Energy audit Energy audit presentation

ENERGY AUDITING
tool to increase
ENERGY EFFICIENCY
Ing. Bronislava Herdová, PhD.
energy auditor
En-efekt, s.r.o., Ambrova 35, 831 01 Bratislava, e-mail: herdova@ecb.sk, Tel.: 0904 220 713

Why energy efficiency?
Overal EU policy objective:
20% GHG emissions – 20% RES – 20% Energy savings (until 2020)
Directive No. 2006/32/ES on on energy end-use efficiency and energy services
New Directive 2012/27/EU of the European Parliament and of the Council of 25
October 2012 on energy efficiency
Tools to increase EE? => energy auditing, energy services

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 need
and consumption going out of valid technical standards,
 analysis of problems (weaknesses and deficiencies),
 EA identifies and in detail quantifies effective possibilities of energy savings tailored
to the object being analyzed,
 „field-work“, economy tool having dynamic character, often basis for grant financing
of projects.

WHAT IS THE AIM OF EA?
 to minimize costs for energy
 to minimize operational costs
 to minimize costs for repairs and reconstruction
 increase quality of environment that contributes to increased work productivity
In case of EA as duty (Industrial consumers with annual energy consumption over 5,5
GWh/year) the procedure of EA as well as content of the report is determined by
Regulation No. 429/2009.
In case of voluntary EA is the content and focus as well as target given by customers
requirement.

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

Step 1: Identification – EA subject
a) Collection of main data about the customer and basic description:
Name of company: OSPRA Invest, Ltd.
Legal status: Ltd
Address: Rovinka, BA (Istrochem)
Responsible person:
Contact:
Sector: Chemical industry
Subject of EA: -buildings (administrative and
production hall) and their
technical equipment
-production technology

Step 1: Identification – EA subject
Identification of activities
Type 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 production
Production 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 0,37
Administrative building and Dressing
1 179,36 0,77
rooms
Container housing units 164,16 1,55
Security building 246,9 1,13

1 STEP: Identification of subject of EA – site plan
b) Description of main activities of EA
c) Site plan
d) List of all buildings and theirs use, description of all
energy consumers
Vstup do areálu
1
2
4
3
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

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 Amount
caloric
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 inputs
Priemerné mes. spotreby a ceny elektrickej energie po mesiacoch za roky 2009-2010 v areále Rovinka
90 000
80 000
70 000
60 000
50 000
90 000
80 000
70 000
60 000
50 000
700 000
650 000
600 000
550 000
500 000
450 000
400 000
350 000
300 000
január
február
marec
apríl
máj
jún
júl
august
september
október
november
december
kWh
40 000
€
spotreba cena
Priemerné mes. spotreby a ceny el. energie po mesiacoch za roky 2008-2010 v areále Istrochem
700 000
650 000
600 000
550 000
500 000
450 000
400 000
350 000
300 000
január
február
marec
apríl
máj
jún
júl
august
september
október
november
december
kWh
40 000
€
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 and
thickness
- check if consumption of electricity for heating/hot water is measured,
- make on site measurement of internal temperature 22oC,
- how is the measurement and regulation (equithermic, hydraulic regulation,
thermostatic valves...)
- check all relevant documentation – project documentation, revisions, and etc.

- 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
Number
Output
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
Počet
Príkon
kW
DHW el. heater 150l 5 2
DHW el. heater 200l Tatramat 1 2,2
DHW 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 30
Parameters of chiller: Qvzd. = 30 000 m3/hod. x 2
= 60 000 m3/hod.
El. input power: 3,0 x 2= 6,0 kW, 3 x 380V, 50Hz.
Coolling output (tout 30 °C and relative humidity 45%): Qch = 100 kW.
Assumed average water consumption: 0,16 m3/hod / pH 5-7 /
Regulation: according to indoor temperature
Measurement: no separate measurement

- 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 x
36W) with conventional ballast, in some technical places are conventional
incandescent lamps 60W
- Production hall – ceilling lamps with IP65, hang down in high of 4,5 m,
linear fluorescent lighting sources type T8 with input power 3x36W,
conventional ballast.......
number
Num
ber of
functi
onal
Power
input
(W)
Pinšt(W) Preal (W)
t
(h/year
)
W
(kWh/year)
W
(kWh/rok)
Main object
Administrative
spaces 14 14 86 1 204 1 204 1 560 1 878,24 1 878,24
Toilet 3 3 60 180 180 520 93,60 93,60
Wellding hall 176 176 139 24 464 24 464 8 640 211 368,96 211 368,96
Toilet 4 4 60 240 240 1 620 388,80 388,80
Office 2 2 86 172 172 8 640 1 486,08 1 486,08
Hall B 134 134 139 18 626 18 626 8 640 160 928,64 160 928,64
Hall B 135 135 139 18 765 18 765 8 640 162 129,60 162 129,60

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 Name
Input power
kW
Output
kW
Number
-
Voltage
V
Year 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 - production
Compressed air – OSPRA Invest (Rovinka) – pneumatic driver
Is the most expensive energy carrier!!!!!
- 3 compressed air production stations – delivery to 2 central
compressed air distribution networks
- Type of compressors – screw compressors
- mater/slave – switch every 24 hours, regulation – according to
pressure in the network 7/8,5 atm.
- no continuous control of compressors (by inverter)
- no regular measurement of pressure decrease in the distribution
network
- no heat recovery
kW bar m3/min ks
Hall A power input Pe
power
output
number
Year 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

Cooling – technology purposes – OSPRA INVEST (Rovinka)
Device Number
Output
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 22
74
(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.

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
Administrative appliances
Input
power
Number
Name kW -
PC 0,3 9
Printer 0,2 3
electric kettle 2 1
Copy maschines 0,5 2
Mikrovawe owen 1,2 1
Fax maschine 0,1 1

STEP 2: analysis and evaluation of current state
OSPRA INVEST - compiling basic energy balance (Rovinka+BA)
Row Indicator MWh/r tisíc eur/r
1 Input of fuels and energy 12 459 1 435 139
2 Change in stocks of fuel - -
3 Consumption of fuels and energy 11 999 1 381 836
4 Sale of energy to other customer 460 53 302
5 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 4 250
Petrol 70 9 300
Propane 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
needs devide into other types of fuels and
energy
Electricity
Heating 366 42 349
Electricity
DHW 34 3 934
Others
- -
8 Energy consumption for technology
purposes and other processes
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 state
OSPRA INVEST – analysis of electricity consumption
Analysis and evaluation of supply tarrifs
3 delivery points with reserved and max. reserved capacity (Rovinka)
Rok 2009 2010
Number 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
Month
1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max. 1/4h max.
kW kW kW kW kW kW
January 226 351 593 227 376 631
February 231 359 603 219 371 619
March 230 348 609 225 354 588
April 223 277 571 229 294 574
May 219 267 565 206 282 589
June 225 266 572 234 273 592
July 225 249 558 219 260 559
August 217 268 568 207 273 564
September 207 263 574 201 308 510
October 218 321 591 241 313 418
November 204 319 579 226 321 581
December 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 of
reserved cap. to 660 kW event.
max. res. cap. to 700 kW
- Electric distribution network and
main electric devices are according
to measurements and revisions in
good technical state
- el. distribution lines are currently
over dimensioned – reason: reserve
for connection of new devices/
retain variability for shifting of
existing technology devices

OSPRA INVEST – analysis of electricity consumption – production technology (Rovinka)
- Assessment of energy consumption going out from
operational 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 – larger
investments – up to 50% of savings per device
Total installed power input and el.
Suma Hala
A
14%
Suma Hala
B + Bialloni
56%
Zvarovňa
10%
Stl. vzduch
3%
Regranulač
ná linka
13%
Chladenie
4%
Zvarovňa
4%
Stl. vzduch
1%
Hall A – input power and assumed consumption.
Hall B – input power and assumed consumption.
B8
23%
B2
2% B4
Suma Hala
A
17%
Suma Hala
B + Bialloni
67%
Chladenie
2%
Regranulač
ná linka
9%
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%
B5
14%
B6
27%
B7
27%
B3
2%
2%
Bialloni
3%
B5
24%
B6
50%
B7
10%
B8
9%
B3
1%
B2
Bialloni 2%
2%
B4
2%

STEP 2: analysis and evaluation of current state
OSPRA INVEST – analysis of electricity consumption – production technology
Measurement and regulation - Production technology:
- Full automatic regime of most of the devices
- Way of operation is putted manually by employees
- Measurement is not provided for large consumers!
- Operation is given by order and type of foils ordered – in case of
Rovinka is not evaluated specific energy consumption of electricity
given by amount of produced foils (too many different processes –
individual processes are not monitored)
- In operation in BA – specific energy consumption has been
evaluated
Compressed air and cooling:
- Consumption of el. for compressed air and cooling presents from
total electricity for production only 3%
- Evaluated as effective – new investments already planned
- No measurement, only regulation – T/p
- No use of heat recovery

OSPRA INVEST – heating and hot water
Evaluation of thermal-technical properties of
heated buildings (no measurement):
- Calculation of heat need for heated buildings
(720540-2)
- Estimation of heat gains
- Estimation of consumption of electricity for
4 000 000
3 900 000
3 800 000
3 700 000
3 600 000
3 500 000
3 400 000
3 300 000
3 200 000
3 100 000
heating
- Technical state – satisfactory, regulation
according internal temperature
- Hot water – only teoretical calculation (no
measurement) – going out of normative
calculation
BUDOVA
Internal
temperatur
e
Heat need for
heating
Thermal
gains from
technology
Consumptio
n of
electricty for
heating
°C kWh/rok kWh/rok kWh/rok
Production hall A,B 22 908 360 630 465 277 895
Administrative
building and dressing
20 52 320 - 52 848
rooms
Container buildings 20 18 173 - 18 356
Security building 20 16 464 - 16 630
Total 995 317 630 465 365 729
Výpočtová potreba tepla na vykurovanie
Výrobná ha l a
A,B; 908 360
kWh/r; 91%
Vrá tni ca ;
16 464 kWh/r;
2%
Budova
a dmi ni s tra tívy
a š a tne;
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
apr - sept okt - mar apr - sept okt - mar
leto 2009 zima 2009 - 2010 leto 2010 zima 2010 - 2011
kWh
334 272
397 185

OSPRA INVEST – indoor lighting
Calculation of consumption (no measurement) – Rovinka:
- Calculation of electricity consumption going out of input power, operation hours and
efficiency of lighting sources and type of ballast – 638,32 MWh/year
- Lighting is under-dimensioned on places with permanent stay of persons
- No regulation of lighting system that would switch or dim according to need –
currently manual
- Partly obsolete lighting – low efficiency of optical system, missing covers of lamps,
used linear fluorescent lamps with low specific output with classical ballast (20%
consumption of power input of lighting source)
- In part of production hall was made reconstruction with appropriate lamps, but some
of new lamps have classical ballast...

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 were
was measured temperature higher by 2,2°C in comparison to normative requirements!
- Lower the reserved capacity to 660 kW eventually max. reserved capacity to 700 kW
in case of el. delivery point 3108116420

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 costs
Total in EUR EUR 36 500
Energy consumption per unit:
Average el. price EUR/kWh 0,11
Energy savings:
Achievable electricity savings MWh/year 150
Cost savings (electricity) EUR/year 16 474
Simple payback period year 2,2

Investment measures – production technology, i.e.:
- Replacement of main driver of the production line B6 with total input power 337 kW.
The main driver input power is 160 kW, replacement with new el. motor with
frequency speed control.
Investment costs
Energy savings:

Investment measures – buildings – thermal protection of buildings, i.e.:
- Building for administrative purposes with dressing rooms – thermal insulation,
replacement of windows, instalation of thermotat with timers on heating bodies
Measure
Investment costs
Thermal insulation EUR 8 496
Roof – thermal insulation EUR 3 297
Replacement of windows EUR 4 665
Installation of thermotats with timers EUR 291
Total costs in EUR EUR 16 749
Unit price of energy:
Average price of electricity/heat EUR/kWh 0,11
Energy savings:
Achievable electricity savings MWh/rok 25,82
Cost savings (electricity) EUR/rok 2 840
Simple payback period rok 7,5

Investment measures – buildings – indoor lighting, i.e.:
- Replacement of existing lamps with lamps with IP65, high efficient optical system –
reflector, linear fluorescent lamps type Master TL5 HE ECO 45W and electronic
ballast.
Investment costs
Energy savings:

3. STEP: Proposal of at least 2 variants of EE measures
OSPRA Invest - Rovinka i.e. - proposal of 2 variants
Measure
Energy
savings
Costs savings
(energy)
Investment
Simple
payback
MWh/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
extruder B5 (Rovinka)
150 16 474 36 500 2,2
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
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 2,1
Total 947 104 213 371 529 3,9

3. STEP: Proposal of at least 2 variants of EE measures
OSPRA Invest - Rovinka i.e. – energy balance after realization for each variant
R. Indicator
Before After
GJ/year
thousand
EUR/year
GJ/year EUR/year
1 Inputs – fuels and energy 12 459 1 435 138 11 512 1 330 925
2 Changed state of resources - - - -
3 Consumption of fuels and energy 11 999 1 381 836 11 052 1 277 623
4 Sale of energy to external consumer 460 53 302 460 53 302
5 Final consumption of fuels and energy 11 999 1 381 836 11 052 1 277 623
6 Losses in el. distribution network 12 1 389 12 1 389
7
Losses in production and distribution of heat
from NG - - - -
8
Consumption 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 period
IN = investment
CF – cash-flow
- Real payback period by considering discount rate TSD
CFt = annual savings (changes of cash flow after realisation of measures)
r – dsicount factor
(1 + r)-t – odúročiteľ
- Net present value
CFt - Cash - Flow of the project in year t
r - discount
t – evaluated timeframe (1 to n years)
Tž – lifetime of equipment
- Internal Rate of Return

5. STEP: Environmental evaluation
Emisssions
Electricity
kg/MWh
Solid particles 0,28
SO2 1,87
NOx 2,88
CO 2,33
CO2 1084

5. STEP: Selection of variant
- Economy evaluation
Indicator Value Unit
Total costs 371 529 EUR
Change of costs for energy (– decrease/+ increase) -104 213 EUR
Change of personal costs, i.e. slaries, insurance, ... (–/+) 0 0
Changes of other operational costs, i.e repairs and maintenance,
0 0
services,insurance of property, ... (–/+)
Change of other individually given costs, i.e emissions, waste and others (–
/+)
0 0
Change of sales, i.e. of heat, electricity, used wastes, ... (–/+) 0 0
Benefits from realisation total -104 213 EUR
Timeframe of evaluation 20 year
Discount factor 5 %
Simple payback (Ts) 3,9 year
Real payback (Tsd) 6,1 year
Net present value (NPV) 756 666 EUR
Internal rate of return (IRR) 23,63 %

5. STEP: Selection of variant
- Environmental evaluation
Emissions
Before
t/year
after
t/year
Difference
t/year
Variant 2
Solid partcles 3,3 3,0 0,3
SO2 6,1 5,6 0,5
NOx 33,7 30,9 2,7
CO 27,2 25,0 2,2
CO2 12 668,7 11 641,7 1 027,0
Selection criterias:
- Economy and environmental benefits
- Technical – lifetime of variants
- Operational – costs/changes of costs on maintenance and operation
- Legislative – if variants can bring from legislative pouint of view any complications

Thank you for your
attention!

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