Technological processes audit
Audit of process technology is one of the most difficult to define from all audit areas, due to the multitude of different technological processes which may be encountered in companies. However, every technological process makes use of energy media, in each technological process there are control systems, as well as the systems that deliver media to the process. These are, as a part of the audit of technological processes, the sources of knowledge about possible energy savings and optimization potential.
Purpose and scope of technological processes audit
The study includes the analysis of the potential reduction of media demand (electricity, heat, cooling water, chilled water, compressed air) by receiving units operating within process equipment. Within the scope of audit, we analyze the performance of technological machines, such as:
- process machines (e.g. mills, pasteurizers, calciners, pelleting machines, dryers),
- exchangers,
- pumps,
- fans,
- electric motors working in the process.
Possibility to implement heat and other media recovery from technological installations, including the possibility of their utilization, is analyzed and measured. Audit will point out the energy-saving technical solutions, the parameters of the recovered medium will be calculated, and the concept of its development will be presented together with the assessment of the real efficiency of the investment.
Scope of research and analysis:
- analysis of process equipment performance, including the balance of demand for electricity, air, heat and cold,
- analysis of selected propulsion systems (propulsion system consists of an engine, gearbox and connected machine with adjustment system),
- analysis of the installation that delivers media to the process, along with the optimization proposals.
Measurements for the above specified scope:
- measurement of real heat, cold, air and electricity flows in the technological process,
- measurement of drive systems, pump performance and control systems,
- measurement of compressed air consumption.
The summary of the audit includes the presentation of economic effects achieved through implemented changes, together with approximate costs of recommended implementations and savings resulting from the upgraded system operation.
Types of modernization which have been so far implemented by DB Energy:
| Investment | Energy savings [MWh] | White Certificates [toe] | Savings [USD/Y] | Investment costs [USD] | SPBT [Y] |
| Modernization of the compressed air system within the technological chain | 1 821.880 | 73.946 | 147 916.24 | 170 571.43 | 1.2 |
| Modernization of process drives | 16 896.863 | 101.906 | 1 383 038.89 | 1 250 202.04 | 0.9 |
| Modernization of the lighting in the area of technological process | 315.417 | 36 466.80 | 36 642.29 | 1.0 | |
| Modernization of the dedusting and ventilation system | 9 044.642 | 1 108 280.51 | 2 051 223.83 | 1.9 | |
| Heat recovery from machinery and process installations | 82 991.092 | 6 563.872 | 3 194 183.57 | 4 763 617.08 | 1.5 |
| Other | 9 851.676 | 681 502.85 | 1 411 648.92 | 2.1 | |
| Total | 438 679.893 | 91 959.584 | 21 370 375.72 | 95 747 520.98 | 4.5 |
Overall, in consequence of the audit recommendations within the scope of technological process, DBE's clients reduced their energy consumption by approximately 438 GWh and thus achieved the average annual savings of nearly USD 22 million. The total payback period covering all investments is only 4.5 years.
DB Energy
Complex management of an energy efficiency improvement process including the designing phase, financing, implementation of energy-saving projects
Skilled engineers with broad experience in managing the process of energy efficiency improvement for the industry
Guaranteed reduction of energy consumption while implementing a project with DB Energy
Substantial effectiveness proved by savings generated by clients and the number of issued energy efficiency certificates (the white certificates) – we have prepared the documentation in order to acquire the white certificates of more than 450k toe which accounts for our leading position on the market
Practical solutions – our projects are bespoke and adjusted to the profile and expectations of a client
Advanced measurement infrastructure – with all measurements types required in the energy efficiency analysis, including the proprietary DiagSYS system
Capital group
Company data
DB ENERGY SA
Al. Armii Krajowej 45
50-541 Wrocław
NIP: 894 299 53 75
REGON: 021249140
Contact
+48 71 337 13 25 biuro@dbenergy.plfor general purposes sprzedaz@dbenergy.plfor commercial purposes
In 2014 the R&D department started to work in our company. We design solutions to improve energy efficiency in industry.
On 22 June 2016, DB Energy signed an agreement with the National Centre for Research and Development to co-finance R&D work for a project called "Development of an innovative drive diagnostics system (DiagSys) based on electrical signal measurements characteristic of mechanical damage to rotating machine components, together with a specialized analyzer of machine operating status and efficiency (APPS 3)".
The project is financed under the Intelligent Development Operational Programme 2014-2020, under sub-measure 1.1.1. "Industrial research and development work carried out by enterprises". No. of the competition: 1/1.1.1/2015. Value of the project 5 974 021.85 PLN. Value of co-financing 3,727,676.11 PLN.
The aim is to develop a system for the diagnosis of rotating machines (DiagSys system), which will be based on the use of power measurements and on-line access to an expert database.
