Our organization provides a broad range of comprehensive energy solutions including auditing energy use, developing projects to reduce energy expenses, preparing measurement and verification plans for efficiency improvement investments. In the industrial area, we are specialized in providing these services in energy-intensive industries primarily in glass.

After winning the tender in 2012 organized by SISECAM Group – one of the largest global glass producers – we have completed detailed energy audits in 12 glass plants including float glass, container, tableware and fiber glass sectors by June 2015.

This has, having been extended to non-glass activities of SISECAM Group as well, been the largest and the most comprehensive detailed energy audit in Turkey since the Energy Efficiency Law was enacted. Content of audits covering process details and equipment in plants are explained briefly in the following page.

Although SISECAM ranks amongst the most energy efficient producers in respective sector benchmarks, these audits identified significant energy saving potentials with more than hundred improvement and process optimization issues, all in full agreement with the respective plant managements, recorded during the audits. It is worth to note that the pay back for the investments associated with these projects averaged less than 3 years with the current energy prices in Turkey.

With the completion of this audit campaign which lasted more than two years, and other assignments taken with other clients in between, ENDÜSTRİYEL ENERJİ has built up an extensive experience in energy efficiency audits in glass plants and has improved its ability to conducting audits outside Turkey. An audit campaign covering all details in a glass plant would be finished within 10 working days from the date all measuring equipment delivered to the site and the report would be prepared in 20 working days following the site work.

As expected, the most important part of the audit in a glass plant is the mass and energy balance calculations of furnace where most of the energy consumed in a glass plant. Here, not only the experience and suitable measuring equipment but analysis tools for the obtained data become critical.

ENDUSRİYEL ENERJİ has built over the years an extensive inventory of such devices and tools in collaboration with international partners including various institutions and universities.

Dr. YILDIRIM TEOMAN, Chemical Engineer,

He is an expert in thermal systems and glass industry and a Member of Society of Glass Technology and Association of Cost Engineers. He worked in various positions in SISECAM for more than 30 years and held the position of Vice-President Technical responsible for R&D and Engineering (including Glass Melting) for 14 years. During this time, he represented SISECAM in Standing Committee of the European Glass Industries which is now Glass Alliance Europe and in Production and Environment Committee of FEVE.

Amongst many other energy efficiency related improvements in glass making as a whole, he developed waste heat recovery and power generation projects by ORC application to glass furnaces.

After his retirement in 2014 he was the Project Development Coordinator in ENDÜSTRİYEL ENERJİ until March 2016. He has been consulting ENDÜSTRİYEL ENERJİ since then.

Prof. Dr. Barrie JENKINS, Chemical Engineer

Currently a visiting professor at Oxford University, Prof. Jenkins is an expert in fuel, combustion and furnace technologies. He worked in combustion equipment manufacturing industries as technical manager of design and manufacturing teams more than 20 years.

With a long academic background in various universities as researcher and lecturer, he is one of the independent assessors of Carbon Trust since 2001, acted as the chairman of Institute of Energy between 2001 and 2005 and a member of British Flame Research Foundation and was the chairman of the organization in between 1995 and 2001. He is an active member of International Flame Research Foundation.

He has a long list of published research papers in numerous journals and a published book, Industrial and Process Furnaces, Principles, Design and Operation with Peter Mullinger to his credit.

He is consulting ENDÜSTRİYEL ENERJİ in furnace audits since 2012.

We believe that ENDÜSTRİYEL ENERJİ is in a strong position to provide detailed energy audits in any glass plant to determine the energy efficiency improvement potentials and develop technically sound, bankable energy efficiency projects. Audits will be conducted according to the European Standard EN 16247-3:2014 Energy Audits Part 3: Processes. Main advantages of proposed detailed audits will be as follows,

ENDÜSTRİYEL ENERJİ is an independent consulting company providing objective assessments. We have no relation with any of the equipment supplier companies. Amount of energy savings are calculated with respect to the performance of best available technology. We provide performance bonds if requested by our customers.

We provide an overall view of the energy efficiency of the plant. Covering all parts of the plant, the effect of integration between the parts and processes would be identified in detail

We could extend this service to your preferred suppliers for saving energy by improving their energy efficiencies.

Glass Plant  Energy Efficiency Expert
Hall: 13 – Stand: G16

CONTENT OF ENERGY EFFICIENCY AUDTIS IN GLASS PLANTS

For all of the plants audit campaign was planned and conducted in two parts:

In Batch House

  • pneumatic loading systems,
  • compressed air leakages in pneumatic actuators
  • conveying systems
  • batch humidity control
  • automation systems for batch preparation

In Furnaces

  • Temperature measurement of both combustion air and exhaust gas at the top of
    regenerators by suction pyrometer,
  • Exhaust gas analyses at top and bottom of regenerators,
  • Actual amount of combustion air measured in ducts after the fans.
  • Surface temperature of all sides of furnace and regenerators and crowns were
    scanned.
  • Detailed mass and thermal energy balance of the melting tank and regenerators and
    whole system was calculated.
  • Furnace Process control system and the historian of the system is analyzed to
    check the bottlenecks and to identify the operational deficiencies if exists
  • Also electrical energy consumption in the following parts of the furnaces system
    were analyzed in detail
  • Combustion air fans
  • Cooling air fans

In tableware and container glass plants the following systems were analyzed after the furnaces

  • working end and the forehearths,
  • thermal efficiency of annealing lehrs were analyzed in detail for each unit
  • compressed air leakage detection in pneumatic actuators of packaging equipment

In float glass plants the following systems were analyzed after the furnaces

  • Energy consumption in waist cooling
  • Waste heat recovery potential in the exhaust of annealing lehr is calculated by the
    temperature and flow measured at the stack
  • Energy saving potential in cooling fans in RET Zone
  • Energy consumption in heating the washing water in washing unit was measured
  • Electrical energy consumption in conveying systems were measured to prepare the
    energy consuming profile of the system

Compressed air systems;

  • Actual running efficiency of air compressors are determined by time recorded
    concurrent measurement of:
  • actual amount of compressed air delivered by the compressors
  • actual energy consumption of the electrical driving the compressors
  • blow-out losses in turbo compressors
  • Analysis of efficiency of air dryers
  • Location and amount of air leaks in the compressed air network determined by
    ultrasonic detectors and calculation of energy waste and its cost,
  • Structure of the compressed air network is assessed with respect to the standards

Cooling Towers;

  • Efficiency of the cooling tower/system is analyzed by following continuous
    measurements over 24 hours or more,
  • Measurements of temperature, pressure and volumetric flow of cooling water,
  • Concurrent measurement of ambient air temperature, pressure and humidity,
  • Energy consumption of the cooling fans and circulating pumps are measured. Actual
    working points of fans and pumps were identified regarding their specific energy
    curves. Possible re-sizing and a replacement program is to be prepared for those
    pumps and fans which were identified inefficient.
  • And finally, water conditioning system and total amount of water discharged is
    analyzed regarding the efficient use of natural resources and energy efficiency

Electrical Power Distribution Systems;

  • H.V and L.V. power transformers are analyzed regarding the load distribution and
    efficiency, energy quality was analyzed at main bars.
  • Energy consumption of the big size electrical motors were measured with energy
    analyzers, replacement program developed old low energy efficiency class motors to
    be replace by the IE3 or higher energy efficiency class motors,
  • All interior and exterior lighting systems are analyzed regarding the lighting efficacy
    and a replacement program to be prepared to improve the efficacy to save energy

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