energy audit energy audit presentation

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


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


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.


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.


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).....


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.


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

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


CASE STUDY – chemical industry



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:


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


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)


Production of re-granulate


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


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


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


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


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)...)


- 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.




- 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



- 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



- 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



- 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



- 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


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


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.


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....


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


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


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.


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


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


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


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.


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


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


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...


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


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




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




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




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 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 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.



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


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


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


5. STEP: Environmental evaluation

EmisssionsElectricity

kg/MWhSolid particles 0,28

SO2 1,87NOx 2,88CO 2,33CO2 1084


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


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


Thank you for your attention!

energy audit energy audit presentation

Documents

energy resources

healthy energy

cheapest energy

energy audit ea

energy services enefekt

energy consumption analysis

energy enduse efficiency

energy efficiency ing