
Power input (W)
Pinšt(W) Preal (W)t
(h/year)
W (kWh/year)
W (kWh/rok)
Main objectAdministrative spaces 14 14 86 1 204 1 204 1 560 1 878,24 1 878,24
Toilet 3 3 60 180 180 520 93,60 93,60
Wellding hall 176 176 139 24 464 24 464 8 640 211 368,96 211 368,96
Toilet 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: [email protected], 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: [email protected], Tel.: 0904 220 713
STEP 2: data collection electricity consumers - production
Wellding hall NameInput power
kWOutput
kWNumber
-Voltage
VYear of
construction
Production of PP and PE bags
M19 18 n.a. 1 230/400 n.a.
Production of PE bags 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. n.a.
COEMTER BETA 1 28 n.a. 1 230/400 n.a.
COEMTER BETA 2 n.a. n.a. 1 n.a.
COEMTER BETA 3 n.a. n.a. 1 n.a.
Production of bags STIEGLER - 1 28 n.a. 1 230/400 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.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - productionCompressed air – OSPRA Invest (Rovinka) – pneumatic driverIs 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
kW bar m3/min ks
Hall A power input Pe
power output
numberYear of
production
Screw compressor 37 8 5,9 2 n.a.
Hala Bielloni
BELT 55-8 60 n.a. n.a. 1 2011
Zvarovňa
Kaeser AS 35 22 7,5 n.a. 1 1986
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - productionCooling – technology purposes – OSPRA INVEST (Rovinka)
Device NumberOutput
Cooling output
Voltage Year of production
kW kW V
Hall B
Coolling device RACA AIR 80 - R1 1 10 28 400 2009
Hall Bielloni
FRIGOSYSTEM RACA2 1 47 140 400 2009
Water treatment EUROWATER 1 2 n.a. n.a. 2000
Welding hall
Cooling device ERS SC64V, 1 2274
(pri 15°C)230/400 2003
Water treatment EUROWATER 1 2 n.a. n.a. 2000
Coolling for regranulation device REMA
Old coolling tower – out of operation
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.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
STEP 2: data collection – main el. consumers - production
Administrative appliancesInputpower
Number
Name kW -PC 0,3 9Printer 0,2 3electric kettle 2 1Copy maschines 0,5 2Mikrovawe owen 1,2 1Fax maschine 0,1 1
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
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
STEP 2: analysis and evaluation of current stateOSPRA INVEST - compiling basic energy balance (Rovinka+BA)
Row Indicator MWh/r tisíc eur/r1 Input of fuels and energy 12 459 1 435 1392 Change in stocks of fuel - -3 Consumption of fuels and energy 11 999 1 381 8364 Sale of energy to other customer 460 53 3025 Final consumption of fuels and energy
(row 3 – row 4) – according to need
devide other types of fuels and energy
Electricity 11 687 1 352 286
Heat - -Diesel 37 4 250Petrol 70 9 300Propane 205 16 000
6 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 - -7 Energy consumption for heating and DHW
(from value given in row 5) – according needs devide into other types of fuels and energy
ElectricityHeating 366 42 349ElectricityDHW 34 3 934
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 11 275 1 304 614
Heat- -
Others - -
Rovinka
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
2 STEP: analysis and evaluation of current stateOSPRA INVEST – analysis of electricity consumption
Analysis and evaluation of supply tarrifs3 delivery points with reserved and max. reserved capacity (Rovinka)
Rok 2009 2010Number of delivery point:
3106043653 3108116420 3108132200 3106043653 3108116420 3108132200
Reserved
capacity [kW]250 340 700 250 340 700
Max. reserved
capacity [kW]300 360* 880 300 360 880
Month1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max.
kW kW kW kW kW kW
January 226 351 593 227 376 631February 231 359 603 219 371 619March 230 348 609 225 354 588April 223 277 571 229 294 574May 219 267 565 206 282 589June 225 266 572 234 273 592July 225 249 558 219 260 559August 217 268 568 207 273 564September 207 263 574 201 308 510October 218 321 591 241 313 418November 204 319 579 226 321 581December 207 336 652 236 393 623
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 ofreserved cap. to 660 kW event.max. res. cap. to 700 kW
- Electric distribution network andmain electric devices are accordingto measurements and revisions ingood technical state
- el. distribution lines are currentlyover dimensioned – reason: reservefor connection of new devices/retain variability for shifting ofexisting technology devices
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
2 STEP: analysis and evaluation of current stateOSPRA INVEST – analysis of electricity consumption – production technology (Rovinka)
- Assessment of energy consumption going out fromoperational 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 – largerinvestments – up to 50% of savings per device
Suma Hala
A
14%
Suma Hala
B + Bialloni
56%
Stl. vzduch
3%
Regranulač
ná linka
13%
Zvarovňa
10%
Chladenie
4%
Suma Hala
A
17%
Suma Hala
B + Bialloni
67%
Chladenie
2%
Stl. vzduch
1%
Zvarovňa
4%
Regranulač
ná linka
9%
Total installed power input and el.
consumption
A4
17%
A5
17%
A7
13%
A2
18%
A1
23%
A3
12%
A4
14%
A5
14%
A7
7%
A2
23%
A1
28%
A3
14%
Hall A – input power and assumed consumption.
B5
14%
B6
27%
B7
27%
B8
23%
B3
2%
B2
2% B4
2%Bialloni
3%
B5
24%
B6
50%
B7
10%
B8
9%
B3
1%
B2
2%Bialloni
2%B4
2%
Hall B – input power and assumed consumption.
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
STEP 2: analysis and evaluation of current stateOSPRA 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 electricitygiven by amount of produced foils (too many different processes –individual processes are not monitored)
- In operation in BA – specific energy consumption has beenevaluated
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: [email protected], Tel.: 0904 220 713
2 STEP: analysis and evaluation of current stateOSPRA INVEST – heating and hot waterEvaluation of thermal-technical properties ofheated 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 normativecalculation
BUDOVA
Internal temperatur
e
Heat need for heating
Thermal gains from technology
Consumption of
electricty for heating
°C kWh/rok kWh/rok kWh/rokProduction hall A,B 22 908 360 630 465 277 895Administrative building and dressing rooms
20 52 320 - 52 848
Container buildings 20 18 173 - 18 356Security building 20 16 464 - 16 630Total 995 317 630 465 365 729
Výpočtová potreba tepla na vykurovanie
Výrobná hala
A,B; 908 360
kWh/r; 91%
Vrátnica;
16 464 kWh/r;
2%Budova
adminis tratívy
a šatne;
52 320 kWh/r;
5%
Unimo bunky;
18 173 kWh/r;
2%
El. energia -
vykurovanie
277 895
kWh/r; 31%
Tepelný zisk
z techn.;
630 465
kWh/r; 69%
Spotreba leto - zima
3 000 000
3 100 000
3 200 000
3 300 000
3 400 000
3 500 000
3 600 000
3 700 000
3 800 000
3 900 000
4 000 000
apr - sept okt - mar apr - sept okt - mar
leto 2009 zima 2009 - 2010 leto 2010 zima 2010 - 2011
kWh
334 272
397 185
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
2 STEP: analysis and evaluation of current stateOSPRA 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 someof new lamps have classical ballast...
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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: [email protected], Tel.: 0904 220 713
OSPRA Invest - Rovinka
NON-COST Measures:
- Monitoring and evaluation of energy consumption on monthly basis
- Monitor and decrease internal temperature especially in administrative part werewas 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 kWin case of el. delivery point 3108116420
3. STEP: Proposal of EE and RES measures
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
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
3. STEP: Proposal of EE and RES measures
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
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 costsTotal in EUR EUR 36 500Energy consumption per unit:Average el. price EUR/kWh 0,11Energy savings:Achievable electricity savings MWh/year 150Cost savings (electricity) EUR/year 16 474Simple payback period year 2,2
3. STEP: Proposal of EE and RES measures
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
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 costsTotal in EUR EUR 24 000Energy consumption per unit:Average el. price EUR/kWh 0,11Energy savings:Achievable electricity savings MWh/year 80Cost savings (electricity) EUR/year 8 750Simple payback period year 2,8
3. STEP: Proposal of EE and RES measures
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
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
MeasureInvestment costsThermal insulation EUR 8 496
Roof – thermal insulation EUR 3 297
Replacement of windows EUR 4 665
Installation of thermotats with timers EUR 291
Total costs in EUR EUR 16 749
Unit price of energy:Average price of electricity/heat EUR/kWh 0,11
Energy savings:Achievable electricity savings MWh/rok 25,82
Cost savings (electricity) EUR/rok 2 840
Simple payback period rok 7,5
3. STEP: Proposal of EE and RES measures
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], 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 costsTotal in EUR EUR 47 000Energy consumption per unit:Average el. price EUR/kWh 0,11Energy savings:Achievable electricity savings MWh/year 208Cost savings (electricity) EUR/year 22 880Simple payback period year 2,1
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
3. STEP: Proposal of at least 2 variants of EE measuresOSPRA Invest - Rovinka i.e. - proposal of 2 variants
MeasureEnergysavings
Costs savings (energy)
InvestmentSimple
paybackMWh/rok EUR/rok EUR rok
Frequency speed control of main driver of extruder A1+replacement of snail, gearbox and extrusion head (Rovinka)
150 16 517 160 000 16,7
Frequency speed control of main driver of extruder B5 (Rovinka)
150 16 474 36 500 2,2
Frequency speed control of main driver of extruder B6 (Rovinka)
80 8 752 24 000 2,8
Frequency speed control of main driver of re-granulation line (BA)
210 23 123 48 000 2,1
Frequency speed control of main driver of automatic mill KUNG (BA)
58 6 412 25 000 4,3
Main production hall in Rovinka – replacement of gates, thermal barriers, copilits and thermotats
66 7 216 14 280 2,0
Administrative and dressing building – thermal insulation, replacement of windows, thermostats -Rovinka
26 2 840 16 749 7,5
Indoor lighting reconstruction - Rovinka 208 22 880 47 000 2,1Total 947 104 213 371 529 3,9
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
3. STEP: Proposal of at least 2 variants of EE measuresOSPRA Invest - Rovinka i.e. – energy balance after realization for each variant
R. IndicatorBefore After
GJ/yearthousand EUR/year
GJ/year EUR/year
1 Inputs – fuels and energy 12 459 1 435 138 11 512 1 330 9252 Changed state of resources - - - -3 Consumption of fuels and energy 11 999 1 381 836 11 052 1 277 6234 Sale of energy to external consumer 460 53 302 460 53 3025 Final consumption of fuels and energy 11 999 1 381 836 11 052 1 277 6236 Losses in el. distribution network 12 1 389 12 1 389
7Losses in production and distribution of heat from NG - - - -
8Consumption of electricity for heating and DHW 400 46 283 309 36 227
9 Consumption of NG for heating and DHW - - - -10 Consumption of el. for technology purposes 11 275 1 304 614 10 419 1 210 457
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
4. STEP: Economy evaluation
- Simple payback periodIN = investmentCF – 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 valueCFt - Cash - Flow of the project in year tr - discountt – 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: [email protected], Tel.: 0904 220 713
5. STEP: Environmental evaluation
EmisssionsElectricity
kg/MWhSolid particles 0,28
SO2 1,87NOx 2,88CO 2,33CO2 1084
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
5. STEP: Selection of variant
Indicator Value Unit
Total costs 371 529 EURChange of costs for energy (– decrease/+ increase) -104 213 EURChange of personal costs, i.e. slaries, insurance, ... (–/+) 0 0Changes of other operational costs, i.e repairs and maintenance, services,insurance of property, ... (–/+)
0 0
Change of other individually given costs, i.e emissions, waste and others (–/+)
0 0
Change of sales, i.e. of heat, electricity, used wastes, ... (–/+) 0 0Benefits from realisation total -104 213 EURTimeframe of evaluation 20 yearDiscount factor 5 %Simple payback (Ts) 3,9 yearReal payback (Tsd) 6,1 yearNet present value (NPV) 756 666 EURInternal rate of return (IRR) 23,63 %
- Economy evaluation
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
5. STEP: Selection of variant
EmissionsBefore t/year
after t/year
Difference t/year
Variant 2Solid partcles 3,3 3,0 0,3
SO2 6,1 5,6 0,5NOx 33,7 30,9 2,7CO 27,2 25,0 2,2CO2 12 668,7 11 641,7 1 027,0
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
- Environmental evaluation
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: [email protected], Tel.: 0904 220 713
Thank you for your attention!