Good practices and investments related to Cleaner Production
Example No. 81
Improvement of energy efficiency as a result of eco-design of the production hall
INTEGRAL Grzegorz Kostowski with its seat in Olsztyn
Place of implementation of the described activity: production hall in Nidzica, Rozdroże 1D
Industry branch: manufacture of metal structures and parts thereof
Main products: stainless steel equipment; packaging made of wood, wood-like materials and metals for road and sea transportation; metal processing services
Resources in question:
- Electrical energy
- Thermal energy
- Fossil fuels (indirectly)
- Emissions (indirectly)
- Waste (indirectly)
(purchase of three destratifiers: PLN 6,000, purchase of 21 LED fixtures: PLN 14,700, the cost of independent electrical circuits and switches (without the cost of the fans themselves, which would have been purchased anyway): PLN 4,000, the difference in price due to the increased thickness of the walls and roof (additional insulation): PLN 23,000)
Description of the problem:
- Reducing heat losses by installing three destratifiers (devices that use the phenomenon of natural convection, i.e., the rising of masses of warm air and its accumulation in the upper parts of the facility – through the use of these devices, warm air is mixed and pushed from the ceiling zone to the floor zone, i.e., the zone of human occupancy).
- Use of energy-efficient LED lighting, 21 fixtures (155 W, 20,500 lm each).
- Separation of independent lighting zones of the hall adapted to the occupied workstations. There are 9 zones (2+2+2+2+2+2+3+3+3=21 fixtures), where lighting is needed for half, rather than the entire work day (the light is turned off during the hours when it is not needed in the given zone).
- Separation of four independent ventilation zones of the hall, adapted to the occupied workstations. Individual zones are activated only in the case of an active workstation requiring ventilation, for example, during grinding work.
- Increasing wall and roof insulation (building structural partitions with the following heat transfer coefficients were used: for walls: Uc 0.18 W/m2K, for the roof: Uc 0.15 W/m2K.
Obtained benefits and effects of the implementation:
- Reduction in thermal energy losses due to destratifiers (compared to the situation in which they would not have been applied): by 7,800 kWh/year (i.e., by 15%). The savings were estimated at PLN 15,858/year
- Reduction in electricity consumption due to LED light fixtures (compared to halogen lights (excluding the introduction of lighting zones): by 12,042 kWh/year (i.e., by 64%). The savings were estimated at PLN 24,084/year
- Reduced electricity consumption by separating lighting zones where lights are only on for 4 hours a day: by 1,613 kWh/year (i.e., by 24%). The savings were estimated at PLN 3,226/year
- Energy reduction associated with introducing ventilation zones and turning it on at selected stations only when needed: by 665 kWh/year (i.e., by 25%). The savings were estimated at PLN 1,131/year
- Reduction in energy consumption for heating the hall due to additional insulation of the walls and roof (compared to the parameters: walls Uc 0.23, roof Uc 0.18): by 7,000 kWh/year (i.e., by 12%). The savings were estimated at PLN 14,000/year
- The total reduction in energy consumption resulting from the above solutions: 29,120 kWh/year (equivalent to saving almost 13 Mg of coal and almost 23 Mg of CO2 emissions from energy production annually).
- Total estimated savings: about PLN 58,500/year
- Report on the Cleaner Production Project No. 9ind.818, developed within the framework of the Cleaner Production Academy: "Improvement of energy efficiency as a result of eco-design of the production hall of INTEGRAL Grzegorz Kostowski"