10 gbe factory exemplary cases

GBE Factory Report on 10 GBE Factory Exemplary Cases

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GREEN-BLUE-ENERGY FACTORY Project GBE Factory

Intelligent Energy – Europe (IEE) - ALTENER

Contract No. IEE/10/232/SI2.593827

D 5.1: Report on 10 GBE FACTORY

Exemplary Cases


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THE GBE FACTORY PROJECT

The project promotes investments in “GREEN-BLUE-ENERGY FACTORIES” : industrial and commercial buildings equipped with single or combined renewable energy sources, able to provide electricity, heating and cooling for the air conditioning of premises, as well as for the business activities housed within.

GBE Factory is coordinated by:

Eurosportello – Unioncamere del Veneto-UCV Via delle Industrie, 19/d 30175 Venice, Italy Tel. +39 041 099 9411 Ms. Erica Holland [email protected] The Secretary General Mr. Gian Angelo Bellati

ABOUT THIS DOCUMENT

This report presents Deliverable 5.1 of the GBE Factory project. It is the official electronic document which includes completed information for identification and selection data for 10 GBE Factory exemplary cases in he consortium participant’s country. This document was prepared in July 2013 by: ERATO Holding Plc 67 Saedinenie Blvd. 6300, Haskovo, Bulgaria M.Sc.Eng. Nikolay Vangelov [email protected] Tel. +359 2 978 3990

INTELLIGENT ENERGY EUROPE

The GBE Factory project is co-funded by the European Union under the Intelligent Energy Europe Programme (Contract No. IEE/10/232/SI2.593827).

The sole responsibility for the content of this publication lies with the authors. It does not necessarily reflect the opinion of the European Union. Neither the EACI nor the European Commission is responsible for any use that may be made of the information contained therein.


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CONTENT

1. INTRODUCTION.............................................................................................. 5

2. EU ENERGY POLICY...................................................................................... 5

3. PROCESS OF IDENTIFICATION.................................................................... 6

4. EVALUATION OF GBE FACTORY EXEMPLARY CASES .......... ................ 10

4.1. TECHNICAL ANALYSES OF GBE FACTORY EXEMPLARY CASES .. ... 10

4.2. FINANCIAL ANALYSES OF GBE FACTORY EXEMPLARY CASES .. .... 15

4.3. RISK AND SENSITIVE ANALYSES OF GBE FACTORY EXEMPLARY CASES .................................... ............................................ 15

4.4. ECOLOGICAL IMPACT AFTER THE GBE FACTORY EXEMPLARY CASES COMPLETION ................................... ........................................... 16

5. GBE FACTORY EXEMPLARY CASES BY COUNTRIES ........... ................. 17

5.1. ITALY .............................................. ........................................................... 17

5.2. AUSTRIA............................................ ........................................................ 19

5.3. BULGARIA........................................... ...................................................... 22

5.4. SLOVAKIA ........................................... ...................................................... 24

5.5. GERMANY ................................................................................................. 27

6. CONCLUSIONS............................................................................................. 29


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ABBREVIATIONS AND ACRONYMS

GBE Factory

Green-Blue-Energy Factories EE Energy efficiency

CA ESD Concerted Action for the Energy Services Directive

RES Renewable Energy Sources

CDM Clean Development Mechanism GHG Greenhouse Gases

EPBD Energy Performance Building Directive

EU European Union

EPC Energy Performance Contracting EC European commission

ESCo Energy Service Company PPPs Public Private Partnerships

ESD Energy Service Directive RETs Renewable-energy and Energy-efficient Technologies

EC European Council TPF Third Party Financing

IEE Intelligent Energy Europe VAT Value Added Tax

JI Joint Implementation NPV Net Present Value

WEC World Energy Council IRR Internal Rate of Return


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1. INTRODUCTION

The main goal of this Deliverable is identification on 10 GBE FACTORY exemplary cases from the point of view of technology, return of the investment and mid term sustainability. The technical partners in the GBE Factory project team FORGREEN, SOLID, ERATO, CCIS and CCIG have made professional efforts and investigated the possibilities to identification the best GBE Factory exemplary cases (two per each country). The PP2, PP4, PP6, PP7 and PP10 selected two GBE Factory exemplary cases, totally 10 based on the the knowledge gained during previous phases of the project. The identification process for 10 GBE Factory exemplary cases was among:

� Existing 30 reference cases presented in Deliverable 4.2.; � New proposals, mainly originated by activity of the Expert Group or coming from

innovative ideas/projects sponsored by the most advanced EPCs or high reputation testimonials from the technology sector.

On the other hand the project team paid attention during the selection stages the possibilities for grant funding, subsidizing, local and regional support energy and renewable measures and utilization of resources under the EU Structural Funds. The opportunity for starting of the selected exemplary cases under the procedure of the related funds was taken into account too. The report on 10 GBE Factory exemplary cases is a starting point and thanks to the support of the GBE Factory project Experts Group the used knowledge and skills of the critical mass analyses will be a base for developing 5 DEMO GBE FACTORY Proposals (one per each country). The presented 10 GBE Factory exemplary cases include cases from Austria, Bulgaria, Germany, Italy and Slovakia. 2. EU ENERGY POLICY

On 10 November 2010, the European Commission has adopted the Communication "Energy 2020 - A strategy for competitive, sustainable and secure energy". The climate and energy package is a set of binding legislation which aims to ensure the European Union meets its ambitious climate and energy targets for 2020. These targets, known as the "20-20-20" targets, set three key objectives for 2020:

� A 20% reduction in EU greenhouse gas emissions from 1990 levels; � Raising the share of EU energy consumption produced from renewable resources to

20%; � A 20% improvement in the EU's energy efficiency.

Across the EU countries in the few last years the governments were prepared a lot of mechanisms which have to promote the advantages of improvement the energy efficiency and renewable in the residential, public and industrial sectors.

The main energy efficiency and RES benefits to the different type of energy users are as follows:

� Reduction of energy cost to users;


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� The significant control over energy costs to customers were given; � Possibility to jobs creating and improve state savings; � Air pollutions reduction including decreasing of GHG; � In a lot of cases the performance at a lower energy cost than new energy supply from

new power sources including renewable. On 15 December 2011, the EC adopted the Communication "Energy Roadmap 2050". The EU is committed to reducing greenhouse gas emissions to 80-95% below 1990 levels by 2050 in the context of necessary reductions by developed countries as a group. In the Energy Roadmap 2050 the Commission explores the challenges posed by delivering the EU's decarbonisation objective while at the same time ensuring security of energy supply and competitiveness. The Energy Roadmap 2050 is the basis for developing a long-term European framework together with all stakeholders. One of the main advantages to using of renewable energy is that it is renewable and therefore sustainable. Renewable energy installation in general require less maintenance and operational cost than traditional facilities using energy sources. Even more importantly, RES produces little or no waste products such as carbon dioxide or other chemical and mechanical pollutants, so has minimal impact on the environment. Renewable energy projects can also bring economic benefits to many regional areas, as most projects are located away from large urban centres and suburbs of the capital cities. These economic benefits may be from the increased use of local services to the different sector of the EU economy and in the public sector as well.

The primary production of renewable energy within the EU-27 in 2010 was 166.6 million tonnes of oil equivalent (toe) — a 20.1 % share of total primary energy production from all sources. The quantity of renewable energy produced within the EU-27 increased overall by 72.4 % between 2000 and 2010, equivalent to an average increase of 5.6 % per annum.

The main benefits of RES using in the environmental and economic aspects are following: � Producing sustainable energy that not generated GHG emissions from fossil fuels

and can decreased some types of air pollution; � Establishing very good economic growth and jobs in many sectors of the economy; � Diversifying energy supply and reducing dependence on imported fuels.

3. PROCESS OF IDENTIFICATION

After the completion of 30 GBE Factory reference cases development included in D 4.2 the Expert Group Commission for the selection of 10 GBE Factory exemplary cases was established. The list of members in the GBE Factory Expert Group includes the following members shown in Table 1. Table 1 List of GBE Factory Expert Group members

No. Expert Name Organization Country 1 Germano Zanini FORGREEN Italy 2 Johannes Luttenberger SOLID Austria 3 Nikolay Vangelov ERATO Bulgaria 4 Giorgio Dovigi CCIS Slovakia 5 Anna Turco CCIG Germany


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The GBE Factory Expert Group has organized 2 PTC (Practice Theme Committee) meetings on Skype regarding evaluation and selection of 10 GBE Factory exemplary cases (two per each country). The 10 GBE Factory exemplary cases were selected on the basis of the following main important criteria:

� Most attractive economic returns; � Degree of mid term sustainability; � Degree of technological innovation.

The selected 10 GBE Factory exemplary cases use high technology equipment, system and processes. The report includes exemplary cases which are planned to be implemented through combination between energy conservation opportunities and using of renewable energy sources. On the other hand this proposed exemplary cases for the potential GBE Factory show remarkable potential for energy savings achievement and greenhouse gas emission reduction. The production of electricity, heat and cooling energy based on high level technology and know how using renewable energy is also presented.

Table 2 presents summary data regarding 10 GBE Factory exemplary cases identification.


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Table 2 Summary data for 10 GBE Factory exemplary cases

No. GBE Factory Exemplary Case

Type of GBE Factory*

Energy Use**

Total*** Installed Power

Country

1

Construction of PV roof plant for electricity generation and heat pump for thermal conversion

One by one plus E/H 39 kW

2 Construction of PV roof plant on the industrial plant

One by one E 925 kW

Italy

3 Solar Process Heat in Meat Factory BERGER

One by one H 650 kW

4 100% solar heated industry building - SUNMASTER

One by one plus E/H/C 848 kW

Austria

5 Biogas Plant in Albena AD One to many E/H 2000 kW

6 Co-generation and biogas plant Momchil One to many

E/H 2000 kW

Bulgaria

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Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa

One to many H 3627 kW

8 CHP plant using ORC One to one E/H 5100 KW

Slovakia

9 BeMobility 2.0. Subproject Micro Smart Grid

One to many E n/a

10 Construction of PV installation on airport building

One to one E 490 kW

Germany

Total: 15679 kW

* Type of GBE Factory based on D2.1. Draft electronic version of the Guide GBE FACTORY concept and Business Models. ** Energy use: E – Electricity, H – Heating, C – Cooling. *** Some of numbers are not available because they are confidential. The total installed power of all 10 GBE Factory exemplary cases is about 16 MW. The one by one GBE Factory exemplary cases are 4. Four exemplary cases are GBE Factory type one to many. GBE Factory exemplary cases type by one plus are tow.


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The selected 10 GBE Factory exemplary cases include completed Energy Efficiency or RES projects and projects in progress in Italy, Austria, Bulgaria, Slovakia and Germany.

Detailed information about the process of evaluation on 10 GBE Factory exemplary cases by countries is given in Chapter 4.

The GBE Factory Expert Group evaluated 10 exemplary cases in different economical sectors of the EU like meat industry, machinery, industrial building, forest industry, textile industry, transport and logistics, food industry, tourism industry, RES area including using of ESCo services (see Figure 1.). Figure 1 Allocation of the evaluated exemplary cases by economical sectors Each exemplary case was evaluated based on the main project characteristics. The Expert Group did detailed analysis of the technical design and proposed technology. The financial project indicators and the green houses gas emissions reduction after the projects implementation were taken into consideration too.

The current financial market in European Union presents an opportunity for sustainability development, environmental policy, and increasing of the standard of live through a wider range of policy and investment tools and mechanisms.

There are many financial bodies with funds for supporting many kinds of Green-Blue Energy Factory Projects. It is important that they are made aware of the financial needs of companies and administrations that are willing to take that step towards energy efficiency and renewable energy sources.

Tourism industry

Industrial building

Meat industry

Transport industry

RES Area

Forest industry

ESCo services

Food industry

Machinery industry

Textile industry


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These financial bodies include banks, Ministries of energy, government agencies, energy partnerships, community foundations, funding groups, institutions and Energy Service Companies (ESCO). The energy supply chains as a part of sustainable development depend on the significant role of producers of energy, its transport and logistic and distributors as well. There is significant interest of different type of stakeholders like producers, logistics, suppliers, project sponsors, promoters, advisors, distributors and local and regional authorities to support energy customers to reduce their energy consumption. The technical and high efficient solutions providing by the designers, installers, providers and equipment producers are warranty to achieving of the foreseen cost energy savings and GHG - greenhouse gas emissions reduction.

The saved and avoided expenses after the energy conservation measures implementation and RES using in the 10 GBE Factory exemplary cases can be redirected to the significant social spheres of the community such as health and education.

4. EVALUATION OF GBE FACTORY EXEMPLARY CASES

Based on the depth analysis of the suggested exemplary GBE Factory cases including technical, constructional, financial, contractual criteria 10 GBE Factory exemplary cases were collected by the GBE Factory Expert Group.

The Expert Group presented 10 GBE Factory exemplary cases in various sectors of the EU economy, strengths and prospects for future implementation.

4.1. TECHNICAL ANALYSES OF GBE FACTORY EXEMPLARY CA SES

The technical analyses of the 10 GBE Factory exemplary cases were implemented by the following other criteria:

� Most attractive economic returns; � Degree of mid term sustainability; � Degree of technological innovation; � Projects technical ability; � Degree of technological innovation and know how; � Appropriateness of the proposed technical solutions; � Understanding of projects requirements; � Approach to standards issues, e.g. interoperability; � Project, construction and account management, project schedule; � Opportunity for project grant funding, local and regional support schemes; � Commissioning and maintenance, after sales service, technical assistance

and training of the staff upon work completion; � Projects compliance with the National or EU applicable law; � Guaranteed cost savings as high as possible; � Procurement contract duration (ESCO, EPC, Public Private Partnership); � Energy management.

The separate and average evaluation of the proposed 10 GBE Factory exemplary cases was rated on the scale from 1 to 5, where the score of 5 were excellent and 1 inferior. The average score is between 4.69-4.81 which means potential for successful implementation of the presented exemplary cases.


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Table 4.1 presents matrix for evaluation of the selected GBE Factory exemplary cases. The technical characteristics of the proposed 10 exemplary cases are given in Table 4.2. The aggregated data regarding the type of technology, financial indicators and emission reduction of the proposed 10 GBE Factory exemplary cases are shown in Table 4.3.


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Table 4.1 Technical criteria for 10 GBE Factory exemplary cases evaluation

GBE Factory Exemplary Cases Criteria for Evaluation

1 2 3 4 5 6 7 8 9 10

Most attractive economic returns 4.5 4.5 4.2 4.0 4.2 4.1 4.5 4.1 4.1 4.4

Degree of mid term sustainability 4.4 4.4 4.9 4.7 4.8 4.7 4.8 4.6 4.8 4.7

Degree of technological innovation 4.5 4.5 4.8 5.0 4.9 4.9 4.7 4.6 4.9 4.7

Projects technical ability 4.6 4.7 4.9 4.9 4.8 4.8 4.9 4.9 4.8 4.7

Degree of technological innovation and know how 4.6 4.5 4.9 5.0 4.7 4.8 4.6 4.8 4.8 4.8

Appropriateness of the proposed technical solutions 4.4 4.4 4.4 4.6 4.4 4.2 4.3 4.3 4.6 4.4

Understanding of projects requirements 5.0 4.9 4.9 4.9 5.0 5.0 5.0 4.8 4.9 4.9

Approach to standards issues, e.g. interoperability 5.0 5.0 5.0 5.0 5.0 5.0 4.9 5.0 5.0 5.0

Project, construction and account management, project schedule 4.8 4.8 4.9 4.9 4.8 4.8 4.9 4.9 4.9 4.8

Opportunity for project grant funding, local and regional support schemes 4.7 4.8 4.5 4.4 4.5 4.5 5.0 5.0 4.8 4.8

Commissioning and maintenance, after sales service, technical assistance and training of the staff upon work completion

4.4 4.4 4.5 4.6 4.4 4.5 4.8 4.8 4.6 4.6

Projects compliance with the National or EU applicable law 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0

Guaranteed cost savings as high as possible 4.7 4.7 4.8 4.8 4.7 4.7 4.8 4.8 4.9 4.7

Procurement contract duration (ESCO, EPC, PPP) 4.8 4.8 4.8 4.9 5.0 5.0 4.9 4.8 4.8 4.8

Energy management 4.9 5.0 5.0 5.0 4.8 4.8 5.0 4.9 5.0 5.0

Average: 4.69 4.69 4.77 4.78 4.73 4.72 4.81 4.75 4.79 4.75


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Table 4.2 Technical characteristics of the proposed GBE Factory exemplary cases*

Installed Power Capacity Revenues/Savings

Electricity Heat Cooling

Total Installed Power

Project Revenues Energy Savings No. GBE Factory Exemplary Case Country

(kWel/p) (kWth) (kWc) (kW) (MWh/yr.) (EUR/yr.) (MWh/yr.) (EUR/yr.)

1 Construction of PV roof plant for electricity generation and heat pump for thermal conversion Italy 39 39 E/H 91 6220 n/a

2 Construction of PV roof plant on the industrial plant Italy 925 925 E 919 7930 n/a

3 Solar Process Heat in Meat Factory BERGER Austria 650 650 H n/a n/a n/a

4 100% solar heated industrial building - SUNMASTER Austria 34 770 44 848 E/H/C 519 170000 519

5 Biogas Plant in Albena AD Bulgaria 1000 1000 2000 E/H 5200 664679 3333

6 Co-generation and biogas plant Momchil Bulgaria 1000 1000 2000 E/H 5100 651897 2500

7 Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa Slovakia 3627 3627 H 8736 n/a n/a

8 CHP plant using ORC Slovakia 1000 4100 5100 E/H 40141 n/a n/a

9 BeMobility 2.0. Subproject Micro Smart Grid Germany n/a n/a E 61 n/a n/a

10 Construction of PV installation on airport building Germany 490 490 E 403 n/a n/a

Total: 4488 11147 44 15679 0 61170 1500727 6352

* Some of numbers are not available because they are confidential.


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Table 4.3 Type of technology, financial indicators and emission reduction of the proposed GBE Factory exemplary cases*

Technology Financial Indicators Emissions reduction

Total Project Cost (EUR)

NPV IRR Pay-back CO2 No. GBE Factory Exemplary Case Country Biomass/Solar/CHP/PV/Heat

Pump/Other

(EUR) (EUR) (%) (yr.) (t/yr.)

1 Construction of PV roof plant for electricity generation and heat pump for thermal conversion Italy PV, Heat pump 133000 n/a 19 5.0 19

2 Construction of PV roof plant on the industrial plant Italy PV 1309767 1571720 21.60 5.0 460

3 Solar Process Heat in Meat Factory BERGER Austria Solar thermal process heat plant 738500 200390 15.00 7.0 173

4 100% solar heated industrial building - SUNMASTER Austria Geothermal / Solar Thermal / PV 3150000 n/a 10.00 12.0 303

5 Biogas Plant in Albena AD Bulgaria CHP, Biogas Plant 3500000 4130000 12.00 7.0 389

6 Co-generation and biogas plant Momchil Bulgaria CHP, Biogas Plant 4000000 4800000 9.00 8.0 310

7 Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa

Slovakia Biomass boiler, solar collectors 6819310 n/a n/a n/a 2097

8 CHP plant using ORC Slovakia CHP with ORC 7 13352 8322622 13.0 n/a 11755

9 BeMobility 2.0. Subproject Micro Smart Grid Germany PV, Wind turbines, CHP 9300000 n/a n/a n/a 40

10 Construction of PV installation on airport building Germany PV 950000 n/a n/a n/a 274

Total: 37013929 15820

* Some of numbers are not available because they are confidential.


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The new energy technologies, equipment and facilities in the proposed 10 GBE Factory exemplary cases which will mount will increase the safety at work of the GBE Factory employees. The equipment is designed and manufactured in accordance with the contemporary European standards for safety at work.

4.2. FINANCIAL ANALYSES OF GBE FACTORY EXEMPLARY CA SES

The 10 GBE Factory exemplary cases financial analyses indicate that each case is very promising. The exemplary case’s pay back period is in the range between 5.0 – 12.0 years, including the construction period for separate cases. The Internal Rate of Return (IRR) is between 9.0% and 21.6% and the Net Present Value (NPV) amounts to the range from EUR 200390 to EUR 8322622.

The total base investment for 10 GBE Factory exemplary cases implementation amounts to EUR 37013929. This base projects cost includes the costs for project design, equipment delivery and its installation and construction works.

There are the opportunities to using actual financial mechanism for supporting of some GBE Factory exemplary cases implementation trough grant funding, local support measures and potential to start the procedure for the related request for funding. This opportunity will be additional warranty for successful exemplary cases implementation and loan disbursement.

The detailed information about the financial indicators of the presented exemplary cases: NPV, IRR and Pay back period is given in Chapter 5. in this Report.

4.3. RISK AND SENSITIVE ANALYSES OF GBE FACTORY EXE MPLARY CASES

The risk and sensitive analyses as a part of the evaluation of 10 GBE Factory exemplary cases was made.

The different scenarios for all presented exemplary cases are based on the GBE Factory Expert Group assumptions and data sheets for each case.

Completion risk:

� Capital cost overrun (construction risk); � Start-up delay risk.

Construction risk The equipment prices are determined on the basis of the preliminary offers, price information and information gathered from similar projects. Possible reasons for underestimation of the equipment costs are:

� Incorrect sizing of the technology, equipment and facilities; � Omitted system and equipment, necessary for the conservation options; � Incorrectly interpreted offers for project implementation.


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The average influence of the construction risk to the GBE Factory exemplary cases will be moderately impacted by the 10-15% increase of the total project cost for each case.

Start-up delay risk Although the complicated financial and economical situation in Europe the conditions are positive for keeping the time schedule of the proposed exemplary cases. The management of each project sponsors is highly motivated and has created structures for project implementation in each country. The start-up delay was analysed due to the following risks:

� Technology and equipment supply and installation will be delayed; � The assembling sites are not ready for operation.

The analyses indicate that the start-up delay does not significantly deteriorate the separate exemplary case’s financial indicators.

Operational risk:

The expected decrease of savings comparing with the baseline option for some of the GBE Factory exemplary case and revenues achieved based on purchasing of electricity and thermal energy for the some cases can be affected by the following circumstances:

� Incorrect impact definition during the project design stage; � The prescribed operation conditions are not complied with; � There is a strong handling and human factor dependence evident. � The proposed technology and equipment cannot technically achieve the impact

forecasted under the conditions of the beneficiaries;

The analyses of this sensitivity scenario show that the influence of the average excepted savings reduction and projects revenues will be 15% compared to the base case.

Worst case scenario:

This worst case scenario tests the combination of all scenarios mentioned above including construction risk, start-up delay, and operational risk amounted to 25 % corresponding sensitivity scenarios presented above.

This scenario affects to all financial indicators of the exemplary cases. The financial analysis shows that the average IRR decreasing is 2-4% and the average NPV is decreased by 10-12%. However, the exemplary case’s financial indicators for this worst case still lead to the conclusion that the each GBE Factory exemplary case is viable. The exemplary cases will generate sufficient cash to repay the possible loan interest and principal.

4.4. ECOLOGICAL IMPACT AFTER THE GBE FACTORY EXEMPL ARY CASES COMPLETION

Determination of the annual emissions of CO2 is according to Commission Decision of 21.01.2004 establishing guidelines for the monitoring and reporting of Greenhouse gas emissions pursuant to Directive 2003/87/EC of the European Parliament and of the Council. The emissions factors elaborated by the MOEW (Methodology for calculation of emissions of noxious substances (pollutants) released into the environment based on balance methods) have been used for the CO2 and other noxious gases emissions assessment.


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The quantitative reduction of the carbon dioxide emissions was estimated through utilisation of the Operational Guidelines for Project Design Documents of Joint Implementation Projects of the Dutch Ministry of Economics as of May 2004.

Data analyses shows that after the exemplary cases implementation the CO2 emissions will be reduced annually by 15820 tons as a result of the energy efficiency savings.

5. GBE FACTORY EXEMPLARY CASES BY COUNTRIES

5.1. ITALY

EXEMPLARY CASE N 1: CONSTRUCTION OF PV ROOF PLANT F OR ELECTRICITY GENERATION AND HEAT PUMP FOR THERMAL CONVERSION

The proposed project uses PV technology for electric generation and use heat pumps for conversion in thermal energy. The photovoltaic and heat pump will be installed in the area of Carrera S.p.A., Verona, Italy. The installed capacity of PV modules is 38.64 kWp.

Carrera is a Italian clothing corporation, founded in the mid 60’s in Verona. Carrera is a small clothing multinational industry as the production units are located in some of the major cotton producing countries, in order to have access to the best raw material, while the logistics and final inspection operations still remain in Italy to ensure the highest Carrera standards.

The expected electric energy production of installed equipment is 38000 kWh/yr. 50% of this generated energy will be converted in thermal energy by heat pump with COP 2.8. The achieved thermal energy production will be in the amount of 53200 kWh/yr.

After this investment, Carrera think about the thermal theme, and decided to begin a study to use a heat pump to produce thermal energy for its office.

EXEMPLARY CASE N 2: CONSTRUCTION OF PV ROOF PLANT O N THE INDUSTRIAL PLANT

ICI Caldaie S.p.A. is machinery plant situated in Campagnola di Zevio, Verona district, Italy. The proposed exemplary case will use photovoltaic modules for generation of electricity for own need. The total installed capacity of PV system is 925 kWp. The expected productivity from the high efficient PV installation is 919 MWh/yr.

The projects technical characteristics are given in Table 5.1. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Italy are shown in Table 5.2.


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Table 5.1 Technical characteristics of the proposed exemplary cases

Installed Power Capacity Energy

Use Revenues/Savings


Total Installed Power (E/H/C) Project Revenues Energy Savings

No.

GBE Factory

Exemplary Case


1


39 39 E/H 91 6220 n/a 16000

2

Construction of PV roof plant on the industrial plant

925 925 E 919 7930 132342

Total: 964 964 1010 14150 148342

Table 5.2 Type of technology, financial indicators and emission reduction of the proposed exemplary cases

Technology Total

Project Cost

Financial Indicators Emissions reduction

No. GBE Factory

Exemplary Case Biomass/Solar/CHP/PV Heat Pump/Other

(EUR) NPV

(EUR) IRR (%)

Pay-back (yr.)

CO2 (t/yr.)

1


PV, Heat pump 133000 n/a 19.0 5.0 19

2 Construction of PV roof plant on the industrial plant

PV 1309767 1571720 21.6 4.9 460

Total: 1442767 1 571720 479


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5.2. AUSTRIA

EXEMPLARY CASE N 3 : SOLAR PROCESS HEAT IN MEAT FACTORY BERGER

The solar thermal process heat plant will be constructed in the area of the meat factory Berger in the town of Sieghartskirchen, Austria. The complete area for installing of solar collectors is 1 077 m2, the installed thermal power of the collectors is 650kWth. The produced hot water and steam will be used from factory for technological needs, heating and domestic hot water. Main characteristics of hot water preheating for dehumidification of maturation chambers:

� 7 m³ /h hot water demand; � 240 kW plate heat exchanger; � Usage of waste heat until 40°C; � Solar heating up to 70°.

Preheating feed water for steam production (ham cooking)

� 2,7 m³/h hot water demand � 200 kW plate heat exchanger � Usage of waste heat until 28°C � Solar heating up to 93°

The main advantages of the proposed solar collector’s type ökoTech – flat plate collectors by SOLID are:

� Higher energy output; � Flow of fluid is designed to suit application; � Easier and faster installation; � Less connections and pipings; � Lower flow indicates smaller pumps.

The heating isntallation will include boiler feed water – preheated 28/93oC, buffer storage with capacity 60m3, hot water circulit unit 40/70OC, valvs, connecting pipes, pumps, flat expanders.. The control system wuth remote control unit will be alco installed.

EXEMPLARY CASE N 4 : 100% SOLAR HEATED INDUSTRIAL BUILDING - SUNMASTER

The industrial building costumer WA Busienss & Service Centre ownd by Sun Master GmbH is located in the town of Eberstalzell, Austria. The Sun Master is the leading producer of solar thermal collectors. The company havs a large selection of solar collectors with accessories: flat plate solar collectors, solar absorbers, mounting systems and components for solar systems.

The Sun Master will invest in renewable energy project of the new production site as a pasive house. The building has a total industrial area of 1100 m² of solar panels for solar air conditioning and electricity. Thermal coupling to the ground provides heating in winter. The entire energy needs of the enterprise – both for cooling and heating as well as for the operation of manufacturing facilities – are thus met by renewable energies.For this purpose 800m2 of solar thermal collectors will be installed on the building roof and 300m2 of solar collectors on facades. A photovoltaic plant with capacity of 33.5 kWp will be installed on the building. During the night the ventilation windows of teh smoke extractors will be oppened in automatic way. The transverse ventilation affects the free cooling of the building.


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Additionnaly absorbtion chillers can be used for cooling of the production premises and offices.

Key data for technical implementation of the proposed exemplary case are: � Thermal coupling of the ground; � Extremely airtight covering; � Natural night cooling; � South-facing shed roofs; � Use of internal heat gained from the machines; � Solar cooling of laser welding machines; � Solar air conditioning of the office building.

The projects technical characteristics are given in Table 5.3. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Austria are shown in Table 5.4.


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Total Installed Power (E/H/C) Project Revenues Energy Savings

No. GBE Factory Exemplary

Case


3

Solar Process Heat in Meat Factory BERGER

650 650 H 517 55370

4

100% solar heated industrial building - SUNMASTER

34 770 44 848 E/H/C 519 170000 519 170000

Total: 34 1420 44 1498 519 170000 1036 225370

Table 5.4 Type of technology, financial indicators and emission reduction of the proposed exemplary

Technology Total

Project Cost

Financial Indicators Emissions reduction

No. GBE Factory


(EUR) NPV

(EUR) IRR (%)

Pay-back (yr.)

CO2 (t/yr.)

3 Solar Process Heat - Meat Factory BERGER

Solar thermal process heat plant

738500 200390 15.0 7.2 173

4 100% solar heated industrial building - SUNMASTER

Geothermal/Solar Thermal/PV

3 50000 n/a 10.0 12.0 303

Total: 3888500 476


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5.3. BULGARIA EXEMPLARY CASE N 5: BIOGAS PLANT IN ALBENA AD EXEMP LARY CASE N 5

The project envisages construction of biogas plant using organic waste, providing energy for heating of hotels, restaurants and other infrastructure in the Albena resort and domestic hot water for the tourists needs. The energy will be generated by anaerobic biogas plant trough installed CHP with nominal electricity production of 1 MWel, and 1 MWth thermal energy production respectively.

The biogas plant will be situated 10 km from the Albena resort, Balchik municipality, north-east Bulgaria. The project sponsor and investor is Perpetuum Mobile BG JSCo.

The technology in the biogas plant will be supplied by MT Energie GmbH. The company AB Energy form Italy will deliver Co-generation. The construction of all facilities will be implemented by Eko Stroy AD, Bulgaria.

The generated electricity will be utilised trough public grid owned by Energo Pro AD.

EXEMPLARY CASE N 6: CO-GENERATION AND BIOGAS PLANT MOMCHIL

The cogeneration and biomass plant Momchil is situated in the area of Albena resort, Balchik municipality, north-east Bulgaria.

The CHP will be installed in biogas plant which will use organic waste, providing:

� Electricity for local consumers and grid; � Heating up a greenhouse; � Utilization of the heat in a processing plant for fruits and vegetables; � Heating of office buildings.

The food company Eko Plod AD will be consumer of the generated heat energy especially for greenhouse and processing plant for fruits and vegetables.

The CHP has nominal electricity power of 1 MWel, thermal power of 1 MWth for combined electricity and hot water.

The generated electricity will be utilised trough public grid owned by Energo Pro AD.

The main project activities will be implemented as follows:

� Biogas plant will be supplied by MT Energie GmbH, Germany; � The Italian company AB Energy will deliver CHP module; � The construction of all facilities will be implemented by Eko Stroy AD, Bulgaria.

The projects technical characteristics are given in Table 5.5. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Bulgaria are shown in Table 5.6.


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Total Installed Power (E/H/C) Project Revenues Energy Savings No.

GBE Factory Exemplary

Case

(kWel) (kWth) (kWc) (kW) (MWh/yr.) (EUR/yr.) (MWh/yr.) (EUR/yr.)

5 Biogas Plant in Albena AD

1000 1000 2000 E/H 5200 664679 3333 312500

6 Co-generation and biogas plant Momchil

1000 1000 2000 E/H 5100 651897 2500 250000

Total: 2000 2000 4000 10300 1316577 5833 562500

Table 5.6 Type of technology, financial indicators and emission reduction of the proposed exemplary cases

Technology Total

Project Cost Financial Indicators

Emissions reduction

No. GBE Factory


(EUR) NPV

(EUR) IRR (%)

Pay-back (yr.)

CO2 (t/yr.)

5 Biogas Plant in Albena AD

CHP, Biogas Plant 3500000 4 130 000 12.0 7.0 389

6 Co-generation and biogas plant Momchil

CHP, Biogas Plant 4000000 4 800 000 9.0 8.0 310

Total: 7500000 699


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5.4. SLOVAKIA

EXEMPLARY CASE N 7: RECONSTRUCTION OF HEATING DISTR IBUTION SYSTEM AND FUEL SWITCHING TO REDUCE GREENHOUSE GAS EMISSIO NS IN HNÚŠŤA

Rimavská Energetická s.r.o. operates a central system of production and distribution of heat in Hnúšťa, district of Rimavská Sobota, Banská Bystrica region, southern Slovakia with population of 7749 people. The project envisages reconstruction of existing heating distribution system and fuel switching to reduce greenhouse gas emissions. The installed capacity and annual production of thermal energy from the new equipment is following:

� One unit of VESKO-B biomass boiler with installed capacity of 3MW; � Total heat production from the biomass boiler is 5833.38 MWh/yr; � 360 psc of solar collectors type Citrin Solar CS 111-SF with total installed capacity of

0.627 MW; � Total heat production from the solar collectors is: 10454 GJ/yr.

A new heating system in Hnúšťa is due to undertaken investments one of the most modern and efficient in Slovakia. New technologies guarantee high efficiency of the system. The main advantage is stability based on the use of three primary energy sources - biomass, solar and natural gas. From the finalization of the project at the end of 2011 more than 95% of the heat in the city is produced from RES. From this point of view, the urban heating system in Hnúšťa is unique not only in Slovakia but also throughout Central Europe.

EXEMPLARY CASE N 8: CHP PLANT USING ORC

The combined heat and power plant is situated in the premises of TOPHOLZ s.r.o., in the village Krnča, district of Topolčany, Nitra Region, Western Slovakia. TOPHOLZ is one of the biggest wood working companies in the region. It deals with wood processing and wood trading. TOPHOLZ s.r.o. has the capacity to cover the entire need for biomass and is a partner in the project. On the other side, TOP PELET as an ESCo will be an exclusive supplier of heat to TOPHOLZ s.r.o.

The applied technology is based on Organic Rankin Cycle (ORC) and include biomass thermal oil boiler of type KOHLBACH K8 with installed capacity of 5150 KWth and ORC turbine type TURBODEN 10 CHP SPLIT.

After the energy efficiency project implementation the CHP plant will generate:

� Heat power 4.1 MWth; � Heat energy generation 118000 GJ/yr.; � Electricity power 1.0 MWel; � Electric energy generation 7323 MWhel/yr.

ORC is a unique technology which combines heat and power from various renewable energy sources. It is particularly advantageous for decentralized production of electricity and heat. ORC devices have a high overall efficiency: 20% of heat coming from the thermal oil is


25

converted into electricity, while 78% remains available at a relatively high temperature to further heat use.

Technical advantages of ORC modules: � High efficiency cycle; � The higher efficiency of the turbine; � Low mechanical turbine burden through low peripheral speed; � High reliability; � Easy start up and shutdown of the plant; � Automatic and smooth operation with low noise; � Low operating and maintenance requirements; � Low specific technical knowledge required; � Long lifetime of the plant.

The added value of the project is that since the beginning of its operation 80% of the generated heat can be used towards their internal consumption and sale to the partners.

The projects technical characteristics are given in Table 5.7. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Slovakia are shown in Table 5.8.


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Electricity Heat Cooli

ng

Total Installe

d Power (E/H/C) Project Revenues Energy Savings

No.

GBE Factory

Exemplary Case


7


3627 3627 H 8736 n/a

8 CHP plant using ORC

1000 4100 5100 E/H 40141 n/a

Total: 1000 7727 8727 48877

Table 5.8 Type of technology, financial indicators and emission reduction of the proposed exemplary

Technology Total


Emissions reduction

No. GBE Factory


(EUR) NPV

(EUR) IRR (%)

Pay-back (yr.)

CO2 (t/yr.)

7


Biomass boiler, solar collectors

6819310 n/a n/a n/a 2097

8 CHP plant using ORC

CHP with ORC 7113352 8322622 13 n/a 11755

Total: 13932662 13852


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5.5. GERMANY

EXEMPLARY CASE N 9: BEMOBILITY 2.0. SUBPROJECT MICR O SMART GRID

The BeMobility 2.0 project will be implemented in Berlin, Germany.

Funded by the Federal Ministry of Transport, Building and Urban Development in Cooperation with Companies from the Science an Industry sector the following energy stakeholders will be included in the project.

� InnoZ; � Schneider Electric; � NBB Netzgesellschaft Berlin-Brandenburg; � TU-Berlin DAI-Labor; � TU-Berlin SENSE; � DB Fuhrpark Services; � Vattenfall Innovation Europe.

Together with the partners mentioned above, the InnoZ built up an intelligent distribution network for electric energy on the EUREF-Campus (European Energy Forum) on the old Gasometer in Berlin Schöneberg. The Micro Smart Grid is part of the Platform for electric Mobility in the InnoZ, which is part of BeMobility 2.0. The Platform for electric mobility can be used for expert forums, events, basic research or meetings. The InnoZ is tenant on the EUREF-Campus which is a project to build the CO2 neutral city of the future. The project includes the following activities:

� Installation of 3 Photovoltaic-Arrays; � Installation of 5 vertical axis wind turbines; � Installation 2 stationary grid buffer batteries; � Construction of an electric carsharing-station with charging infrastructure for up

to 28 simultaneous charging cars; � Access to an operating e-carsharing-fleet; � Real time monitoring of all component in the grid; � Constant calculation of the optimized state of the grid and control of all

components.

EXEMPLARY CASE N 10: CONSTRUCTION OF PV INSTALLATIO N ON AIRPORT BUILDING

The project envisages installation of the PV modules with 490 kWp. The electricity will be produced for the Flughafen Hannover-Langenhagen GmbH own needs. The annual electric energy production in the amount 403000 kWhel will be expected.

The project sponsor is Flughafen Hannover-Langenhagen GmbH. The applied technology delivery and installation of high quality poly crystal PV modules will be installed on the roof of the airport in order to produce electricity for self-consumption.

The innovative aspect includes the focus on the system as a PV electricity generation.

The projects technical characteristics are given in Table 5.9. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Germany are shown in Table 5.10.


28





Total Installed Power (E/H/C) Project Revenues Energy Savings No.

GBE Factory Exemplary

Case


9

BeMobility 2.0. Subproject Micro Smart Grid

n/a n/a E 61 n/a

10

Construction of PV installation on airport building

490 490 E 403 n/a n/a 98400

Total: 490 490 464 98400

5.10 Type of technology, financial indicators and emission reduction of the proposed exemplary

Technology Total


Emissions reduction

No. GBE Factory

Exemplary Case Biomass/Solar/CHP/PV Heat Pump/Other (EUR)

NPV (EUR)

IRR (%)

Pay-back (yr.)

CO2 (t/yr.)

9

BeMobility 2.0. Subproject Micro Smart Grid

PV, Wind turbines, CHP 9300 000 n/a n/a n/a 40

10

Construction of PV installation on airport building

PV 950000 n/a n/a n/a 274

Total: 10250000 314


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6. CONCLUSIONS

The following conclusions for the selected 10 GBE Factory exemplary cases can be made:

� The proposed exemplary cases have high degree of mid term sustainability and technological innovation;

� The GBE Factory Expert Group selected 10 cases from the 30 reference cases presented in D 4.2;

� The exemplary cases have compliance with there national or EU applicable law and standards;

� The report on 10 GBE Factory exemplary cases will be used to preparation of 5 project proposals for the future realization of a DEMO GBE FACTORY;

� The D 5.1. will contribute the project development and reaching of the project performance indicators;

� The report and the further DEMO GBE Factory implementation will lead to direct benefits to the SME’s;

� Using dissemination tools after the project completion multiplying effect will be expected to the different type of stakeholders;

� Support the transfer and adoption of technology and/or know-how, the technology upgrading, the development of research facilities and the updating of the exciting facilities;

� Investment in upgrading and modernization of production technology and equipment; � Raise the ability of EU Small and Medium Enterprises to cope with competitive

pressure within European market; � Improvement the living standards of the employers in the factories; � Significant decreasing of energy carriers cost to the industrial sectors; � Sustainable growth establishment; � Reduction of GHG emission and environmental ecological impact will be achieved.

10 gbe factory exemplary cases

Documents

gbe factory project

energy factories

renewable energy sources

eu energy policy

european union

european commission

official electronic

completed information