GBE Factory
Report on 10 GBE Factory Exemplary Cases
GREEN-BLUE-ENERGY FACTORY Project GBE Factory Intelligent Energy – Europe (IEE) - ALTENER
Contract No. IEE/10/232/SI2.593827
D 5.1: Report on 10 GBE FACTORY Exemplary Cases
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GBE Factory
Report on 10 GBE Factory Exemplary Cases
THE GBE FACTORY PROJECT The project promotes investments in “GREEN-BLUE-ENERGY FACTORIES”: industrial and commercial buildings equipped with single or combined renewable energy sources, able to provide electricity, heating and cooling for the air conditioning of premises, as well as for the business activities housed within. GBE Factory is coordinated by: Eurosportello – Unioncamere del Veneto-UCV Via delle Industrie, 19/d 30175 Venice, Italy Tel. +39 041 099 9411 Ms. Erica Holland erica.holland@eurosportelloveneto.it The Secretary General Mr. Gian Angelo Bellati
ABOUT THIS DOCUMENT This report presents Deliverable 5.1 of the GBE Factory project. It is the official electronic document which includes completed information for identification and selection data for 10 GBE Factory exemplary cases in he consortium participant’s country. This document was prepared in July 2013 by: ERATO Holding Plc 67 Saedinenie Blvd. 6300, Haskovo, Bulgaria M.Sc.Eng. Nikolay Vangelov n_vangelov@erato.bg Tel. +359 2 978 3990
INTELLIGENT ENERGY EUROPE The GBE Factory project is co-funded by the European Union under the Intelligent Energy Europe Programme (Contract No. IEE/10/232/SI2.593827).
The sole responsibility for the content of this publication lies with the authors. It does not necessarily reflect the opinion of the European Union. Neither the EACI nor the European Commission is responsible for any use that may be made of the information contained therein.
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GBE Factory
Report on 10 GBE Factory Exemplary Cases
CONTENT 1.
INTRODUCTION.............................................................................................. 5
2.
EU ENERGY POLICY...................................................................................... 5
3.
PROCESS OF IDENTIFICATION .................................................................... 6
4.
EVALUATION OF GBE FACTORY EXEMPLARY CASES .......................... 10 4.1.
TECHNICAL ANALYSES OF GBE FACTORY EXEMPLARY CASES ..... 10
4.2.
FINANCIAL ANALYSES OF GBE FACTORY EXEMPLARY CASES ...... 15
4.3.
RISK AND SENSITIVE ANALYSES OF GBE FACTORY EXEMPLARY CASES ................................................................................ 15
4.4.
ECOLOGICAL IMPACT AFTER THE GBE FACTORY EXEMPLARY CASES COMPLETION .............................................................................. 16
5.
6.
GBE FACTORY EXEMPLARY CASES BY COUNTRIES ............................ 17 5.1.
ITALY ......................................................................................................... 17
5.2.
AUSTRIA.................................................................................................... 19
5.3.
BULGARIA................................................................................................. 22
5.4.
SLOVAKIA ................................................................................................. 24
5.5.
GERMANY ................................................................................................. 27 CONCLUSIONS............................................................................................. 29
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GBE Factory
Report on 10 GBE Factory Exemplary Cases
ABBREVIATIONS AND ACRONYMS GBE Factory
Green-Blue-Energy Factories
EE
CA ESD
Concerted Action for the Energy RES Services Directive
Renewable Energy Sources
CDM
Clean Development Mechanism
Greenhouse Gases
EPBD
Energy Performance Directive
EPC
Energy Performance Contracting EC
European commission
ESCo
Energy Service Company
PPPs
Public Private Partnerships
ESD
Energy Service Directive
RETs
Renewable-energy and Energyefficient Technologies
EC
European Council
TPF
Third Party Financing
IEE
Intelligent Energy Europe
VAT
Value Added Tax
JI
Joint Implementation
NPV
Net Present Value
WEC
World Energy Council
IRR
Internal Rate of Return
GHG
Building EU
Energy efficiency
European Union
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GBE Factory
1.
Report on 10 GBE Factory Exemplary Cases
INTRODUCTION
The main goal of this Deliverable is identification on 10 GBE FACTORY exemplary cases from the point of view of technology, return of the investment and mid term sustainability. The technical partners in the GBE Factory project team FORGREEN, SOLID, ERATO, CCIS and CCIG have made professional efforts and investigated the possibilities to identification the best GBE Factory exemplary cases (two per each country). The PP2, PP4, PP6, PP7 and PP10 selected two GBE Factory exemplary cases, totally 10 based on the the knowledge gained during previous phases of the project. The identification process for 10 GBE Factory exemplary cases was among: Existing 30 reference cases presented in Deliverable 4.2.; New proposals, mainly originated by activity of the Expert Group or coming from innovative ideas/projects sponsored by the most advanced EPCs or high reputation testimonials from the technology sector. On the other hand the project team paid attention during the selection stages the possibilities for grant funding, subsidizing, local and regional support energy and renewable measures and utilization of resources under the EU Structural Funds. The opportunity for starting of the selected exemplary cases under the procedure of the related funds was taken into account too. The report on 10 GBE Factory exemplary cases is a starting point and thanks to the support of the GBE Factory project Experts Group the used knowledge and skills of the critical mass analyses will be a base for developing 5 DEMO GBE FACTORY Proposals (one per each country). The presented 10 GBE Factory exemplary cases include cases from Austria, Bulgaria, Germany, Italy and Slovakia.
2.
EU ENERGY POLICY
On 10 November 2010, the European Commission has adopted the Communication "Energy 2020 - A strategy for competitive, sustainable and secure energy". The climate and energy package is a set of binding legislation which aims to ensure the European Union meets its ambitious climate and energy targets for 2020. These targets, known as the "20-20-20" targets, set three key objectives for 2020: A 20% reduction in EU greenhouse gas emissions from 1990 levels; Raising the share of EU energy consumption produced from renewable resources to 20%; A 20% improvement in the EU's energy efficiency. Across the EU countries in the few last years the governments were prepared a lot of mechanisms which have to promote the advantages of improvement the energy efficiency and renewable in the residential, public and industrial sectors. The main energy efficiency and RES benefits to the different type of energy users are as follows: Reduction of energy cost to users; 5
GBE Factory
Report on 10 GBE Factory Exemplary Cases
The significant control over energy costs to customers were given; Possibility to jobs creating and improve state savings; Air pollutions reduction including decreasing of GHG; In a lot of cases the performance at a lower energy cost than new energy supply from new power sources including renewable. On 15 December 2011, the EC adopted the Communication "Energy Roadmap 2050". The EU is committed to reducing greenhouse gas emissions to 80-95% below 1990 levels by 2050 in the context of necessary reductions by developed countries as a group. In the Energy Roadmap 2050 the Commission explores the challenges posed by delivering the EU's decarbonisation objective while at the same time ensuring security of energy supply and competitiveness. The Energy Roadmap 2050 is the basis for developing a long-term European framework together with all stakeholders. One of the main advantages to using of renewable energy is that it is renewable and therefore sustainable. Renewable energy installation in general require less maintenance and operational cost than traditional facilities using energy sources. Even more importantly, RES produces little or no waste products such as carbon dioxide or other chemical and mechanical pollutants, so has minimal impact on the environment. Renewable energy projects can also bring economic benefits to many regional areas, as most projects are located away from large urban centres and suburbs of the capital cities. These economic benefits may be from the increased use of local services to the different sector of the EU economy and in the public sector as well. The primary production of renewable energy within the EU-27 in 2010 was 166.6 million tonnes of oil equivalent (toe) — a 20.1 % share of total primary energy production from all sources. The quantity of renewable energy produced within the EU-27 increased overall by 72.4 % between 2000 and 2010, equivalent to an average increase of 5.6 % per annum. The main benefits of RES using in the environmental and economic aspects are following: Producing sustainable energy that not generated GHG emissions from fossil fuels and can decreased some types of air pollution; Establishing very good economic growth and jobs in many sectors of the economy; Diversifying energy supply and reducing dependence on imported fuels.
3.
PROCESS OF IDENTIFICATION
After the completion of 30 GBE Factory reference cases development included in D 4.2 the Expert Group Commission for the selection of 10 GBE Factory exemplary cases was established. The list of members in the GBE Factory Expert Group includes the following members shown in Table 1. Table 1 List of GBE Factory Expert Group members No. Expert Name Organization 1 Germano Zanini FORGREEN 2 Johannes Luttenberger SOLID 3 Nikolay Vangelov ERATO 4 Giorgio Dovigi CCIS 5 Anna Turco CCIG
Country Italy Austria Bulgaria Slovakia Germany 6
GBE Factory
Report on 10 GBE Factory Exemplary Cases
The GBE Factory Expert Group has organized 2 PTC (Practice Theme Committee) meetings on Skype regarding evaluation and selection of 10 GBE Factory exemplary cases (two per each country). The 10 GBE Factory exemplary cases were selected on the basis of the following main important criteria: Most attractive economic returns; Degree of mid term sustainability; Degree of technological innovation. The selected 10 GBE Factory exemplary cases use high technology equipment, system and processes. The report includes exemplary cases which are planned to be implemented through combination between energy conservation opportunities and using of renewable energy sources. On the other hand this proposed exemplary cases for the potential GBE Factory show remarkable potential for energy savings achievement and greenhouse gas emission reduction. The production of electricity, heat and cooling energy based on high level technology and know how using renewable energy is also presented. Table 2 presents summary data regarding 10 GBE Factory exemplary cases identification.
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Report on 10 GBE Factory Exemplary Cases
Table 2 Summary data for 10 GBE Factory exemplary cases No.
1
2
3
4 5
GBE Factory Exemplary Case Construction of PV roof plant for electricity generation and heat pump for thermal conversion Construction of PV roof plant on the industrial plant Solar Process Heat in Meat Factory BERGER 100% solar heated industry building SUNMASTER Biogas Plant in Albena AD
Type of GBE Factory*
Energy Use**
Total*** Installed Power
One by one plus
E/H
39 kW Italy
One by one
E
925 kW
One by one
H
650 kW
One by one plus
E/H/C
848 kW
One to many
E/H
2000 kW
6
Co-generation and biogas plant Momchil
One to many
7
Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa
One to many
8
CHP plant using ORC
9
BeMobility 2.0. Subproject Micro Smart Grid
10
Construction of PV installation on airport building Total:
Country
E/H
H
2000 kW
Austria
Bulgaria
3627 kW Slovakia
One to one
E/H
5100 KW
One to many
E
n/a Germany
One to one
E
490 kW 15679 kW
* Type of GBE Factory based on D2.1. Draft electronic version of the Guide GBE FACTORY concept and Business Models. ** Energy use: E – Electricity, H – Heating, C – Cooling. *** Some of numbers are not available because they are confidential. The total installed power of all 10 GBE Factory exemplary cases is about 16 MW. The one by one GBE Factory exemplary cases are 4. Four exemplary cases are GBE Factory type one to many. GBE Factory exemplary cases type by one plus are tow. 8
GBE Factory
Report on 10 GBE Factory Exemplary Cases
The selected 10 GBE Factory exemplary cases include completed Energy Efficiency or RES projects and projects in progress in Italy, Austria, Bulgaria, Slovakia and Germany. Detailed information about the process of evaluation on 10 GBE Factory exemplary cases by countries is given in Chapter 4. The GBE Factory Expert Group evaluated 10 exemplary cases in different economical sectors of the EU like meat industry, machinery, industrial building, forest industry, textile industry, transport and logistics, food industry, tourism industry, RES area including using of ESCo services (see Figure 1.).
Figure 1 Allocation of the evaluated exemplary cases by economical sectors Meat industry RES Area
Transport industry
Industrial building
ESCo services
Machinery industry
Forest industry
Textile industry
Tourism industry
Food industry
Each exemplary case was evaluated based on the main project characteristics. The Expert Group did detailed analysis of the technical design and proposed technology. The financial project indicators and the green houses gas emissions reduction after the projects implementation were taken into consideration too. The current financial market in European Union presents an opportunity for sustainability development, environmental policy, and increasing of the standard of live through a wider range of policy and investment tools and mechanisms. There are many financial bodies with funds for supporting many kinds of Green-Blue Energy Factory Projects. It is important that they are made aware of the financial needs of companies and administrations that are willing to take that step towards energy efficiency and renewable energy sources. 9
GBE Factory
Report on 10 GBE Factory Exemplary Cases
These financial bodies include banks, Ministries of energy, government agencies, energy partnerships, community foundations, funding groups, institutions and Energy Service Companies (ESCO). The energy supply chains as a part of sustainable development depend on the significant role of producers of energy, its transport and logistic and distributors as well. There is significant interest of different type of stakeholders like producers, logistics, suppliers, project sponsors, promoters, advisors, distributors and local and regional authorities to support energy customers to reduce their energy consumption. The technical and high efficient solutions providing by the designers, installers, providers and equipment producers are warranty to achieving of the foreseen cost energy savings and GHG - greenhouse gas emissions reduction. The saved and avoided expenses after the energy conservation measures implementation and RES using in the 10 GBE Factory exemplary cases can be redirected to the significant social spheres of the community such as health and education.
4.
EVALUATION OF GBE FACTORY EXEMPLARY CASES
Based on the depth analysis of the suggested exemplary GBE Factory cases including technical, constructional, financial, contractual criteria 10 GBE Factory exemplary cases were collected by the GBE Factory Expert Group. The Expert Group presented 10 GBE Factory exemplary cases in various sectors of the EU economy, strengths and prospects for future implementation.
4.1.
TECHNICAL ANALYSES OF GBE FACTORY EXEMPLARY CASES
The technical analyses of the 10 GBE Factory exemplary cases were implemented by the following other criteria: Most attractive economic returns; Degree of mid term sustainability; Degree of technological innovation; Projects technical ability; Degree of technological innovation and know how; Appropriateness of the proposed technical solutions; Understanding of projects requirements; Approach to standards issues, e.g. interoperability; Project, construction and account management, project schedule; Opportunity for project grant funding, local and regional support schemes; Commissioning and maintenance, after sales service, technical assistance and training of the staff upon work completion; Projects compliance with the National or EU applicable law; Guaranteed cost savings as high as possible; Procurement contract duration (ESCO, EPC, Public Private Partnership); Energy management. The separate and average evaluation of the proposed 10 GBE Factory exemplary cases was rated on the scale from 1 to 5, where the score of 5 were excellent and 1 inferior. The average score is between 4.69-4.81 which means potential for successful implementation of the presented exemplary cases. 10
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 4.1 presents matrix for evaluation of the selected GBE Factory exemplary cases. The technical characteristics of the proposed 10 exemplary cases are given in Table 4.2. The aggregated data regarding the type of technology, financial indicators and emission reduction of the proposed 10 GBE Factory exemplary cases are shown in Table 4.3.
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GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 4.1 Technical criteria for 10 GBE Factory exemplary cases evaluation GBE Factory Exemplary Cases Criteria for Evaluation
1
2
3
4
5
6
7
8
9
10
Most attractive economic returns
4.5
4.5
4.2
4.0
4.2
4.1
4.5
4.1
4.1
4.4
Degree of mid term sustainability
4.4
4.4
4.9
4.7
4.8
4.7
4.8
4.6
4.8
4.7
Degree of technological innovation
4.5
4.5
4.8
5.0
4.9
4.9
4.7
4.6
4.9
4.7
Projects technical ability
4.6
4.7
4.9
4.9
4.8
4.8
4.9
4.9
4.8
4.7
Degree of technological innovation and know how
4.6
4.5
4.9
5.0
4.7
4.8
4.6
4.8
4.8
4.8
Appropriateness of the proposed technical solutions
4.4
4.4
4.4
4.6
4.4
4.2
4.3
4.3
4.6
4.4
Understanding of projects requirements
5.0
4.9
4.9
4.9
5.0
5.0
5.0
4.8
4.9
4.9
Approach to standards issues, e.g. interoperability
5.0
5.0
5.0
5.0
5.0
5.0
4.9
5.0
5.0
5.0
Project, construction and account management, project schedule
4.8
4.8
4.9
4.9
4.8
4.8
4.9
4.9
4.9
4.8
Opportunity for project grant funding, local and regional support schemes
4.7
4.8
4.5
4.4
4.5
4.5
5.0
5.0
4.8
4.8
Commissioning and maintenance, after sales service, technical assistance and training of the staff upon work completion
4.4
4.4
4.5
4.6
4.4
4.5
4.8
4.8
4.6
4.6
Projects compliance with the National or EU applicable law
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
Guaranteed cost savings as high as possible
4.7
4.7
4.8
4.8
4.7
4.7
4.8
4.8
4.9
4.7
Procurement contract duration (ESCO, EPC, PPP)
4.8
4.8
4.8
4.9
5.0
5.0
4.9
4.8
4.8
4.8
Energy management
4.9
5.0
5.0
5.0
4.8
4.8
5.0
4.9
5.0
5.0
Average:
4.69
4.69
4.77
4.78
4.73
4.72
4.81
4.75
4.79
4.75
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Report on 10 GBE Factory Exemplary Cases
Table 4.2 Technical characteristics of the proposed GBE Factory exemplary cases* Installed Power Capacity
No.
GBE Factory Exemplary Case
Country
Electricity
Heat
Cooling
(kWel/p)
(kWth)
(kWc)
Total Installed Power
Revenues/Savings
Project Revenues
Energy Savings
(kW)
(MWh/yr.)
(EUR/yr.)
(MWh/yr.)
(EUR/yr.)
1
Construction of PV roof plant for electricity generation and heat pump for thermal conversion
Italy
39
39
E/H
91
6220
n/a
2
Construction of PV roof plant on the industrial plant
Italy
925
925
E
919
7930
n/a
3
Solar Process Heat in Meat Factory BERGER
Austria
650
H
n/a
n/a
n/a
4
100% solar heated industrial building - SUNMASTER
Austria
34
770
848
E/H/C
519
170000
519
5
Biogas Plant in Albena AD
Bulgaria
1000
1000
2000
E/H
5200
664679
3333
6
Co-generation and biogas plant Momchil
Bulgaria
1000
1000
2000
E/H
5100
651897
2500
7
Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa
Slovakia
3627
3627
H
8736
n/a
n/a
8
CHP plant using ORC
Slovakia
1000
4100
5100
E/H
40141
n/a
n/a
9
BeMobility 2.0. Subproject Micro Smart Grid
Germany
n/a
n/a
E
61
n/a
n/a
10
Construction of PV installation on airport building
Germany
490
490
E
403
n/a
n/a
15679
0
61170
1500727
6352
Total:
650
4488
11147
44
44
* Some of numbers are not available because they are confidential.
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Report on 10 GBE Factory Exemplary Cases
Table 4.3 Type of technology, financial indicators and emission reduction of the proposed GBE Factory exemplary cases* Technology
No.
GBE Factory Exemplary Case
Emissions reduction
Financial Indicators Total Project Cost (EUR)
Country
NPV
IRR
Pay-back
CO2
(EUR)
(EUR)
(%)
(yr.)
(t/yr.)
Biomass/Solar/CHP/PV/Heat Pump/Other
1
Construction of PV roof plant for electricity generation and heat pump for thermal conversion
Italy
PV, Heat pump
133000
n/a
19
5.0
19
2
Construction of PV roof plant on the industrial plant
Italy
PV
1309767
1571720
21.60
5.0
460
3
Solar Process Heat in Meat Factory BERGER
Austria
Solar thermal process heat plant
738500
200390
15.00
7.0
173
4
100% solar heated industrial building - SUNMASTER
Austria
Geothermal / Solar Thermal / PV
3150000
n/a
10.00
12.0
303
5
Biogas Plant in Albena AD
Bulgaria
CHP, Biogas Plant
3500000
4130000
12.00
7.0
389
6
Co-generation and biogas plant Momchil
Bulgaria
CHP, Biogas Plant
4000000
4800000
9.00
8.0
310
7
Reconstruction of heating distribution system and fuel switching to reduce greenhouse gas emissions in Hnúšťa
Slovakia
Biomass boiler, solar collectors
6819310
n/a
n/a
n/a
2097
8
CHP plant using ORC
Slovakia
CHP with ORC
7 13352
8322622
13.0
n/a
11755
9
BeMobility 2.0. Subproject Micro Smart Grid
Germany
PV, Wind turbines, CHP
9300000
n/a
n/a
n/a
40
10
Construction of PV installation on airport building
Germany
PV
950000
n/a
n/a
n/a
274
Total:
37013929
15820
* Some of numbers are not available because they are confidential.
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GBE Factory
Report on 10 GBE Factory Exemplary Cases
The new energy technologies, equipment and facilities in the proposed 10 GBE Factory exemplary cases which will mount will increase the safety at work of the GBE Factory employees. The equipment is designed and manufactured in accordance with the contemporary European standards for safety at work.
4.2.
FINANCIAL ANALYSES OF GBE FACTORY EXEMPLARY CASES
The 10 GBE Factory exemplary cases financial analyses indicate that each case is very promising. The exemplary case’s pay back period is in the range between 5.0 – 12.0 years, including the construction period for separate cases. The Internal Rate of Return (IRR) is between 9.0% and 21.6% and the Net Present Value (NPV) amounts to the range from EUR 200390 to EUR 8322622. The total base investment for 10 GBE Factory exemplary cases implementation amounts to EUR 37013929. This base projects cost includes the costs for project design, equipment delivery and its installation and construction works. There are the opportunities to using actual financial mechanism for supporting of some GBE Factory exemplary cases implementation trough grant funding, local support measures and potential to start the procedure for the related request for funding. This opportunity will be additional warranty for successful exemplary cases implementation and loan disbursement. The detailed information about the financial indicators of the presented exemplary cases: NPV, IRR and Pay back period is given in Chapter 5. in this Report.
4.3.
RISK AND SENSITIVE ANALYSES OF GBE FACTORY EXEMPLARY CASES
The risk and sensitive analyses as a part of the evaluation of 10 GBE Factory exemplary cases was made. The different scenarios for all presented exemplary cases are based on the GBE Factory Expert Group assumptions and data sheets for each case. Completion risk: Capital cost overrun (construction risk); Start-up delay risk. Construction risk The equipment prices are determined on the basis of the preliminary offers, price information and information gathered from similar projects. Possible reasons for underestimation of the equipment costs are: Incorrect sizing of the technology, equipment and facilities; Omitted system and equipment, necessary for the conservation options; Incorrectly interpreted offers for project implementation.
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Report on 10 GBE Factory Exemplary Cases
The average influence of the construction risk to the GBE Factory exemplary cases will be moderately impacted by the 10-15% increase of the total project cost for each case. Start-up delay risk Although the complicated financial and economical situation in Europe the conditions are positive for keeping the time schedule of the proposed exemplary cases. The management of each project sponsors is highly motivated and has created structures for project implementation in each country. The start-up delay was analysed due to the following risks: Technology and equipment supply and installation will be delayed; The assembling sites are not ready for operation. The analyses indicate that the start-up delay does not significantly deteriorate the separate exemplary case’s financial indicators. Operational risk: The expected decrease of savings comparing with the baseline option for some of the GBE Factory exemplary case and revenues achieved based on purchasing of electricity and thermal energy for the some cases can be affected by the following circumstances: Incorrect impact definition during the project design stage; The prescribed operation conditions are not complied with; There is a strong handling and human factor dependence evident. The proposed technology and equipment cannot technically achieve the impact forecasted under the conditions of the beneficiaries; The analyses of this sensitivity scenario show that the influence of the average excepted savings reduction and projects revenues will be 15% compared to the base case. Worst case scenario: This worst case scenario tests the combination of all scenarios mentioned above including construction risk, start-up delay, and operational risk amounted to 25 % corresponding sensitivity scenarios presented above. This scenario affects to all financial indicators of the exemplary cases. The financial analysis shows that the average IRR decreasing is 2-4% and the average NPV is decreased by 1012%. However, the exemplary case’s financial indicators for this worst case still lead to the conclusion that the each GBE Factory exemplary case is viable. The exemplary cases will generate sufficient cash to repay the possible loan interest and principal.
4.4.
ECOLOGICAL IMPACT AFTER THE GBE FACTORY EXEMPLARY CASES COMPLETION
Determination of the annual emissions of CO2 is according to Commission Decision of 21.01.2004 establishing guidelines for the monitoring and reporting of Greenhouse gas emissions pursuant to Directive 2003/87/EC of the European Parliament and of the Council. The emissions factors elaborated by the MOEW (Methodology for calculation of emissions of noxious substances (pollutants) released into the environment based on balance methods) have been used for the CO2 and other noxious gases emissions assessment. 16
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The quantitative reduction of the carbon dioxide emissions was estimated through utilisation of the Operational Guidelines for Project Design Documents of Joint Implementation Projects of the Dutch Ministry of Economics as of May 2004. Data analyses shows that after the exemplary cases implementation the CO2 emissions will be reduced annually by 15820 tons as a result of the energy efficiency savings.
5.
GBE FACTORY EXEMPLARY CASES BY COUNTRIES
5.1.
ITALY
EXEMPLARY CASE N 1: CONSTRUCTION OF PV ROOF PLANT FOR ELECTRICITY GENERATION AND HEAT PUMP FOR THERMAL CONVERSION The proposed project uses PV technology for electric generation and use heat pumps for conversion in thermal energy. The photovoltaic and heat pump will be installed in the area of Carrera S.p.A., Verona, Italy. The installed capacity of PV modules is 38.64 kWp. Carrera is a Italian clothing corporation, founded in the mid 60’s in Verona. Carrera is a small clothing multinational industry as the production units are located in some of the major cotton producing countries, in order to have access to the best raw material, while the logistics and final inspection operations still remain in Italy to ensure the highest Carrera standards. The expected electric energy production of installed equipment is 38000 kWh/yr. 50% of this generated energy will be converted in thermal energy by heat pump with COP 2.8. The achieved thermal energy production will be in the amount of 53200 kWh/yr. After this investment, Carrera think about the thermal theme, and decided to begin a study to use a heat pump to produce thermal energy for its office. EXEMPLARY CASE N 2: CONSTRUCTION OF PV ROOF PLANT ON THE INDUSTRIAL PLANT ICI Caldaie S.p.A. is machinery plant situated in Campagnola di Zevio, Verona district, Italy. The proposed exemplary case will use photovoltaic modules for generation of electricity for own need. The total installed capacity of PV system is 925 kWp. The expected productivity from the high efficient PV installation is 919 MWh/yr. The projects technical characteristics are given in Table 5.1. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Italy are shown in Table 5.2.
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Table 5.1 Technical characteristics of the proposed exemplary cases
No.
GBE Factory Exemplary Case
Energy Total Use Installed Cooling Power (E/H/C)
Installed Power Capacity Electricity
Heat
(kWel/p) (kWth)
(kWc)
(kW)
Revenues/Savings Project Revenues
Energy Savings
(MWh/yr.) (EUR/yr.) (MWh/yr.) (EUR/yr.)
1
Construction of PV roof plant for electricity generation and heat pump for thermal conversion
39
39
E/H
91
6220
2
Construction of PV roof plant on the industrial plant
925
925
E
919
7930
132342
Total:
964
964
1010
14150
148342
n/a
16000
Table 5.2 Type of technology, financial indicators and emission reduction of the proposed exemplary cases Technology
Total Project Cost
Biomass/Solar/CH P/PV Heat Pump/Other
(EUR)
NPV (EUR)
IRR (%)
Payback (yr.)
CO2 (t/yr.)
1
Construction of PV roof plant for electricity generation and heat pump for thermal conversion
PV, Heat pump
133000
n/a
19.0
5.0
19
2
Construction of PV roof plant on the industrial plant
PV
1309767
1571720
21.6
4.9
460
1442767
1 571720
No.
GBE Factory Exemplary Case
Total:
Financial Indicators
Emissions reduction
479
18
GBE Factory
5.2.
Report on 10 GBE Factory Exemplary Cases
AUSTRIA
EXEMPLARY CASE N 3: SOLAR PROCESS HEAT IN MEAT FACTORY BERGER The solar thermal process heat plant will be constructed in the area of the meat factory Berger in the town of Sieghartskirchen, Austria. The complete area for installing of solar collectors is 1 077 m2, the installed thermal power of the collectors is 650kWth. The produced hot water and steam will be used from factory for technological needs, heating and domestic hot water. Main characteristics of hot water preheating for dehumidification of maturation chambers: 7 m³ /h hot water demand; 240 kW plate heat exchanger; Usage of waste heat until 40°C; Solar heating up to 70°. Preheating feed water for steam production (ham cooking) 2,7 m³/h hot water demand 200 kW plate heat exchanger Usage of waste heat until 28°C Solar heating up to 93° The main advantages of the proposed solar collector’s type ökoTech – flat plate collectors by SOLID are: Higher energy output; Flow of fluid is designed to suit application; Easier and faster installation; Less connections and pipings; Lower flow indicates smaller pumps. The heating isntallation will include boiler feed water – preheated 28/93oC, buffer storage with capacity 60m3, hot water circulit unit 40/70OC, valvs, connecting pipes, pumps, flat expanders.. The control system wuth remote control unit will be alco installed. EXEMPLARY CASE N 4: 100% SOLAR HEATED INDUSTRIAL BUILDING - SUNMASTER The industrial building costumer WA Busienss & Service Centre ownd by Sun Master GmbH is located in the town of Eberstalzell, Austria. The Sun Master is the leading producer of solar thermal collectors. The company havs a large selection of solar collectors with accessories: flat plate solar collectors, solar absorbers, mounting systems and components for solar systems. The Sun Master will invest in renewable energy project of the new production site as a pasive house. The building has a total industrial area of 1100 m² of solar panels for solar air conditioning and electricity. Thermal coupling to the ground provides heating in winter. The entire energy needs of the enterprise – both for cooling and heating as well as for the operation of manufacturing facilities – are thus met by renewable energies.For this purpose 800m2 of solar thermal collectors will be installed on the building roof and 300m2 of solar collectors on facades. A photovoltaic plant with capacity of 33.5 kWp will be installed on the building. During the night the ventilation windows of teh smoke extractors will be oppened in automatic way. The transverse ventilation affects the free cooling of the building. 19
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Additionnaly absorbtion chillers can be used for cooling of the production premises and offices. Key data for technical implementation of the proposed exemplary case are: Thermal coupling of the ground; Extremely airtight covering; Natural night cooling; South-facing shed roofs; Use of internal heat gained from the machines; Solar cooling of laser welding machines; Solar air conditioning of the office building. The projects technical characteristics are given in Table 5.3. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Austria are shown in Table 5.4.
20
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 5.3 Technical characteristics of the proposed exemplary cases Energy Installed Power Capacity Revenues/Savings Total Use GBE Factory Installed No. Exemplary Electricity Heat Cooling Power (E/H/C) Project Revenues Energy Savings Case (kWel/p) (kWth) (kWc) (kW) (MWh/yr.) (EUR/yr.) (MWh/yr.) (EUR/yr.)
3
Solar Process Heat in Meat Factory BERGER
4
100% solar heated industrial building SUNMASTER
34
770
Total:
34
1420
650
650
H
44
848
E/H/C
44
1498
517
55370
519
170000
519
170000
519
170000
1036
225370
Table 5.4 Type of technology, financial indicators and emission reduction of the proposed exemplary Technology No.
GBE Factory Exemplary Case
Total Project Cost
Financial Indicators
Emissions reduction
Biomass/Solar/CHP/ PV Heat Pump/Other
(EUR)
NPV (EUR)
IRR (%)
Payback (yr.)
CO2 (t/yr.)
3
Solar Process Heat Meat Factory BERGER
Solar thermal process heat plant
738500
200390
15.0
7.2
173
4
100% solar heated industrial building SUNMASTER
Geothermal/Solar Thermal/PV
3 50000
n/a
10.0
12.0
303
Total:
3888500
476
21
GBE Factory
5.3.
Report on 10 GBE Factory Exemplary Cases
BULGARIA
EXEMPLARY CASE N 5: BIOGAS PLANT IN ALBENA AD EXEMPLARY CASE N 5 The project envisages construction of biogas plant using organic waste, providing energy for heating of hotels, restaurants and other infrastructure in the Albena resort and domestic hot water for the tourists needs. The energy will be generated by anaerobic biogas plant trough installed CHP with nominal electricity production of 1 MWel, and 1 MWth thermal energy production respectively. The biogas plant will be situated 10 km from the Albena resort, Balchik municipality, northeast Bulgaria. The project sponsor and investor is Perpetuum Mobile BG JSCo. The technology in the biogas plant will be supplied by MT Energie GmbH. The company AB Energy form Italy will deliver Co-generation. The construction of all facilities will be implemented by Eko Stroy AD, Bulgaria. The generated electricity will be utilised trough public grid owned by Energo Pro AD. EXEMPLARY CASE N 6: CO-GENERATION AND BIOGAS PLANT MOMCHIL The cogeneration and biomass plant Momchil is situated in the area of Albena resort, Balchik municipality, north-east Bulgaria. The CHP will be installed in biogas plant which will use organic waste, providing: Electricity for local consumers and grid; Heating up a greenhouse; Utilization of the heat in a processing plant for fruits and vegetables; Heating of office buildings. The food company Eko Plod AD will be consumer of the generated heat energy especially for greenhouse and processing plant for fruits and vegetables. The CHP has nominal electricity power of 1 MWel, thermal power of 1 MWth for combined electricity and hot water. The generated electricity will be utilised trough public grid owned by Energo Pro AD. The main project activities will be implemented as follows: Biogas plant will be supplied by MT Energie GmbH, Germany; The Italian company AB Energy will deliver CHP module; The construction of all facilities will be implemented by Eko Stroy AD, Bulgaria. The projects technical characteristics are given in Table 5.5. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Bulgaria are shown in Table 5.6.
22
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 5.5 Technical characteristics of the proposed exemplary cases Energy Total Use Installed Cooling Power (E/H/C)
Installed Power Capacity No.
GBE Factory Exemplary Case
Electricity
Heat
(kWel)
(kWth)
(kWc)
(kW)
Revenues/Savings Project Revenues (MWh/yr.)
(EUR/yr.)
Energy Savings (MWh/yr.) (EUR/yr.)
5
Biogas Plant in Albena AD
1000
1000
2000
E/H
5200
664679
3333
312500
6
Co-generation and biogas plant Momchil
1000
1000
2000
E/H
5100
651897
2500
250000
Total:
2000
2000
4000
10300
1316577
5833
562500
Table 5.6 Type of technology, financial indicators and emission reduction of the proposed exemplary cases
No.
GBE Factory Exemplary Case
Technology
Total Project Cost
Biomass/Solar/CHP/PV Heat Pump/Other
(EUR)
NPV (EUR)
IRR (%)
Pay-back (yr.)
CO2 (t/yr.)
Financial Indicators
Emissions reduction
5
Biogas Plant in Albena AD
CHP, Biogas Plant
3500000
4 130 000
12.0
7.0
389
6
Co-generation and biogas plant CHP, Biogas Plant Momchil
4000000
4 800 000
9.0
8.0
310
Total:
7500000
699
23
GBE Factory
5.4.
Report on 10 GBE Factory Exemplary Cases
SLOVAKIA
EXEMPLARY CASE N 7: RECONSTRUCTION OF HEATING DISTRIBUTION SYSTEM AND FUEL SWITCHING TO REDUCE GREENHOUSE GAS EMISSIONS IN HNÚŠŤA Rimavská Energetická s.r.o. operates a central system of production and distribution of heat in Hnúšťa, district of Rimavská Sobota, Banská Bystrica region, southern Slovakia with population of 7749 people. The project envisages reconstruction of existing heating distribution system and fuel switching to reduce greenhouse gas emissions. The installed capacity and annual production of thermal energy from the new equipment is following: One unit of VESKO-B biomass boiler with installed capacity of 3MW; Total heat production from the biomass boiler is 5833.38 MWh/yr; 360 psc of solar collectors type Citrin Solar CS 111-SF with total installed capacity of 0.627 MW; Total heat production from the solar collectors is: 10454 GJ/yr. A new heating system in Hnúšťa is due to undertaken investments one of the most modern and efficient in Slovakia. New technologies guarantee high efficiency of the system. The main advantage is stability based on the use of three primary energy sources - biomass, solar and natural gas. From the finalization of the project at the end of 2011 more than 95% of the heat in the city is produced from RES. From this point of view, the urban heating system in Hnúšťa is unique not only in Slovakia but also throughout Central Europe. EXEMPLARY CASE N 8: CHP PLANT USING ORC The combined heat and power plant is situated in the premises of TOPHOLZ s.r.o., in the village Krnča, district of Topolčany, Nitra Region, Western Slovakia. TOPHOLZ is one of the biggest wood working companies in the region. It deals with wood processing and wood trading. TOPHOLZ s.r.o. has the capacity to cover the entire need for biomass and is a partner in the project. On the other side, TOP PELET as an ESCo will be an exclusive supplier of heat to TOPHOLZ s.r.o. The applied technology is based on Organic Rankin Cycle (ORC) and include biomass thermal oil boiler of type KOHLBACH K8 with installed capacity of 5150 KWth and ORC turbine type TURBODEN 10 CHP SPLIT. After the energy efficiency project implementation the CHP plant will generate: Heat power 4.1 MWth; Heat energy generation 118000 GJ/yr.; Electricity power 1.0 MWel; Electric energy generation 7323 MWhel/yr. ORC is a unique technology which combines heat and power from various renewable energy sources. It is particularly advantageous for decentralized production of electricity and heat. ORC devices have a high overall efficiency: 20% of heat coming from the thermal oil is 24
GBE Factory
Report on 10 GBE Factory Exemplary Cases
converted into electricity, while 78% remains available at a relatively high temperature to further heat use. Technical advantages of ORC modules: High efficiency cycle; The higher efficiency of the turbine; Low mechanical turbine burden through low peripheral speed; High reliability; Easy start up and shutdown of the plant; Automatic and smooth operation with low noise; Low operating and maintenance requirements; Low specific technical knowledge required; Long lifetime of the plant. The added value of the project is that since the beginning of its operation 80% of the generated heat can be used towards their internal consumption and sale to the partners. The projects technical characteristics are given in Table 5.7. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Slovakia are shown in Table 5.8.
25
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 5.7 Technical characteristics of the proposed exemplary cases No .
GBE Factory Exemplary Case
7
Reconstruc tion of heating distribution system and fuel switching to reduce greenhous e gas emissions in Hnúšťa
8
CHP plant using ORC Total:
Installed Power Capacity Electricity
Heat
Cooli ng
(kWel/p)
(kWth)
(kWc)
Energy Total Use Installe d (E/H/C) Power (kW)
Revenues/Savings Project Revenues
Energy Savings
(MWh/yr.)
(EUR/yr.)
3627
3627
H
8736
n/a
1000
4100
5100
E/H
40141
n/a
1000
7727
8727
(MWh/yr.)
(EUR/yr.)
48877
Table 5.8 Type of technology, financial indicators and emission reduction of the proposed exemplary Technology
Total Project Cost
Biomass/Solar/CHP/PV Heat Pump/Other
(EUR)
NPV (EUR)
IRR (%)
Pay-back (yr.)
CO2 (t/yr.)
7
Reconstruction of heating distribution system and fuel Biomass boiler, solar switching to collectors reduce greenhouse gas emissions in Hnúšťa
6819310
n/a
n/a
n/a
2097
8
CHP plant using CHP with ORC ORC
7113352
8322622
13
n/a
11755
Total:
13932662
No.
GBE Factory Exemplary Case
Financial Indicators
Emissions reduction
13852
26
GBE Factory
5.5.
Report on 10 GBE Factory Exemplary Cases
GERMANY
EXEMPLARY CASE N 9: BEMOBILITY 2.0. SUBPROJECT MICRO SMART GRID The BeMobility 2.0 project will be implemented in Berlin, Germany. Funded by the Federal Ministry of Transport, Building and Urban Development in Cooperation with Companies from the Science an Industry sector the following energy stakeholders will be included in the project. InnoZ; Schneider Electric; NBB Netzgesellschaft Berlin-Brandenburg; TU-Berlin DAI-Labor; TU-Berlin SENSE; DB Fuhrpark Services; Vattenfall Innovation Europe. Together with the partners mentioned above, the InnoZ built up an intelligent distribution network for electric energy on the EUREF-Campus (European Energy Forum) on the old Gasometer in Berlin Schรถneberg. The Micro Smart Grid is part of the Platform for electric Mobility in the InnoZ, which is part of BeMobility 2.0. The Platform for electric mobility can be used for expert forums, events, basic research or meetings. The InnoZ is tenant on the EUREF-Campus which is a project to build the CO2 neutral city of the future. The project includes the following activities: Installation of 3 Photovoltaic-Arrays; Installation of 5 vertical axis wind turbines; Installation 2 stationary grid buffer batteries; Construction of an electric carsharing-station with charging infrastructure for up to 28 simultaneous charging cars; Access to an operating e-carsharing-fleet; Real time monitoring of all component in the grid; Constant calculation of the optimized state of the grid and control of all components. EXEMPLARY CASE N 10: CONSTRUCTION OF PV INSTALLATION ON AIRPORT BUILDING The project envisages installation of the PV modules with 490 kWp. The electricity will be produced for the Flughafen Hannover-Langenhagen GmbH own needs. The annual electric energy production in the amount 403000 kWhel will be expected. The project sponsor is Flughafen Hannover-Langenhagen GmbH. The applied technology delivery and installation of high quality poly crystal PV modules will be installed on the roof of the airport in order to produce electricity for self-consumption. The innovative aspect includes the focus on the system as a PV electricity generation. The projects technical characteristics are given in Table 5.9. Type of technology, financial indicators and emission reduction of the proposed exemplary cases for Germany are shown in Table 5.10. 27
GBE Factory
Report on 10 GBE Factory Exemplary Cases
Table 5.9 Technical characteristics of the proposed exemplary cases Energy Total Use Installed Cooling Power (E/H/C)
Installed Power Capacity No.
GBE Factory Exemplary Case
Electricity
Heat
(kWel/p) (kWth)
9
BeMobility 2.0. Subproject Micro Smart Grid
Construction of PV 10 installation on airport building
Total:
(kWc)
(kW)
Revenues/Savings Project Revenues
Energy Savings
(MWh/yr.) (EUR/yr.) (MWh/yr.) (EUR/yr.)
n/a
n/a
E
61
n/a
490
490
E
403
n/a
490
490
n/a
98400
464
98400
5.10 Type of technology, financial indicators and emission reduction of the proposed exemplary
No.
9
10
GBE Factory Exemplary Case
BeMobility 2.0. Subproject Micro Smart Grid Construction of PV installation on airport building
Total:
Technology
Total Project Cost
Biomass/Solar/CHP/PV Heat Pump/Other
(EUR)
NPV (EUR)
IRR (%)
Pay-back (yr.)
CO2 (t/yr.)
PV, Wind turbines, CHP
9300 000
n/a
n/a
n/a
40
950000
n/a
n/a
n/a
274
PV
Financial Indicators
Emissions reduction
10250000
314
28
GBE Factory
6.
Report on 10 GBE Factory Exemplary Cases
CONCLUSIONS
The following conclusions for the selected 10 GBE Factory exemplary cases can be made: The proposed exemplary cases have high degree of mid term sustainability and technological innovation; The GBE Factory Expert Group selected 10 cases from the 30 reference cases presented in D 4.2; The exemplary cases have compliance with there national or EU applicable law and standards; The report on 10 GBE Factory exemplary cases will be used to preparation of 5 project proposals for the future realization of a DEMO GBE FACTORY; The D 5.1. will contribute the project development and reaching of the project performance indicators; The report and the further DEMO GBE Factory implementation will lead to direct benefits to the SME’s; Using dissemination tools after the project completion multiplying effect will be expected to the different type of stakeholders; Support the transfer and adoption of technology and/or know-how, the technology upgrading, the development of research facilities and the updating of the exciting facilities; Investment in upgrading and modernization of production technology and equipment; Raise the ability of EU Small and Medium Enterprises to cope with competitive pressure within European market; Improvement the living standards of the employers in the factories; Significant decreasing of energy carriers cost to the industrial sectors; Sustainable growth establishment; Reduction of GHG emission and environmental ecological impact will be achieved.
29