Replacement of ventilation units with supply and exhaust systems

The modernization of ventilation units to supply and exhaust systems with heat recovery reduced energy consumption by 2.55 GWh per year and improved thermal comfort in production halls.

The challenge

In the production facilities of one of the clients, there were 7 supply units used to ensure thermal comfort and proper air exchange in the production halls. Each unit had a water heater with a capacity of approx. 150 kW and insulated ventilation ducts.

Despite relatively new equipment, the audit indicated the possibility of significantly improving energy efficiency through optimization of the supply method and heat recovery. The existing units drew air largely from inside the hall, causing inefficient use of thermal energy in the winter period.

Our approach

DB Energy engineers carried out:

measurements and analysis of the current supply units and thermal energy consumption,
assessment of savings potential through the use of supply and exhaust systems with heat recovery,
selection of new ventilation units considering heat recovery efficiency and hall air temperature,
calculation of energy savings and investment payback period.

Based on this, a replacement project was developed to improve both thermal comfort and energy consumption optimization.

Solution

The modernization included:

replacement of 7 supply units with supply and exhaust units with heat recovery,
ensuring intake of external air during winter instead of drawing air from inside the hall,
implementation of systems with heat recovery efficiency of 67%,
integration of new units with existing ducts and heaters to maximize the use of available thermal energy.

The total investment cost amounted to 425,000 PLN.

Effects

The implemented modernization resulted in:

reduction of energy consumption: 2.55 GWh per year,
financial savings: 212,500 PLN per year,
improved thermal comfort in ventilated spaces,
reduced heat energy losses thanks to heat recovery,
increased efficiency of the ventilation system operation with minimal impact on existing infrastructure.

Conclusions

Replacing supply units with supply and exhaust systems with heat recovery is an effective action that improves working comfort and reduces heating costs. Even for relatively new installations, measurable energy savings can be achieved with relatively low investment expenditures.

Nasze najnowsze realizacje, które Cię zainteresują

The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.

Przejdź do artykułu

Higher production and lower emissions – a chemical industry client on the path to net zero

At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.

Przejdź do artykułu

Zero-emission in practice – emission reduction in pharmaceutical chemistry

Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.

Przejdź do artykułu