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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 +

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


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 Production Energy Costs Total Production Costs Sales Revenues Gross Profit Return on Sales Energy Cost / Total Costs Energy Costs / Tonne of Production

    Tonnes € 1000 € 1000 € 1000 € % % €

    January 27.000 € 236.912 € 1.160 € 1.000 -€ 160 -16,0% 20,4% € 8,77

    February 28.000 € 237.224 € 1.130 € 1.750 € 620 35,4% 21,0% € 8,47

    March 28.000 € 236.424 € 1.140 € 1.500 € 360 24,0% 20,7% € 8,44

    April 28.000 € 248.102 € 1.190 € 1.500 € 310 20,7% 20,8% € 8,86

    May 27.000 € 247.900 € 1.090 € 1.000 -€ 90 -9,0% 22,7% € 9,18

    June 25.000 € 225.071 € 1.000 € 1.000 € - 0,0% 22,5% € 9,00

    July 12.000 € 128.255 € 750 € 900 € 150 16,7% 17,1% € 10,69

    August 20.000 € 196.546 € 1.000 € 1.500 € 500 33,3% 19,7% € 9,83

    September 25.000 € 222.016 € 1.100 € 2.000 € 900 45,0% 20,2% € 8,88

    October 26.000 € 222.576 € 1.050 € 1.500 € 450 30,0% 21,2% € 8,56

    November 27.000 € 232.736 € 1.150 € 1.000 -€ 150 -15,0% 20,2% € 8,62

    December 20.000 € 194.645 € 900 € 750 -€ 150 -20,0% 21,6% € 9,73

    Total 293 € 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

  • Number Measure Energy 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 1 Light sensors in Storage area 10.00 6.27 € 476 € 550 1.16 0.02% 0.02%

  • SAG 2 Meters on Steam Production 2,590.99 521.05 € 58,542 € 5,000 € 20,000 0.31 2.23% 2.32%

  • SAG 3 Improved maintenance of steam traps 5,181.99 1,042.10 € 117,083 € - 0.00 4.45% 4.27%

  • SAG 4 Upgrade insulation on steam pipes 1,036.40 208.42 € 23,417 € 15,000 0.64 0.89% 0.85%


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