Pilot Projects on Energy Modernisation in Industry

1. The Poltava Machine-Building
Plant, PJSC specialises on the
manufacturing of machinery and
equipment for a variety of indus-
tries, first of all, for meat pro-
cessing, energy, oil and gas and
railroad industries. The resource
and technical base of the plant
provides for fully integrated
production of technological ma-
chinery, spares and components
for a variety of applications. The
plant currently batch-produces
more than 314 items of machin-
ery and spare parts for it. Follow-
ing modern trends, the plant has
recently amended its product line
with solid fuel boilers made using
own-made components.
For its manufacturing pro-
cesses the plant us-es electric-
ity, natural gas and biomass to
replace some of the natural gas
consumed during the heating
season.
About the Company
heat-power and other equipment.
Despite complex challenges, the
plant managed to increase its
production capacity and become
one of Ukraine’s lead agricultural
machinery manufacturers as well
as produce equipment for other
industries. Its products are well-
known both in Ukraine and abroad.
The use of modern high-
end equipment enabled the
company the chance to optimise
technological cycles, considerably
improve quality and reliability of
its products and expand its output
capacities.
Nowadays the plant is ac-
tively developing; it improves its
management, information and
marketing operations, designs new
products, implements innovative
methods of improving quality of its
products and increases energy effi-
ciency of manufacturing processes.
The enterprise was established
in 1951; it has been designing
and manufacturing technological
equipment for the agroindustri-
al sector for more than 40 years.
After 1991, struggling through
economic crisis due to energy
carrier and metal price hikes, the
plant began to gradually expand
its product range. In 2005, the
enterprise went beyond meat
processing machinery to produce
Path to Success
Establishment date
Location
Industry
No. shops
No. working shifts
Working shift duration
Staff
Output
1951
Poltava
Machine-building
4
2
8
206
40 116
hours
tons/year
Electricity
Natural gas
Biomass
Total emissions
1 819,90
21 234
183,4
1 989
1 830,43
19 098
164,5
1 964
MWh/year
m3
t
tCO2eq
/year
2018 2019
Indicators
Review
Pilot Projects
on Energy Modernisation
in Industry
Poltava Machine-Building
Plant, PJSC
МІНІСТЕРСТВО ЕКОНОМІКИ УКРАЇНИ
CO
M
PA
N
Y

2. Withinayeartheenterpriseimplemented
four energy efficiency measures from
the list of recommended ones. Three
of them concerned modernisation of
the existing systems and installation
of additional equipment; one of the
measures was aimed at improving
properties of the biomass used as the
fuel for thermal energy generation.
Energy Efficiency
Measures
Participation in the Advisory
Services for Energy Efficiency in
Companies Project implemented in
Ukraine by Deutsche Gesellschaft
fürInternationaleZusammenarbeit
(GIZ) GmbH commissioned by the
German Government in political
partnership with the Ministry of
Economy of Ukraine has provided
a range of measures recommend-
ed for implementation to improve
efficiency of energy consumption,
reduce enterprise expenditures
and СО2
emissions. Given the en-
ergy-intensive production and
ambitious development plans, the
mentioned targets have become of
extreme importance for the plant.
the enterprise with new possibili-
ties of energy modernisation.
In autumn of 2018 the team
comprising national and interna-
tional certified energy auditors
held energy efficiency audit of
the enterprise according to the
standard ISO 50002, type 2. The
audit resulted in the designing of
Therefore, the implementation of
the measures begun already at the
end of 2018. During their imple-
mentation, training was conducted
for plant employees on specialised
topics, which also contributed to
the achievement of successful
results.
Decentralisation of
Compressed Air System
Photo:
The enterprise has a compressed
air system that due to long length
of pipes is inefficient. To decen-
tralise it, a separate compressor
was installed at the turbine blade
shop (power: 30 kW; output: 5.2 l/
min). To fully furnish the sys-tem,
a compressed air dryer and pip-
ing were bought besides the com-
pressor. A compressed air receiver
was made with the plant’s own
resources; the piping system was
also installed by the working staff.
A specialised installation organ-
isation was contracted to install
the compressor unit, connect it to
the system and carry out commis-
sioning works.
The decentralisation allowed re-
ducing the load onto the exist-
ing compressed air system and
transportation costs as well as a
possibility of using the compressor
only when technologically neces-
sary. It has also become possible
to achieve nearly twofold reduc-
tion of electricity consumption
by the system and save around
UAH 505 thousand a year. The
enterprise optimised its measure
implementation costs by using its
own resources to produce certain
equipment and perform individual
works. The total energy consump-
tion of the system was reduced
by 45%.
Duration of procurement procedure
Duration of implementation
Implementation period
Implementation costs
Energy consumption
before implementation
after implementation
Energy savings
Savings from implementation
Simple payback period
Emission reduction
2 months
2 months
08.2019
710 000
444 400
242 400
202 000
505 000
1 year 4 months
184
UAH
MWh/year
MWh/year
MWh/year
UAH/year
tCO2eq
/year
Indicators
Decentralisation of Compressed Air System

3. Installation of Reactive Power Compensators
During the energy audit a low
value of the power factor, cosα,
at low-level machinery load with-
in one month was identified. It
proves that the plan is consum-
ing more than it needs to oper-
ate. In order to bring the factor to
its characteristic value, reactive
power compensating devices are
generally installed.
In this case, the enterprise
installed at its transformer sub-
stations TP-2 and TP-5 capacitor
banks with 200 kVar capacitance.
cosα value before the installation
of compensators was at 0.74; af-
ter the measure implementation
it was brought to the statutory
value of 0.95. This means the
efficiency of capacity utilisation
has increased. The reactive pow-
er compensators installed reduce
electricity bills of the enterprise
by UAH 144 thousand a year. The
payback period for the measure
was 6 months.
Duration of implementation
Implementation period
Implementation costs
Energy consumption
before implementation
after implementation
Energy savings
Savings from implementation
Simple payback period
Emission reduction
13 months
12.2018 – 2019
75 000
1 830,43
1 772,83
57,60
144 000
6 months
53
UAH
MWh/year
MWh/year
MWh/year
грн/рік
tCO2eq
/year
Indicators
Thermal Insulation of Heating Pipes
Up to 30% heat energy in the en-
terprise heating system is lost due
to uninsulated pipes. The total
uninsulated surface area stands
at 127.5 m2
. As a rule, the plant’s
premises are heated 120 days a
year.
To assess the viability of pipe
thermal insulation measures, the
plant launched a pilot project to
insulate a small pipe surface area
of 12.5 m2
with insulation material
5 cm thick with thermal conduc-
tivity of 0.041 W/(m·К). To save on
costs, the works were carried out
by enterprise’s own efforts.
The project implementation
showed simple thermal insulation
measures do reduce heat losses.
Minimal investments (UAH 1.2
thousand) allowed saving 2.6 %
heat energy and paid back in 2
months. Thermal insulation of all
uninsulated sections of the heat
supply system will save the plant
20% its heat losses.
Implementation period
Implementation costs
Energy consumption
before implementation
after implementation
Energy savings
Savings from implementation
Simple payback period
Emission reduction
2019
1 200
499,29
486,53
12,77
2 920
2 months
5,2
UAH
MWh/year
MWh/year
MWh/year
UAH/year
tCO2eq
/year
Indicators
Theenterpriseusesbiomass(chaff)
as an alternative fuel during the
heating season. The fuel used to be
stored in the open. Such conditions
affected fuel characteristics of the
biomass by increasing its moisture
content. Relative moisture identi-
fied during the survey was at 26.4%
equivalenttofuel’scalorificvalueof
2,651 Kcal/kg.
To reduce fuel moisture and
consequently increase its calorific
value at combustion, its storage
in an empty shop behind the boil-
er plant was arranged with due
regard to all statutory fire safety
regulations as well as in-house
requirements applying to all plant
divisions. This allowed reducing
fuel moisture from 26.4% to 10%
and increase its calorific value to
2,920 Kcal/kg.
The improvements to fuel
quality led to 10% reduction of
its quantity needed for heating
and higher heating temperatures
inside plant premises. This rather
simple and zero-cost measure has
been saving the enterprise more
than UAH 86 thousand during the
heating season.
Duration of implementation
Implementation period
Implementation costs
Energy consumption
before implementation
after implementation
Energy savings
Savings from implementation
Simple payback period
Emission reduction
2 months
08–09.2019
n/a
499,29
449,37
49,92
86 075
n/a
20,2
Implementation of Biomass Drying Process
UAH
MWh/year
MWh/year
MWh/year
UAH/year
tCO2 eq
/year
Indicators

4. Regular upgrades of personnel
knowledge of efficient use of
resources at the enterprise is
among the range of measures
aimed at improving energy effi-
ciency of the whole production
cycle.
Within the framework of
the Advisory Services for Energy
Efficiency in Companies Project
the plant employees underwent
trainings on a range of relevant
topics: Lighting Systems and
Heating Systems. Now they can
successfully put the received
knowledge to good use thus
contributing to energy efficient
operation of the enterprise.
Staff Training
In the nearest future the en-
terprise plans to go on with
measures capitalising on the
obtained positive experience.
This will include, first of all,
finalisation of thermal insu-
lation of uninsulated heating
pipes with 115 m2
area to po-
tentially reduce heat supply
losses by 18%. After success-
ful installation of static bat-
tery stacks at two transform-
er substations, the enterprise
will install reactive power
compensators at TP-4 sub-
station to efficiently use the
capacity and achieve better
electricity savings.
Company’s Plans for the Future
© GIZ 2021
Pilot Projects on Energy Modernisation
in Industry
01004, Кyiv
16b Antonovycha St.
T: +38 044 594 07 60
F: +38 044 594 07 61
I: www.giz.de/ukraine-ua
www.eeplatform.org.ua
Fb: www.facebook.com/energyefficiency.ua
Total energy savings
Total reduction of emissions
Total cost savings
Investments
322,30
262,1
737 999
786 200
MWh/year
tCO2eq
/year
UAH/year
UAH
Total
energy savings
Indicators
12%
The modernisation of the existing compressed air and heat supply
systems increased their performance. Proper logistics and biomass
storage coordination provided conditions for an alternative fuel of
better quality.
As a result of measure implementation, the enterprise cut on its
energy consumption by 12% and considerably reduced its costs.
The total savings amounted to around UAH 738 thousand/year.
Emission reduction in СО2eq
made 262 tons.
Anothernonethelessimportantoutcomehasbeenthenewknowledge
acquired by the staff owing to energy efficiency trainings held with
due account of plant operation specifics. The combining of the range
of measures with staff training enables the enterprise to stick to its
energy-saving strategy, which on the whole positively affects the
energy intensity of the production cycle.
The implementation of energy efficiency measures brought a range of
benefits for the enterprise:
Cumulative Results
•
•
•
•
«In pursuit of brisk development, our plant not
only improves management and marketing,
develops new products, introduces advanced
methods of improving product quality, but also
constantly increases the energy efficiency of
production processes»
Viktor Kolomiiets
Director
Thermal Insulation of Heating Pipes
Photo: