Audit and modernization of the lighting installation in a steel mill
The modernization of the lighting installation in a steel mill is an example of an investment that combines cost and emission reduction with obtaining white certificates. Thanks to the audit and replacement of fixtures with LEDs, the client reduced energy consumption by up to 60%.
Challenge
One of the largest steel plants in Poland was struggling with high electricity consumption in lighting installations – both indoor and outdoor. The old fixtures had low luminous efficiency and high operating costs, while also generating significant CO2 emissions.
The goal was to carry out an energy efficiency audit (EEA), which would precisely determine the savings potential, and then implement an investment qualifying for energy efficiency certificates (white certificates).
Our approach
The DB Energy team carried out a detailed audit of the lighting installation:
- an inventory of existing fixtures and an analysis of the actual operating time was performed,
- the energy and environmental effects of the planned modernization were determined,
- new solutions based on high-efficiency LED fixtures were designed,
- documentation was prepared for participation in the white certificate tender organized by the President of URE.
The adopted solution allowed the existing infrastructure (including poles and wiring) to be retained, which reduced investment costs.
Solution
Outdoor lighting
- previous power: 251.6 kW (approx. 1,123 MWh/year),
- after modernization: LED fixtures 110 W (997 units), consumption 450.1 MWh/year,
- energy consumption reduction: approx. 60%.
Indoor lighting
- previous power: consumption of approx. 3,000 MWh/year,
- after modernization: LED fixtures 120 W (1,247 units), consumption 1,310.3 MWh/year,
- energy consumption reduction: approx. 56%.
Results
The modernization of lighting brought measurable technical, economic and environmental results, which directly translated into lower operating costs for the plant. In particular:
- total primary energy savings: 609.7 toe,
- significant reduction of CO2 emissions,
- substantial reduction of energy costs,
- extended lifespan of light sources,
- reduced operating costs,
- obtaining energy efficiency certificates (white certificates).
Conclusions
Lighting modernization in the steel mill shows that even in seemingly secondary areas – such as lighting installations – it is possible to make investments that deliver measurable technical, financial and environmental results. Thanks to the audit and support from DB Energy, the client not only reduced energy consumption by more than half, but also gained additional benefits in the form of white certificates, which accelerated the payback period.
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