Energy efficiency – what is it and can it be achieved?

What is energy efficiency?

Energy efficiency is the ratio between the energy used and the results achieved in the performance of systems, processes or devices. In the context of industrial production plants, it is a key indicator of operational efficiency. It includes the reduction of energy consumption and the optimization of the use of energy resources in production processes.

It aims to reduce the costs of energy used for activities such as heating, cooling or driving inefficient machines. Thanks to this, the share of energy costs in the price of the entire product decreases. Maximizing energy efficiency allows for achieving better results at lower costs.

The International Energy Agency estimates that improving energy efficiency can reduce global energy demand by one-third. Optimizing industrial processes, transport or buildings can bring such a result as early as 2050. These actions will simultaneously reduce greenhouse gas emissions, including carbon dioxide.

How to achieve energy efficiency?

Making energy-saving investments is a key step in improving energy efficiency in industrial plants. Below are some actions that can be included in a comprehensive plan to improve energy efficiency: 

Modernization of lighting in the plant

Using energy-saving light sources, such as LEDs, can significantly reduce the energy consumption associated with lighting in the plant. Using outdated and inefficient lighting systems leads to the consumption of a large amount of energy and, as a result, the generation of unnecessary costs, especially in larger enterprises.

Additionally, improperly used and poorly adapted light reduces the safety and comfort of work. Such lighting systems are always worth modernizing. Typical savings in this area reach 45-85% of costs, and investments rarely exceed a 3-year payback period.

Heat recovery from various sources

Heat recovery allows the reuse of waste energy emitted by compressors, welders, turbines, engines, pumps, furnaces, chimneys, sterilizers and other production or energy-generating equipment.

The basic methods of heat recovery are recuperation, recirculation and regeneration. The recovered energy can be used to power DHW installations, ventilation systems and technological processes.

Cogeneration or trigeneration installation

Cogeneration enables simultaneous production of electricity and heat from the same source, which increases the efficiency of the entire system and reduces energy losses. Combined production of electricity and heat, also known as cogeneration, involves the useful use of heat generated in the process of generating electricity in a gas engine.

Trigeneration, on the other hand, additionally enables the production of cold. Thanks to cogeneration and trigeneration, it is possible to achieve very high efficiency of using the energy contained in the fuel and minimize losses compared to the separate production of electricity and heat.

Use of own energy sources

Industrial energy sources are a key element of infrastructure in large, energy-intensive enterprises. They provide control over energy and production costs and also protect against interruptions in the supply of energy from the network or regulatory actions that may temporarily suspend supplies.

Modernization of own energy sources usually requires significant financial outlays, but also brings above-average savings.

Modernization of industrial machinery

Old, inefficient machinery is often the main source of energy waste in the plant. Modernizing or replacing them with more modern and technologically efficient devices can significantly reduce energy consumption.

Energy-saving investments not only contribute to improving energy efficiency but also generate a number of benefits for industrial companies. Here are some of them:

• Reduction of operating costs - reducing energy consumption also means reducing the costs associated with its purchase, which translates into greater competitiveness of the company.
• Increasing infrastructure reliability - modern, energy-saving technological solutions are often characterized by greater reliability and durability, which minimizes the risk of infrastructure failure.
• Improving the image and sustainable development - investments in energy efficiency are an important element of the CSR strategy (corporate social responsibility), which contributes to a positive image of the company among external stakeholders. 

Energy efficiency is a major challenge for modern industrial production plants. Its improvement requires the use of comprehensive energy-saving investments, including, among others, modernization of infrastructure and optimization of production processes. The benefits of these investments are multi-dimensional, covering both economic, social and environmental aspects. Therefore, for many companies, investing in energy efficiency is not only a way to reduce costs, but also a key step towards sustainable development.