Good Practice
Fourteen more Good Practice Case Studies Published by SETatWork
February 2010
The second set of Good Practice Case Studies (GPs) produced by SETatWork project partners were published on the website in February 2010. These cover a range of technologies and industries including:
- Improving energy efficiency in dairy industry, pulp and paper and other energy intensive industries, Sweden, as well as in the fertiliser production industry in India
- Improving energy efficiency and introduction of renewable energies in buildings in Bulgaria and Thailand
- Use of waste heat in from iron and steel, refining and processing industries in China, Sweden and India
- Wind and biodiesel production and use in the Swedish forest, pulp and paper industries
- Combined Cycle Power Plant, Slovak Republic
SETatWork and T@W Good Practices are currently in the process of being incorporated into the Case Studies search section of the SETatWork database.
- View all the SETatWork and T@W Good Practice case studies
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Click on the links below to view the new case studies:
Download SGP25 (150 Kb PDF) - 2003-23
Hi-Tech Carbon (HTC) is a unit of Aditya Birla Nuvo Ltd., a flagship company in the fold of Aditya Birla Group of companies. HTC manufacturs Carbon Black from highly aromatic petroleum oils, which are thermally cracked at high temperature in specially designed reactors. HTC has three lines of carbon black production namely line 1, 2 and 3. Carbon Black product is produced from petroleum fraction called Carbon Black Feed Stock (CBFS). CBFS stored in tank is pumped to the reactor where thermal cracking takes place. The thermal cracking process leads to formation of two products. One is the solid product, fine in size which comes out as smoke and the other one is waste gas. Waste gas from the reactor that goes to boiler through main bag filter at 280-300°C is of significant volumes. Smoke enters through the bottom of filter bags and Carbon Black particles are deposited inside the bags. Low calorific value waste gas separated from accompanying carbon black particles in bag filter section are collected in the waste gas header.
In the project activity, low calorific value waste gas coming out of new carbon black lines (line 2 & 3 of capacities 55,000 & 60,000 Tonnes/year respectively) is utilized in 52 and 70 TPH (B 2 & B 3) boilers respectively, specially designed to generate high pressure steam. This high pressure steam in turn drives the turbo-generators (TGs) of capacity 8 MW and 17.2 MW (TG 3 & 4 respectively) to generate power. The project activity displaces electricity from grid connected fossil fuel based power plants connected to southern regional grid. Thereby, the project activity reduces approximately 87,305 tCO2e/year.
Download SGP24 (150 Kb PDF) - 2004-19
The objective of this project was the upgrade of existing plant equipment through the use of new technology alternatives, retrofits, new design and waste heat recovery in order to reduce the Specific Steam Consumption Ratio (SSCR) of the Ammonia plant of Urea fertilizer units. Following process profile analysis of their Ammonia Urea fertilizer operations, IFFCO plans to upgrade their existing plants in three separate site locations with specific energy saving process technologies. 8 specific technologies are to be employed throughout the three plants that ultimately will contribute to a reduction in Specific Steam Consumption Ratio (SSCR), thereby reducing overall plant specific steam consumption of the plant, hence resulting in a reduction in the fossil fuel requirement which is fed to the boilers.
Download SGP21 (177 Kb PDF) - 2006-7
Levice Combined Cycle Power Plant (CCPP) 80MW was commissioned in September 2007 in Levice, Slovak republic. Owner of this plant is Slovintegra Energy, s.r.o. being a 100 % daughter company of the Slovakian international investment company Slovintegra, a.s. It was established as a new company mainly for the Levice power plant. Slovintegra Energy focuses on production, distribution and sales of electric energy for the energy system. It also produces, distributes and sells steam-based heat and hot water supplies for companies operating in the area of Levice Industrial Park, and distributes heat to the town of Levice. The activities also include supporting services in the form of primary, secondary and tertiary regulations of the output capacity and supplies of regulation electric power for Slovenska Elektrizacna Prenosova Sustava, a.s., a company in charge of transmitting electricity throughout the whole territory of Slovakia and ensuring electricity transmission from power plants to the distribution network and major customers connected to the 220 kV and 400 kV grids.
Download SGP20 (182 Kb PDF) - 1970s-
Industrial excess heat is generated as a result of the industrial production processes such as refining. Some of the primary energy needed to run a production process is not consumed and must be cooled away if the process is to work. Traditionally the excess heat has been cooled away to the ambient air and/or water and is wasted. Using waste heat from industry in a local district heating network is a way of covering some of society’s heat demand without causing any additional greenhouse gas emissions.
Download SGP19 (260 Kb PDF)
The 1 July 2004 the tax on electricity for the processing industry in Sweden was raised from 0 to 0.5 öre/kWh (0.50 Euro/Mwh). However, by participating in a program for energy efficiency, companies can get exempted from the tax. Swedish companies belonging to energy intensive industries can therefore apply to the PFE program which is five years long. Work must be performed in a structured manner and measures should be taken to increase energy efficiency. The objective of the program is to contribute to an economically and environmentally sustainable energy system in which the industry has a central role. Through the program companies lower their energy cost, the employees gain knowledge about energy efficiency and the environmental impacts are reduced.
Download SGP18 (182 Kb PDF)
A new evaporation plant will replace the three existing evaporation lines and will improve energy efficiency at Värö mill. The evaporation plant is an important part of the pulp mill’s recovery process. The mill will also be equipped with a bark dryer which will transform the bark surplus to high-grade biofuel. Through this investment, bark with an energy content of 200 GWh/year will become available for sale, which corresponds to a reduction of fossil carbon dioxide emissions by 75,000 tons per year. The investment will boost energy efficiency, make the mill virtually independent from fossil energy and enhance productivity.
Download SGP17 (208 Kb PDF)
There are many good wind sites on land belonging to Södra members and at Södra mills. Södra is therefore investing in electricity production from wind turbines. The first wind power plant is now being built at one of Södra’s pulpmills. Turbines will thereafter be built on other industrial sites and on members’ forest holdings in Götaland. The objective is to realize as many profitable wind power projects as possible on Södra members’ lands.
Download SGP16 (181 Kb PDF) - 2008-10
As the first refinery in the world Preemraff Göteborg shifts its production so that biomass from the Swedish Forests will be refined to diesel. Preemraff Göteborg is retrofitted at a cost of 280 million SEK and will 2010 refine 100 000 tons of biomass to diesel. The adjustment makes it possible to refine not only crude oil, but also different kinds of raw material such as vegetable oils and animal fat to high-quality diesel fuels. Preem will primarily use wood based raw material in the purpose of not competing with the food industry.
Download SGP15 (194 Kb PDF) - 2002-
Norrmejerier’s management unit Ersboda dairy plant produces milk, sour milk, yoghurt, cream, butter, cheese and milk powder. Norrmejerier wanted to increase its production of cheese which also would increase emissions in the wastewater. Since the municipal wastewater treatment plant did not allow increased emissions Norrmejerier was forced to seek alternative sewage cleaning. It was found that the Biotrans project would solve the problems with the wastewater and also reduce the energy need. The Biotrans project includes: A biogas plant (anaerobic) to convert the wastewater into an energy source; A heat pump to recuperate heat in the wastewater after the biogas plant; An ultra-filtration plant for extraction of high-grade whey protein. Changes in production, mainly increased cheese production.
Download SGP12 (219 Kb PDF) - 2007-2008
In total, AIT consumes about 13,000 MWh/year of electricity (on an average from 2003 to 2007) which leads to about 9,300 tons/year of CO2 emission at power generation. SERD consists of 6 buildings which consume about 1,000 MWh/year which leads to about 720 tons of CO2 emission in 2007. The Energy building consumes about 120 MWh/year and generates about 86.4 tons of CO2/year. Lighting consumes about 38% and 27% of the total electricity consumption during weekday and weekend, respectively.
Many of the existing lighting fixtures at the Energy Building were equipped with T8 (36 W) lamps with magnetic ballasts and covered with gloomy covers which reduce amount of illuminance on the working space. The measured illuminance of the existing T8 fixtures in 5 selected rooms was in a range of 148-380 lux which is lower than standard of 300-500 lux. T5 (28 W) lamps with electronic ballasts and reflectors were selected to replace the existing fixtures. T5 lamp with electronic ballast consumes about 31 W or about 32% saving as compared to 46 W of T8 with magnetic ballast.
Adaptors can be used to fit T5 into the existing T8 fixtures or use new reflectors. As the existing fixtures gave low illuminance, therefore, high efficiency reflectors (95% reflectance) were bought which can be fitted with T5 without using adaptors. Each reflector can hold two T5 lamps.
Download SGP11 (239 Kb PDF) - 2004-2005
Phyathai hospital is located in Sriracha town, Chonburi province, about 120 km. east of Bangkok. An energy audit was done at the hospital in 2003. Total energy consumption was about 4,195,000 kWh and cost about 10,884,000 Baht in 2003. Average electricity cost was 2.60 Baht/kWh. The hospital has 5 air-cooled reciprocating chillers (each 210 TR-ton of refrigeration) and they had been in operation for 10 years. Two chillers were in operation and 3 chillers could not operate properly. It was found that the existing air-cooled chillers have a very low efficiency in a range of 1.66-2.17 kW/TR. Efficiency of a new air-cooled chiller is about 1.1-1.18 kW/TR. The maintenance costs were also high, about 500,000 Baht/year/unit. From the energy audit report, the chillers consumed about 2.06 million kWh/year (operated 24 hours/day and 365 days/year) or about 5.63 million Baht/year or about 50% of total energy consumption. From the existing conditions, the hospital decided to replace the worn out chillers. The hospital’s energy consultant, Innovation Technology Co., Ltd., proposed and compared 3 options for consideration.
Download SGP10 (214 Kb PDF) - 2008-2009
Royal Orchid Sheraton hotel was opened for business about 25 years ago. It is located near by the Chaopraya river and has 740 rooms.
The hotel has 2 boilers (1 stand-by), 5 tons/hour each, to produce steam for laundry, kitchen and domestic hot water supply. Average fuel consumption (bunker oil A) of boiler was about 2,000 liter/day. There are 5 hot water generator using steam as heat source. Temperature of domestic hot water supply is about 55 oC. Average hot water consumption is about 95 m³/day at 70% occupancy.
When the price of fuel oil was increased to over 25 Baht/liter (about US$ 0.7/liter) in 2008, the hotel decided to use solar water heating system to save energy cost. At the same time, there was an incentive from the Department of Alternative Energy Development and Efficiency (DEDE) which provided hotel with a subsidy of 4,500 Baht/m² of solar collector area.
Download SGP9 (166 Kb PDF) - 2009-2019
The project is located in the main body of the iron and steel production facility operated by Wuhan Iron and Steel (Group) Co. To increase the utilization rate of available energy in Wugang, the specific project will construct dry quenching equipment with 140t/h dealing capacity matching a power station. The project will have a rated total installed capacity of 6MW, and an actual total installed capacity of 4.225MW. The annual utilizing hour is 8,280h, thus the annual power generation is 34,980MWh. After auxiliary consumption and losses, annual net electricity supply via a 10kV power line to the internal electricity system of Wugang is expected to be 21,687MWh. Additional to electricity supply, the project will also generate and supply heat (not claimed emission reductions due to the supply of heat). In the baseline, Wugang received 38.15% of its electricity requirement from an on-site 400MW power plant (i.e. two 200 MW generators) and the remaining 61.85% from the Central China Power Grid. The specific project activity will therefore effectively replace electricity generated both in the power plant and on the Central China Power Grid (which is dominated by coal-fired thermal power plants) and reduce emissions with around 16,738tCO2e annually.
Download SGP4 (259 Kb PDF) - 2003-2004
The objective was to carry out a renovation of multi-dwelling building which flats are owned by the inhabitants, leading to lower energy consumption and improvement of the comfort of the flats. Given the fact that in Bulgaria there are about 95 thousand multifamily buildings with 3 and more floors built predominantly in the 60th and 70th with poor energy characteristics, the potential of replication of the project is huge.
