Industrial Energy Efficiency Guide
Industrial Energy Efficiency Guide
Efficiency in Industries
23/1/2019
CONTENTS
1. INTRODUCTION-LEGAL CONTEXT
3. EXAMPLES-OPPORTUNITIES FOR EE
4. INTERNATIONAL EXPERIENCE
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1.1 Unexploited potential for industrial EE
Preliminary
energy audit
Detailed
energy audit
• technically simple Monitoring audit
• no and low cost
measures (follow up)
• medium & high
cost measures
• capital intensive
• system audits projects
• complicated
applications
DIRECTIVE 27/2012/EC
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2.1 Energy Audit steps
Initial meeting
Step 1. Preparation-data collection
Data collection
Initial visit
Step 2. Walk-through visit
Preliminary
analysis
Step 3. Analysis of energy data
Measurements
Step 4- Measurements
Detailed
analysis
EE proposals
Step 5. Data analysis
Financial
analysis
Reporting
Step 6. Report
Presentation
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2.2 Energy Audit report
Chapter Contents
Executive Summary • Procedures followed
• Key figures on baseline Example-A1
• List of all measures and outlook of techno-economic results
• Recommended action plan.
CHAPTER 1 • Brief outlook of installations
Introduction- Site • Description processes-buildings
description • Description of utilities
• Raw materials-products-waste
• Energy management, monitoring and accounting procedures followed - current sub-
metering practices
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2.2 Energy Audit report
Chapter Contents
CHAPTER 4 • Technical description
• Estimation of CAPEX, OPEX
EE proposals
• Calculation of energy savings and other resource savings
• Calculation of GHG emissions reduction
• Financial savings
CHAPTER 5 • Possibilities for improvement in the processes that can result to:
• Process optimization
Proposals for process • Raw material savings
improvement • Increase in quality of production
• Modernization of production procedures
• Improvement of regular operation and management
CHAPTER 6 ▪ Assumptions (tariffs, discount rate etc)
▪ Lifecycle costs per measure
Financial analysis ▪ Cash-flow analysis
▪ Extraction of financial indicators (IRR and NPV)
▪ Risk-sensitivity analysis
CHAPTER 7 ▪ Key findings report
▪ Proposal of financially viable improvements
Conclusions
▪ Follow up- action plan
Annexes - Measurement data
- Technical calculation data sheets
- Financial analysis flow sheets etc.
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2.3 Minimum criteria for an audit
Demand Addressing
Be based on up-to-date, measured, • Methodology for systematic collection of primary
traceable operational data on energy information.
consumption • Targeted measurements for the acquisition of
integrated and reliable data needed for energy balances
Comprise a detailed review of the • Analysis at discrete Energy Cost Centres to be defined
energy consumption profile of at early stage.
buildings or groups of buildings,
industrial operations or installations,
including transportation
Build, whenever possible, on life-cycle • Analytical approach and calculation of O&M costs of each
cost analysis (LCCA) instead of Simple action
Payback Periods (SPP) • Tools for financial viability analysis
• Risk and sensitivity analysis .
Be proportionate, and sufficiently • Transparent criteria for selection of targeted objects
representative to permit the drawing • Determine relationship of energy vs critical parameters
of a reliable picture of overall energy (production etc), interactive effects
performance and the reliable
identification of the most significant
opportunities for improvement.
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2.4 Good practices-analysis
Detailed - Correlation of energy with critical Representative – appropriate baseline
parameters consumption
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2.5 Good practices-justification
Detailed: Benchmarking
To Heat 37oC
Pumpe
T40 A/B
28-32oC 34-37oC
Direct Heat
Exchange 38oC
SP03
SP08 SP04
SP07 EE proposals:
1. Clear and analytical, with technical evidence
SP05
SP06
34.6°C Example-A2
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2.6 Good practices-measures
2. Target on no/low cost measures 3. Put focus on processes
4. Financial analysis :
based on LCCA
Example-A3
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3.1 Examples of BATs
Sub-metering 13.8%
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3.2 Example: Heat recovery
Example: HR in ventilation in
Sources of waste heat agribusiness
Area Waste heat source Utilisation
Industrial Heating at industrial Low temperature waste heat Heat use before=22772 MWh/y
processes processes High temperature waste heat Heat used after = 9678 MWh/y
Drying Gas savings = 261885 EUR/y
Heat stored in products
etc. CAPEX: = 500,000 EUR
Auxiliaries: = 125,000 EUR
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3.3 Example: Smart Cooling
Concept: adiabatic evaporative pre-cooling system
- Cooling the incoming air without increasing its humidity ratio
- Sprays fine water mist to cool intake air
- Instant evaporation without touching the condenser
- Intake air reduces between 10-20°C through this process
- Increased efficiency (>20%) and cooling capacity
- Minimal water consumption
RESULTS
Energy use before = 1,210 MWh/y
Energy used after = 995 MWh/y
Savings = 18,000 EUR/y
Energy Savings: = 18% or 56 kWh/tn
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3.4 Example: Ice Storage
Concept: adiabatic evaporative pre-cooling system
- Ice-making mode: Stores heat during nighttime by using off-peak electricity
- Ice-melting mode: Produces chilled water during daytime replacing chiller's output
- Viable when used with multiple tariff
Example: Ice Storage in chocolate manufacturing industry
P eriod tariff Demand Chiller U se for I ce Storage Charging Storage Charge/Discharge
(€ /k Wh) (k W) Cooling Sy stem P ower Sy stem M ode (% )
(k W) Discarge (k W)
1:00 0.088 466 466 (contribution)
0 253 Charging 19%
2:00 0.088 466 466 0 253 Charging 33%
3:00 0.088 453 453 0 253 Charging 46%
4:00 0.088 426 426 0 253 Charging 60%
5:00 0.088 453 453 0 253 Charging 73%
6:00 0.088 453 453 0 253 Charging 87% Source: Calmac
7:00 0.088 480 480 0 253 Charging 100%
8:00 0.099 520 520 0 0 StandBy 100%
9:00 0.099 546 546 0 0 StandBy 100%
10:00 0.099 626 626 0 0 StandBy 100%
11:00 0.099 813 813 0 0 StandBy 100%
12:00 0.099 959 879 80 0 Discharging 96%
13:00 0.099 1066 879 187 0 Discharging 87%
14:00 0.099 1146 879 266 0 Discharging 75%
15:00 0.099 1199 879 320 0 Discharging 60%
16:00 0.099 1239 879 360 0 Discharging 43%
17:00 0.099 1199 879 320 0 Discharging 28%
18:00 0.099 1159 879 280 0 Discharging 15%
19:00 0.099 1052 879 173 0 Discharging 7%
20:00 0.099 919 879 40 0 Discharging 5%
21:00 0.099 733 733 0 0 StandBy 5%
22:00 0.099 653 653 0 0 StandBy 5%
23:00 0.099 546 546 0 0 StandBy 5%
0:00 0.088 493 493 0 253 Charging 5%
RESULTS
Savings > 5% of thermal
energy use
CAPEX: <0.1 EUR/kWh saved
Payback: < 1 year
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3.6 EE measures key results
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3.7 EE measures key results
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3.7 Energy maturity sequence
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4. International experience
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4.1 Energy audits in EU-key facts
Number of obliged
companies
De minimis Representativeness
Source: https://deep.eefig.eu/viewcharts/industry/ 27
4.4 ISO 50001
Energy Management is a systematic approach to the continuous setting, implementation and monitoring of energy
performance of a company/organization, aiming to reduce energy consumption, along with assuring the
sustainability of results in the long-term..!!!
ISO 50001: ISO standard that specifies requirements for establishing, implementing, maintaining and improving an energy
management system.
Main elements
Key area Main issues
Aim of energy management
Energy consumption
Policy Energy management policy statement without energy
Energy consumption
management
Planning Significant energy systems identified and reviewed Energy consumption
Measurable energy objectives and targets set with energy
Programme with responsibilities and time frame defined management
communicated to employees
Documentation and control of documents
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4.5 ISO 50001
EnMS system
Energy Policy
ISO Standard Energy planning
Plan-Do-Check-Act Model Continual EnMS Manual & -legal
improvement Procedures -energy Review
-energy Baseline
Management review Energy policy
-EnPI's
- inputs -objectives, targets, action plans
- outputs Energy -communications Plan
planning -training Plan
Management - set-up EMIS
review
Implementation Implementation &
& operation M&T operation
-competency, training &
awareness
Checking
-communications
-monitoring, Monitoring,
-documentation
measurement & analysis measurement
-operational Control
-legal & other and analysis
Checking -design
requirements
-procurement
-internal audit
-non-conformities Nonconformities,
-control of records correction, corrective
Internal audits and preventive
of EnMS action
Supervision: O&M
From the start of the EM
Manager
plan and every 3 years or
(if implemented
2. Implementation of energy audit when there is
internally then energy
process/equipment
audit is also under the
replacement
O&M)
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4.7 EMS- success stories
Item Cost (EURO)
Paper industry Computer 3,000
20,000 tons/y paper products; 2MEuro energy Software and configuration
Data logger (64 input)
15,000
12,000
Installation of complete EnMS system & 32 electricity meters 19,000
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4.9 Key issues
• Quality: requirement for minimum criteria
should prevail over cost-effectiveness
• Added value: lead to actions or are tools
for compliance??
• Availability of support actions
o Experience on energy audit programmes in
industry show that if ran in isolation, have
limited impacts
o Benefits are multiplied if combined with Source: A study in energy efficiency in enterprises, EC, DNV, 2016
complementary measures
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4.10 Maximising impacts
• Provision of incentives: financing EE KENYA
measures THE ENERGY (ENERGY MANAGEMENT) REGULATIONS,
2012
Energy conservation measures.
• Minimisation of risks: Certification of EE
8. (1) The owner or occupier shall take measures to
projects including project development and realize at least fifty percent of the identified and
QA (eg ICP Europe) recommended energy savings specified in the energy
investment plan by the end of three years and
• Mandatory energy performance thereafter at every audit reporting date.
targets? Source;
https://www.erc.go.ke/index.php?option=com_content&view=arti
cle&id=249:public-notice-the-energy-energy-management-
Example: Instruments in Denmark regulations-2012&catid=108&Itemid=700
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LDK Consultants
Σελίδα 35
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THANK YOU!!!
BACK
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A2.Data sheets
Project No PI-1A
Biogas generation-separation
Project No yyyy-3
Optimisation of refrigerators
BACK
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A4. Sensitivity analysis
BACK
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References
1. DEEP-De-risking energy efficiency platform; https://deep.eefig.eu/factsheet/quick/#
2. European Industrial Energy Efficiency Good practices platform; http://www.eumerci-portal.eu/web/guest/home
3. Concerted actions, European Energy Efficiency Directive; https://www.ca-eed.eu/Expert-areas/Expert-Areas/Energy-audits-and-
management-systems
4. Reference documents under the IPPC Directive and the IED; http://eippcb.jrc.ec.europa.eu/reference/
5. RICARDO Development of recommendations on the implementation of certain aspects of Article 8 and Annex VI of the Energy
Efficiency Directive , 2018; https://ec.europa.eu/energy/sites/ener/files/final_report_-
_development_of_guidelines_and_recommendations_on_the_impl.pdf
6. Waide, European Experience With Energy Management , 2017
7. European Commission, A Study on Energy Efficiency in Enterprises: Energy Audits and Energy Management Systems; 2016;
https://ec.europa.eu/energy/sites/ener/files/documents/EED-Art8-Implementation-Study_Task12_Report_FINAL-approved.pdf
8. REPORT FROM THE COMMISSION TO THE EUROPEAN PARLIAMENT AND THE COUNCIL;2017;
https://ec.europa.eu/info/sites/info/files/171011-ssm-review-report_en.pdf
9. JRC; Energy Consumption and Energy Efficiency Trends in the EU-28 2000-2015; 2018;
http://publications.jrc.ec.europa.eu/repository/bitstream/JRC110326/efficiency_trends_2017__final_lr.pdf
10. EVALUATION OF THE ENERGY SAVINGS OPPORTUNITY SCHEME, Impact evaluation scoping report , 2017;
https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/650881/Evaluation_of_ESOS_Im
pact_evaluation_scoping_report.pdf.
11. Energy Efficiency Trends and Policies In Industry , ODYSEE-MURE;2015; http://www.odyssee-mure.eu/publications/br/energy-
efficiency-trends-policies-industry.pdf
12. ICF, STUDY ON ENERGY EFFICIENCY AND ENERGY SAVING POTENTIAL IN INDUSTRY AND ON POSSIBLE POLICY MECHANISMS,
2015, https://ec.europa.eu/energy/sites/ener/files/documents/151201%20DG%20ENER%20Industrial%20EE%20study%20-
%20final%20report_clean_stc.pdf
13. G. Kukushkina, Indirect adiabatic cooling, 2011,
https://www.theseus.fi/bitstream/handle/10024/32531/Kukushkina_Galina.pdf?sequence=1
14. Investors Confidence Project, http://europe.eeperformance.org/
15. M. Matteini, L. Barbier, Requirements of EED Article 8 and implementation experiences and challenges from different countries,
UNIDO, 2018, http://www.economy.ge/uploads/files/2017/reitingebi/samrecvelo_energoefeqturoba/2_1_eu_eed_article_8.pdf
16. DEA, Energy Policy Toolkit on Energy Efficiency in Industries, Experiences from Denmark, 2015;
https://ens.dk/sites/ens.dk/files/Globalcooperation/ee_in_industries_toolkit.pdf
17. DTU, Best Practices and Case Studies for Industrial Energy Efficiency Improvement; 2016; http://www.unepdtu.org/-
/media/Sites/energyefficiencycentre/Publications/C2E2%20Publications/Best-Practises-for-Industrial-EE_web.ashx?la=da
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