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