Compressor room efficiency with the replacement of 3 units with fixed-speed with a single machine with variable revolutions of 315 kW with integrated thermal recovery unit.
The intervention generated electricity and natural gas savings. The heat produced by the compressor, instead of being dissipated through the traditional cooling system of the machine, is recovered and made available to preheat water in the water supply network destined for a steam production plant.
The intervention consisted in the replacement of 4 hydraulic presses with the same number of high efficiency hybrid models. The new presses are equipped with the best technology available, with inverter motors that allow to adjust the rotation speed of the hydraulic pumps required for injection according to the actual needs of the work cycle. The savings achieved range from 20 to 40% depending on the type of finished product. In addition to the direct saving of the presses, the consumption of the chillers used for the mold cooling circuit decreased.
The intervention consisted in revamping a hot galvanizing tank. In particular, pilot burners, gas flow control valves and flame controls have been replaced, with new components of the latest generation and high efficiency. The galvanizing tank has also been modified in order to allow the simultaneous immersion of a greater quantity of product with consequent optimization of time and therefore of thermal energy consumptions.
The intervention consisted in the relamping of the shed area destined for production lines and the revamping of the cooling towers. In particular, all the luminaires with metal halide lamps were replaced with new lighting bodies having high efficiency magnetic induction lamps. For cooling towers, on the other hand, the inverter was installed on the cooling fans to modulate the speed of the same according to the thermal loads and the external atmospheric conditions.
types of intervention
Since 2015, about 200 energy audits were carried out (pursuant to Legislative Decree 102/2014) in the different industrial sectors and in the tertiary sector. The audits allowed to identify about 50 different types of interventions with a total saving of around 40 GWh/year. Some of these interventions were carried out directly by Tecno through EPC contracts. So far, Tecno has a qualified team (Energy Management Experts certified UNI CEI 11339) that operates with adequate measurement equipment in the field to shortly comply with legal obligations.
Below are the sectors already analyzed in the context of the aforementioned energy audits: mining industry; food industry; textile industry; footwear industry; paper industry; chemical industry; pharmaceutical industry; rubber and plastic processing industry, glass and ceramic processing industry; metallurgical industry; motor vehicle industry; other manufacturing companies.
reduction in consumptions
Monitoring of the electricity consumption of the production lines and of the gas consumption of the spray booths. The monitoring was carried out partly with new tools provided with EMS service and partly with the remote reading of instruments already in the field, adjusted through appropriate software interfaces. Monitoring enabled consumption to be reduced by around 6%. The system provides for the control of some remote systems and an alert system that signals the exceeding of the consumption and efficiency limits values of the main users. The system allowed to plan new energy efficiency measures that will be carried out by 2020.
reduction in consumption
Monitoring of presses, extruders, chillers, additional services and offices. Monitoring enabled consumption to be reduced by around 9% in just one year. The system allowed to reduce waste and to identify an energy performance index of each press, defining a new order of operation to manage orders. The system also allowed to verify the real savings resulting from the energy efficiency measures carried out. On the basis of the monitored data, new energy efficiency measures were planned through EPC contracts based precisely on the EMS system measures.
FATTUROK software platform allowed to replace some resources within the company, who manually used to load the billing data, through the FATTUROK drag and drop system. The software, which is automatically updated according the variations of the billing rules, also allowed to operate without any possible error. The creation of customized reports made possible to improve the management of the documentation as to grow the purchasing power with the energy supplier.