The investigation has shown that several million euros in mineral oil tax can be saved annually through measures for heat extraction in test bench operation alone. In addition, heat and electricity procurement costs can also be reduced to a considerable extent. In contrast, the investments for heat extraction are relatively low.
Final consumers with high electricity consumption are entitled to an individual grid charge if their electricity consumption reaches a number of hours of use of at least 7,000 h/a per calendar year. For this reason, eta Energieberatung has developed and implemented a concept for load management with two emergency power supply systems.
Based on the measurements carried out, a detailed representation of the energy flows in the electroplating shop was created. For several plants a power adjustment with frequency converters was proposed. Unused tax advantages for the natural gas used in the TNV were shown.
The company Borgers has been supported by eta Energieberatung for many years. The main focus of the consulting services was the establishment and maintenance of an energy management system according to ISO 50001, among other things a catalogue of efficiency measures was compiled, which shows annual CO2 savings of approx. 3,200 t resp. cost savings of 8 %.
In the investigation of the energy purchase conditions carried out, it was found that the ordered load for district heating was clearly too high. By reducing the ordered heating power, the costs for district heating could be reduced by about 15 %.
The study identified interesting approaches to reduce energy costs. For example, it was recommended that sterilisation be switched to external steam supply. The use of a CHP is economical. This also allows the grid replacement power capacities to be expanded.
Through eta Energieberatung, approaches to reducing energy consumption were shown in all production areas with relevant energy consumption. The possible economic savings totalled more than 1 million euros and most of them had payback periods of well under three years.
The analysis of the existing cogeneration plant showed that the operation of the natural gas cogeneration plant is still economical. The use of biomethane would make ecological sense, but is currently not economical. The production of cold from the absorber is only recommended if the heat comes from the CHP. In addition, an electricity/natural gas tender was carried out.
By implementing an innovative steam generation system using CHP, consisting of a conventional steam boiler with micro gas turbine and gas turbine exhaust gas burner, renewal of the steam distribution system with a pure steam generator and a new ventilation system to supply highly hygienic areas, CO2 emissions were reduced by almost 20 %.