10 December 2024

In production facilities, the majority of energy consumption, often exceeding 75%, is directly related to production processes. The remaining portion, around 25%, may include energy usage for HVAC systems (e.g., technological cooling), heating of premises, ventilation, or the preparation of hot water for sanitary facilities. To properly plan investments and evaluate improvements in energy efficiency, it is necessary to precisely determine the potential for savings in various areas of the facility.

The Importance of Data in Assessing Energy Efficiency

The foundation of a reliable analysis is the availability of detailed data, which should include:

  • Total energy consumption in the facility.
  • A breakdown of consumption by specific areas, processes, and equipment.
  • A time profile of energy consumption (e.g., data from the EMS system for the past 24 months).

The lack of such data may hinder the identification of the actual savings potential. In such cases, it is advisable to rely on estimates using a methodology for assessing energy potential.

How to Determine Energy Potential?

An example approach involves:

  • Identifying the installed and actually utilized capacity of key devices in the facility.
  • Determining the operating hours of devices and their simultaneity of use.
  • Differentiating between the types of energy used by individual devices (e.g., electrical energy, thermal energy).
  • Compiling total energy consumption by summing readings from main meters and converting everything to a common unit (usually kWh).
A table showcasing energy efficiency assessment data for an industrial facility. It includes details on installations, types of energy used, power in kW, operating hours per year, energy consumption in MWh, and simultaneity factors.
A sample template for evaluating the potential for improving energy efficiency in industrial facilities, including energy consumption data for installations such as heating, hot water, and air compressors.

Here you can download a sample Template for Assessing the Potential for Improving Energy Efficiency – in an xlsx spreadsheet.

What Does the Estimation of Energy Potential Reveal?

The estimation of energy potential will primarily identify areas with the greatest potential for improving energy efficiency, i.e., locations where significant energy savings are possible. Simultaneously, it will reveal the difference between the total energy consumption by devices and the facility’s overall energy usage, which may indicate missing measurements, such as operating devices not included in the analysis. Furthermore, this analysis helps identify energy losses, defined as the difference between final energy and useful energy. However, to fully account for these aspects, the use of an advanced monitoring system, such as EnobEMS, may be necessary. Such a system enables precise identification of savings potential and supports the planning of investments aimed at improving energy efficiency.

What do we know about the investment and where did the idea even come from?

Investment description:
The idea, or description, of how an energy efficiency improvement project will function is a critical element in identifying specific actions to improve energy efficiency. The project must clearly define the goal and nature of the investment. For example, a project like “Heat recovery from chillers to the hall” indicates the application of technology that enables the reuse of heat from the cooling process. A well-formulated name helps in understanding the scope of the project and facilitates the analysis of its profitability. It allows managers and investors to better estimate potential benefits, as well as technological, financial, and organizational requirements.

What are the assumptions for evaluating the return on investment?

Investment estimation [EUR]:

The investment estimate is a key part of any project profitability analysis. It covers the total cost of implementing new technology or process modernization. The estimate should include not only the purchase of equipment but also the costs of installation, implementation, service, and potential infrastructure modifications. Here, more about implementations. Accurate investment estimates help managers calculate the return on investment and understand how long it will take for energy savings to cover the incurred costs.

Change in energy consumption [MWh/year]:

The change in energy consumption refers to the expected reduction in energy use, typically expressed in megawatt-hours (MWh) per year. This is one of the most important metrics when evaluating the energy efficiency of an investment, as it directly impacts savings and return on investment. Improving energy efficiency, for example, by using modern technologies, reduces energy consumption, which translates into lower operational costs and a smaller environmental impact. This metric helps assess the scale of actual energy savings.

Project page for heat recovery from chillers, describing the use of waste heat to improve the energy efficiency of a production hall, including investment, savings, and return on investment (ROI) data.
Description of the heat recovery project from chillers to the production hall aimed at improving energy efficiency, reducing costs, and lowering CO2 emissions.

Change in costs [EUR/year]:

Cost change refers to the anticipated yearly financial savings resulting from reduced energy consumption. This is a crucial metric, as it allows managers to assess how the investment in energy efficiency will translate into direct financial benefits. Reducing energy use lowers energy bills, and in the case of high energy costs, these savings can significantly impact a company’s operational budget. The greater the cost reduction, the quicker the investment pays off.

Change in CO2 emissions [tons/year]:

CO2 emissions reduction refers to the expected decrease in carbon dioxide emissions due to energy efficiency improvements. This is a key metric from both an environmental and sustainability perspective. Lower CO2 emissions signify reduced energy use, which in turn means less environmental impact. Companies can also benefit from tax credits, ecological certifications, or improved public image by reducing greenhouse gas emissions. Here, more about the future of the industry in the New Realities.

How to calculate return on investment?

SPBT (Simple Payback Time) [years]:

SPBT, or simple payback time, represents the number of years in which the investment will fully pay for itself through the savings generated. It is a key indicator used by managers to evaluate the profitability of an investment, as it shows how quickly the company can recoup the invested funds. A shorter payback period suggests that the investment will generate benefits sooner, which is often preferred in financial planning, especially for energy efficiency projects.

TCO (Total Cost of Ownership) [EUR/year]:

TCO, or total cost of ownership, includes all costs associated with the energy efficiency investment throughout its entire lifecycle. In addition to the purchase and installation costs, TCO also accounts for ongoing maintenance, servicing, potential repairs, and the consumption of any operating materials. Analyzing TCO allows for a comprehensive economic assessment of the project, as it shows the total amount the company will need to allocate for maintaining the investment over the long term, impacting its overall profitability.

Product lifespan [years]:

Product lifespan refers to the anticipated period during which a given solution will operate efficiently and without failure before needing replacement or major repairs. The length of this period is critical to the overall assessment of the investment, as it impacts long-term profitability. A longer product lifespan reduces the costs associated with replacement and servicing, which translates to a lower TCO (total cost of ownership) and a higher return on investment (ROI).

ROI (Return on Investment) [%]:

ROI, or return on investment, expressed as a percentage, measures the ratio of the profits generated by the investment to the costs incurred. This is a key metric for evaluating a project’s profitability, as it allows managers to determine how effectively the invested funds generate financial returns. A higher ROI means that the investment produces greater profits relative to the costs. ROI is often a decisive factor in determining whether to pursue an energy efficiency project.

Table comparing energy recovery projects including investment, reduction in energy usage, cost savings, CO2 emission changes, Simple Payback Time, Total Cost of Ownership, and Return on Investment for three projects.
Overview of three energy recovery projects focusing on investment, energy savings, CO2 emission changes, and financial metrics like Simple Payback Time, Total Cost of Ownership, and ROI.

In summary, evaluating investments in energy efficiency improvements for industrial facilities requires considering key factors such as the project’s name, which clearly defines the investment’s goal, the investment’s cost estimate, changes in energy consumption and costs, as well as CO2 emissions. Other essential metrics include SPBT (simple payback time), TCO (total cost of ownership), product lifespan, and ROI (return on investment). These elements together provide a complete picture of a project’s profitability, enabling better planning and decision-making by managers.

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