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Vardar Dolomit Dooel Global Energy Management System Implementation: Case Study Republic of Macedonia Vardar Dolomit dooel “The EnMS is a perfect tool for every Achievement by company company which recognizes that energy saving enhances business opportunities and maximizes competitiveness.” —Remzi Abdulai - General Manager Case Study Snapshot Industry Refractories Production Product/Service Dolomite based refractories Dolomite producing facility Location Gostivar, Macedonia Business Case for Energy Management Energy Management System ISO 50001 Vardar Dolomite is company specialized for Energy Performance 1 Improvement Period producing sintered dolomite and dolomite based refractories. Production of sintered dolomite is Energy Performance 3% energy intensive process and the cost of purchasing Improvement (%) energy represents an important part of the over improvement period company's production costs. Total energy cost savings 68 375 $USD Primary driver for implementing EnMS (energy over improvement period management system) was opportunity to reduce financial impact on production costs by decreasing Cost to implement EnMS 18 450 $USD energy consumption, without compromising high Payback period (years) 0.27 years quality, occupational health and safety. on EnMS implementation Other drivers that contribute for EnMS implementation were: good company reputation, Total Energy Savings 3 527 (GJ) sustainability, environment care, compliance with over improvement period legal requirements related to energy etc. Total CO2-e emission 125 000 t CO2 Availability of high-quality training and EnMS reduction Implementation support from GEF-UNIDO Project over improvement period “Catalyzing market transformation for industrial energy efficiency and accelerate investments in best available practices in Macedonia” was crucial for successful implementation. А key moment for the achieved savings was competitive spirit among the companies participating in the project. 1 Global Energy Management System Implementation: Case Study Republic of Macedonia Implementation of EnMS brings big differences in Calculated with current light fuel oil price this company’s energy reduction approach. Almost all savings are 23 168 $ energy reduction measures realized before EnMS Last but not least, we achieve 41 670 kg heavy fuel implementation can be explained with following oil consumption reduction, or 1.89% from previous statements: year consumption. Calculated with current heavy o Low investment projects fuel oil prices this savings are 24 474 $ o Replacement of equipment that has lower Calculating the sum of savings from all energy efficiency with equipment with higher sources we get that total annual savings in 2017 efficiency was 68 375 $ o No measuring and verification of achieved savings EnMS Development and Implementation o Poor monitoring or no monitoring at all of implemented ideas after implementation Our company holds ISO 9001 Certificate from After EnMS implementation approach to energy 15.02.2006 and ISO 14001 from 07.01.2008 so reduction is completely different implementation of ISO 50001 was logical course of o Priority of implementing no cost measures events. As I mention before, Implementation of EnMS in whenever they are applicable, prior to Vardar Dolomit was supported by the GEF-UNIDO make any investments Project. This project provides all necessary training for 2 o Our field of inquiry, while searching for national consultants involved in EnMS implementation ideas for energy reduction, besides the and one company representative. Trainings were equipment, has expanded both to the divided in 4 phases: Building commitment, Planning, processes and to the staff. Implementing and Checking o We are focused on whole system efficiency instead of single system parts efficiency Organizational o We measure achieved savings whenever it’s Implementation process began in 2015 and lasted until applicable, or at least we verify them end of 2016. We finished 2017 as first year of fully through the mathematical model for implemented system with respectable savings and with monitoring energy performances successfully passed certification audit. ISO 50001:2011 nd o Energy performance of every significant Certificate was issued on 22 January 2018 energy user is monitored at weekly intervals From the very beginning we have Top Management support and I thing this was crucial for smooth and Business Benefits Achieved ontime EnMS implementation As I mention before Vardar Dolomit already has 2 Year 2017 was very successful for our Energy ISO standards in place so for the folowing EnMS Management System and for Company in general. We requirements we already have established practice achieved savings that not only satisfied but also exceed and we just need to make small adjustments related our expectations. to energy: We achieve savings of 260 629 kWh of electricity or o Top Management Responsibility (4.2.1) 7.92% from the 2016 annual electricity o Competence Training and awareness (4.5.2) consumption. Taking into account average o Communication (4.5.3) electricity price for 2017 this savings worth 20 763$ o Documentation (4.5.4) Reduction of light fuel oil consumption was 24 134 o Nonconformities, corection, corrective and liters or 5.92% from the previous year consumption. preventive actions (4.6.4) 2 Global Energy Management System Implementation: Case Study Republic of Macedonia o Control of records (4.6.5) Energy Review and Planning o Management Review (4.7) e.t.c First Energy Review was done in all facilities at once Some of the EnMS requirements althow well known at the beginning of EnMS implementation. This was from before, demanded bigger changes toward done mainly to get basic understanding of energy energy use and energy consumption but we also get o Policy (4.3) – We have build completely new interesting energy saving oportunities as output Energy Policy from this review . Now we have practise that in o Legal and other requirements (4.4.2) each facility in the company, energy review must be o Competence Training and awareness (4.5.2) done at least once per year. In the review team at . Energy Manager passed complete least one facility employee must be included and EnMS implementation training that employee must be different in each next . Another 2 Energy Team mebmers review. attend EnMS user training We also use employee interviews and other tupes . All current employees attend at of communication tehniques for collecting energy least on 1 Awareness building saving oportunities. Also we review successful presentation and this kind of ideas from other companies and we evaluate their presentations are organised at applicability in our company. All energy saving regulary oportunities collected with above mentioned . New workers must attend techniques are recorded in our ECO List (energy Awarenes building training as part conservation opportunity list). of their training period For all opportunities from ECO List we prepare . All achievments are comunicated basics calculations of investment costs (if needed), within all company levels energy saving potential, and basic estimates of o Internal Audits (4.6.3) feasibility. Regarding energy saving budget for next . First internal audits were done by year we chose which opportunities will be approved national EnMS consultants, now we and from their energy saving potential we calculate have onsite trained internal next year saving target. This is how we define our auditors Objectives, Targets and Action Plans What was relatively new and moreless unknown in Setting the Baseline was really big challenge and EnMS, and therefore a bigger chalenge for whole was given the necessary attention but due to close Energy Team were the folowing topics relation it will be explained together with Energy o Energy Review (4.4.3) Performance Indicators in next sub-header o Energy Baseline (4.4.4) o Energy Performance indicators (4.4.5) o Energy Objectives, energy targets and energy management action plans (4.4.6) o Energy Efficient Design (4.5.6) o Proqurement of energy services, products, equipment and energy (4.5.7) Some more details about overcoming chalenges from above mentioned topics you can find in the folowing sub-headers 3 Global Energy Management System Implementation: Case Study Republic of Macedonia “Putting EnMS in place give us Most of the implemented ideas were low and no opportunity to quantify achieved energy cost and total amount of investment In energy savings with acceptable accuracy which eficient project in 2017 was about 12350 $ is best tool for gaining Top If we devide sum of money spend for labor hour and investment in energy efficient projects Management Support.” (6100+12350) with annual energy savings for 2017 —Zlatko Gjurchinoski - Energy Manager of 68375 $ we get payback period of only 3.3 months Approach used to determine whether energy This has motivated the company to significantly performance improved increase the budget for 2018 and it amounts about First step to compare performances is to define 100 000 $! baseline for comparison. On our UNIDO training we were trained to use following methodology for defining Approach used to validate results baseline and for monitoring energy performances. First For validating achieved results we use different all necessary data (monthly energy consumption, methodology regards of what is applicable. Here are monthly production and all other relevant variables that some different examples affect energy consumption) for а certain time period When we want to
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