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CARE +. Supporting Chemical SMEs to Improve Energy Efficiency. What Is CARE+ About?. CARE+ helps chemical SMEs to analyse their energ y consumption, chose the right measures to save energy and to increase their profit!. What Is CARE+ About?.

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Care

CARE +

Supporting Chemical SMEs

to Improve Energy Efficiency


What is care about

What Is CARE+ About?

CARE+ helps chemical SMEs to

analyse their energy consumption,

chose the right measures to save

energy and to increase their profit!


What is care about1

What Is CARE+ About?

  • CARE+ Helps small and medium sized enterprises in thechemical industry to improve energy efficiency.


What is care about2

What Is CARE+ About?

CARE+ aims at:

• Developing, testing and offering an energy efficiencyscheme for SMEs in the European chemical industry

• Disseminating most recent information about energyefficient technologies and energy management systems toSMEs


What is care about3

What Is CARE+ About?

  • Offering Training and Auditing to determine energyefficiency reserves and the cost-effectiveness of suchmeasures

  • Improving the chemical sector’s energy efficiencyperformance


Care tools

CARE+ TOOLS

CARE+ Offers You The Right

Tools For Energy Efficiency

Improvements

CARE+ has developed two maininstruments to help you saving onyour energy bill:

• The Self Audit Guide

• The Best Practices


Self audit guide

Self Audit Guide

  • They guide you through a stepby-step approach to determineenergy savings and pay-backtimes.


Energy efficiency best practices

Energy Efficiency Best Practices

  • Do you want to know more about what iscurrent bestpractice in the main energy consuming areas in chemicalSMEs?

  • Then the Best Practices are for you.


Energy efficiency best practices1

Energy Efficiency Best Practices

  • Best Practice 1 How to Set Up and Work With an Energy Management Programme

  • Best Practice 2 How to Account and Analyse Your Energy Use

  • Best Practice 3 How to Set Up and Run an Energy Information System

  • Best Practice 4 How to Improve Your Steam Generation Performance

  • Best Practice 5 How to Reduce Energy Use in Your Compressed Air System

  • Best Practice 6 How to Reduce the Energy Use in Your Buildings

  • Best Practice 7 How to Improve Energy Efficiency With Your Motors And Drives

  • Best Practice 8 How to Improve Energy Efficiency in Your Process Plant


Energy efficiency self audit guide

Energy Efficiency Self Audit Guide

  • AUDIT PREPARATION

  • INFORMATION GATHERING

  • ANALYSIS & EVALUATION

  • REPORTING

  • IMPLEMENTATION


Care

Energy Efficiency Self Audit Guide

  • Audit preparation

    • STEP 1 INITIAL BUSINESS CASE

    • STEP 2 OVERVIEW INFORMATION ON THE SITE AND COMPANY TO BE AUDITED

  • STEP 3 ENERGY WALK ROUND

  • Informationgathering

  • Qualitative

    • STEP 4 ENERGY MANAGEMENT STRENGTHS AND WEAKNESSES

    • STEP 5 ENERGY TRANSFORMATION AND MAJOR PRODUCTION PROCESSES

    • STEP 6 SITE ENERGY USAGE

  • Qualitative

    • STEP 7 SITE PRODUCTION AND FINANCIAL DATA

    • STEP 8 ENERGY TRANSFORMATION DATA

    • STEP 9 PRODUCTION LINE DATA

  • Analysis & evaluation

  • STEP 10 PROCESS ENERGY CONSUMING DEVICES

    • STEP 11 BUILDINGS ENERGY USE

    • STEP 12 MAIN INDICATORS

    • STEP 13 ENERGY ANALYSIS

    • STEP 14 ENERGY SAVINGS OPTIONS

    • STEP 15 RECOMMENDATIONS FOR IMPLEMENTATION

  • Implementation


  • Audit preparation

    AUDIT PREPARATION

    STEP 1

    • Define initial business case. Determine the added value by improving energy efficiency

      STEP 2

    • Site to be subject of audit

    • General site overview data

    • Site production overview

    • Site energy transformation equipment


    Business case criteria

    Business case criteria

    IF YOUR ENERGY COST IS

    < 5% It is always worth to increase energy efficiency, but there might be other activities with a higher impact on your competitiveness.

    > 5% and <15% Check your business for energy savings, you can have an impact.

    > 15% If you did not yet work on energy efficiency, it is high time to get started and focus on this important competitiveness and cost factor.


    Information gathering qualitative

    INFORMATION GATHERINGQUALITATIVE

    STEP 3 Energy Walk Around

    • Steam system

    • Imported heat

    • HVAC

    • Compressed air

    • Refrigeration

    • Lighting

    • Metering

    • Production process


    Information gathering qualitative1

    INFORMATION GATHERINGQUALITATIVE

    STEP 4Energy management strengths & weakness

    • Energy policy

    • Roles & Responsibilities

    • Goals& projects

    • Performance monitoring

    • Awareness & Training

    • Communication


    Information gathering qualitative2

    INFORMATION GATHERINGQUALITATIVE

    STEP 5Energy transformation & major production processes

    Aims at collecting the relevant qualitative information on these items, including for example

    age and state of installations, capacity and use pattern.


    Information gathering quantitative

    INFORMATION GATHERINGQUANTITATIVE

    STEP 6Site energy usage

    • Conversion factors

    • Monthly purchased energy quantities

    • Imported heat


    Information gathering quantitative1

    INFORMATION GATHERINGQUANTITATIVE

    STEP 7Site production & financial data

    Monthly Financial Data

    Total ProductionEnergy CostsTotal Production CostsSales RevenuesGross ProfitReturn on SalesEnergy Cost / Total CostsEnergy Costs / Tonne of Production

    Tonnes€1000 €1000 €1000 €%%€

    January27.000 € 236.912 € 1.160 € 1.000 -€ 160 -16,0%20,4% € 8,77

    February28.000 € 237.224 € 1.130 € 1.750 € 620 35,4%21,0% € 8,47

    March28.000 € 236.424 € 1.140 € 1.500 € 360 24,0%20,7% € 8,44

    April28.000 € 248.102 € 1.190 € 1.500 € 310 20,7%20,8% € 8,86

    May27.000 € 247.900 € 1.090 € 1.000-€ 90 -9,0%22,7% € 9,18

    June25.000 € 225.071 € 1.000 € 1.000 € - 0,0%22,5% € 9,00

    July12.000 € 128.255 € 750 € 900 € 150 16,7%17,1% € 10,69

    August20.000 € 196.546 € 1.000 € 1.500 € 500 33,3%19,7% € 9,83

    September25.000 € 222.016 € 1.100 € 2.000 € 900 45,0%20,2% € 8,88

    October26.000 € 222.576 € 1.050 € 1.500 € 450 30,0%21,2% € 8,56

    November27.000 € 232.736 € 1.150 € 1.000 -€ 150 -15,0%20,2% € 8,62

    December20.000 € 194.645 € 900 € 750-€ 150 -20,0%21,6% € 9,73

    Total293 € 2.628.407 € 12.660 € 15.400 € 2.740 17,8%20,8% € 8,97


    Information gathering quantitative2

    INFORMATION GATHERINGQUANTITATIVE

    STEP 8Energy transformation data

    Collect the data by using the data sheetsprovided as excel files.


    Information gathering quantitative3

    INFORMATION GATHERINGQUANTITATIVE

    STEP 9Production line data

    Collect the data by using the data sheetsprovided as excel files.


    Information gathering quantitative4

    INFORMATION GATHERINGQUANTITATIVE

    STEP 10Process energy consuming devices

    • Compressed air

    • Motor & drives

    • Refrigeration

    • HAVC

    • Other thermal equipment


    Information gathering quantitative5

    INFORMATION GATHERINGQUANTITATIVE

    STEP 11Buildings energy use

    Collect the data by using the data

    sheetsprovided as excel files.


    Analysis evaluation

    ANALYSIS & EVALUATION

    STEP 12Main indicators

    • Operating figures

    • Energy costs

    • Energy consumption

    • Co2 emissions

    • Process data


    Analysis evaluation1

    ANALYSIS & EVALUATION

    STEP 13Energy analysis

    • Organization

    • General site

    • Specific product lines

    • Energy transformation process


    Analysis evaluation2

    ANALYSIS & EVALUATION

    STEP 14Energy savings options

    • List of possible projects


    Analysis evaluation3

    ANALYSIS & EVALUATION

    STEP 15Recommendations for implementation

    • Example

  • NumberMeasureEnergy Savings (MWh)CO2 Savings (Tonnes)Energy Cost Savings (€)Other Cost Savings (€)Investment

  • Cost (€)Payback Period (years)Impact of Measure on energy Costs (%)Impact of Measure on Gross Margin (%)

  • Totals8,819.381,777.83€ 199,518€ 5,000€ 35,5500.537.59%7.46%

  • SAG 1Light sensors in Storage area10.006.27€ 476€ 5501.160.02%0.02%

  • SAG 2Meters on Steam Production2,590.99521.05€ 58,542€ 5,000€ 20,0000.312.23%2.32%

  • SAG 3Improved maintenance of steam traps5,181.991,042.10€ 117,083€ -0.004.45%4.27%

  • SAG 4Upgrade insulation on steam pipes1,036.40208.42€ 23,417€ 15,0000.640.89%0.85%


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