ENERGY MANAGEMENT SYSTEM

IN USJE (TITAN GROUP) Presenter: Mr. Stathis Politis – Technical Director

The business case for energy efficiency in North Macedonian industries

21 November 2019

Aleksandar Palace, Skopje, North Macedonia

TITAN Group and Usje

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Build in 1955

Under TITAN Group from 1998

Today we have around 270

employees and around 200

contractors

With implemented best available

techniques, the production capacity

is approximately 1.4 million

tons/year

Ready Mix Concrete unit

Usje is the only cement manufacturer in the country

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Brief introduction

USJE & ISO Standards

• ISO 9001 certified since year 2004

• ISO 14001 certified since year 2006

• BS OHSAS 18001 certified since year 2010

• 2020 - ISO 45001:2018

• Next step ….

WHY Energy Management System (EnMS)?

… ENERGY Management (in line with ISO 50001) is

more than expected next step

Systems and procedures will help to:

Improve energy performance

Oversight of energy use and efficiency

Implement an optimized Mix of energy

WHY Energy Management System (EnMS)?

Save energy – save money: measurable savings

Reduce carbon footprint

Increase credibility – green company

Most popular worldwide energy certification

Steps of Energy Management System

implementation in USJE

• Group Decision to implement EnMS in 2018 for all BUs

• Beginning of 2019 - Decision of EnMS implementation in Usje

• July 2019 – Run Tenders for EnMS Implementation

• August 2019 – Sign contract with consultant for EnMS implementation

• September 2019 – EnMS Implementation Started

• April 2020 – Expected completion of implementation process

• June 2020 – Expected ISO 50001:2018 Certification

• Team of four engineers to work together with consultant

• Delivered training – Introducing to EnMS, attended by more than 30 employees with significant direct and indirect impact on energy consumption

• Classification of Energy uses by their significance on energy consumption

• Discussing energy saving possibilities hidden in employees behavior change

• Possibility to change current EnPI (Energy Performance Indicator)

• At the moment SEC (Specific Energy Consumption) is used for monitoring overall company energy performances

Steps of Energy Management System

implementation in USJE

What has changed so far from EnMS

Implementation

• Much work already there because of IPPC requirements, Cembureau reporting & ISO 14001

• Idea is to replace SEC with more advanced model for monitoring energy performances

• Model was build using mathematical regression of all relevant independent variables that affect energy consumption

• This is the most innovative (unique) idea regarding other standards and therefore it will be also biggest challenge to accept it!

• Determined baseline to compare

The goal is to influence energy behavior

Energy consumption baseline and projects for EE

The goal is to influence energy behavior

Energy consumption 2018 Midyear 2019

Thermal energy consumption STEC (kcal/kg clinker) 872,0 861,4

total (GJ/year) 2.731.887 1.175.124

Electrical energy consumption

SEEC (kWh/t cement) 95,5 95,4

total (GJ/year) 373.014 170.756

Projects completed which will support the EnMS

• Study for compressed air optimization (CASO) – already savings 95k€/year

• Study for energy efficiency and possibilities for waste heat recovery

• Energy audits for administration buildings

Allocated level of resources for EnMS for 2020

and expected payback time

The most important is commitment from the top management

Project/Activity related to EnMS Allocated resources (k euros)

payback time of invested resources

1. Frequency converter for ID fan K3 – 1500 MWh/year 250 2 years

2. Replacement of compressors in packing plant – 400 MWh/year 100 2 years

3. Reduction of false air in the Raw Mill departments - 250 MWh/year 120 2 years

4. Modification of the preheater on Kiln 3 (Vortex) – 6 kcal/kg clinker 40 2,5 years

5. Investments in EE of buildings – 326 MWh/year 30 2-7 years

6. Study for energy efficiency and possibilities for waste heat recovery – 171

MWh/year

50-500 4-10 years

We believe in our contribution to overall sustainable development in our society

THANK YOU FOR YOUR ATTENTION

COMMITMENT TO ENERGY EFFICIENCY

for more information please visit www.usje.com.mk

APPENDIX

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14

Benefits achieved through CASO

After implementation of Energy Conservation Opportunities, following savings are measured: Annual savings- energy cost of operation 80 000 €/year (36.5%) Annual savings- energy consumption 1 126 752 kWh/year

Annual savings- maintenance man hours, >15 000 €/year

wear & tear, parts, lubricants etc..

Other benefits: Improved performance and better stability of the compressed air system, higher degree of redundancy

STUDY FOR ENERGY EFFICIENCY AND POSSIBILITIES

FOR WASTE HEAT RECOVERY

Installation of new boiler with lower capacity

Waste Heat Recovery (WHR) for electricity production using waste gasses from clinker cooler (IRR 6-12 years)

Rankine Cycle (water/steam)

ORC (Organic Rankine Cycle) Cycle

Kalina Cycle

WHR for drying of marl using waste gasses from clinker cooler – total savings of fuel ~250k – 700k €/year (depending from process and production)

WHR from kiln bearings and electric motors from mills (low temperature)

Installed capacity

(kW)

Investment cost (€)

Efficiency rate,

min(%)

Energy savings (kWh)

Fuel savings (Nm3)

Fuel costs savings

(€)

Payback period (years)

1000kW 30,000 95 171,724 18,455 7,751 3.9

ENERGY AUDITS FOR ADMINISTRATION BUILDINGS

5 Administration buildings with total of ~4000 m2 heated area:

• Annual energy cost for the buildings is 97 020 €/y (calculated three year

average)

• Annual energy consumption for the buildings is 1 544 151 kWh/y

(calculated three year average)

• Estimated energy saving potential for the buildings is 326 573 kWh/y

(projection)

• The financial saving potential for the buildings by implementation of the

considered measures is 20 494 € (projection)

[CATEGORY

NAME][PERCENTAG

E]

Ventilation

9%

Lighting system

2%

Cooling system

33%

Other el. energy

consumers

36%

Annual financial energy cost

Annual energy consumption %

Estimated energy saving potential