Audyt EED Ang

ENERGY AUDIT
(xxxxxxxxxxxxxx, Pozna)
Part of a project:
Conducting the energy audit of a plant in accordance with the EED 2012/27/UE directive
Audited areas:
Electrical energy, heat and cold sources
Energy of the buildings and the manufacturing network
Electricity system of the buildings and the network
Technological process

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.
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Project file:
Project
leader:
Object:
xxxxxx
The basis for

the audit:
Advisory services contract
Duration:
28.04.2016 12.05.2016
Aim:
Audit of energy efficiency of the plant
Analyzed on:
03.06.2016
Audit
contractor:
xxxxxxxxx
DB Energy Sp. z o.o.

Al. Armii Krajowej 45
50-541 Wrocaw
mobile: +48 71 337 13 25
Technical director of the project:
Processed by:
Anna Pasiak, MSc., eng.

Robert Drewicz, MSc., eng.
Waldemar Jakubowski, MSc., eng.

mobile: +48 516 173 806

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Table of contents:
1.
Introduction .................................................................................................................................... 7
2.
Methodology................................................................................................................................. 12
3.
Energy balance and selecting energy consumption indicators of the plant .................................. 18
4.
The choice of activities to improve energy efficiency ................................................................. 28
4.1.
The areas of heat and cold sources ........................................................................................... 28
4.1.1.
The boiler room ..................................................................................................................... 28
4.1.2.
Drying process balance ......................................................................................................... 30
4.1.3.
Cooling requirements during germination process ............................................................... 44
4.2.
The electromagnetic area of the buildings and transmission network ...................................... 58
4.2.1.
Compressed air system .......................................................................................................... 58
4.2.2.
Lighting system ..................................................................................................................... 62
4.2.3.
Electric drives ........................................................................................................................ 64
4.3.
Technological process area ....................................................................................................... 70
4.3.1.
Soaking process balance........................................................................................................ 70
4.3.2.
Germination balance ............................................................................................................. 74
4.3.3.
Analysis of processing ventilators......................................................................................... 83
4.3.4.
Dust removal systems............................................................................................................ 89
5.
Energy policy of the plant ............................................................................................................ 95
6.
Summary....................................................................................................................................... 98
List of Figures .................................................................................................................................... 104

List of Tables ..................................................................................................................................... 106

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1. Introduction
Audited plant xxxxxxxxxxx in Pozna works in branch of malting industry. Barley delivered
to the plant undergoes processing giving as a product barley malt. The main recipient is xxxxxxxxx In
the structure of the plant there are several areas in which electricity and heat are used:
Elevator
Barley and the final product, barley malt, is stored in the elevators silos. They are transported
by chain conveyors and bucket conveyors. Because of high dust levels there is a system of dust removal
installed. Grain waste is a byproduct of the technological process and it is granulated and used as
fertilizer.
Electricity is essential for proper functioning of the elevator. Its main recipients are the drives
of bucket conveyors (Fig. 1) and chain conveyors with the power between 1.5kW to 22kW. It is also
essential in the functioning of ventilator drives (Fig. 2) with the power between 11kW and 18,5kW as
well as the drive working in granulation line for the grain waste with the power 45kW. Next important
recipient are compressors producing compressed air with the power between 22kW and 45kW.
Analysis of the way other selected drives work is given further in this document. Regulating efficiency
of ventilators and settings of filter cleaning appliances in the dust removal system were examined
during the audit.
Fig 1. Bucket conveyor drive
Source: own.

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Fig 2. Dust removal ventilator drive
Source: own.
Soaking and germination building

There are areas of soaking and germination of seeds in this building. It also contains a boiler
room, a water pressure station and a control room. Electricity and cold are required for proper
functioning of the building.
o Soaking process
Main recipients of electricity are three ventilator drives which remove carbon dioxide from the
grains, each with the power of 15kW and steered by inverters. Regulating efficiency of ventilators and
their condition were audited. Another key recipient is variable speed compressor with the power of
119,7kW that delivers oxygen to the grains.
o Germination
Main recipients of electricity are eight ventilators which aerate and remove carbon dioxide
from grains resting in crates. They are driven by engines with power 37kW and steered by inverters.
During the stay in the plant efficiency of ventilators was measured. In addition, air distribution
in individual openings under and above crates was measured. On the basis of gathered data air currents
directed under crates and removed from the chamber were calculated. Results of these calculations are
presented further in this analysis.

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In summertime air delivered to crates requires cooling. This process is conducted with ice water
within parameters 7/12oC. It is produced in ice water units with total cooling power of 6MW. Water
circulation is imposed with a set of nine pumps driven by engines with the power of 22kW. Planned
implementation of enclosing heat pumps stipulates partial change in method of cooling ice water. This
is why need for cooling in germination process is indicated. Spraying fresh air from water nozzles
supports air cooling in individual crates. In result the temperature lowers and humidity rises. However,
it is not an optimal system and does not allow to make full use of adiabatic cooling phenomenon, which
is why optimalization was proposed.
Dryer
There is a requirement for electricity and heat in this area. Two drives of ventilators with
nominal power 500kW, powered by inverters, are the biggest recipients of electricity. They impose air
circulation in the drying appliance. Heat required for drying is created by three G50/2-A gas burners
with nomial power of 5,4MW each.
As part of the audit several issues were addressed, that is analyzing the condition of ventilators,
determining the energy and heat balance as well as verifying the concept of enclosing heat pump
system and cogeneration unit.
Powering the plant with electricity

Audited plant is powered by two 15kV lines, each powering a separate section in the MV main
switchboard. Leading out of the switchboard are 15kV lines powering six medium/low voltage
transformers. Purchasing electricity is conducted by B23 fare of the provider in accordance with
distribution services and purchasing electricity contracts signed respectively with Xxxxx Operator Ltd
and XXXXX Xxxxx S.A. In the distribution agreement the contracted power for connection no. 1 was
established at 1400kW. For connection no. 2 ordered power is established for particular billing cycles
based on usage predictions. Billing factor tg was established at 0.4. The plants indirect measurementbilling system is located in the main HV connection.

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Supplying the plant with heat

Heat in the audited plant comes from methane-rich natural gas which is burnt in burners in the
drier appliances and boilers of central heating. Gas purchase is conducted by W-7A fare in accordance
with the comprehensive agreement for purchase and distribution with PGNiG Obrt Detaliczny
sp. z o.o. contracted power was established at 12 069kWh/h which equates to about 1092m3/h.
Supplying the plant with compressed air

Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant has compressed air appliance at operating
pressure 6.0bar. the system provides air to machines used in production process, including cyclone
filters and scales. Three compressors from Atlas Copco produce compressed air. They are GA22,
GA45 and GA45+ models. These devices work in a classic pressure cascade. During the measuring
week the GA45 compressor participated in producing compressed air. Compressed air is processed
using ALD 065 SPUC drier from Donaldson and subsequently transported through pipelines to
individual areas of the plant.
Illuminating the plant

Lighting appliance in xxxxxxxxxxx plant consist mostly of linear fluorescent fixtures with
2x58W power. In the soaking and germination building modernization of crate chambers has begun.
One of suggested actions is changing lighting to energy saving LED lamps. In addition, there are 400W
sodium lamp fixtures in the crate room. In the technical rooms of the elevator lighting is seldom used.
Lighting is mostly used in rooms like communication passages or control room. More in depth analysis
of light system is presented further in this document.
The aim of the energy audit conducted in Xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxx plant is to
present solutions based on the auditors best available practices and experience which would enable
the plat to reduce energy consumption and lowering the levels of CO2 emission. After consulting the
people in charge of the project on the side of the plant, the following activities were chosen as the ones
likely to reduce energy consumption of the plant:

Changing the method of steering the air compressor (enclosing the inverter)
Implementing speed regulation in the dust removal drives
Modernizing lighting system
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2. Methodology
Methodology of measurements conducted in the audited plant

The aim of each measurement is measuring physical quantities and then measuring
characteristic values in order to determine indicators allowing to define the potential of savings. With
each measurement there was an estimation of accuracy and measurement uncertainty. Accuracy of
conducted measurement depends on many factors that can be divided into so called observational
errors and measurement uncertainties.
Observational errors can be divided into three groups:
o Approximations
o Omission errors (systematic errors)
o Mistakes
Approximations are a result of simplifying the conditions of measurement or applying
approximated formulas (e.g. sin= for small angles).
Omission errors (systematic errors) are a result of inaccuracy of instruments applied, erroneous
method of measurement or the actions of hardly noticeable outside factors. Faulty ruler or inaccurately
calibrated gauge can cause the results to be systematically lower or higher than real value. Finding the
source of systematic errors is difficult and requires a comparison of used instruments with standard
instruments as well as an in depth analysis of the measurement method.
Mistakes (serious mistakes) are caused by incorrectly read data, incorrectly written results and
so on. Mistakes are easy to see and easy to eliminate because the received result is vastly different than
other results of measurements of the same value. The result of a measurement with a serious mistake
is to be omitted in further analysis.
Examining the causes of all uncertainties allows for dividing of all uncertainties to:
o Calibration uncertainty
o Research conductors uncertainty
o Incidental uncertainty
Calibration uncertainty is caused by the use of standard measuring instruments that are forever
burdened with a particular uncertainty of measurement. Manufacturers of measuring instrument are

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obliged to guarantee measurement results that dont differ by more than one line of graduations on the
instrument from real values.
Research conductors uncertainty is quantitative assessment of the results uncertainty cause
by, e.g. bad visual conditions (of the pointer, scale), noise related quick changes in readings etc. The
conductor of research must estimate it on their own.
Incidental uncertainty with the measurement value of X is cause by limited cognitive abilities
(of ears, eyes), the nature of the phenomenon of instability of external conditions. Its characteristic is
dispersion of results and the source of such dispersion cannot be discerned. The measure of such
dispersion is relative standard error. Incidental errors are unavoidable. However, the theory of
measurement uncertainty offers rules that help establish their value.
Conducting the audit in Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant in Pozna required
conducting the following types of measurements with the use of specialized measuring instruments:
o Electricity usage measurement in the main connection and in individual power
circuits powering ventilators. The measure was handled with power network analyzer
APPS manufactured by Sidus Novum Sp. z o.o. and APPS Sp. z o.o.
o Measure of light intensity was conducted with an AB 1308 luxmeter
o Speed of air flow was conducted with a CEM DT-8894 vane anemometer, a pitot tube
with a differential pressure gauge anemometer Peaktech PT-5145 or
thermoanemometer Airflow TA-410
o Pressure gauge was conducted with a pitot tube and differential preassure gauge
anemometer Peaktech PT-5145
o Temperature measure was conducted with the thermoanemometer airflow TA-410
Annual balance of electricity and gas was determined on the basis of the received results which
are legalized by the providers.
The means and venue of all the aforeementioned measurements, as well as the method of
determining savings were included in subsequent chapters of this document and describe individual
modernizations.

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Methodology of calculating financial and ecological parameters of suggested activities

Companies usually base their decisions concerning taking action towards reducing energy
requirements on analysis of profitability of implementing changes with an estimation of basic

economic markers. Based on indicated energy effects they calculate annual savings in energy usage
costs after implementation of modernization, avoided emergencies costs and current operating costs,
as a basis of operating costs for a particular energy area, machine or device. Values specified in this
way are used in calculating cash flows for every year of the systems functioning.
The simplest and most common indicator of economical efficiency assessment is Single pay
back time (SPBT). It is a method that illustrates the investment without taking into consideration
money value changing over time and can be expressed by a simple formula:
=
)
+
in which:
KI0 cost of investment increased at the beginning of investment, expressed in z;
KE1- alteration of operating costs in one year expressed in z or the average alteration in
operating costs during the life of investment.
Assessment based on SPBT is merely a guideline referring to particular company and cannot
be the decide about the profitability of analyzed point of energy saving.
Another method of assessing an investment is finding the Net present value (NPV) indicator.
It compares the predicted expenditures based on calculated cash flows (CF) but not before discounting
them at the moment of starting the investment, taking into consideration the cost of the engaged capital.
In other words, values calculated in previous years of investment exploitation are taken to their current
value by discounting. Discount rate is adopted as minimal expected profit rate which is to be involved
while pursuing a particular project or, if financing with own resources, as minimal required rate of
investors income. With current capital costs, discount rate is usually adopted at 7% based on the
analyzed companys financial data. Updated net value is calculated from the following formula:
6
= ) +
27+
2
1+
+
2
2
1+

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in which:
KI0 cost of investment increased at the beginning of the investment, expressed in z;
CFt yearly cash flows, usually net proceeds in t moment, in which net proceeds are profit increased
by depreciation expense (that is sale reduced by operating costs without depreciation) expressed in
z. For most projects it is an alteration in operating costs stemming from actions undertaken to
improve energy efficiency;
r discount rate, expressed in percentage,
1/(1+r)t discount factor
t length of calculation period including years of construction and exploitation (t = 1, , n) ;
Rt value of the installment in the final year of exploitation t or proceedings from its
decommissioning, expressed in z.
In vast majority of proposed actions, large investment expenditures occur always at the
beginning of investment and the exploitation expenditures do not exceed the income connected with
generating savings.
An investment is profitable if in predicted exploitation period NPV 0. It is the minimal
effectiveness requirement for any enterprise examined in this way. However, if several enterprises are
compared to one another, the most advantageous is the one for which this value is the biggest. If NPV
= 0 the investor regains the invested capital but does not gain anything besides refurbishment and
modernization of machines and devices.
Another tool of assessing profitability of an investment is Internal Rate of Return method (IRR)
which is based on the same formula as capital value method, though finding NPV is not the key. The
key is finding the discount rate r for which NPV equals 0. To achieve that linear interpolation must be
implemented. For the increasing values of r determine (decreasing) values of NPV until negative
values are met. Value of rw is calculated from the following formula:
rw = ri - NPVi
r j - ri
NPV j - NPVi

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in which:
NPVi the smallest positive value of capital;
NPVj the highest negative value of capital;
r1 discount rate used to calculate NPVi;
rj discount rate used to calculate NPVj.
An investment is profitable if value of rw is higher than required rate of investors income. If
two enterprises are to be compared, the more advantageous one has higher rw value.
Additionally, indicator of dynamic unit cost of CO2 emission reduction has been calculated, in
accordance with guidelines by NFOiGW (National Fund for Environmental Protection and Water
Management). It is the indicator of profitability of environment friendly, energy efficient investments.
It is determined by the following correlation:
KI t + KE t
(1 + i ) t
DGC = t =0t =n
EE t
t
t = 0 (1 + i )
t =n
in which:
DGC dynamic generation growth;
KIt investment costs in year t;
KEt operating costs in year t;
EEt ecological effect in year t;
i discount;
n investment life period.
This indicator links value of discount cash flows with ecological effect expressed in physical
units connected with emission reduction in examined action. It illustrates the amount of costs incurred

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in order to reduce CO2 emission by 1 ton . For effective actions DGC value is negative and means that
apart from achieving ecological effect the investment has also delivered savings.
Energy savings expressed in tons of oil equivalent is in accordance with the definition included
in point 10 of Article 3 of Energy Efficiency law from April 15th 2011, which states that the [toe] (tona
oleju ekwiwalentnego equivalent oil ton) ratio in relation to saved energy must be:
1 toe = 41,868 [GJ]
The ratio (2) is a consequence of calorific value of a tone of equivalent oil equal to 41868kJ/kg.
Calculating of tones of equivalent oil to MWh was achieved according to the equation:
1 [toe] = 41,868 [GJ]/3 600[s] 1 000 = 11,630[MWh]
Calculating the final energy to a [toe] unit was achieved with the following equation:
EL [toe] = EL [MWh]/11,63 [MWh/toe]

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3. Energy balance and selecting energy consumption indicators of the plant
Electric energy
Electricity balance of the plant between January 1st 2015 and December 31st 2015 was written
based on conducted measurements, individual meter readings and invoices data. Information about
using energy via cooling is the exception, as that data was sourced from archival data from 2014. It is
the result of a lack of data from 2015. Because of temperature differences the amount of energy taken
by the ice water units may be underestimated in relation to those from 2015. Compilation of individual
areas and usages is presented in the Tab. below.
Tab. 1. Energy balance of Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant
Electric energy use for the period
Area
of 01.01.2015 31.12.2015
[MWh]
Drying
4 554,269
Germination Production
Soaking
Source: own.
2 109,810
6 880,640
216,561
Cooling
1 889,870
Compressed air
355,482
Lighting
164,265
Other
1 716,405
Total
11 006,662

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Fig. 3. Percentage balance of electricity use at Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx malthouse
Source: own. (translators note: produkcja production; chodnictwo cooling; sprone powietrze compressed air; owietlenie
illumination; pozostae other)
The main recipients of electricity in the plant are devices taking part in the manufacturing
process, such as the drives of ventilators dispersing warm air in the drying room, the drives of
ventilators aerating grains in crates. Another significant recipient of electricity is cooling. Smaller
recipients of electricity, such as boiler room, water pressure station, office building, warehouse,
workshop, are behind the blanket name other.
Cost of 1MWh of electrical energy for the period between January 1st 2015 and December
31st 2015 was determined based on data on usage and energy costs.
Tab. 2. Electricity cost for the period of 01.01.2015 to 31.12.2015
Billing cycle
January 15
Abount of
Cost of purchase
Cost for MWh
electricity
and distribution of
of electricity
imported (MWh)
energy [z]
[z]
920,296
302 970,65
329,21

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Abount of
Cost of purchase
Cost for MWh
electricity
and distribution of
of electricity
imported (MWh)
energy [z]
[z]
February 15
808,493
271 160,47
335,39
March 15
861,568
286 135,35
332,11
April 15
909,083
295 451,98
325,00
May 15
843,436
266 230,57
315,65
June 15
991,806
342 520,20
345,35
July 15
1 398,900
439 338,53
314,06
August 15
500,290
183 561,40
366,91
September 15
1 038,721
337 771,29
325,18
October 15
924,162
304 067,78
329,02
November 15
898,591
296 795,62
330,29
December15
911,316
300 415,32
329,65
Total of 12 m-s
11 006,662
3 626 475,00
329,48
Billing cycle
Source: own.
The average price of an electricity unit in the analyzed period was 329.48z/MWh and
this rate was adopted in all further calculations.
Indicator of amount of energy per ton of manufactured product was determined based on the
analysis of gathered manufacturing data and imported electric energy. The indicator is presented in
the Tab. below.
Tab. 3. Energy usage indicator per ton of product for individual months.
Amount of
Malt
imported
production
energy [MWh]
[Mg]
January 15
920,296
10 256,28
0,090
February 15
808,493
8 538,07
0,095
Billing cycle
Indicator
[MWh/Mg]

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Amount of
Malt
imported
production
energy [MWh]
[Mg]
March 15
861,568
9 303,55
0,093
April 15
909,083
9 120,96
0,100
May 15
843,436
9 964,80
0,085
June 15
991,806
8 728,07
0,114
July 15
1 398,900
9 619,83
0,145
August15
500,290
2 271,50
0,220
September 15
1 038,721
8 708,98
0,119
October 15
924,162
9 418,20
0,098
November 15
898,591
9 201,35
0,098
December 15
911,316
9 591,96
0,095
Total of 12 m-s
11 006,662
104 723,55
0,105
Billing cycle
Indicator
[MWh/Mg]
Source: own.
The conducted analysis indicates that the average factor of electricity use per product unit is
0.105MWh/Mg. The differences between individual months are a matter of variable energy intake,
mostly due cooling units operating during summer. In addition the production of malt in August was
much reduced and continuously operating supporting systems (lighting, compressed air) significantly
affected the factor.
Natural gas
The amount of produced heat was indicated based on the analysis of invoices provided by
Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx. The year 2015 was designated as the billing cycle. The
amount of produced heat in relation to natural gas usage is illustrated in the Tab. below. The
calculations were done at the average efficiency of the burners and boilers of 91%.

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Tab. 4. The use of gas and heat production in 2015
Month
Gas usage
Gas usage
Gas usage
energy content
energy content
[m3]
in fuel
in fuel
[kWh]
[GJ]
Produced heat
usable energy
[GJ]
January 15
546 428
6 036 390
21 731,004
19 775,214
February 15
469 491
5 188 345
18 678,042
16 997,018
March 15
499 430
5 521 199
19 876,316
18 087,448
April 15
464 846
5 105 404
18 379,454
16 725,304
May15
472 775
5 251 585
18 905,706
17 204,192
June 15
406 862
4 544 242
16 359,271
14 886,937
July 15
411 789
4 633 450
16 680,420
15 179,182
August 15
89 675
1 014 493
3 652,175
3 323,479
September 15
419 883
4 729 982
17 027,935
15 495,421
October 15
488 941
5 429 690
19 546,884
17 787,664
November 15
480 958
5 330 458
19 189,649
17 462,580
December 15
496 165
5 504 455
19 816,038
18 032,595
Total
5 247 243
58 289 693
209 842,895
190 957,034
Source: own.

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Fig. 4. Heat production.
Source: own.(translators note: ilo wytworzonego ciepa heat produced; sty-gru Jan-Dec.)
The amount of heat production is dependent on how much was produced in a particular month
as well as on weather conditions. The lower the outside temperature, the more gas is used for heating
the plant and warming the air led to the burners heating the air in the dryer.
Compiling an exact balance (one that would take into consideration the plants gas demand for
both production and heating) is not possible due to the lack of measuring systems and meters to record
the amount of gas directed to each burner and boiler.
After analysing the received data the unit cost of 1GJ of heat. The costs connected with gas
usage were formulated for the next 12 months.

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Tab. 5. Heat costs analysis

Gas usage energy
Month
content in fuel
[GJ]
Source: own.
Gas cost
Heat cost
[z]
[z/GJ]
January 15
21 731,004
855 668,65
39,38
February 15
18 678,042
737 331,12
39,48
March 15
19 876,316
786 190,17
39,55
April 15
18 379,454
671 076,42
36,51
May15
18 905,706
690 494,55
36,52
June 15
16 359,271
601 836,93
36,79
July 15
16 680,420
614 206,78
36,82
August 15
3 652,175
167 531,58
45,87
September 15
17 027,935
624 739,08
36,69
October 15
19 546,884
712 524,06
36,45
November 15
19 189,649
698 849,82
36,42
December15
19 816,038
721 680,12
36,42
Total
209 842,895
7 882 129,28
37,56

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Fig. 5. The price of 1GJ of produced heat in relation to each month
Source: own. (translators note: cena 1GJ ciepa price for 1GJ of heat; Zuycie ciepa w paliwie heat usage in fuel; zuycie ciepa
heat usage; sty-gru Jan-Dec)
The average cost of 1GJ of heat contained in the fuel in the analised period was 37,56z/GJ.
This price was adopted for the calculations in further parts of the audit. The costs of fuel purchase
fluctuate during the year. Price differences for 1GJ in the adopted billing cycle are clear. These
differences depend on how much product was manufactured.
The quantity ratio of imported gas per 1Mg of product was determined. The ratios for individual
months are illustrated below.
Tab. 6. Gas usage ratio per ton of malt production

Month
Gas usage
3
Production quantity
Ratio [m3/Mg]
[m ]
[Mg]
January 15
546 428
10 256,28
53,28
February 15
469 491
8 538,07
54,99
March 15
499 430
9 303,55
53,68

Page 26 of 107
Month
Gas usage
3
Production quantity
Ratio [m3/Mg]
[m ]
[Mg]
April 15
464 846
9 120,96
50,96
May15
472 775
9 964,80
47,44
June 15
406 862
8 728,07
46,62
July 15
411 789
9 619,83
42,81
August 15
89 675
2 271,50
39,48
September 15
419 883
8 708,98
48,21
October 15
488 941
9 418,20
51,91
November 15
480 958
9 201,35
52,27
December15
496 165
9 591,96
51,73
Total
5 247 243
104 723,55
50,11
Source: own.
Fig. 6. Gas usage ratio per ton of malt production
Source: own.(translators note: zuycie gazu gas usage, produkcja sodu malt production)

Page 27 of 107
The conducted analysis indicates that the average ratio of gas usage per 1Mg of finished product
is 50,11m3/Mg. The clearly higher ratio in the winter months stems from the higher amount of fuel
used for heating the plant. However for most months the ratio is at a similar level, the only exception
being August 2015. The ratio is definitely lower, which may be cause by low production of malt in
that month.

Page 28 of 107
4. The choice of activities to improve energy efficiency

4.1.
The areas of heat and cold sources
4.1.1.
The boiler room
The plant is heated by two Viessmann gas boilers with total power of 2.1MW (Tab. 7). The
energy content of the gas heats the water used for central heating to over 500C. The boiler room system
is secured from adding too cold water by the use of heat buffer circuit. While water does not achieve
the right heat parameters it circulates the buffer in a closed circuit. Only when it reaches temperature
allowing for heating rooms it is added to the CO system. Warm utility water in the plant is heated by
electric continuous flow water heaters.
Tab. 7. Types of gas boilers
Boiler
K1
K2
Type of boiler
Not specified
SM 140
Boiler capacity [MW]
0,7
1,4
Type of burner
Not specified
Weishaupt G8/1-D
Source: own.
Fig. 7. Boiler room
Source: own.

Page 29 of 107
Measurements of substances emitted into the airstream are conducted on average every six
months. In regards to energy efficiency an important parameter is the average temperature of exhaust
gas of the boilers, 196.50C for K1 and 157oC for K2. On that basis it can be concluded that the boilers
exhaust gas has energy potential.
Due to the high temperature of exhaust gas at discharge point it is recommended to use heat
recovery. This solution prevents discharge loss, and what follows, reduces the amount of gas required
to heat the water because the heat (lost up till now) would be directed back to the combustion chamber.
The Tab. below illustrates the potential for heat recovery from gas exhaust.
Tab. 8. Heat recovery from the boilers
Heat recovery from boilers
K1
K2
Exhaust temperature before recovery [oC]
196,5
157,0
Exhaust stream [kg/h]
1 690,5
1 886,0
Exhaust temperature after recovery [oC]
120,0
Recovery capacity [kW]
36,64
19,77
Energy saved [GJ]
507,338
273,768
Gas usage reduction [m ]
12 686,291
6 845,730
Savings [z/year]
19 058,07
10 284,05
Source: own.
Applying economizers allows for the recovery of 781.106GJ which translates into
29.3 thous. z.
To achieve said savings an economizer needs to be connected to the exhaust pipeline. The
exhaust flowing through the exchanger raises the temperature of the boiler water. In order to have
operation continuity it is recommended to use a bypass on the exhaust path which would allow for
disconnecting the economizer from the system (e.g. for servicing purposes). An overview schematics
of and exchanger installment is illustrated below.

Page 30 of 107
Fig. 8. Operating schematics of an economizer
Source: own. (translators note: kocio boiler; spaliny exhaust fumes; gorca woda zasilajca powering hot water; ekonomizer
economizer; zimna woda zasilajca powering cold water; wyjcie spalin exhaust fumes exit)
Estimated costs of assembly and installation economizers are presented below.

Tab. 9. The cost of economizers
Element
Costs [z]
Economizer K1
48 000,00
Economizer K2
42 750,00
Assembly costs
36 300,00
Total
127 050,00
Source: own.
Suggested exchangers are of the following capacity, respectively: 36.64kW for the boiler with
the 0.7 capacity and 19,77kW for the boiler with 1.4MW. The total cost of supplying gas boilers in
heat recovering and water heating economizers was estimated to be 127.1 thous. z.
4.1.2. Drying process balance

Malt drying is conducted in the system of a dryer built as a silo with two nets where grain is
piled. It is a system of great energy efficiency thanks to an exchanger recovering the heat from humid
gases expelled from the dryer (the glass exchanger) as well as recycling circuit which directs the air
back to the process after achieving properly low humidity. The ventilators drives are equipped with
frequency inverters that regulate their efficiency.

Page 31 of 107
An illustrative schematics of the dryer working in the Soufflet malthouse.

Fig. 9. Schematics of the dryer
Palnik
Palnik
Palnik
P5
P6
Siatka 2
P1
P2
Siatka 1
P3
P4
Source: own. (translators note: Siatka net, Palnik burner)
The biggest recipients of energy are gas burners at 5.4MW capacity, each powered by high
methane natural gas (E). Hot gas produced by the burners are directed to exchangers, in which the heat
is transferred to drying air. Each net has a designated burner. The system is also equipped with an
assisting burner that heats the air collected from the surroundings. It is installed behind the glass
exchanger. The air initially collected for the process of burning gas is from the vicinity, which is not a
beneficial solution in winter.

Page 32 of 107
The drying process is divided into four stages and occurs independantly for each net. The start
is shifted in time by sixteen hours. This procedure allows for optimal use of the recirculation system.
For net 1 the process is as follows:
o Pre-drying
After loading the net the process of pre-drying starts. It lasts about 16h and the ventilator works
at maximum capacity throughout. At this stage it is required to heat the drying air with a preburner and
then with the main burner. The former device works at an average capacity of 50% and the latter
reaches between 30-60% power. At the same time the net number 2 is in the middle of the main drying
cycle. The humidity level of air is low enough for it to be used in both nets as a drying means, which
allows for reducing the gas usage. During the pre-drying cycle throttle P3 is open for net 1 and throttles
P4 and P5 are closed.
o Main drying
After about sixteen hours, once breaking occurs, the main drying stage begins. In that time the
efficiency of ventilators is reduced. The heat requirement rises because the amount of moisture in
grains lessens and it is also bonded to the grain more firmly. In result, the temperature of the process
rises quickly. While the main drying process is happening on net 1, the pre-drying process starts on
net 2. Thanks to that shift it is possible to reclaim heat between nets, either directly because of
recirculation units or indirectly because of the glass exchanger. During the main heating cycle the
throttle P4 is open and throttles P3 and P5 are closed.
o Cooling
The last stage of malt production is cooling which means lowering the temperature of the grain
to the value at which it can be transported. During that stage room temperature air is directed at the net
through the open P5 throttle. The air becomes significantly heated from the grain and it is possible to
reclaim that energy through the recirculation system by opening throttle P3.
In the following subchapters the effectiveness of each device is analyzed and the balance of
each stage of the process is determined.

Page 33 of 107
Burners in the dryer
The pre-burner and the main burner are mostly used in the first two stages of the drying process.
Their capacity changes in each hour of the cycle and depends on the setpoint temperatures below the
net. The Fig. below illustrates the efficiency cycle for individual drying cycle of the nets. The data
comes from the system supervising the process.
Fig. 10. Burner efficiency during individual drying cycle
Source: own. (translators note: data/czas date/time, r- Wed.- Czw Thu, palnik pomocniczy auxiliary burner; palnik siatka
burner net)
Analyzing the chart for the first net it may be seen that in the first stage the burner is off. At
that time the offloading and reloading the grain is conducted. Next is the pre-drying process where at
which time one may observe the initial increase in the burners efficiency and then a gradual
diminishing. This is mostly because of introducing the heat reclaiming through the recirculation
system. In the final drying process when high temperature is required (about 800C) the burner increases
its capacity. The burner for net 2 works in a similar way. Individual stages are offset by 16 hours. The
auxiliary burner capacity depends on the amount of reclaimed heat in the glass exchanger.

Page 34 of 107
As mentioned in the introduction, the burners draw primary atmospheric air which causes the
need for an additional portion of fuel required for heating the air, especially during winter time. The
amounts of air drawn by individual burners was measured as part of the audit. Knowing the ambient
temperature, which is recorded in the measuring system of the malthouse, and maximum possible
temperature that the burners may have, energy savings possible to achieve during heating primary air
were determined.
Tab. 10. Analysis of increasing the temperature of primary air for the burners
Device
Auxilary burner
Burner net 1
Burner net 2
Average air stream

[m3/s]
0,54
0,74
0,56
Weighted average year

temperature [C]
8,8
Setpoint burning
temperature [C]
40,0
Average capacity
reduction [kW]
19,31
25,87
19,48
Average annual energy

reduction [GJ]
600,197
808,905
609,156
Savings [z]
22 546,27
30 386,37
22 882,82
Total savings [z]
75 815,47
Source: own.
Average annual savings stemming from heating primary air for the burners are
1 018.258GJ, which translates to 75,8 thous. z. The recommended heat source at present
technological system of the drying room is the exhaust gas from the burners. Water heaters should be
installed on the sampling inlets of the burners and an exhaust gas exchanger should be installed on the
exhaust pipeline parallel to the chimney. Circulation pumps should be planned into the systems.
Estimated cost of installation is 300 thous. z. In the economical calculation energy intake of the pumps
should be predicted (2 thous. z per year). Due to the planned investment of enclosing the heat pumps
in the drying room the gas usage will drop significantly. This is the reason why the investment in this
chapter
should
only
be
considered
after
implementing
the
heating
pump
system.

Page 35 of 107
Analysis of the glass exchanger efficiency
The glass exchanger reclaims humid gases leaving the drying room during the preliminary
drying cycle. Air reaches the device from the nets through throttles P2 or P3. In order to determine the
temperature related condition of the exchanger the analysis of fresh air temperatures before and after
the exchanger and the temperature of gases leaving the drying room before the exchanger. All the
aforementioned values are measured and recorded by the computer system supervising the operating
of the dryer room. Knowing the air flows through the exchanger it is possible to determine the
reclaiming capacity for the balance. Gas from the nets coming into the exchanger has the relative
humidity of 100%. With the cooled down medium in the exchanger a phenomenon called condensation
occurs which increases the effectiveness of heat reclaiming. A chart of temperatures of fresh air before
and
after
the
exchanger
was
prepared
based
on
the
measured
data.
Fig. 11. Air temperatures before and after the exchanger
Source: own. (translators note: st-degrees; N-Sunday; r-Wed, So-Sa; Wt-Teu; Pt-Fri; Pn-Mon; Czw-Thu; data/czas date/time,
temperatura zewntrzna outside air temperature; temp. pow. wie. za wym. fresh air temperature after the exchanger)
In the analyzed period temperatures close to 00C and 250C both occurred. This range allows
for analyzing the condition of the exchanger on a large scale of used temperatures (operating

Page 36 of 107
throughout the year). As one might see on the chart, the temperature after the exchanger has stable
values. It can be deemed that heating the air at lower ambient temperatures has higher efficiency.
The third temperature vital to determining the condition of the exchanger was based on the
measurements of air over the net. A conditional function was applied in the spreadsheet that determined
the throttles moment of switching. This way the temperature of humid air before the exchanger was
determined. Due to a breakdown of the computer system supervising the operating of the drying room,
it was only possible to analyze the data for 32 hours.
Fig. 12. Temperatures of humid air before exchanger
Source: own. (translators note: st-degrees; r-Wed, Czw-Thu; data/czas date/time)
Temperature before the exchanger has the constant value around 270C. Momentary increases
come from the net reaching breaking point which allows for the change in configuration of the throttles.
Thanks to that he hot air from the net in which the breaking point was reached is directed to the process
and cooler humid air from the second net reaches the exchanger.
Based on the aforementioned temperatures the thermal efficiency of the exchanger was
determined. It is illustrated on the chart below.

Page 37 of 107
Fig. 13. Thermal efficiency of the exchanger
Source: own (translators note: Sprawno temperaturowa temperature efficiency; temperatura zewntrzna outside temperature;
data/czas date/time, temperatura gazw wilgotnych przed wymiennikiem temperature of humid gases before the exchanger)
The recuperators efficiency is variable in time. It is largely dependent on outside temperature.

The lower it gets, the bigger the differences between temperatures. The temperature of humid air
getting into the exchanger also affects the exchanger.
Because the glass recuperator operates on gases of relative humidity at 100% it is essential to
have an analysis of total efficiency determined on gas enthalpy. This factor is variable in time and
depends on temperatures and humidity.
The difference of enthlapy determined on the temperatures o fresh air before and after the
exchanger is illustrated in the chart below. Based on this factor one might also determine the power
reclaimed by the device.

Page 38 of 107
Fig. 14. Enthlapy differences in the glass exchanger
Source: own. (translators note: data/czas date/time, r-Wed, Czw-Thu; moc odzysku recovery power; rnica entlapii- enthlapy
difference)
Reclaiming capacity varies in time and also depends on the ambient temperature. The lower
the temperature, the stronger the condensation phenomenon gets and the higher the level of energy
reclaiming. Another parameter essential for determining the reclaiming capacity in the glass exchanger
is the enthlapy of humid gases leaving the nets. Comparing both enthlapies allows for determining
total capacity.

Page 39 of 107
Fig. 15. The difference of enthlapy of humid air before and after the exchanger as well as total
capacity
Source: own. (translators note: data/czas date/time, rnica entlapii- enthlapy difference, sprawno cakowita total capacity)
Total capacity is at 22%, which is a high level considering such low temperature and high
humidity of the gases. The condition of the exchanger points to the further possibility of heat
management (especially latent heat) of humid exhaust gases by the use of heat pumps.
Knowing total capacity and enthlapy difference of fresh air thanks to the I X chart it is
possible to determine the temperature of humid air after the exchanger. This factors is very significant
considering the planned implementation of heat pumps.

Page 40 of 107
Fig. 16. Humid gases temperature after the exchanger
Source: own. (translators note: data/czas date/time, r-Wed, Czw-Thu)
When air leaves the exchanger it reaches over 200C even at low ambient temperatures (below
100C). That guarantees the possibility of reclaiming heat in the heat pumps system.
Operating of the glass exchanger causes a reduction of heat energy generated by the pre-burner
and main burner. It is estimated that the device allows for saving gas by 69 890.625GJ a year, which
translates to 2 mln 885.1 thous. z a year.
Electricity balance of the process

The biggest recipients of electricity in the drying room are two electric drives of the ventilators,
each at 500kW capacity. During the audit the levels of electricity collected by the devices.

Page 41 of 107
Fig. 17. Electricity collected by the ventilators of the drying room
Source: own (translators note: wentylator ventilator; siatka- net; N-Sunday; r-Wed, So-Sa; Wt-Teu; Pt-Fri; Pn-Mon; Czw-Thu;
data/czas date/time)
The chart above shows a fragment of a three week measurement process of the ventilators.
Throughout the whole process the drying room operated with no disturbances. The differences of
maximum capacities of each unit is clearly visible. They are a result of geometric differences of the
rotors and rated compression ratios. Regulating the capacity of the ventilators is also used, depending
on the stage of the cycle. The steering process is better analyzed on a chart of individual cycles.

Page 42 of 107
Fig. 18. Electricity collected by the drives of the ventilators in the drying room during a single cycle
Source: own.(translators note: wentylator ventilator; siatka- net; r-Wed, Czw-Thu; data/czas date/time)
While analyzing the chart for net 1 it is possible to identify individual stages of the process.
During the first step from the start of the process to the breaking, the drive operates at fixed capacity
of about 390kW. Momentary reductions of capacity are caused by the necessity to lower the speed of
air flow during the time of reconfiguring the throttles. After about 16 hours the main drying process
starts, during which the ventilators capacity is slowly lowered. Because of that the power consumption
by the drive is also reduced (310, 230, 200kW). In the last stage of the process the cooling starts and
the ventilators drive consumes 110kW. Similarly, the capacity of the ventilator for net 1 changes.
Each step is shifted by 16h between the nets.
Heat balance of the process

Based on the gathered data the heat balance of the process was determined. Power flows vary
in time and depend on the stage of the cycle. However, using two nets shifted in time by sixteen hours,
results in power flows at a steady level. Energy consumprion of the process depends on the weather
conditions. This is why the power was designated based on the temperature charts for each hour
between March 13th 2016 and May 12th 2016. The schematics of measurement points where power
was determined are illustrated in the Fig. below.

Page 43 of 107
Fig. 19. Measurement points for the heat balance of the drying room
W5
W2
W1
Palnik
Palnik
Palnik
W3
P5
P6
W4
Siatka 2
P1
P2
P3
Siatka 1
P4
Source: own (translators note: siatka - net; palnik burner)
Measurement data and calculation date are illustrated in the Tab. below.
Tab. 11. The drying process balance

Glass exchanger
Parameter
Point
min.
average
max.
Fresh air temperature before [C]
W1
-2,34
9,63
25,67
Mass air flow current [kg/s]
W1
98,62
164,28
191,52
Fresh air temperature after[C]
W2
17,92
23,87
36,60
W2
98,62
164,28
191,52

Page 44 of 107
Glass exchanger
Heating capacity [kW]
W2
4,80
2 344,66
10 873,62
Humid air temperature before [C]
W3
26,30
28,99
37,54
W3
98,62
164,28
191,52
Heating capacity of humid gas [kW]
W3
732,09
10 550,62
25 139,54
Temperature of humid air after [C]
W5
9,94
25,40
35,97
Mass air current [kg/s]
W5
98,62
164,28
191,52
Heat reclaiming capacity [kW]
4,80
2 344,66
10 873,62
Yearly recovery utilization [h]
8 280
Recovered energy [GJ]
69 890,625
Recirculation system
Net temperature [C]
W4
27,08
36,52
80,51
Mass air current [kg/s]
W4
98,62
164,28
191,52
Heating power [kW]
W4
1 081,79
4 108,60
12 417,79
Time of utilization [h]
4 656
Recovered energy [GJ]
68 888,940
Source: own.
Analyzing the balance it may be noticed that application of heat recovery (glass exchanger,
recirculation system), significantly limits gas usage in the process. Humid gas current after the glass
exchanger still has high energy potential. However, it is low temperature heat. Relative humidity at
100%. In order to manage this potential applying heat pumps is necessary.
4.1.3.
Cooling requirements during germination process
Germination process has to be conducted in strictly specified temperature. That is why in the
production system ice water units cooperating with air coolers are used (during summer period May
to September) along with air sprinkler system. The latter system is applied as the basic one (is first to
start operating). Mechanical cooling is started only when sprinkling does not lower the temperature to
set parameters. Maintenance services of the plant made a remark towards the auditor that the cooling
process is not optimal. At present the sprinkling is conducted at about a 3 bar pressure, which does not
allow for quick evaporation of water in air, and what follows, heat reception and cooling. In result the
relative humidity reaches up to 80%. Modernization of the sprinkling process based on a high pressure
system is suggested in this document. Even the aforementioned optimization will not completely
eliminate the cooling units.

Page 45 of 107
Implementing the planned investment of enclosing the heat pumps cooperating with the
cogeneration unit takes into account utilizing the operating factor condensation working in the cooling
system of germination room as a lower heat source. In order to do that, it is necessary to enclose the
new cooling appliances, which would relieve the ice water cooling units system. At present the author
of the concept does not predict a complete replacement of ice water cooling units.
In order to determine the need for replacing the ice water cooling units with the heating pumps,
the cooling energy requirements of the germination room were determined. Based on the hourly
electricity usage by the units and the 2014 temperatures spreadsheet for Pozna, the factor of energy
efficiency and cooling capacity of ice water cooling units was determined. The chart (no. 13, Fig. 19),
includes cooling capacity generated by the planned heat pumps transferring the condensation heat to
the drying room system by the exchanger.
The data for the months when mechanical cooling is used is illustrated below. The main
parameter influencing the cooling capacity is the ambient temperature (designated green on the charts).
Fig. 20. Cooling capacity of the ice water cooling units in May
Source: own. (translators note: moc chodnicza cooling power; pompa ciepa moc chodnicza cooling power of heat pump;
temperatura otoczenia ambient temperature; moc power; st. C. - degr. C; N-Sunday; r-Wed, So-Sa; Wt-Teu; Pt-Fri; Pn-Mon;
Czw-Thu)

Page 46 of 107
Fig. 21. Cooling capacity generated by the ice water cooling units in June
Source: own. (translators note: moc chodnicza cooling power; pompa ciepa moc chodnicza cooling power of heat pump;
temperatura otoczenia ambient temperature; moc power; st. C. degr. C)
Fig. 22. Cooling capacity generated by the ice water cooling units in July
Source: own. (translators note: moc power; st. C. degr. C; moc chodnicza cooling power; pompa ciepa moc chodnicza
cooling power of heat pump; temperatura temperature)

Page 47 of 107
Fig. 23. Cooling capacity generated by the ice water cooling units in August
Source: own.(translators note: moc power; st. C. degr. C; moc chodnicza cooling power; pompa ciepa moc chodnicza
Fig. 24. Cooling capacity generated by the ice water cooling units in September
Source: own. (translators note: moc power; st. C. degr. C; moc chodnicza cooling power; pompa ciepa moc chodnicza

Page 48 of 107
The higher the ambient temperature, the higher the power generated by the ice water cooling
units. A noteworthy fact is that mechanical cooling starts at higher ambient temperatures than required
(13-150C). Mechanical cooling starts only when the ambient temperature is above 200C for a longer
period. It is the result of using a sprinkling system with the potential for optimalization.
Based on the date from the charts above, the cold sources balance (taking into account the
operating of heat pumps transferring heat of condensation to the drying room) was determined.
Fig. 25. Cooling energy balance (with the heat pumps)
Source: own.(translators note: energia chodnicza cooling energy; pompa ciepa heat pump; energia energy; maj may;
czerwiec june; lipiec july; sierpie august; wrzesie september)
The analysis indicates that 73% of cooling energy on average will be provided by the planned
heat pump.
Optimizing adiabatic cooling

Present air cooling system conducted by sprinkling with network water does not meet
expectations. Drops are not too big, they fall to the bottom of the crate recovering very little heat from
the air.

Page 49 of 107
New, adiabatic air cooling system is recommended. In order to achieve the required air
humidity, compression nozzles are installed evenly throughout the cross-section of the channel. The
nozzles, where pressured water (at 70 bar) is transferred, atomizes the water and turns it into mist
which completely evaporates. The required cooling level can be achieved by turning on or turning off
the nozzle system and regulating the constant pressure by the use of frequency inverter.
Fig. 26. Water temperature after sprinkling
Source: own. (translators note: temperatura zewntrzna outside temp; temperatura powietrza po zraszaniu air temp. postsprinkling; nowy system new system; maksymalna temperatura powietrza do procesu max. air temp. for process; N-Sunday; rWed, So-Sa; Wt-Teu; Pt-Fri; Pn-Mon; Czw-Thu)
High pressure method is much more effective than the present sprinkling system. In the chart
below the weakly operating of the present and new sprinkling system in May is analyzed. Cooling
system worked practically every day (the temperature of air channeled into the process is higher than
130C). By applying the new adiabatic method better heat transference from external air to the
sprinkling system can be achieved, and what follows, lowering the temperature. This way in the
transitional period there will be no need to start the ice water cooling units to cool the air. It will result
in savings in electricity usage. The savings from the new system in the May September period are

Page 50 of 107
illustrated in Tab. 12. The time when temperature is higher than required for the process was included
in the calculations.
Tab. 12. Savings resulting from implementing the new sprinkling system
Sprinkling system
Present sprinkling
system
New sprinkling
system
Operating time based on

IWCU [h]
2 267
1 538
Electricity used in cooling

[MWh/year]
1 889,870
1 282,144
Difference in energy usage

[MWh/year]
607,726
Savings[z/year]
200 230,58
Source: own.
Changing the system will allow to reduce electricity use by reducing the operating time of the
cooling system by 607.726MWh, which translates into annual savings of 200.2 thous. z. The costs of
the adiabatic system, using one system for two chambers, are estimated at 434.3 thous. z.
Further optimization to the system can be the parallel work of adiabatic sprinkling and
mechanical cooling system. Connecting them should be determined empirically. The cooperation
could be conducted by applying the sprinkling system and when the right temperature was not
achieved, supplementing it by the mechanical cooling system which would lower the temperature and
dry the air.
4.1.4. Electricity, cold and heat production system based on cogeneration and heat pumps.
This audit verifies the concept of enclosing heat pumps cooperating with cogeneration units.
Heat energy is necessary for the drying process. In the present system it is mainly obtained
from burning natural gas in the burners. At the same time humid air with significant energy potential
is removed from the process. By using the heat pumps it is possible to partly manage this energy,
mostly by condensing water from the air leaving the drying chamber and then heating the air entering
the chambers.
Compression pumps with the operating medium R-134a are planned in the system.

Page 51 of 107
Fig. 27. Conceptual schematic diagram of the heat pump
Source: www.zieloneciepo.eu (translators note: skraplacz condensor; sprarka compressor; parownik evaporator;
termostatyczny zawr rozprny thermostat valve)
The heat from the humid gas will be received in the evaporator, where the operating medium
will evaporate and will then be sucked in by the compressor. In the process of compressing the
operating gas, its temperature rises (to about 800C). Because of that it is possible to transfer the energy
from lower temperature environment to a higher level environment. The heat from the operating
medium is received in the condenser the exchanger heating the air stream. For the system to work it
is necessary to transfer mechanical energy to the compressor. It is obtained by an electric engine.
Another element of the system is the cogeneration system.
Because of the large amount of electricity and heat used in the plant, the cogeneration system
was considered. It is comprised of two basic elements: the drive and the electric generator.
Heat from the reclaiming system is produced along electricity. The capacity of heat production
throughout the cogeneration system is about 45% and electricity capacity 40-54%. In order to achieve
such a high result heat reclaiming systems from the engines water jacket (about 90-1000C) and also
from
reclaiming
the
energy
from
exhaust
gas
(300-6000C).
Using cogeneration units is especially beneficial in Polish economic conditions because of:

High prices of electricity;
Uncertain electromagnetic power supply;
Support system of cogeneration sources.
Page 52 of 107
Additionally applying heat pumps along with cogeneration enables managing the heat from
cooling unit condensers working at the germination room. At present the condensation heat is lost. It
is especially important during summer period because of the high ambient temperatures. Heat
exchange is more difficult then because there is a low difference of temperatures between the medium
in the condenser and the surrounding environment.
In the analysis the option given is enclosing one heat pump on humid gases from the auxiliary
drying room with cogeneration and a heat pump functioning as ice water cooler for the germination
room. Condensation heat of that pump is transferred to the system of the heat pump in the drying room.
In the Fig. below there is an illustration of the concept of enclosing the system.

Fig. 28. Scheme of the planned heat pump system with a cogeneration unit
Page 53 of 107

Page 54 of 107

Page 55 of 107
Source: Drying Process Sp. z o. o. (translators note: suszarnia dryer; kiekownia germination room; powietrze air; gaz gas; olej
oil; prd electricity; woda water; glikol glycol)
The most important element is the heat pump (no. 7), which uses the evaporator (no. 6) to
receive the heat from condensing the vapor from humid gases after the glass exchanger (no.12). In
addition in exchanger no. 13 heat is received and the operating medium from the compression unit (no.
16, operating for the germination room) is condensed. The heat from the pump raises the fresh air
temperature (indirectly by the exchanger R134a - glycol and glycol air) after the glass exchanger.
The second essential element of the system is the cogeneration unit producing electricity for
the heat pumps, compression units cooling the germination room and for all the other miscellaneous
recipients in the plant. Exhaust heat from cogeneration is used to raise the temperature of fresh air
driving the drying room. Heating is conducted in two stages. In the first stage the heat from cooling
the unit is transferred into the water circuit. Next, in the water-air exchanger (no. 11) the heat is
transferred into the fresh air in the drying room. In the second stage of heating, the exhaust fumes of
the unit are used. In this case the exhaust-air exchanger (no. 10) is used, in which fresh air is heated.
The result of this system working is the reduction of the burnet operating and reduction in electricity
production. Also the condition of cooling in the germination room will improve because there are
stable condensing conditions in the system, which are provided by the heating pump.
In the Tab. below the balance of the plant including the operating heat pump with cogeneration
system in the drying room.
The following was included in the calculations:
Unit price of electricity, 300.00z/MWh;
Unit price of gas 30.56z/GJ;
Support system yellow certificate, 115z/MWh produced electricity;
Support system white certificate, one-time subsidy, which is dependent on energy effect
(3 900 000z was imposed).
Electricity and gas prices are different from the present charges to the plant. Because of the
large investment costs of this plan the prognostic prices for upcoming years were used.

Page 56 of 107
Tab. 13. The balance of the plant including operating of the heat pump along with cogeneration
Type
Gas purchase
Electricity purchase
(without cooling)
Electricity purchase for
cooling
Total
Consumption
[GJ]
Total cost
[z/year]
30,55 z/GJ
6 429 738,17
300,00 z/MWh
2 735 037,60
[MWh]
210 427,795
Unit cost
9 116,792
1 889,870
566 961,00
210 427,795
11 006,662
9 731 736,77
Balance with the cogeneration unit

Heat pump, heat
131 186,939
1 379,605
8 697,510
276,45 z/MWh
2 404 439,57
71 884,800
510,265
276,45 z/MWh
141 063,44
8 936,222
276,45 z/MWh
2 470 430,99
180,570
300,00 z/MWh
54 170,99
Gas purchase
7 356,056
30,55 z/GJ
224 768,37
Total
210 427,795
19 704,170
5 294 873,36
Difference
4 436 863,40
production
Saving electricity on
cooling due to operating
of heat pumps
Electricity used by heat
pumps
Heat from cogeneration
Electricity for cooling
from cogeneration
Electricity for
cogeneration
Electricity purchase
from the network
Certificates
(till 2018r.)
Source: own.
2 086 560,00
Operating costs
600 000,00
Yearly profit
5 923 423,40

Page 57 of 107
Implementing the investment will bring average annual savings of 4mln 436.9 thous. z. Yearly
operating costs are estimated at 600 thous. z. The estimated budget of the investment is 15mln 500
thous. z. In investments with high investment costs there should be an analysis of NPV and IRR
parameters which will illustrate the real value of currency in the multi-year perspective. While
determining the factors the support system in the form of yellow and white certificates was included.
In addition a simple investment return period in case of lack of support and with subsidies separately.
Tab. 14. Economical parameters of the investment in the heat pumps cooperating with cogeneration
Source: own.
Parameter
Value
NPV (16 years)
30 679 350 z
IRR
38%
SPBT without the subsidy
3,84
SPBT with the yellow certificates
2,57
SPBT with the white certificates
2,88

Page 58 of 107
4.2.
The electromagnetic area of the buildings and transmission network

The plants electromagnetic infrastructure is comprised of medium and high voltage
networks, medium and low voltage transformer stations, main switchboards and subdistribution
switchboards. Electricity is transferred via two cable lines of medium voltage that supply the main MV
switchboard, which in turn supplies six MV/LV transformers. They are relatively new units produced
post 2005. Their technical condition is good. Only the TR-5 transformer is an old unit, to be replaced,
used sporadically as a backup device. The transformers supply the main LV switchboards, which in
turn supply bigger energy recipients and smaller subdistribution switchboards.
4.2.1. Compressed air system

Three Atlas Copco compressors operate in the plant. They are fixed-speed devices. Steering
the compressors is based on a classic pressure cascade. During the week of measurements the
compressor GA45+ was used in the air production. The GA45 compressor was switched off.
In
the
Tab.
below
the
list
of
presently
used
compressors
is
presented.
Tab. 15. List of installed compressors

Power
Pressure
Efficiency
[kW]
[bar]
[m3/min]
GA22
22
6,0
3,77
Atlas Copco
GA45
45
6,0
8,20
Atlas Copco
GA45+
45
6,0
8,94
Lp.
Producer
Type
Atlas Copco
2
3
Source: own.
There was a technical defect found in the GA22 unit which caused constant operating while
idling. In Fig. 29 one can see that the power consumed by the compressor does not achieve the power
rate of the device and corresponds to the level of running without load (lack of air production). It
results in an annual consumption of 63.753MWh of energy, which translates into 21 thous. z. After
reporting the defect, maintenance service removed it.

Page 59 of 107
Fig. 29. Power consumption of compressor GA22
Source: own. (translators note: data/czas date/time; N-Sunday; r-Wed, So-Sa; Wt-Teu; Pt-Fri; Pn-Mon; Czw-Thu)
At present the Atlas Copco GA45+ device is able to cover the total needs for compressed air
in the plant. In the chart below, an eight hour fragment of measurement of GA45+ capacity load is
presented.

Page 60 of 107
Fig. 30. Capacity load of GA45+
Source: own. (translators note: data /czas date/time; Pn-Mon)
Analysis of the chart above shows that the compressor has a lot of periods where it was idling
(about 40% of operating time), when it was not producing compressed air. Operating this way causes
average annual energy consumption of 74.904MWh, which translates into 24.7 thous. z. The auditor
estimates the the process of compressing air can be improved by reducing the amount of idling.
Based on the gathered data and obtained information about operating time the annual
cost of compressed air production in the system was determined and it amounted to 96,1
thous. z. The average price of producing a cubic meter of air is 0.034z. Energy consumption of
producing compressed air is 0.104kWh/m3. Based on the measurements it was calculated that the
annual compressed air production in the plant is 2 790 520m3.
In order to eliminate idling of GA45+ compressor it is recommended to build a system of
efficiency steering, which would have the operating element of an inverter modulating the rotational
speed of the main drive of the compressor depending on its current needs. The other two compressors
would become backup units.

Page 61 of 107
Annual savings achieved due to the recommended modernization are presented in the Tab.
below.
Tab. 16. Annual savings due to modernization
Annual
production
[m3]
2 790 520
Energy
Energy
consumption consumption
before
after
3
[kWh/m ]
[kWh/m ]
0,104
0,078
Energy usage Energy usage

before
after
[MWh]
[MWh]
291,547
216,643
Savings
[MWh]
74,904
Source: own.
Average annual savings stemming from implemented modernization of the compressed

air production system are 74.904MWh, which at a price of 329.475z/MWh translates into
24.7thous. z. Costs of realizing the investment are 15thous. z. and the simple investment return
period is less than a year.
Leakage in the compressed air system

An inspection of the compressed air system for leakages was conducted during the audit. It
reads that the system is fine and leakages are few. Places were leakages were found are presented
below.
Fig. 31. Leakage in the valve in the room at the top of the new elevator
Source: own.

Page 62 of 107
Fig. 32. Leakage at the junction of the actuator hose in the room at the top of the new elevator
Source: own.
After inspecting the system it can be said that the level of leakages does not exceed 10% of
produced air, which means that the system is exploited correctly.
Compressed air treatment
ALD 065 SPUC dryer by Donaldson is responsible for the quality of air in the plant. According to the
information
obtained
from
the
maintenance
services
the
device
operates
correctly.
4.2.2. Lighting system

A necessary factor for proper functioning of production in the
Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant is maintaining the right level of illumination in the
production rooms. Basic illumination in the elevator building is based on light fixtures with linear
sources 2x58W. In other buildings there are fluorescent fittings 2x58W, sodium lamps 400W and
LED fittings. Steering the lighting in the plant is conducted by switches installed on walls by the
entrances.
Because of its very short time of operating time in the elevators rooms there is no valid
reason to replace the illumination fittings. As for the other areas, the analysis was conducted in
places like passageways where lighting operates for the longest time. For those areas possible
savings are suggested in the form of energy saving illumination systems. Products from
Globuslighting were analyzed.

Page 63 of 107
In the following subchapters the analysis of possible savings on electricity costs are
presented.
Illumination in the soaking and germination buildings

Lighting was analyzed in places like passageways and control room where it is used
continuously while the plant operates. Illumination is carried out by the fixtures with linear sources
2x58W.
Based on interviews with the employees, the time of operating of the fixtures was estimated at
8 568 hours per year. The analysis of financial viability of remodeling the illumination system was
conducted (Tab. 17).
Tab. 17. Potential savings stemming from lighting system modernization
Light source
Present linear fixtures

2x58W
LED hermetic beam

52 W GL-BSL
Power of the fixture [W]
124
52
Amount [item]
71
71
Time of operating a year

[h]
8 568
8 568
Energy usage a year

[MWh]
75,433
31,633
Unit cost of energy

[z/MWh]
329,475
329,475
Annual cost of energy [z]
24 853
10 422
Annual savings [z]
14 431
Estimated modernization
cost [z]
22 720
Lightsource lifetime[h]
Straight payback
[months]
10 000
50 000
19
Source: own.
The effect of modernizing the lighting system in the malthouse to LED beams from
Globuslighting will reduce energy usage by 43.800MWh, which translates into 14,4thous. z. Straight
payback time is 19 months.

Page 64 of 107
External lighting
Sodium vapor lights illuminate the premises of Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx in
Pozna. All were deemed to be working properly. In the auditors view, modernizing the present
system has no economic validation.
4.2.3. Electric drives

Electric asynchronous motors with capacity between 0.5kW and 500kW are used in production
processes.
The motors operating in the plant are mostly devices with increased effectiveness IE2. Because
of the age of the machines and their satisfying condition the main problem in this area might be a
breakdown of a unit. It is necessary to decide then whether the motor needs to be repaired or replaced.
It is given that the average motor operating lifetime (including repairs) is:
12 years for 1 to 7.5kW motors;
15 years for 7.5kW to 75kW motors;
30 years for machines over 75kW1.

The criterion telling us whether a particular driving unit should be repaired or replaced is how
many hours the unit operates per year. If motor, works longer than 1 500 hours a year and the cost of
repairs is higher than 57% of the price of a new model, replacement is more advantageous than
repairing it. The choice is simplified by applying the formula below.
= 6\]^ _`a\62
In which:
t annual exploitation of the drive [h];

1
www.portal.pemp.pl
2

6

Page 65 of 107
M local energy rate [z/kWh];

6\]^ _`a\62 - change in efficiency [%];
CR cost of repairs [z];

CN cost of new motor [z];
Et energy used by current motor [MWh];
En energy used by new motor [MWh].
Fig. 33 shows a model that represents an interpretation of the results.
Fig. 33. Model of the factor determining the financial viability of repairing or replacement of the
motor
1083
WYMIANA
1006
929
851
WSPCZYNNIK
774
696
619
542
PRG
464
387
310
232
155
77
REMONT
Source: Inynieria i utrzymanie ruchu zakadw przemysowych, Sept. 2013, issue 8 (96). (translators note: wspczynnik factor;
wymiana replacement; remont repair; prg limit)
From the model we can see that the most important value for the factor is the operating time of
the machine, the cost of energy and the difference between the efficiency of the new and repaired unit.
If the result is in the middle of the scale, purchasing a premium or super premium class motor is viable
to take advantage of its increased efficiency and benefit from the reduced energy requirements. They
are more dependable than their older counterparts and at the same time the assumed time of operating
time without breakdowns is several times longer. In case of an unpredicted breakdown of an old model
the financial consequences of a maintenance shutdown may be much more problematic that the costs
of repairing or replacing the product. The efficiency of the machine may diminish by 0.1% each year

Page 66 of 107
it is exploited. In case of motors with power rated below 11kW repairing a motor is not financially
viable unless it is an unusual component of a special machine.
The smaller the motors power, the larger the differences in efficiency, which means that the
payback time for replacing the older machine to an energy efficient one, is shorter. EU regulates energy
efficiency labeling of motors. They apply to 2, 4, 6 and 8 pole motors with the power range of 0.12kW
to 1MW and voltage to 1kV. According to the of labels (Eff) the engines were classified only by their
power capacity up to 90kW. In the current directives there are four levels of efficiency:
IE1 standard motors (Eff 2);
IE2 increased capacity motors (Eff 1);
IE3 premium motors (no Eff equivalent)
IE4 super premium motors (no Eff equivalent)

In Fig. 34 there is a difference in efficiency of standard and energy efficient motors.
Fig. 34. Characterization of the efficiency of power from 4 pole motors for each IE
Source: own. (translators note: sprawno capacity; moc power)
Energy efficient motors do not diminish their efficiency with a less than full load, in fact, it
increases slightly (for 75% load). In that case, underloading motors, which is so often seen in operating

Page 67 of 107
conditions, does not diminish their efficiency. Considering the data gathered and the experience
from other plants, the auditor recommends replacing the motors of low voltage up to 90kW to
machines with the highest efficiency, in case of a breakdown. For bigger units, determining the
repairs/replacement
factor
is
suggested
and
deciding
on
that
basis.
Regulating the rotor speed of selected drives

On-site verification indicates that some of the ventilators drives are powered by voltage
convertors. In most cases it is an energy efficient steering method, comparing to others, e.g. throttling.
According to maintenance services, the soaking process requires maximum capacity of the
ventilators in that room. At present, two of them are powered by inverters that only gently start the
drives. In consequence, the voltage converters have the set value of 50Hz while operating. It is noneconomic because of the superfluous use of the inverter which oscillates around a 95% capacity. It is
recommended to use the soft start system to gently start the drives. It will reduce the annual energy
intake at 2.733MWh, which translates into 900.54z. The cost of soft start devices is about 4thous. z.
Modernizing selected electric drives

Selected motors taking part in the technological process were analyzed. The criterions of choice
were legibility of rating plate, operating time throughout the year and drive capacity. Siemens Premium
Efficiency (IE3) motors were selected for comparison.
Based on the interviews with employees the determined operating time of driving units is
illustrated in the Tab. below.
Tab. 18. Tata of the analyzed electric drives
No.
Name
Operating Power
Type of motor
time
rating
[h/year]
[kW]
Load
[kW]
Bucket conveyor
drive P5
S1 160 L-4
2 630
15,0
5,72
Bucket conveyor
drive P1
180L 08
2 630
22,0
8,40

Page 68 of 107
No.
Name
Operating Power
Type of motor
time
rating
[h/year]
[kW]
Load
[kW]
Dust removal
ventilator V13
S1 180 M-4
5 727
18,5
4,80
Dust removal
ventilator V7
S1 160 1-2 A
3 295
11,0
7,80
Source: own.
The average load of motors was determined based on electric measurements.

The efficiency of the old units was calculated based on statistical data 2 , taking into
consideration age and repair related efficiency losses.
Replacing the motor is not always profitable. That is because higher efficiency devices have
also a higher rotary speed rating, which causes higher capacity, but also higher energy intake. In the
Tab. below potential savings on replacing selected drives in the plant are illustrated.
Tab. 19. Potential savings from replacing motors to energy efficient ones
Price of
the
motor
[z]
Pay back
period
[year]
No.
Name
Type of
substitute
Bucket
conveyor
drive P5
1LE10031CA13-4AB4
15,0
0,264
86,93
2 308,80
26,6
Bucket
conveyor
drive P1
1LE15031EA23-4AA4
22,0
0,270
89,01
3 822,84
42,9
Dust removal
system
ventilator
V13
1LE15031EB23-4AB4
18,5
0,737
242,84
2 957,71
12,2
Dust removal
1LE1003system
1DB23-4AB4
ventilator V7
11,0
1,185
390,40
2 131,20
5,5
Source: own.
Power
Energy
Savings
rating
savings
[z/year]
[kW] [MWh/year]
www.portal.pemp.pl

Page 69 of 107
For the devices above the payback period exceeds 5 years. Modernization is financially
invalid.
Financial viability of replacement or repairing of motors in case of a potential breakdown is
presented in the Tab. below. The motors which payback period is more than 5 years and capacity is
higher than 10kW were analyzed. The estimation was done based on the factor described at the
beginning of the chapter.
Tab. 20. Profitability estimation of repairing or replacing motors in case of a breakdown
No.
Name
Type of
substitute
Power
rating
[kW]
Factor
Repair
costs
[z]
Motor
costs
[z]
Assessment
Bucket
conveyor
drive P5
1LE10031CA13-4AB4
15,0
1531
1200
2 308,80
Replacement
Bucket
conveyor
drive P1
1LE15031EA23-4AA4
22,0
907
2000
3 822,84
Replacement
Dust removal
system
1LE1503ventilator
1EB23-4AB4
V13
18,5
2871
1800
2 957,71
Replacement
Dust removal
1LE1003system
1DB23-4AB4
ventilator V7
11,0
2338
900
2 131,2
Replacement
Source: own.
In case of an emergency it is profitable to replace all the analyzed drives with new units.

4.3.
Technological process area
4.3.1.
Soaking process balance
Page 70 of 107
Soaking is barley preparation process during which the grains are sufficiently watered to allow
for germination and starts the increased activity of enzymes and biochemical transformations. It lasts
over 24 hours. The relative moisture content of the grain is between 15 to 43% on average. The speed
of water intake is dependent on its temperature. The higher the temperature, the shorter the time of
moisture intake. Oxygen is essential in grain soaking. With the increase of water, the intensity of
breathing increases as well and in result CO2 is produced. As a result gas needs to be transferred.
Fig. 35. Soaking process scheme
Source: own.(translators note: doprowadzenie wody - water supply; wentylator wycigowy ventilator; odprowadzenie CO2 - CO2
dispersion; czyszczenie zbiornika - cleaning the container)
There are three soaking devices in the malthouse. They are cylindrical, with the diameter of
13m and capacity of 249t of product (Fig. 35). A scraper evenly distributes and unloads the grain in
the container. The grain is soaked and hauled out in rotation. While in soaking stage grain is mixed
and oxygenated with compressed air. During the air break it is intensively ventilated to eliminate
carbon dioxide and hear and also to provide large amounts of oxygen. Ventilating is conducted by
Solyvent-Ventec ventilators at rated capacity of 36 000m3/h for each soaking device individually.
During the audit the ventilators were measured to evaluate electric power and ventilators efficiency.
Electric load of individual ventilators at standard operating during the measuring week is
presented in the charts below.

Page 71 of 107
Fig. 36. Ventilator load in soaking device 1
Source: own. (translators note: data/czas date/time; niedz. -Sunday; r-Wed, sob.-Sa; wt-Teu; pt-Fri; pon-Mon; czw-Thu)
Analysis of the chart indicates that the ventilator operates in cycles. Its capacity for removing
CO2 is about 10.6kW. Considering the operating time the amount of electricity used consumed by
the ventilator was determined. The ventilator uses 21.798MWh annually. At the average proce of
329.475z/MWh the costs are 7.2thous. z.

Page 72 of 107
In the case of the ventilator is soaking device 2 the electric power is higher and it is 14.7kW,
which means larger energy consumption (33.478MWh) per year. The costs are 11thous. z.

Page 73 of 107
Here the electric load of the motor in soaking device 3 is at 12kW. Operating of the ventilator
uses 26.760MWh of energy per year, which is 8.8thous z a year. Comparison of the measurement
results (including capacities) is illustrated in the Tab. below.
Tab. 21. Parameters of ventilators
Electric
energy
Energy costs
usage
[z/year]
[kWh/year]
Efficiency
[m3/h]
Soaking
device
Electric
power
[kW]
10,6
21 797,976
7 181,89
19 910,11
14,7
33 478,330
11 030,27
19 440,80
12,0
26 759,552
8 816,60
19 477,61
Source: own.
Ventilators efficiency in each soaking device is at similar levels. Their measured capacity is
not close to their rating capacity which is 36.000m3/h. The reason is the grain resistance. The difference
of operating of ventilator was tested that is, with the soaking device full and during ventilating the
empty cylinder. Measurements without grain were taken on May the 4th 2016 at 14:00 and with the
grain in on the next day at 13:00. The results are presented in the Tab. below.
Tab. 22. Ventilator operating with and without grain in soaking devide 2
Soaking
device
Electric
power
[kW]
Capacity
[m3/h]
With grain
12,9
19 440,80
Without
grain
11,8
29 449,54
Source: own.
Based on the chart of ventilator load in soaking device 2 (Fig. 37), it can be seen that grain
resistance increases the electric power of the ventilators motor by over 1kW and thus higher electric
energy intake. Grain resistance can also be observed in the ventilators capacity, which significantly
decreases with the grain presence. Ventilators installed in the plant have too low operating static
pressure. Recommended replacement is presented in subchapter 4.3.3.

Page 74 of 107
4.3.2. Germination balance

Barley prepared in the soaking rooms is directed to eight Saladin type boxes, each 50x7m.
Grain layered on a perforated slab germinates. The process of germination is dependent on
temperature, oxygen levels and grain moisture content. Oxygen prevents fermentation and is necessary
to produce enzymes in grains and depends on the frequency and intensity of aerating grains. Initially,
oxygenation should be bigger. On the last day the ventilator is switched to a lower gear and completely
switched off in the last two hours. Grain moisture content should be kept at a stable level of about 45%
throughout the germination process. Germination temperature is about 12-130C and is optimal for
creating enzymes. In order to lower the temperature of air directed towards the box, the sprinkling
system is applied. During high temperature periods the ice water cooling system is used.
After more than 5 days, during which grain is regularly mixed and sprinkled, green malt is
made.
Ventilating the grain is done by Ventmeca ventilators at 32m3/s (115 200m3/h) capacity for
each box. During the audit selected boxes were measured for ventilator capacity and their drives
electricity intake. The balance of air distribution through consecutive openings under the box as well
as outlets at its top was also measured. Fig. below represents the schematics of the box. Roman digits
designate the places where measurements were taken.

Page 75 of 107
Fig. 39. Box schematics
Source: own. ((translators note: ziarno z zamaczalni grain from soaking room; poweitrze zewntrzne outside air; chodzenie
cooling; recyrkulacja recyrculation; zraszanie sprinkling; wentylator ventilator; przekrj cross-section)
Box 2
Crate no. 2 was modernized. Air extraction is done via extraction grills installed at on the wall
of the chamber. Before modernization the air was also let in through a chimney. Maintenance services
reported the issue of too high pressure in the boxes, which made opening the doors difficult. That
problem appeared after modernization. A number of measurements of air output (with doors closed
and open) was conducted. The balance of flow rate distribution into individual openings is presented
below.

Page 76 of 107
Tab. 23. Air distribution balance in box 2

Measurement
point
Point
Leading air
into the
ventilatir
Air
distribusion
Exhaust air
closed door
option
Exhaust air
open door
option.
Capacity
[m3/h]
Gear I
Gear 2 III
Gear V
62 392,88
62 619,77
82 207,35
II
29 692,08
25 465,97
43 681,97
III
27 170,76
33 314,22
46 046,88
IV
15 753,60
22 449,60
32 356,80
Total
72 616,44
81 229,79
122 085,65
105,68
129,59
193,43
VI
63,46
86,60
119,29
VII
63,46
80,75
120,94
VIII
60,66
92,96
119,16
IX
Total
293,25
389,90
552,81
95,76
89,40
110,38
VI
41,71
49,60
66,89
VII
50,36
45,91
54,94
VIII
54,68
44,38
74,90
IX
39 884,40
60 426,00
85 276,80
Total
40 126,91
60 655,29
85 583,92
Source: own.
Air distribution underneath the boxes is not even. In case of gear III and V, the biggest air
stream is directed to the grain through the second opening (point III). The weakest air stream is directed
at the end of the crate which can result in weaker oxygenation of this part of the crate. There are
whirlpools underneath the crate, the sum of air distribution to points II, III and IV is larger than the
ventilators capacity. Two options were analyzed when it comes to air leaving the crate. There was a
significant difference in air streams with closed and open doors. Four openings one the wall (V, VI,
VII, VII) do not fulfill their air extraction function in case of soiling. Cleaning recommended.

Page 77 of 107
The amount of air discharged is minimal compared to ventilator capacity. It may suggest lack of
tightness. There is also a difference in air stream entering through the openings when the door is open.
A lot of air comes in through the door, which confirms the necessity of unclogging the openings on
the wall of the top germination box.
The chart below presents ventilator load in box no. 2 at individual gears.
Fig. 40. Ventilator load in box no. 2 at individual gears
Source: own. (translators note: data/czas date/time; czw-Thu)
Tab. 24. Parameters of ventilator in box 2 depending on the gear
Source: own.
Gear
Electric
power
[kW]
Ventilator
capacity
[m3/h]
10,8
62 392,88
II
16,3
62 404,70
III
23,0
62 619,77
IV
32,5
64 708,98
36,9
82 207,35

Page 78 of 107
Electric power, as seen in the measurements, increases with the ventilators efficiency.
However, in box 2, the difference in capacity of ventilator between the first and third gear is not visible
and its power is twice as big. Only at the fifth gear the ventilator can produce enough compression
ratio increase the efficiency. It is still lower than 33thous. m3/h comparing to the rating. To increase
the efficiency of the ventilator the resistance needs to be decreased by unclogging the air flow openings
or applying a ventilator with higher compression ratio.
The next chart presents the electric load of the ventilator in box 2 at normal operating time
during the measurement week.
Fig. 41. Box 2 ventilator load
According to this chart, the ventilators power to deliver air to the grain is at 36.9kW. The
process was led from 15:00 on May the 6th 2016 to 10:00 on May the 11th 2016. During most of the
process, operating of the ventilator at lowest gear is the most visible. At the end of the process where
ventilating the grain can be decreased, the ventilator switches to the second gear.

Page 79 of 107
Tab. 25. Energy consumption of box2 ventilator

Box
number
Electric
power
[kW]
36,9
Electricity Electricity
Energy costs
usage
usage
[z/year]
[kWh/cycle] [kWh/year]
3 423,559
218 857,560
72 108,09
Source: own.
Operating of the ventilator causes the use of 21.8857MWh, which at the average price of
329.475z/MWh translates into 72.1thous. z.
Box 3
Box 3 was modernized as well. Air dispersion is conducted like in box 2. Because of the issue
with the air leaving through the openings of the back wall in box 2, lids on the openings were removed
on box 3 and measurements of efficiency were conducted. The balance is presented in the Tab. below
(in accordance with Fig. 39).
Tab. 26. Air dispersion balance for box 3
Measurement
point
Point
Leading air
into the
ventilatir
Air
distribusion
Exhaust air
closed door
option
Source: own.
Capacity
[m3/h]
Gear I
Gear III
Gear V
61 008,57
83 866,21
109 326,29
II
25 640,84
28 919,72
37 466,67
III
41 791,03
56 477,20
71 465,69
IV
30 378,24
44 988,48
57 196,80
Total
97 810,11
130 385,40
166 129,16
225,85
371,85
434,92
VI
181,60
274,69
288,93
VII
168,88
231,96
377,44
VIII
57,48
84,95
192,28
IX
Total
633,82
963,44
1 293,57

Page 80 of 107
There are also whirlpools of air under box 3. However, due to removing of the lids on the
exhaust openings, air dispersion is more even. The ventilators capacity is much closer to the rated
capacity. The too high pressure above the crate also changed. The exhaust air stream increased twice
its amount. Removal of lids on all boxes is recommended.
It was not possible to measure box 3. Because boxes 2 and 3 are the same, it may be deemed
that the electricity usage is the same.
Box 4
Box 4 was not modernized. Air is exhausted through via extract grills on the walls and a
chimney. Air dispersion balance is presented in the Tab. below (in accordance with Fig. 39).
Tab. 27. Air dispersion balance in box 4
Measuring
point
Point
Leading air
into the
ventilatir
Air dispersion
under the box
Exhaust air
closed door
option
Exhaust air
open door
option
Capacity
[m3/h]
Gear I
Gear III
Gear V
55 917,26
61 504,26
80 630,20
II
20 092,25
37 033,13
55 740,96
III
29 186,28
42 306,54
63 043,14
IV
21 398,40
35 798,40
48 052,80
Total
70 676,93
115 138,07
166 836,90
127,81
181,73
214,92
VI
76,30
140,78
199,53
VII
59,77
107,71
150,06
VIII
67,15
114,20
157,56
IX
22 873,50
32 274,84
42 383,38
Total
23 204,52
32 819,25
43 105,45
71,09
92,20
120,81
VI
63,84
90,93
108,09
VII
41,97
64,86
92,83
VIII
43,11
96,65
96,65

Page 81 of 107
Measuring
point
Capacity
[m3/h]
Point
Gear I
Gear III
Gear V
IX
36 622,80
41 104,80
51 343,20
22 873,50
32 274,84
42 383,38
Total
59 716,30
73 724,27
94 144,97
Source: own.
Air dispersion is highly influenced by the amount of air exhausted from the crate. In case of
chamber 3, proper dispersion was cause by removing the lids, in crate 4 the air removed through the
chimney. However, the ventilator capacity is lower in box 4. The cause may be the chimney which
is a source of resistance for the ventilator. Ventilator loads in box 4 for individual gears are presented
in the chart below.
Fig. 42. Ventilator loads in crate 4 for individual gears
Source: own. (translators note: data/czas date/time; czw-Thu)

Page 82 of 107
Tab. 28. Gear related parameters of ventilator in box 4

Gear
Electric
power [kW]
Ventilator
capacity
[m3/h]
8,0
55 917,26
III
19,1
61 504,26
37,2
80 630,20
Source: own.
One can notice that electric power increases proportionately to capacity based on the
measurements. The next chart presents electric load of the ventilator in box 4 during standard operating
week. The process was conducted between May the 2nd 2016 from 15:00 to May 7th 2016 at 10:00.
Fig. 43. Ventilator loads in crate 4
Chart analysis indicates that the power of the ventilator delivering air to grains is at 37.2kW.
Mostly throughout the process one can see the ventilator running on highest gear. Power fluctuation
on May 5th 2016 are a result of measurements being taken on that day.

Page 83 of 107
Tab. 29. Energy consumption of ventilator of box 4

Crate
number
Electric
Electric
energy
power [kW]
usage
[kWh/cycle]
37,2
3 264,708
Electric
enrgy usage
[kWh/year]
Energy costs
[z/year]
221 154,146
72 864,76
Source: own.
The ventilator uses 221.154MWh of energy a year. At the average price of 329.475z/MWh the
costs are 72.9thous. z.
4.3.3. Analysis of processing ventilators

The plant uses a range of ventilators which data is compiled in Tab. 30. In the soaking room
and germination room the ventilators ventilate the grains, providing the right mounts of oxygen and
removing carbon dioxide. In the drying room air is heated by burners at 3x5.4MW capacity and it dries
the grain which produces the final product malt.
Tab. 30. Rating data of ventilators installed in the plant

Ventilator
Soaking room
Germination room
Drying room 1
Drying room 2
Company
Solyvent-Ventec
Ventmeca
Pollrich
Ventilatoren
Pollrich
Ventilatoren
Ventilator type
HU90922VP
VFB120-49-6SP
BP LG270
BP RG270
36 000
115 200
680 000
680 000
Brak danych
637
1 920
1 560
15,0
37,0
434,7
365,1
Capacity [m /h]
Compression
ratio[Pa]
Motor rating
power[kW]
Amount [items]
Source: own.
Measurements of air flow, pressure and ventilator power were conducted in order to propose
optimization which will improve the conditions for the grain soaking, sprouting and drying.

Page 84 of 107
Soaking room
Measurement results of soaking room ventilators are presented in the Tab. below.
Tab. 31. Soaking room ventilators parameters
Ventilator
Soaking device 1
with grain
Soaking device 2
with grain
Soaking device 2
without grain
Soaking device
3
with grain
Capacity[m3/h]
19 910,11
19 440,80
29 449,54
19 477,61
Total compression
ratio [Pa]
652
767
913
615
Efficiency [%]
34,0
28,2
63,3
27,7
Electric power [kW]
10,6
14,7
11,8
12,0
Source: own.
Capacity levels of ventilators in normal conditions (filled with grain) are at similar levels. Their
capacity is lower than rating capacity because of the resistance of the grain. Soaking device 2 ventilator
has higher compression ratio and therefore intakes more electricity. However it is unable to defeat the
grain resistance so the flows are at the same levels. Because of that, the system has low efficiency.
Ventilators of soaking devices 1 and 3 have similar compression ratio. The difference in electric power
intake is caused by different power supplies. Soaking device 1 drive is not equipped in an inverter
which causes further power losses. In soaking device 3 the inverter is steered at 100% capacity all the
time, so it does not allow for savings. Conversely, it causes losses of active power.
During the measurement a test was undertaken. Capacity and compression ratio of the
ventilator of soaking device 2 was measured during standard operating and during container
ventilation, without grain. The resistance of grain for the ventilator is clearly visible Without grain it
can almost reach the rating parameters, the only differences may come from the degree of soiling of
the ventilator.
Auditor estimates that in order to achieve the right flows for soaking (36 000m3/h), it is
necessary to replace the ventilators with units with higher compression ratio (which would allow for
overcoming the resistance. It will increase energy usage but also significantly increase the amount of
air flowing through grain. Properly chosen units will have higher efficiency.

Page 85 of 107
Tab. 32. Rating parameters of suggested ventilators for the soaking room
Ventilator
Soaking room
Company
Owent
Type
WWOax-71
Capacity [m3/h]
36 000,0
Capacity [m3/s]
10,0
Compression ratio
[Pa]
2 900
Efficiency [%]
82,0
Motor rating power

[kW]
45,0
Amount [items]
Source: own.
Ventilators with higher compression ratio will have higher efficiency. Choosing the
abovementioned ventilators will allow for increasing air flow in the grains.
Tab. 33. Costs of ventilator replacement
Costs
Soaking room
Ventilators[z/]
98 250,00
Motors [z/]
20 040,00
Inverter [z/]
41 460,00
Wiring replacement
[z]
28 000,00
Labour [z]
66 400,00
Total costs [z]
254 150,00
Total cost of replacing the ventilators in the soaking room is estimated at 254.15thous. z.

Page 86 of 107
Germination room
Ventilator measurement results on selected crates are presented below.

Tab. 34. Germination room ventilator parameters
Ventilator
Crate 2
Crate 3
Crate 4
Capacity [m3/h]
82 207,35
109 326,39
80 630,20
Total compression
ratio [Pa]
624
640
708
Efficiency [%]
38,6
52,7
42,9
Motor rating power

[kW]
36,9
36,9
37,2
Source: own.
The ventilators in the soaking room have parameters corresponding to rating parameters. The
parameters are dependent on the level of modernization of the crates. In crate 2 and 3 modernization
meant removing the chimney. The compression ratio increased and capacity went up to 52.7% because
of removing the lids on exhaust openings in crate 3. Low parameters in crate 4 are caused by soiling
levels of exhaust openings and the chimney which causes static pressure loss in the system. It is
recommended to modernize the crates in the way crates 2 and 3 were, including cleaning.
After cleaning, the ventilator operates well. However, capacity issues caused by soiling and
meeting just the minimal requirements for air flow, replacing the ventilators was considered.
Tab. 35. Rating parameters of suggested ventilators for germination room
Source: own.
Ventilator
Germination room
Company
Owent
Type
WPWX-140
Capacity [m3/h]
115 200,0
Capacity [m3/s]
32,0
Compression ratio
[Pa]
1 200
Efficiency [%]
82,0
Motor rating power

[kW]
75,0
Amount [items]

Page 87 of 107
Applying recommended ventilator will increase the air flow in the grain. A 75kW motor will
provide very good air flow. A 55kW motor is also viable. Its power supply is adapted to the electricity
infrastructure. The ventilator would have lower compression ratio and constant soiling levels
monitoring would be vital. The costs of modernization are the costs of replacement of the ventilator
for the 75kW motor (option I), including the wiring changes, and for the 55kW motor. Data is compiled
below.
Tab. 36. Costs of ventilator replacement in germination room
Costs
Germination drive
75 kW
Germination drive
55 kW
Ventilators [z/]
1 099 600,00
1 099 600,00
Motors[z/]
92 400,00
68 640,00
Inverters [z/]
138 800,00
Wiring changes [z]
21 750,00
Labour[z]
534 820,00
469 796,00
Total costs [z]
1 887 370,00
1 638 036,00
Source: own.
Total costs of replacement for the 75kW motors is estimated at 1mln 887.4 thous.z, for 155kW
motors it is at 1mln 638thous. z.
Drying room
The Tab. below illustrates the parameters of ventilators in the drying room based on conducted
measurements.
Tab. 37. Parameters of ventilators in the drying room

Ventilator
Drying room 1
Drying room 2
Ventilator
632 541,55
538 618,46
Capacity [m /h]
2 090
1 535
Compression ratio
[Pa]
87,4
59,2
Efficiency [%]
420
388
Source: own.

Page 88 of 107
There are two types of ventilators installed in the drying rooms. According to the
measurements, their rating compression ratios are not achieved which lowers the capacity. It means
that there is too big resistance of the system towards the ventilators. Replacing them with high
efficiency radial fans is recommended. Rating parameters are compiled in the Tab. below.
Tab. 38. Rating parameters of suggested ventilators for the drying room
Ventilator
Drying room
Company
Owent
Type
WPWXD-180
Capacity [m3/h]
680 400,0
Capacity[m3/s]
189,0
Compression ratio
[Pa]
2 250
Efficiency[%]
82,0
Motor rating
power[kW]
650,0
Amount [items]
Source: own.
The costs of replacement are presented in the Tab. below.

Tab. 39. Costs of replacing the ventilators in the drying room
Costs
Drying room
Ventilators[z]
1 241 600,00
Motors[z]
440 400,00
Inverters [z]
176 350,00
Cable changes [z]
12 000,00
Labour [z]
745 840,00
Total costs [z]
2 616 190,00
Source: own.
Enclosing higher compression ratio ventilators will also allow for implementation of an
algorithm for capacity setting applied in other malthouses of the concern.

Page 89 of 107
4.3.4. Dust removal systems

A significant amount of dust is produced during production process. It is removed by dust
removal system. Air flow is forced by ventilators which efficiency is regulated by throttling. Most dust
removal centrals have filters. During standard operating they get clogged with dust which lowers the
air flow. In order to prevent that dust removal systems use compressed air to blow the dust off the
filters. Current pneumatic installation of dust removal centrals estimates cleaning individual filters
(depending on the device) at between 10 to 30 seconds. Selected dust removal stations were equipped
with the dust cleaning system which is corresponds the time between cleaning to pressure differences
before and past the filters.
Their efficiency may be improved in three areas.
Modification of filter cleaning time
During on-site verification the time cycle of filter cleaning system was observed. It appears to
be a better solution in some conditions than the system of pressure difference estimation system. That
is the reason why the auditor is of the opinion that remaining with the cyclical filter cleaning impulses
steering is a good solution, with empirically fitted break times (e.g. based on break time of current dust
removal system).
On site verification indicates that the dust removal system muses 30% of compressed air
produced in the plant. That makes the dust removal stations the biggest recipients of compressed air
on the premises.
The Tab. below illustrates the time cycle and steering frequency of cleaning impulses in
selected cyclone filters.
Tab. 40. Comparison of selected aspirators in the plant
Source: own.
Filter cleaning impulse

time [s]
Aspirator
(cyclone filter
label)
Way of
steering
FC3
Cyclical
30
60
FC4
Cyclical
10
20
FC5
Pressure
FC6
Cyclical
12
24
FC7
Cyclical
25
50
FC11
Cyclical
20
40
Set
actual
Over 2 min
Suggested filter
cleaning impulse
time [s]

Page 90 of 107
The longest impulses are in the systems steered based on pressure differences (delta P). An
interesting comparison was made between two aspirators on 11th and 12th floor of the elevator building
(FC4 and FC5) which work in identical installations. One uses the delta P impulse steering and the
other one uses the cyclical impulse steering. In the system with cyclical impulse steering a short break
was set between each cycle (10s) and the delta P system triggered the impulse in much longer
timeframes.
The experiment shows that doubling the time between impulses does not cause
irregularities in the cyclically steered devices in which the time of the cycle is on factory settings. It
is recommended to empirically increase the breaks between impulses. First, double it and observe
functioning. If there are no irregularities, continue increasing the breaks until the time level of systems
steered by pressure difference impulses. Excessive filter clogging will cause lowering of power intake
via the ventilator drive of the given dust removal system. Monitoring with a current clam meter is
recommended.
Doubling the time between each filter cleaning impulses with cyclical steering mentioned
in Tab. 14 will cause average annual savings of 354 181m3 of compressed air, which is 24.4thous.
z.
Applying nozzles to air releasing openings
Though it was not possible to physically take apart a dust removal system, by air used and noise
during operating, it can be deemed that openings releasing compressed air (Fig. 4) are not equipped
with nozzles thaw would steer the stream. Nozzles reduce the air flow by steering the stream while
keeping the same strenth of the impulse. Nozzle producer provides a reduction of compressed air usage
up to 30%. Assuming that 30% of compressed air with 6bar pressure produced in the plant is
used by dust removal systems it is possible to achieve savings around 26.239MWh, which
translates into 8.6thous.z. Budget for implementing nozzles is 41.8thous. z. Exact determination
of savings and modernization costs stemming from implementing nozzles will be possible after
measuring flows, determining the time of the cycle and the number of nozzles for each station.

Page 91 of 107
Fig. 44. Possible manner of air releasing into filters
Source: own.
Silvent company makes their products available for testing and sampling. It allows for
choosing a nozzle for the station and assessing it in operating conditions.
Fig. 45. Filter cleaning impulse nozzle by Silvent
Source: www.silvent.com
Besides reducing compressed air intake, nozzles reduce the noise of pressurized air flow. It
increases working comfort. Because of the large investment costs it is recommended to regulate
the time between impulses and to reconsider nozzle implementation once again.
Using frequency exchangers for the ventilator drives
During on site verification, it was observed that the regulation of air flow of the dust removal
system is conducted by throttling lids. While regulating by throttling method, which is currently used
to change the air flow in the system, closing the throttle caused the change in the character of the
pipeline from S1curve to S2. (Fig. 46) which results in changing the operating point of the system

Page 92 of 107
from A1 to B1. It is the simplest way of regulation, but not effective because the ventilators energy
intake decreases slightly in comparison to requirements of the point of operating. The best way of
regulating ventilators capacity is changing the ventilators characteristics by changing is rotation
speed. Lowering the speed of the rotor from 1 to 2 and 3 results in shifting the operating points
to A2 and A3.
Fig. 46. Regulating ventilator capacity by throttling lid
Source: own.
Comparing both methods, the method of regulating by means of rotation speed of the rotor is
economically more beneficial because it allows to achieve efficiency at a level close to rating
efficiency. Using the frequency exchanger will enable operating of a high efficiency motor and lower
electricity usage.

Page 93 of 107
Fig. 47. Regulating the capacity by throttling method and regulating the rotation speed of the rotor
method
Source: own.
High throttling level cause low efficiency. Lowering air flows to the right pipeline can be
achieved by reducing the rotation speed. Using that method the parameters of the system can be
determined as follows:
=
c c
in which:
Q assumed flow;
Q rating flow;
n calculated rotation speed of the drive at assumed flow Q;
n rating rotation speed of the drive.
Using the constant value of the air flow stream frequency regulation enables reduction in the
motors energy intake, which can be determined with the following formula:
= c
c
in which:
P power at speed corresponding to set flow;
P power at rating speed.

Page 94 of 107
Calculations were based on conducted measurements of active power intake of the drives.
Potential savings from using this method are presented in the Tab. below. They are approximate
savings. Exact determination of savings will be possible after measuring the air flow and energy intake
with the open lid.
Tab. 41. Potential savings from applying frequency exchangers in dust removal systems
Ventilator
Rating
power of
the drive
[kW]
Current
energy
usage
[MWh]
Energy
usage post
modernizin
g [MWh]
Savings
[MWh]
Savings [z]
Moderniza
tion costs
[z]
SPBT
[months]
V1
30,0
20,122
5,610
14,512
4 781,24
9 963,10
25
V3
37,0
50,211
13,999
36,212
11 931,01
11 993,10
12
V5
18,5
5,740
1,600
4,140
1 363,90
7 423,10
65
V6
11,0
8,308
2,316
5,992
1 974,10
5 213,10
32
V7
11,0
25,701
7,165
18,536
6 107,00
5 213,10
10
V9
18,5
18,629
5,194
13,435
4 426,60
7 423,10
20
V10
18,5
22,737
6,339
16,398
5 402,71
7 423,10
16
V11
18,5
5,811
1,620
4,191
1 380,79
7 423,10
65
V12
18,5
34,482
9,613
24,868
8 193,45
7 423,10
11
V13
18,5
27,490
7,664
19,825
6 532,01
7 423,10
14
V15
15,0
11,213
3,126
8,086
2 664,28
6 473,10
29
V16
15,0
4,074
1,136
2,938
968,12
6 473,10
80
V17
22,0
20,728
5,779
14,949
4 925,24
8 663,10
21
V18
22,0
32,202
8,978
23,224
7 651,75
8 663,10
14
V19
20,0
24,921
6,948
17,973
5 921,66
8 663,10
18
Total
312,367
87,088
225,279
74 223,87
115 856,50
19
Source: own.

Page 95 of 107
5. Energy policy of the plant

Top management of Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant is committed to
implementing and maintaining the energy policy based on continuing current activities in production
area to provide effective energy usage. Energy safety of the company will be based on planned repairs,
modernizations and developing current infrastructure. The company will conduct campaigns and
trainings about energy efficiency for employees . Reasonable energy management and concern for
natural environment are and aim of utmost importance for the company.
High energy efficiency will be conducted through:
Identifying and monitoring high energy usage areas;
Proper electricity and heat usage in production process;
Constant monitoring of energy carriers;
Providing necessary finances for research and development of new projects as well as
purchasing products and services;
Applying energy efficiency criteria in research and developement of new projects as well as in
purchasing new products and services;
Investing in technology development which will increase the competitiveness of the company.
To reduce energy consumption the plant commits to implementing the investment of changing
the steering compressed air devices, implementing the steering system based on ventilators capacity
in aspirators and replacing the illumination system in passageways and control rooms. These
modernizations will reduce energy usage and therefore lower CO2 emissions.
The Tab. below is the auditors suggestion about the most advantageous order of implementing
preo-efficiency activities for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx in Pozna.

Page 96 of 107
Tab. 42. Summary of activities from the audit with implementation schedule
Lp.
Action
Energy
savings
[MWh]
Energy
savings
[toe]
Savings [z]
Costs
[z]
White
certificate
profits* [z]
STAGE I
1.
2.
3.
4.
5.
6.
Modifying adiabatic
cooling system in the
germination room
Removing the defect in
GA22 air compressor
Enclosing the inverter
in compressor GA45+
Replacing the selected
illumination fixtures
Modyfying the cleaning
impulse in selected dust
removal systems
Applying frequency
exchangers in the drives
of dust removal system
607,726
156,765
200 233,56
434 434,35
145 791,53
63,753
16,445
21 005,34
100,00
15 294,14
74,904
19,322
24 679,37
15 000,00
17 969,23
44,100
11,376
14 530,07
22 720,00
10 579,45
36,835
9,502
12 136,40
100,00
225,279
58,112
74 224,92
115 856,50
54 043,72
29 339,94
127 050,00
19 085,49
900,47
4 000,00
STAGE II
7.
Heat recovery from

boilers
216,974
20,522
STAGE III
5.
Enclosing soft start

systems driving the
ventilators in the
soaking room
2,733
0,705
*930 z/toe, minimal requirements 10 toe.

Source: own.
The Tab. below illustrates the effects of suggested actions on basic factors.

Page 97 of 107
Tab. 43. The effect of actions taken to improve energy efficiency on basic factors
Action
Factor
Natural gas factor pre-modernization
50,11 [m3/Mg]
Heat reclaiming from CO boiler exhaust fumes
0,187 [m3/Mg]
Natural gas factor post-modernization
49,92 [m3/Mg]
Electricity basic factor pre-modernization
0,105 [MWh/Mg]
Adiabatic air cooling modification in germination room
0,006 [MWh/Mg]
Removal of air compressor GA22 defect
0,001 [MWh/Mg]
Enclosing the inverter in compressor GA45+
0,001 [MWh/Mg]
Replacing the selected illumination fixtures
<0,001 [MWh/Mg]
Enclosing soft start system to motors driving the ventilators in the

soaking room
Modifying cleaning impulse time in selected dust removal
systems
Using frequency exchangers in ventilator drives in dust removal
systems
Electricity basic factor post-modernization
<0,001 [MWh/Mg]
<0,001 [MWh/Mg]
0,002 [MWh/Mg]
0,095 [MWh/Mg]
Source: own.
Implementing all these changes will reduce the plants energy consumption by 0.010MWh/Mg
for electricity, that is 9.6%, and 0.187m3/Mg for heat, that is 0.37%.

Page 98 of 107
6. Summary
The conducted audit recommends technical and formal changes that will reduce costs and
energy consumption. Compilation of these changes is presented in the Tab. below. Values correspond
to costs and energy usage for the period between January 2015 and December 2015.
Energy savings are illustrated in the form of a Tab. below.
Option 1 no investment in cogeneration unit cooperating with heat pump
Tab. 44. Summary of suggested actions and possible savings

Energy usage reduction
[MWh]
Action
Savings
[z/year]
Implementation
costs[z]
Payback
period
[month]
Energy audit of electricity, heat and cold sources

Heat recovery from boiler
exhausts
216,974
0,37% heat usage
29 339,94
127 050,00
52
Modifying adiabatic air cooling in

germination room
607,726
5,52% electricity usage
200 233,56
434 434,35
26
21 005,34
100,00
24 679,37
15 000,00
14 530,07
22 720,00
19
900,47
4 000,00
53
Electric energy audit of buildings and network

Removal of defect in GA22 air
compressor
Enclosing the inverter in air
compressor GA45+
Replacing selected illumination
units
Enclosing softstart systems for
motors driving ventilators in
soaking room
63,753
74,904
44,100
2,733
Energy audit of technological processes

Modifying cleaning impulse time
in selected dust removal systems
36,835
12 136,40
100,00
Applying frequency exchangers in

ventilators in dust removal
systems
225,279
74 224,92
115 856,50
19
Source: own.
Implementing these recommendations 377.1thous. z savings can be achieved, which is 3.3%

of the total costs of electricity and gas, which are 11mln 508.6thous. z. Estimated cost of all actions
is 719.3thous. z.
In each area investment costs were estimated (implementing changes, energy effect in changing
operating costs, fuel reduction costs). For all proposed actions financial and ecological factors were

Page 99 of 107
calculated. The results for a 10 year period are in the Tab. below. NPV value was determined for
discount rate at 7%, DGC is for discount rate at 8%.
Tab. 45. Summary of all actions through the financial factor of suggested investments and the
ecological DGC factor
No.
Action
EEN
[GWh]
KI0
[z]
KE1..KE10
[z]
EE1
[tCO2]
NPV
[z]
IRR
[%]
DGC
SPBT
[z/tCO2] [years]
Heat recovery from

boilers
0,217
127 050,00
29 339,94
43,601
79 021,48
19,06
-238,66
4,33
Modifying adiabatic
germination room
0,608
434 434,35
200 233,56
540,876
971 922,40
44,97
-250,50
2,17

GA22 air compressor
0,064
100,00
21 005,34
56,740
147 432,71
21
005,34
-369,94
0,00
0,075
15 000,00
24 679,37
66,665
158 337,57
164,52
-336,67
0,61
0,044
22 720,00
14 530,07
39,249
79 333,12
63,48
-283,93
1,56

systems driving the
ventilators in the
soaking room
0,003
4 000,00
900,47
2,432
2 324,52
18,33
-125,13
4,44

removal systems
0,037
100,00
12 136,40
32,783
85 140,97
12
136,40
-369,75
0,01
Applying frequency
0,225
115 856,50
74 224,92
200,498
405 468,31
63,60
-284,09
1,56
1,272
719 260,85
377 050,07
982,845
1 928 981,07
51,60
-2
258,66
1,91
4
5
Enclosing the inverter in

compressor GA45+
Summary
Source: own.
Balance limits of energy requirements of the audited plant are presented below.
Energy utilities
Usage
[MWh]
Emission
[tCO2]
Electricity
11 006,662
9 795,929
Heat
58 289,693
11 713,430
Total
69 296,355
21 509,360
Emission per
energy unit
Source: own.
0,310 [tCO2/MWh]
After changes
Tab. 46. Balance limits of energy requirements

Usage [MWh]
Emission
[tCO2]
9 951,332
8 856,685
58 072,719
11 669,829
68 024,051
20 526,515
0,302 [tCO2/MWh]

Page 100 of 107
The next Tab. shows the influence of the pro-efficiency actions on the change in the plants
basic factors.
Tab. 47. The influence of the pro-efficiency actions on the change in the plants basic factors
Action
Factor
Natural gas factor pre-modernization
50,11 [m3/Mg]
0,187 [m3/Mg]
Natural gas factor post-modernization
49,92 [m3/Mg]
0,105 [MWh/Mg]
0,006 [MWh/Mg]
0,001 [MWh/Mg]
0,001 [MWh/Mg]
<0,001 [MWh/Mg]

soaking room
systems
systems
<0,001 [MWh/Mg]
<0,001 [MWh/Mg]
0,002 [MWh/Mg]
0,095 [MWh/Mg]
Source: own
Option 2 implementing the investment including cogeneration unit cooperating with

heat pumps
Tab. 48. Summary of actions and potential savings

[MWh]
Action
Savings
[z/year]
Implementation
costs[z]
Payback
period
[months]
Energy audit of electricity, heat and cold sources

Heat recovery from boiler
exhausts
216,974
0,37% heat usage
23 862,79
127 050,00
64
Modifying adiabatic air cooling

in germination room
607,726
168 005,85
434 434,35
31
Applying cogeneration unit with

heat pumps in the drying room
5 923 423,40
15 500 000,00
31
100,00
Electric energy audit of buildings and network

Removal of defect in GA22 air
compressor
63,753
17 624,52

Page 101 of 107
Action

[MWh]
Enclosing the inverter in air

compressor GA45+
Replacing selected illumination
units
Enclosing softstart systems for
motors driving ventilators in
soaking room
74,904
44,100
2,733
Savings
[z/year]
Implementation
costs[z]
Payback
period
[months]
20 707,21
15 000,00
12 191,45
22 720,00
22
755,54
4 000,00
64
Energy audit of technological processes

Modifying cleaning impulse time
in selected dust removal systems
36,835
10 183,04
100,00
0,33
Applying frequency exchangers

in ventilators in dust removal
systems
225,279
62 278,38
115 856,50
2,05
Source: own.
Implementing the changes may save 6mln 239thous. z, which is 54.21% of total electricity and
gas costs which were 11mln 508.6 thous. z. Estimated implementation costs are 16mln 219.3thous.
z.
In each area investment costs were estimated (implementing changes, energy effect in changing
operating costs, fuel reduction costs). For all proposed actions financial and ecological factors were
calculated. The results for a 10 year period are in the Tab. below. NPV value was determined for
discount rate at 7%, DGC is for discount rate at 8%.
No.
Action
EEN
[GWh]
KI0
[z]
KE1..KE10
[z]
EE1
[tCO2]
NPV
[z]
IRR
[%]
SPBT
DGC
[z/tCO2] [years]
Heat recovery from

boilers
0,217
127 050,00
23 862,79
43,601
40 552,24
13,48
-113,04
5,32
0,608
434 434,35
168 005,85
540,876
745 568,46
37,01
-190,92
2,59
0,000
15 500 000,00
5 923
423,40
11
347,786
29 232
852,87
43,78
-359,14
2,58
2
3
Modifying adiabatic
germination room
Applying cogeneration
system with heat pumps

GA22 air compressor
0,064
100,00
17 624,52
56,740
123 687,23
17
624,52
-310,36
0,01
Enclosing the inverter in

compressor GA45+
0,075
15 000,00
20 707,21
66,665
130 438,78
138,02
-277,09
0,72

0,044
22 720,00
12 191,45
39,249
62 907,61
52,89
-224,35
1,86

Page 102 of 107
No.
Action
EEN
[GWh]
KI0
[z]
KE1..KE10
[z]
EE1
[tCO2]
NPV
[z]
IRR
[%]

systems driving the
ventilators in the
soaking room
0,003
4 000,00
755,54
2,432
1 306,58
13,62
-65,54
5,29

removal systems
0,037
100,00
10 183,04
32,783
71 421,38
10
183,04
-310,16
0,01
Applying frequency
0,225
115 856,50
62 278,38
200,498
321 560,78
52,99
-224,50
1,86
1,272
16 219 260,85
6 239
032,18
12
330,631
30 730
295,92
58,52
-2
075,10
1,69
Summary
DGC
SPBT
[z/tCO2] [years]
Source: own.
Balance limits of energy requirements are presented below.

Usage
[MWh]
Electricity from
11 006,662
network
Current method
of heat
58 289,693
production
Electricity from
cogeneration
Total
Emission per
energy unit
69 296,355
Emission
[tCO2]
Usage
[MWh]
Emission
[tCO2]
9 795,929
21 631,903
4 346,974
18 648,842
7 454,051
40 280,745
11 801,025
11 713,430
21 509,360
0,310 [tCO2/MWh]
After changes
Energy utilities
0,293 [tCO2/MWh]
Source: own.
The next Tab. shows the influence of the pro-efficiency actions on the change in the plants
basic factors.

Page 103 of 107
Action
Factor
Natural gas basic factor pre-modernization
50,11 [m3/Mg]
0,187 [m3/Mg]
Natural gas basic factor post-modernization
49,92 [m3/Mg]
0,105 [MWh/Mg]
0,006 [MWh/Mg]
0,001 [MWh/Mg]
0,001 [MWh/Mg]
<0,001 [MWh/Mg]

soaking room
systems
systems

Source: own.
<0,001 [MWh/Mg]
<0,001 [MWh/Mg]
0,002 [MWh/Mg]
0,095 [MWh/Mg]

Page 104 of 107
List of Figures
Fig 1. Bucket conveyor drive ................................................................................................................. 7
Fig 2. Dust removal ventilator drive ...................................................................................................... 8
Fig. 3. Percentage balance of electricity use at Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx malthouse ... 19
Fig. 4. Heat production. ....................................................................................................................... 23
Fig. 5. The price of 1GJ of produced heat in relation to each month .................................................. 25
Fig. 6. Gas usage ratio per ton of malt production............................................................................... 26
Fig. 7. Boiler room ............................................................................................................................... 28
Fig. 8. Operating schematics of an economizer ................................................................................... 30
Fig. 9. Schematics of the dryer ............................................................................................................ 31
Fig. 10. Burner efficiency during individual drying cycle................................................................... 33
Fig. 11. Air temperatures before and after the exchanger.................................................................... 35
Fig. 12. Temperatures of humid air before exchanger ......................................................................... 36
Fig. 13. Thermal efficiency of the exchanger ...................................................................................... 37
Fig. 14. Enthlapy differences in the glass exchanger........................................................................... 38
Fig. 15. The difference of enthlapy of humid air before and after the exchanger as well as total
capacity ................................................................................................................................................ 39
Fig. 16. Humid gases temperature after the exchanger ........................................................................ 40
Fig. 17. Electricity collected by the ventilators of the drying room .................................................... 41
Fig. 18. Electricity collected by the drives of the ventilators in the drying room during a single cycle
.............................................................................................................................................................. 42
Fig. 19. Measurement points for the heat balance of the drying room ................................................ 43
Fig. 20. Cooling capacity of the ice water cooling units in May ......................................................... 45
Fig. 21. Cooling capacity generated by the ice water cooling units in June ........................................ 46
Fig. 22. Cooling capacity generated by the ice water cooling units in July ........................................ 46
Fig. 23. Cooling capacity generated by the ice water cooling units in August.................................... 47
Fig. 24. Cooling capacity generated by the ice water cooling units in September ............................. 47
Fig. 25. Cooling energy balance (with the heat pumps) ...................................................................... 48
Fig. 26. Water temperature after sprinkling ......................................................................................... 49
Fig. 27. Conceptual schematic diagram of the heat pump ................................................................... 51
Fig. 28. Scheme of the planned heat pump system with a cogeneration unit ...................................... 53
Fig. 29. Power consumption of compressor GA22 .............................................................................. 59
Fig. 30. Capacity load of GA45+ ......................................................................................................... 60
Fig. 31. Leakage in the valve in the room at the top of the new elevator ............................................ 61
Fig. 32. Leakage at the junction of the actuator hose in the room at the top of the new elevator ....... 62
Fig. 33. Model of the factor determining the financial viability of repairing or replacement of the
motor .................................................................................................................................................... 65
Fig. 34. Characterization of the efficiency of power from 4 pole motors for each IE ......................... 66
Fig. 35. Soaking process scheme ......................................................................................................... 70
Fig. 36. Ventilator load in soaking device 1 ........................................................................................ 71
Fig. 37. Ventilator load in soaking device 2 ........................................................................................ 72
Fig. 38. Ventilator load in soaking device 3 ....................................................................................... 72
Fig. 39. Box schematics ..................................................................................................................... 75

Page 105 of 107
Fig. 40. Ventilator load in box no. 2 at individual gears ..................................................................... 77

Fig. 41. Box 2 ventilator load .............................................................................................................. 78
Fig. 42. Ventilator loads in crate 4 for individual gears ...................................................................... 81
Fig. 43. Ventilator loads in crate 4 ....................................................................................................... 82
Fig. 44. Possible manner of air releasing into filters .......................................................................... 91
Fig. 45. Filter cleaning impulse nozzle by Silvent............................................................................... 91
Fig. 46. Regulating ventilator capacity by throttling lid ...................................................................... 92
Fig. 47. Regulating the capacity by throttling method and regulating the rotation speed of the rotor
method.................................................................................................................................................. 93

Page 106 of 107
List of Tables
Tab. 1. Energy balance of Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx plant
18
Tab. 2. Electricity cost for the period of 01.01.2015 to 31.12.2015
19
Tab. 3. Energy usage indicator per ton of product for individual months.
20
Tab. 4. The use of gas and heat production in 2015
22
Tab. 5. Heat costs analysis
24
Tab. 6. Gas usage ratio per ton of malt production
25
Tab. 7. Types of gas boilers
28
Tab. 8. Heat recovery from the boilers
29
Tab. 9. The cost of economizers
30
Tab. 10. Analysis of increasing the temperature of primary air for the burners
34
Tab. 11. The drying process balance
43
Tab. 12. Savings resulting from implementing the new sprinkling system
50
Tab. 13. The balance of the plant including operating of the heat pump along with cogeneration 56
Tab. 14. Economical parameters of the investment in the heat pumps cooperating with cogeneration
57
Tab. 15. List of installed compressors
58
Tab. 16. Annual savings due to modernization
61
Tab. 17. Potential savings stemming from lighting system modernization
63
Tab. 18. Tata of the analyzed electric drives
67
Tab. 19. Potential savings from replacing motors to energy efficient ones
68
Tab. 20. Profitability estimation of repairing or replacing motors in case of a breakdown
69
Tab. 21. Parameters of ventilators
73
Tab. 22. Ventilator operating with and without grain in soaking devide 2
73
Tab. 23. Air distribution balance in box 2
76
Tab. 24. Parameters of ventilator in box 2 depending on the gear
77
Tab. 25. Energy consumption of box2 ventilator
79
Tab. 26. Air dispersion balance for box 3
79
Tab. 27. Air dispersion balance in box 4
80
Tab. 28. Gear related parameters of ventilator in box 4
82
Tab. 29. Energy consumption of ventilator of box 4
83
Tab. 30. Rating data of ventilators installed in the plant
83
Tab. 31. Soaking room ventilators parameters
84
Tab. 32. Rating parameters of suggested ventilators for the soaking room
85
Tab. 33. Costs of ventilator replacement
85
Tab. 34. Germination room ventilator parameters
86
Tab. 35. Rating parameters of suggested ventilators for germination room
86
Tab. 36. Costs of ventilator replacement in germination room
87
Tab. 37. Parameters of ventilators in the drying room
87
Tab. 38. Rating parameters of suggested ventilators for the drying room
88
Tab. 39. Costs of replacing the ventilators in the drying room
88
Tab. 40. Comparison of selected aspirators in the plant
89
Tab. 41. Potential savings from applying frequency exchangers in dust removal systems
94

Page 107 of 107
Tab. 42. Summary of activities from the audit with implementation schedule
Tab. 43. The effect of actions taken to improve energy efficiency on basic factors
Tab. 44. Summary of suggested actions and possible savings
Tab. 48. Summary of actions and potential savings
96
97
98
99
99
100
100
101
102
103

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ENERGY AUDIT

Electrical energy, heat and cold sources

Energy of the buildings and the manufacturing network

Electricity system of the buildings and the network

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

The basis for

Advisory services contract

Audit of energy efficiency of the plant

DB Energy Sp. z o.o.

Anna Pasiak, MSc., eng.

Waldemar Jakubowski, MSc., eng.

The choice of activities to improve energy efficiency ................................................................. 28

The areas of heat and cold sources ........................................................................................... 28

The boiler room ..................................................................................................................... 28

Drying process balance ......................................................................................................... 30

Cooling requirements during germination process ............................................................... 44

The electromagnetic area of the buildings and transmission network ...................................... 58

Compressed air system .......................................................................................................... 58

Lighting system ..................................................................................................................... 62

Electric drives ........................................................................................................................ 64

Technological process area ....................................................................................................... 70

Soaking process balance........................................................................................................ 70

Germination balance ............................................................................................................. 74

Analysis of processing ventilators......................................................................................... 83

Dust removal systems............................................................................................................ 89

Energy policy of the plant ............................................................................................................ 95

List of Figures .................................................................................................................................... 104

Fig 2. Dust removal ventilator drive

Soaking and germination building

Powering the plant with electricity

Supplying the plant with heat

Supplying the plant with compressed air

Illuminating the plant

Implementing speed regulation in the dust removal drives

Modernizing lighting system

Methodology of measurements conducted in the audited plant

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Methodology of calculating financial and ecological parameters of suggested activities

requirements on analysis of profitability of implementing changes with an estimation of basic

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

3. Energy balance and selecting energy consumption indicators of the plant

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Fig. 3. Percentage balance of electricity use at Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx malthouse

Cost for MWh

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Cost for MWh

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Tab. 4. The use of gas and heat production in 2015

Fig. 4. Heat production.

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Tab. 5. Heat costs analysis

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Fig. 5. The price of 1GJ of produced heat in relation to each month

Tab. 6. Gas usage ratio per ton of malt production

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Fig. 6. Gas usage ratio per ton of malt production

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

4. The choice of activities to improve energy efficiency

The areas of heat and cold sources

The boiler room

Boiler capacity [MW]

Fig. 7. Boiler room

Energy audit report for Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxx Sp. z o. o.

Exhaust temperature before recovery [oC]

Exhaust stream [kg/h]