You are on page 1of 52

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: OSPRA Invest, Ltd.


Legal status: Ltd
Address: Rovinka, BA (Istrochem)
Responsible person:
Contact:
Sector: Chemical industry
Subject of EA: -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) 2222
4 (PH – administrative part, administrative building,
Number of heated buildings: portable container housing units, building for
security)
Site plan:
Production of PE and PP folies (Rovinka)
Purpose of production
Production of re-granulate (BA)
Number of employees 100 (Rovinka) + 30 (BA, Istrochem)
Operation regime (days a week) 24 hours/ 7 days
Shape factor of building
Buidings Heated volume V [m3]
A/V [1/m]
Main building- production hall 26 890,0 0,37
Administrative building and Dressing
1 179,36 0,77
rooms
Container housing units 164,16 1,55
Security building 246,9 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 1 – security
d) List of all buildings and theirs use, description of all
2 – AB, dressing rooms, showers
energy consumers
3 – new storage hall
5 4 – main production hall (offices,
social spaces, production hall
4 Bielloni, production hall A, B,
7
6 welding hall)
8 5 – storage hall – tent
2
3 6 – crusher of waste follies -
1 recycling
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
Energy Annual costs
Input – fuels and energy Unit Amount
caloric
value
content EUR excl. - Collection of monthly energy
in MWh VAT
Purchase – electricity MWe 12 147,15 - 12 147 1 405 588 and water consumption of at
Purchase - heat GJ - - - - least of 3 last years!
Natural gas m3 - - - -
Brown coal t - - - -
- Collect data on costs coupled
Black coal t - - - - with purchase of energy for
Coke t - - - -
Other solif fossil fuels t - - - -
relevant 3 years
Heavy heating oil t - - - - - Most of the data from
- -
Biomass
Light heating oil
t
t
-
- - -
-
-
INVOICES
Diesel t 3,19 11, 66 37 4 250 - If possible – readings from
Petrol t 5,73 12,22 70 9 300 meters or data collected
Other energy gases (Propane) t 16,03 12,78 205 16 000
Secondary energy devided into
through e-manager application
- - - -
not used heat and others if available
RES devided into solar, wind,
geothermal and others
- - - - - Energy consumption that is
Other fuels - - - - given by climate conditions
Total fuel and energy input 12 459 1 435 139 should be re-calculated with
External customers 460 53 302
decree-days!!!
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: 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


OSPRA Invest, Ltd. (Rovinka+BA):
650 000
spotreba cena
- 97,4% of all energy consumed is
80 000
600 000
ELECTRICITY (57% Rovinka, 43%
550 000
70 000
BA)
kWh

500 000 €

450 000
60 000
- No Natural gas consumption
400 000
50 000 - 2,6% - fuels
350 000

300 000 40 000

október

december
november
jún
február

marec

september
august
máj

júl
apríl
január

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

550 000
70 000
kWh

500 000 €

60 000
450 000

400 000
50 000
350 000

300 000 40 000


máj

jún
marec

júl
apríl
január

február

august

október

november

december
september

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
Output Príkon
Number Počet
kW kW
DHW el. heater 150l 5 2
El. heaters FAICO 8 9-14
DHW el. heater 200l Tatramat 1 2,2
El. convectors Technotherm 19 2,0 DHW flow el. heater 5l 3 2
E. convectors Technotherm 2 0,5
El. heater Heler 2 0,7
Oil el. radiators 2 2,0

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: 2


Type: evaporative chillers JH 30
Parameters 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 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 in-
built 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.......
Num
t
ber of Power W W
Pinšt(W) Preal (W) (h/year
functi input (kWh/year) (kWh/rok)
)
number onal (W)
Main object
Administrative
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: 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
Input power Output Number Voltage Year of
Wellding hall Name
kW kW - V construction
Production of PP and PE
M19 18 n.a. 1 230/400 n.a.
bags
Production of PE bags BSM 1300 28 1 230/400 2009

Production of bags –
ROLO 3 16 n.a. 1 230/400 n.a.
welding of bags

Production of bags –
ROLO2 n.a. n.a. n.a.
welding of bags
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


BRUCHER 18 n.a. 1 230/400 n.a.
foil

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
kW bar m3/min ks
power Year of
Hall A power input Pe number
output 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: 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)
Cooling
Output Voltage Year of
Device Number output
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
74
Cooling device ERS SC64V, 1 22 230/400 2003
(pri 15°C)
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: 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
Input
Administrative appliances Number
power
Name kW -
PC 0,3 9
Printer 0,2 3
electric kettle 2 1
Copy maschines 0,5 2
Mikrovawe owen 1,2 1
Fax maschine 0,1 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 Indicator MWh/r tisíc eur/r
1 Input of fuels and energy 12 459 1 435 139
2 Change in stocks of fuel - -
3 Consumption of fuels and energy 11 999 1 381 836 Rovinka
4 Sale of energy to other customer 460 53 302
5 Final consumption of fuels and energy Electricity
(row 3 – row 4) – according to need 11 687 1 352 286
devide other types of fuels and energy Heat - -
Diesel 37 4 250
Petrol 70 9 300
Propane 205 16 000
6 Losses in own sources and distribution Electricity
(from value given in row 5) – according 12 1 389
needs devide into other types of fuels and Heat - -
energy
Others - -
7 Energy consumption for heating and DHW Electricity
(from value given in row 5) – according Heating 366 42 349
needs devide into other types of fuels and Electricity
energy DHW 34 3 934
Others
- -
8 Energy consumption for technology Electricity 11 275 1 304 614
purposes and other processes
(from value given in row 5) – according Heat
- -
needs devide into other types of fuels
and energy Others - -

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. Rok 2009 2010
Number of
Blue - overrunning of reserved capacity delivery point:
3106043653 3108116420 3108132200 3106043653 3108116420 3108132200
- Delivery point 3108116420 is Reserved
250 340 700 250 340 700
overrunning these values (winter - capacity [kW]
Max. reserved
el. heating, external consumer) capacity [kW]
300 360* 880 300 360 880

- Delivery point 3108132200 – Month


1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max.
kW kW kW kW kW kW
possible measure – lowering of January 226 351 593 227 376 631
reserved cap. to 660 kW event. February 231 359 603 219 371 619
max. res. cap. to 700 kW March 230 348 609 225 354 588
April 223 277 571 229 294 574
- Electric distribution network and May 219 267 565 206 282 589
main electric devices are according June 225 266 572 234 273 592
July 225 249 558 219 260 559
to measurements and revisions in August 217 268 568 207 273 564
good technical state September 207 263 574 201 308 510
- el. distribution lines are currently October 218 321 591 241 313 418
November 204 319 579 226 321 581
over dimensioned – reason: reserve December 207 336 652 236 393 623
for connection of new devices/
retain variability for shifting of
existing technology devices

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 Regranulač
Suma Hala
Zvarovňa
Regranulač
ná linka Suma Hala
A
ná linka
operational hours, power input and load factors, 13%
14%
4%

Stl. vzduch
9% A
17%

- Division of consumption according technological areas Zvarovňa


10%
1%

Chladenie
- Technical state – satisfactory even most of the production Stl. vzduch
2%

3%
devices are old and energy intensive
- Motors with input power up to 100 kW are replaced by Chladenie
4%

asynchrony motors with inverter, large motors – larger Suma Hala


B + Bialloni
Suma Hala
56%

investments – up to 50% of savings per device B + Bialloni


67%

Hall A – input power and assumed consumption. Hall B – input power and assumed consumption.
B2
B2 B3 B3
Bialloni 2%
A7 2% 2% B4 1%
A1 A7 Bialloni 2% B4
13% 23% 7% A1 3% 2% B8
B5 2%
28% 9%
A5 B8 14%
14% 23% B7
10% B5
24%
A5
17%

A4
14%
A2
18% B6
27%
A4 A3 B7
17% 14% 27% B6
A3 A2
12% 23% 50%

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 – 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
Consumptio
OSPRA INVEST – heating and hot water Internal
Heat need for
Thermal
n of
temperatur gains from
Evaluation of thermal-technical properties of BUDOVA heating electricty for
e technology
heating
heated buildings (no measurement):
°C kWh/rok kWh/rok kWh/rok
- Calculation of heat need for heated buildings Production hall A,B 22 908 360 630 465 277 895
(720540-2) Administrative
- Estimation of heat gains building and dressing 20 52 320 - 52 848
rooms
- Estimation of consumption of electricity for Container buildings 20 18 173 - 18 356
heating Security building 20 16 464 - 16 630
- Technical state – satisfactory, regulation Total 995 317 630 465 365 729
according internal temperature
- Hot water – only teoretical calculation (no Spotreba leto - zima
measurement) – going out of normative 4 000 000
3 900 000
calculation 3 800 000

Výpočtová potreba tepla na vykurovanie


3 700 000 334 272
3 600 000
Uni mo bunky;

kWh
Vrá tni ca ;
18 173 kWh/r; 3 500 000
Budova
16 464 kWh/r; 397 185
2% 2%
a dmi ni s tra tívy 3 400 000
a š a tne;
52 320 kWh/r; El. energia - Tepelný zisk 3 300 000
5% vykurovanie z techn.;
277 895 630 465
3 200 000
kWh/r; 31% kWh/r; 69%
3 100 000
3 000 000
apr - sept okt - mar apr - sept okt - mar

Výrobná ha l a leto 2009 zima 2009 - 2010 leto 2010 zima 2010 - 2011
A,B; 908 360
kWh/r; 91%

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 EUR 36 500
Energy consumption per unit:
Average el. price EUR/kWh 0,11
Energy savings:
Achievable electricity savings MWh/year 150
Cost savings (electricity) EUR/year 16 474
Simple payback period year 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 EUR 24 000
Energy consumption per unit:
Average el. price EUR/kWh 0,11
Energy savings:
Achievable electricity savings MWh/year 80
Cost savings (electricity) EUR/year 8 750
Simple payback period year 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 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

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 EUR 47 000
Energy consumption per unit:
Average el. price EUR/kWh 0,11
Energy savings:
Achievable electricity savings MWh/year 208
Cost savings (electricity) EUR/year 22 880
Simple payback period year 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
Energy Costs savings Simple
Investment
Measure savings (energy) payback
MWh/rok EUR/rok EUR rok
Frequency speed control of main driver of
extruder A1+replacement of snail, gearbox 150 16 517 160 000 16,7
and extrusion head (Rovinka)
Frequency speed control of main driver of
150 16 474 36 500 2,2
extruder B5 (Rovinka)
Frequency speed control of main driver of
80 8 752 24 000 2,8
extruder B6 (Rovinka)
Frequency speed control of main driver of re-
210 23 123 48 000 2,1
granulation line (BA)
Frequency speed control of main driver of
58 6 412 25 000 4,3
automatic mill KUNG (BA)
Main production hall in Rovinka – replacement of
66 7 216 14 280 2,0
gates, thermal barriers, copilits and thermotats
Administrative and dressing building – thermal
insulation, replacement of windows, thermostats - 26 2 840 16 749 7,5
Rovinka
Indoor lighting reconstruction - Rovinka 208 22 880 47 000 2,1
Total 947 104 213 371 529 3,9

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 After
R. Indicator thousand
GJ/year GJ/year EUR/year
EUR/year
1 Inputs – fuels and energy 12 459 1 435 138 11 512 1 330 925
2 Changed state of resources - - - -
3 Consumption of fuels and energy 11 999 1 381 836 11 052 1 277 623
4 Sale of energy to external consumer 460 53 302 460 53 302
5 Final consumption of fuels and energy 11 999 1 381 836 11 052 1 277 623
6 Losses in el. distribution network 12 1 389 12 1 389
Losses in production and distribution of heat
7
from NG - - - -
Consumption of electricity for heating and
8
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: 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

Electricity
Emisssions
kg/MWh
Solid particles 0,28
SO2 1,87
NOx 2,88
CO 2,33
CO2 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 Value Unit

Total costs 371 529 EUR


Change of costs for energy (– decrease/+ increase) -104 213 EUR
Change of personal costs, i.e. slaries, insurance, ... (–/+) 0 0
Changes of other operational costs, i.e repairs and maintenance,
0 0
services,insurance of property, ... (–/+)
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 0
Benefits from realisation total -104 213 EUR
Timeframe of evaluation 20 year
Discount factor 5 %
Simple payback (Ts) 3,9 year
Real payback (Tsd) 6,1 year
Net present value (NPV) 756 666 EUR
Internal rate of return (IRR) 23,63 %

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
Before after Difference
Emissions
t/year t/year t/year
Variant 2
Solid partcles 3,3 3,0 0,3
SO2 6,1 5,6 0,5
NOx 33,7 30,9 2,7
CO 27,2 25,0 2,2
CO2 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

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

You might also like