Training Course:

INNOVATION SERVICE PROVISION

Baku, Azerbaijan October, 6th-8th 2015

Energy Efficiency in industry

PINE project

Contract number: IEE/11/885/SI2.615936 – PInE – Duration: from 17 03 2012 to 16 03 2015 – Date of creation: 4 June 2015

PInE = Promoting Industrial Energy Efficiency

Partnership: Technical partners and stakeholder representatives in 7 EU

countries (Austria, Bulgaria, Cyprus, Italy, Rumania, Slovakia and Spain)

Target group: Industrial SMEs Manufacturing sector

Objectives:

increasing energy efficiency in industrial SMEs

up-taking of cost-effective measures, technologies and smart solutions to

improve energy performances and cut down energy consumption and related

emissions.

building a self-financing network/system capable of continuing the activities

started during the project lifetime after the end of the project.

fostering investments in highly energy-efficient equipment and machinery.

PInE: project summary

Contract number: IEE/11/885/SI2.615936 – PInE – Duration: from 17 03 2012 to 16 03 2015 – Date of creation: 4 June 2015

background Only 29% of European SMEs have introduced measures for preserving

energy and resources in their enterprises (compared with 46% of large

enterprises);

European SMEs are a very significant potential market to stimulate in

order to implement energy-saving and energy efficiency measures;

The estimated potential energy savings that SMEs can obtain is 30%;

The main barriers to the improvement of energy efficiency performances in

SMEs are: lack of adequate information (i.e. legislation, subsidies, training

on energy management, energy experts), lack of appropriate incentives

and insufficient energy management capacity .

Contract number: IEE/11/885/SI2.615936 – PInE – Duration: from 17 03 2012 to 16 03 2015 – Date of creation: 4 June 2015

main steps

1. Creation of a common model and tools for auditing procedures,

including a set of benchmarks and checklists structured in such a way to

be easily replicable also in other countries;

2. Training for scouts and auditors;

3. Scouting: preliminary auditing that will lead to the selection of those

companies that will benefit from the full audits;

4. Auditing: in-depth auditing activity, including professional technical advice

that will identify short-term and low-investment measures and more

significant, longer-term measures, envisaging higher investments;

5. Development of a self-sustaining system: after the end of the project,

companies interested in achieving energy savings and increasing their

energy efficiency will share the demonstrated energy savings and the

consequent monetary savings with the auditors

Contract number: IEE/11/885/SI2.615936 – PInE – Duration: from 17 03 2012 to 16 03 2015 – Date of creation: 4 June 2015

results

280 preliminary audits carried out in the scouting phase

140 full audits in the coaching phase

During project lifetime

• € 1.614.000: investments made by

SMEs in energy efficient equipment

and other energy-saving devices

• 1.668 toe in energy savings,

equivalent to 2.224 toe in primary

energy savings and 4.949 t CO2

reduction of greenhouse gas

emissions

Within 3 years after project end

• € 10.753.000: Cumulative

investments in energy efficient

equipment and other energy-saving

devices

• 4.498 toe in energy savings,

equivalent to 6.511 toe in primary

energy savings and 13.506 t CO2

reduction of greenhouse gas

emissions

Guide on energy audits (common methodology and tools to guide auditors and scouts)

Energy Audits in SMEs

• Focus on cross cutting technologies:

• compressed air (leakages, optimized pressure level, control of

compressors), lighting (control, bulbs), electric motors (size, control),

boilers (return of condensate, pressure level, air/fuel ratio, size, control,

preheating of combustion air and/or feed water), CHP, Waste heat

recovery (from hot waste water, from hot exhaust air, preheat )

• Organizational and behavioural issues • parasitic loads (equipment running idle), process control,

organization (responsibilities, planning, procedures, set points),

Monitoring energy consumption

1

Energy Audits in SMEs

Main results of energy audits:

•Energy saving 5% to 15%

1

Energy Audits in SMEs

Main results of energy audits:

•Energy saving 5% to 15%

•Cost effective: payback 0,5 to 5 years

•SMEs accepted 60% recommended actions

Energy Audits

are a valuable activity for SMEs

1

Lack of data

• Remerkable lack of data on energy consumption

– Bills (monthly readings)

– General meters for Gas and Electricity

3

Lack of data

• lack of data on energy consumption

– Bills (monthly readings)

– General meters for Gas and Electricity

• Missing:

– Sub-meters

– Load curves

3

On site measurements

3

Linear Regression

3

An example of linear regression on monthly electricity

consumption. A company consumes electricity for the production line

and different cooling processes but does not have measures of such

consumption. Linear Regression analysis indicates a weak correlation

(R2 = 69%) between energy consumption and CDD (Cooling Degree

Days) and suggests that there are also other relevant factors

Linear Regression

3

Estimating energy consumption of key processes using multiple

linear regression analysis. Multiple Linear Regression variables: NP, number

of pieces produces, HDD, Heating Degree Days and CDD proved to be significant

predictors of energy consumption - T-test (confidence interval 5%, R2 = 78%).

Regression coefficients can then be used to estimate the distribution of the energy

consumption of the production line (NP) and cooling processes (CDD), without

detailed measurements of their actual energy consumption.

Information barriers

• information barriers

to energy efficiency

– Lack of internal

technical skills

– Scarce information

on energy efficiency

– Lack of personnel

awareness

– Lack of managerial

awareness

4

Behavioural barriers

• factors influencing decision

making:

– expectations of the decision

makers

– credibility and trust of

information sources

– risk perception,

set a high threshold for

profitability of energy

efficiency investments

5

Economic & Financial

• Economic factors are significant barriers to

energy efficiency

– limited access to capital

– expectation of excessively high profitability <1y

– limited use of available incentives

6

Control & Bahaviour

• There is a gold mine of options to save energy

at little or no investment

– “good housekeeping”

– Improve use of existing control systems

– Improve behaviour of production line operators

• setting rules,

• defining appropriate metrics

• establishing new habits

7

Methodology

• An appropriate method for energy auditing

is key to success

– Reduce cost of auditing

– post-audit support (6 months – 1 year)

– Measurements to verify energy saving

– Energy Management system ISO 50001

8

Conclusions

• This study provided a survey of key factors

influencing an energy auditing procedure, leading

the adoption of energy-efficiency measures

• Energy policy makers can use such information

to define specific measures to promote energy

efficiency

• Energy auditors can follow the above mentioned

hints to design more successful energy audit

campaigns for SMEs.

8

Energy audit as a service

• Energy Audits are a valuable activity for SMEs

yet not a viable option for consultancy on a

commercial basis

• SMEs underestimate the value of energy audit

– Need to invest resources (cost, time, management)

– willing to pay less than 1700€ for energy auditing

• Need for support or obligation

– Energy auditing

– Implementing energy management schemes

2

Fabio Morea +39 040 375 5288 fabio.morea@areasciencepark.it www.innovereast.eu info@innovereast.eu