The three level guidance of energy audit

activity

Official Guidelines for energy audits

Ministry of Trade and Industry

Audit models,
Guidelines for reporting and implementing
audits for different sectors
Motiva Oy

Energy Auditor’s Handbook

Motiva Oy

26.10.2004
 Starting of energy audits

• The company’s special needs, targets

• The content, meaning and instructions of energy
auditing procedure supported by the ministry
• Voluntary energy conservation agreements
• Links of energy auditing to environmental, quality
and other functional systems or procedures of
the company
• Resources for auditing (own work or outsourcing)
• Bidding
• Evaluation of the tenders
• Decision of energy auditing

Filling the forms for subsidies ,

Decision of the support
Start

26.10.2004
 The same targets in every
audit model
• Comprehensive study
• Heating/electricity/fuels/renewables/water costs
and energy consumption

• Results:
• Break down of consumption
• Better understanding about energy costs, energy
consumption etc.
• Proposals for saving measures
 Justification
 Economy (savings, investments…
 Other effects and impacts

26.10.2004
 Energy consumption break down Sankey diagram

Nitrogen factory Lighting Com pressed air Air cooling Ventilation Other

260 [kW] 190 [kW] 80 [kW ] 220 [kW] 65 [kW ] 200 [kW]

Electricity
3165 [kW]

530 [kW] 50 [kW ] 220 [kW]

Heat recovery

2600 [kW]
30 [kW ]

6900 [kW] Heat recovery boiler

Direct process removals

4000 [kW]
Raw m aterial
preprocessing 1400 [kW]

520 [kW]

Oxy gen burner

550 [kW] 1630 [kW] Lehr

Float bath
1320 [kW]
1110 [kW]

W ater cooling
Melting 3600 [kW]
1300 [kW]
1380 [kW]

Natural gas 17730 [kW ]

1220 [kW]

10620 [kW ] Room

26.10.2004
 MOTIVA Energy Audit Report

Table 1. Summary of the energy consumption and energy saving potential

Energy consumptionSaving potential Total investments

Fuels, heat
160 000
MWh/a MWh/a %
ECU/a ECU/a % ECU 140 000

120 000
Electricity

Savings [ECU/a]
100 000 Fuels
MWh/a MWh/a %
ECU/a ECU/a % ECU 80 000 Electricity
Water
60 000
Water
40 000
m³/a m³/a %
ECU/a ECU/a % ECU 20 000

0
Total consumption Total savings Total investments 0 0-1 1- 2- 3- 5-
2 3 5 10
ECU/a ECU/a % ECU
Pay back time [a]

26.10.2004
 TAULUKKO 2
YHTEENVETO ENERGIANSÄÄSTÖTOIMENPITEISTÄ

Paataulun CO2-versio 1.0 16.5.2003

TO IMENPITEEN SÄÄSTÖ TMA INVES- CO 2 SÄÄSTÖ SÄÄSTÖ SÄÄSTÖ

KUVAUS YHTEENSÄ TO INTI VÄHENEMÄ LÄMPÖ SÄHKÖ VESI
YHTEENSÄ energia CO 2 kustannukset energia CO 2 kustannukset vesi kustan-
energia muut energia muut nukset
no EUR/a a EUR t MWh/a t EUR/a EUR/a MWh/a t EUR/a EUR/a m 3 /a EUR/a
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
YHTEENSÄ 0 0 0 0 0 0 0 0 0 0 0 0 0

26.10.2004
 Energy Analyses in Industry
Report Model (MOTIVA)
7. Saving
measures
6. Process and economy A
5. Process p
services p.
4. Building

3. Consum
ption, TABLE 2
2. Basic info
costs Savings
€
Invest.
€
Pay back
period
TABLE 1
Saving
Cons. Saving Invest. measur. 1
Kauppa- ja teollisuusministeriön
1. Summary now pot. Saving
- text
tukema energiakatselmushanke
DNro: 333/954/93
Päätöksen pvm 30.12.1993
measur. 2
Electr.
JP-TALOTEKNIIKKA :
ENERGY ANALYSES REPORT
- tables 1,2 Fuels : recycling material from clients

Company Ltd Total

recycling material fromclients - econ.prof. Water
stock
compressed
chruched aggregate

electr. air Ven ti lat ion hot air Ot h er

- Sankey
Ni tro gen fact ory Co mp ress ed air Ai r co oli ng

Total N2
L igh tin g
stock
chruched aggregate
electr. water natural gas a-powder
compressed cooling N water
2 60 [kW ] 1 90 [kW ] 8 0 [k W] 2 20 [kW ] 6 5 [k W] H2 2 2 00 [kW ] electr.
electr. water electr. air N2 hot air natural gas warter electr. electr. electr.
N a-powder
cooling
warter
H2 2
electr.
water
electr. electr.
electr. E lect ricit y natural gas O2 electr. SO2 compr. air
natural gas O2 electr. SO2 compr. air 3 16 5 [k W]
natural gas natural gas 2 20 [kW ]
5 30 [kW ] 5 0 [k W]
Prehandling Delivering
Prehandling He at recov ery
Delivering

diagram
Tin- Washing Cutting
of raw Smelt Cooling + stock Tin- 2 60 0 [k W]
Cooling Washing Cutting
material ing bath and and 3 0 [k W]
of raw Smelt + stock
hot
combustion compr.air
checking bundling
6 90 0 [k W] He at recov ery bo iler
ing bath and and
lime sand
air
gas compr.air
cooling. cooling
cooling
air compr. air
drying air heat
Savings Raw m ateri al
p repro cess ing
material
4 00 0 [k W] hot
combustion
Di rect pro cess rem ov als

compr.air
1 40 0 [k W]
checking bundling
air water air
€
Na2SO4 air Regen.
copr. air electr. gas compr.air

- process
soda
lime cooling
5 20 [kW ]

sand cooling. cooling drying air heat

heating water waste heat Ox yg en b urn er air compr. air
boiler Continued
air Regen. air water
handling 5 50 [kW ] Na2SO4
Flo at bat h
1 63 0 [k W] L ehr

combustion gas 1 32 0 [k W] soda 1 11 0 [k W]

copr. air electr.

block diagr.
W ate r coo lin g

Helsinki 0 1 2 3-4 5-
M elt in g 3 60 0 [k W]
heating water waste heat 1 30 0 [k W]
1 38 0 [k W]
Continued
boiler
5.9.1999 Na tu ral ga s 1 77 30 [kW ]

1 22 0 [k W]
handling
combustion gas
1 06 20 [kW ] Ro om

Company Oy

Jaakko Pöyry Group

PL 27, 00131 HELSINKI

Puh. 09 - 46911
Fax. 09 - 4691 311

26.10.2004
 Energy audits in industry
Energy audit
• process service systems
• facilities

Energy analysis
• processes
• process sevice systems
• facilities

Energy audits in process industry

will be carried out in two phases
26.10.2004
 •Energy•-•analyses for process industry
•Phase 1: Factory audit
•Audit, phase 1 •Survey phase = Factory audit carried out by a team
•of professionals

•Report of the factory audit (Preliminary Plan for Energy Saving)

•Audit •••energy breakdown, saving potential
•Audit•report
•report •••saving proposals
•••needs for Complementing Analyses, rough saving potential and profitability, preliminary project plans

•Phase 2. Complementing analyses

•••saving meas. . •CA

•••training •Complementing analyses
•••... •CA •••More detailed •studyof
•report
•report •saving potential found in
•CA •factory audit
•report
•report
•report
•report •Report •Strategic
•••measures •planning
•••saving potential •of the unit
•••investments •••Strateg•. invest.
•Budjeting •••pay back period

•Scheduling

•Annual Reports to
•the Finnish
•PES •Plans for energy saving •(requirements of Agreement of Energy Saving)
•Industrial •••potential / targets
•organisations •••shedules•and costs

26.10.2004
 Energy efficiency in process services
Example: Load and energy efficiency analyses of compressed
air systems
95
120
90
100
85
Electric load [kW]

80

Electric load [kW]

80
60
75

70 40

65 Week end 20
60
0
time
1 11 21 31 41 51 61 71 81 91 101111121131141151161171181191201
time [s]
Electric load change (15 min average) during a week Idling and working load

• need of compressed air and possibilities to replacements

• pressure level, condition of the network
• production costs, efficiency of use
• energy efficiency of production of compressed air,
possibilities to improve the efficiency
• heat recovery etc.
26.10.2004
 Total consumptions, energy costs, saving
potentials and investments of 20 energy audits
in the industry sector with total energy
consumption of 70-500 GWh/a during the
period 1992-2002

Present consumption INDUSTRY, Energy consumption 70 - 500 GWh/a

20 Savings potential 1992-2002
Heat
2 453 499 MWh/a 323 356 MWh/a 13,2 %
27 314 818 €/a 4 932 586 €/a 18,1 %
Electricity
709 220 MWh/a 26 990 MWh/a 3,8 %
25 064 750 €/a 1 334 138 €/a 5,3 %
Water
8 829 155 m3/a 1 355 338 m3/a 15,4 %
3 534 098 €/a 573 183 €/a 16,2 %
Total consumptions Total savings Investments

55 913 667 €/a 6 839 907 €/a 12,2 % 11 329 766 €

26.10.2004
 Energy savings potential
found in energy audits (in
industry in Finland)
• Fuels 10-15 %
• Electricity 4-8 % (even lower in process industry)
• Water 10-15 %

• Average pay-back time for investments 2-3 years

• About one third of the savings potential can be
realised without major investments (operational
measures)
• Two thirds of the savings potential will be realised
during next 3-5 years period after the audit
26.10.2004