Implemented projects

The largest LNG-powered cogeneration unit in southern Poland – the next stage of investment in Schumacher Packaging.

At the Schumacher Packaging plant in Myszków, we have successfully completed the second energy modernization, which significantly increased the energy efficiency of the factory. Thanks to the introduction of a modern cogeneration installation, in addition to several other projects, the plant is able to independently produce a total of almost 9 MW of electricity, which is about 80% of the energy demand of the entire facility. The cogeneration installation was put into operation in September 2024, and its cost will be paid off in about 3 years!

Greater production and lower emissions – Chemical industry Client on the way to net zero

The company team at the plant in southern China prepared a zero-emission strategy with an auditing company, which did not meet its expectations. The client turned to us for this, and in 4 months our engineering team developed a specific path to reduce emissions by 70%. Although in our latest projects we focus mainly on designing and implementing energy-saving investments, in this case we used our competences primarily in consulting activities. The client has already started implementing the strategy we developed and, among other things, reduced steam consumption in their plant by 50%.

Zero emission in practice – our road from 7% to 60%

We incorporate zero emissions and energy consumption reduction into our everyday work in all cases. This time was no different. We started cooperation with a client from the pharmaceutical chemicals industry who was looking for opportunities to reduce the energy consumption of a group of plants throughout Europe. Based on the identified opportunities, we created a CO2 reduction map that meets the corporation's strategic assumptions. Effect? Identification of opportunities to reduce the energy consumption of a plant in Ireland by approximately 60% in a location where the client's team estimated this reduction at 7%.

From the Company Energy Audit to reducing emissions by 40%

The combination of DB Energy's competencies related to energy efficiency - design, financing and implementation of energy-saving investments - with the client's knowledge in the field of production technology allows us to implement investments that bring the greatest savings and have a real impact on reducing CO₂ emissions. After carrying out a mandatory energy audit of the company at the Soufflet Polska Słodownia plant, we identified, then implemented and financed an investment that reduced emissions by 9.5 thousand tons of CO₂ per year.

Heat recovery in a production process

The belt dryer of OSB wood chips has been retrofitted in a plant which manufactures wood-based products. A low-temperature pre-drying machine has been implemented. Waste heat recovered from a production process has been used to cover energy needs of the new unit.

Heat and power plant improvement

Schumacher Packaging is a worldwide manufacturer of various types of paper packaging. Having 29 subsidiaries, the company is one of the biggest solid and corrugated board manufacturer in Europe. DB Energy has entered into cooperation with Schumacher Packaging in Myszków to improve energy efficiency of the plant. The first stage of the local heat and power improvement project has been nearly completed. DB Energy has renovated in a complex manner one of the company’s boiler, the second boiler will soon undergo the same process.

From A to Z, from auditing, project concepts and implementation to financing

In one of the plants of the Simoldes Plasticos group, located in Jelcz-Laskowice near Wrocław, we carried out a series of comprehensive projects worth over EUR 630,000. Initially, the client conducted an energy audit with us and then decided to successively modernize the lighting system in the hall, the compressed air control system, the cooling installation, heat recovery from compressors, and the modernization of plastic injection molding machines. The entire project was financed in the ESCO model.

Optimizing the pressure in the cooling system

Modernization of the cooling system makes it possible to achieve remarkable savings in facilities where production processes require cooling – e.g. in food industry. From the point of view of our engineers, cooling of the products and storage chambers seems to be an interesting area to perform analysis.

Frecooling

In audited companies, we often face specific requirements concerning the supply of cooling to the technological process. The need to cool the injection molds, which requires the supply of coolant at low temperature, may serve as an example. Possibility of using free cooling in chilled- water units is worth considering.

Increasing the cooling temperature of molds

Wherever chill water is used, it is possible to look at its parameters and try to optimize them for the purpose of the company's production process. This may often bring interesting energy effects.

Application of gas turbine for the production of electricity

In some industries, including metallurgical, we deal with significant energy of blast furnace gas produced in the manufacturing process. In order to use it, it is necessary to check if it is possible from the technical point of view and economically justified. DBE has been involved in the preparation of such design concepts. The study made in this case has demonstrated profitability of using turbines to produce electricity.

Installation of a steam turbine for the production of electricity

In many plants, including in the chemical industry, process heat is generated with the use of steam boilers. Parameters of process steam, upon leaving the boiler, are often adapted to the requirements of the process at the reducing and cooling station. This situation provides an opportunity to assess whether the replacement of reduction and cooling station with the steam turbine equipped with the generator will eliminate the energy losses resulting from the reduction of the parameters of steam, which passes through the reduction station.

Application of high speed doors

In many companies we encounter that the production process is carried out in many buildings that are not directly connected. During internal transport we can deal with significant energy losses through gates and other transitions. The use of high speed doors allows you to avoid these losses and save significant amounts of energy.

Installation of the fan control system

The investment involved the installation of an override fan performance control system. In case of this modernization, inverters controlled by outlet exhaust air temperature were used. Modernized buildings are intended for commercial and warehouse purposes.

Replacement of air compressors and construction of the override system

The purpose of the works carried out in a company operating in the metallurgical industry was to determine the energy and ecological effect of the investment involving the replacement of the compressors and the development of an override control system.

Modernization of fan drives

Modernization of process drives has repeatedly resulted in interesting energy effects. In case of one of our clients, the optimization of fan drive control led to savings of 9,868,927 MWh! Such considerable savings were attributed to the company's needs in the area of ventilation, which was connected with the high dusting of production processes.

Modernization of lighting in the area of technological process

Many companies can reduce electricity consumption in the area of lighting by undertaking simple actions, considered to be included in the broadly understood scope of the so called best practice. In one of the plants, 103,564 MWh of energy was reduced by using the solutions described below.

Installation of the compressed air recovery system from the process machine

At one of our clients' plants, DBE has installed the compressed air recovery system. As expected, this proved to be not only technically desirable, but also economically efficient.

Optimization of dedusting system

In the woodworking industry, where high amounts of dust can be observed, a dust extraction system was installed for the purpose of reducing the concentration of dust on the work stations. During the audit, the conclusion was drawn that the system failed to work effectively.

Preheating furnace trolleys

Heat from the tunnel furnace was used to preheat the furnace trolleys, which reduced the consumption of gas by the burners installed on the furnace. The design concept was to build a closed canal with two locks for a dozen or so trolleys, located between the entrance to the furnace and the loading of the raw material.

Isolation of dyeing machines

As a part of the DBE audit carried out at the textile industry's client, the modernization of the dyeing machines was proposed.

Replacement of transformers

There were 19 transformers installed in the audited company, with the power ranging from 800 kVA to 1 600 kVA. Most of the implemented units were manufactured in the 1970s. In case of old transformers, it is usually justified and profitable to replace them with new ones

Improvement of insulation of the heating network

The energy audit of the heat transmission network concerns the optimization of heat losses in the transmission piping and fittings. In the audited company, the analysis included the steam power supply system (steam pipelines) and the water supply system for central heating. Based on the measurements taken, proposals for investments to improve energy efficiency were presented.

Replacement of ventilation units

At one of our clients' production facilities, there were 7 air handling units aimed at providing the thermal comfort of the rooms and adequate air exchange in the production halls. Each central station was equipped with a 150 kW water heater. The air handling units were relatively new and each had insulated ventilation ducts. In spite of that, it was an interesting area to improve energy efficiency.

Combined heat and power

Upon preparation of the balance sheets of heat and electricity supply, our proposal to one of our clients was to build a CHP system. Combined production of electricity and heat has, in this case, measurable benefits

Modernization of the blower on the evaporators

Process installations implemented by the client from steel industry operated on the basis of gas-powered electrolyte vaporizers. Modernization in the area of systems supplying air to gas burners have resulted in very beneficial effects to the plant.

Automatic adjustment of the excess air ratio

After analyzing the work of steam boilers in the food industry, it turned out that the biggest energy loss in boilers is the loss through the chimney. Its range is determined by the coefficient of excess air in the exhaust gases behind the boiler (λ) and the temperature of the exhaust gases.

Delivery of hot air to the burners

We were able to achieve interesting savings in a cement production facility. Rotary kilns operate in this type of plants, while the burners are often a central tube introduced into the furnace. Optimization of the operation of such burners can bring significant reductions in energy consumption.

Modernization of steam exchangers

In case of this company, the source of heat supplied to the process was a steam exchanger inserted into the company's heating system. The analysis covered 17 heat exchangers serving individual parts of the process, with a rated power of an exchanger of approximately 2 MWc.

Elimination of air leaks

As a part of the work on the energy efficiency program, we have been able to achieve exceptionally good effect of elimination of air leaks for one of our clients from construction industry.

Audit of lighting installation in the steelworks

As part of preparation of the documentation for participation in the 5th tender for obtaining white certificates, the eAs a part of preparation of the documentation necessary to participate in the 5th tender for white certificates, the external lighting system of the steelworks and the installation of internal lighting within one of the buildings were analyzed.

Company data

DB ENERGY SA
Al. Armii Krajowej 45
50-541 Wrocław

NIP: 894 299 53 75
REGON: 021249140

Contact

+48 71 337 13 25 biuro@dbenergy.plfor general purposes sprzedaz@dbenergy.plfor commercial purposes

In 2014 the R&D department started to work in our company. We design solutions to improve energy efficiency in industry.

On 22 June 2016, DB Energy signed an agreement with the National Centre for Research and Development to co-finance R&D work for a project called "Development of an innovative drive diagnostics system (DiagSys) based on electrical signal measurements characteristic of mechanical damage to rotating machine components, together with a specialized analyzer of machine operating status and efficiency (APPS 3)".

The project is financed under the Intelligent Development Operational Programme 2014-2020, under sub-measure 1.1.1. "Industrial research and development work carried out by enterprises". No. of the competition: 1/1.1.1/2015. Value of the project 5 974 021.85 PLN. Value of co-financing 3,727,676.11 PLN.

The aim is to develop a system for the diagnosis of rotating machines (DiagSys system), which will be based on the use of power measurements and on-line access to an expert database.