Realizations

Modernization of the Simoldes Plasticos plant

DB Energy optimized energy consumption at the Simoldes Plasticos plant, one of the main producers of plastic products in Europe! Planned energy savings are over 25%!

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Optimizing the pressure in the cooling system

Modernization of the cooling system makes it possible to achieve remarkable savings in facilities where production processes require cooling – e.g. in food industry. From the point of view of our engineers, cooling of the products and storage chambers seems to be an interesting area to perform analysis.

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Frecooling

In audited companies, we often face specific requirements concerning the supply of cooling to the technological process. The need to cool the injection molds, which requires the supply of coolant at low temperature, may serve as an example. Possibility of using free cooling in chilled- water units is worth considering.

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Increasing the cooling temperature of molds

Wherever chill water is used, it is possible to look at its parameters and try to optimize them for the purpose of the company's production process. This may often bring interesting energy effects.

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Application of gas turbine for the production of electricity

In some industries, including metallurgical, we deal with significant energy of blast furnace gas produced in the manufacturing process. In order to use it, it is necessary to check if it is possible from the technical point of view and economically justified. DBE has been involved in the preparation of such design concepts. The study made in this case has demonstrated profitability of using turbines to produce electricity.

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Installation of a steam turbine for the production of electricity

In many plants, including in the chemical industry, process heat is generated with the use of steam boilers. Parameters of process steam, upon leaving the boiler, are often adapted to the requirements of the process at the reducing and cooling station. This situation provides an opportunity to assess whether the replacement of reduction and cooling station with the steam turbine equipped with the generator will eliminate the energy losses resulting from the reduction of the parameters of steam, which passes through the reduction station.

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Application of high speed doors

In many companies we encounter that the production process is carried out in many buildings that are not directly connected. During internal transport we can deal with significant energy losses through gates and other transitions. The use of high speed doors allows you to avoid these losses and save significant amounts of energy.

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Installation of the fan control system

The investment involved the installation of an override fan performance control system. In case of this modernization, inverters controlled by outlet exhaust air temperature were used. Modernized buildings are intended for commercial and warehouse purposes.

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Compressed air recovery from the process machine

Within the field of compressed air, we seek for savings not only in modernization of the compressor room or elimination of leaks - there are ways of modernization which allow for the compressed air recovering and returning it to the process. Such modernization is recommended to companies from the plastics industry.

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Replacement of air compressors and construction of the override system

The purpose of the works carried out in a company operating in the metallurgical industry was to determine the energy and ecological effect of the investment involving the replacement of the compressors and the development of an override control system.

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Modernization of fan drives

Modernization of process drives has repeatedly resulted in interesting energy effects. In case of one of our clients, the optimization of fan drive control led to savings of 9,868,927 MWh! Such considerable savings were attributed to the company's needs in the area of ventilation, which was connected with the high dusting of production processes.

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Modernization of lighting in the area of technological process

Many companies can reduce electricity consumption in the area of lighting by undertaking simple actions, considered to be included in the broadly understood scope of the so called best practice. In one of the plants, 103,564 MWh of energy was reduced by using the solutions described below.

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Installation of the compressed air recovery system from the process machine

At one of our clients' plants, DBE has installed the compressed air recovery system. As expected, this proved to be not only technically desirable, but also economically efficient.

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Optimization of dedusting system

In the woodworking industry, where high amounts of dust can be observed, a dust extraction system was installed for the purpose of reducing the concentration of dust on the work stations. During the audit, the conclusion was drawn that the system failed to work effectively.

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Preheating furnace trolleys

Heat from the tunnel furnace was used to preheat the furnace trolleys, which reduced the consumption of gas by the burners installed on the furnace. The design concept was to build a closed canal with two locks for a dozen or so trolleys, located between the entrance to the furnace and the loading of the raw material.

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Isolation of dyeing machines

As a part of the DBE audit carried out at the textile industry's client, the modernization of the dyeing machines was proposed.

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Replacement of transformers

There were 19 transformers installed in the audited company, with the power ranging from 800 kVA to 1 600 kVA. Most of the implemented units were manufactured in the 1970s. In case of old transformers, it is usually justified and profitable to replace them with new ones

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Improvement of thermal efficiency of warehouse chambers

As a part of the energy audit conducted in a facility operating in the food industry, a comprehensive improvement of thermal efficiency of cold rooms was proposed. It was necessary to determine the energy and technological effect of such modernization and to suggest specific solutions.

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Improvement of insulation of the heating network

The energy audit of the heat transmission network concerns the optimization of heat losses in the transmission piping and fittings. In the audited company, the analysis included the steam power supply system (steam pipelines) and the water supply system for central heating. Based on the measurements taken, proposals for investments to improve energy efficiency were presented.

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Replacement of ventilation units

At one of our clients' production facilities, there were 7 air handling units aimed at providing the thermal comfort of the rooms and adequate air exchange in the production halls. Each central station was equipped with a 150 kW water heater. The air handling units were relatively new and each had insulated ventilation ducts. In spite of that, it was an interesting area to improve energy efficiency.

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Combined heat and power

Upon preparation of the balance sheets of heat and electricity supply, our proposal to one of our clients was to build a CHP system. Combined production of electricity and heat has, in this case, measurable benefits

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Modernization of the blower on the evaporators

Process installations implemented by the client from steel industry operated on the basis of gas-powered electrolyte vaporizers. Modernization in the area of systems supplying air to gas burners have resulted in very beneficial effects to the plant.

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Automatic adjustment of the excess air ratio

After analyzing the work of steam boilers in the food industry, it turned out that the biggest energy loss in boilers is the loss through the chimney. Its range is determined by the coefficient of excess air in the exhaust gases behind the boiler (λ) and the temperature of the exhaust gases.

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Delivery of hot air to the burners

We were able to achieve interesting savings in a cement production facility. Rotary kilns operate in this type of plants, while the burners are often a central tube introduced into the furnace. Optimization of the operation of such burners can bring significant reductions in energy consumption.

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Modernization of steam exchangers

In case of this company, the source of heat supplied to the process was a steam exchanger inserted into the company's heating system. The analysis covered 17 heat exchangers serving individual parts of the process, with a rated power of an exchanger of approximately 2 MWc.

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Elimination of air leaks

As a part of the work on the energy efficiency program, we have been able to achieve exceptionally good effect of elimination of air leaks for one of our clients from construction industry.

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Audit of lighting installation in the steelworks

As part of preparation of the documentation for participation in the 5th tender for obtaining white certificates, the eAs a part of preparation of the documentation necessary to participate in the 5th tender for white certificates, the external lighting system of the steelworks and the installation of internal lighting within one of the buildings were analyzed.

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