At a time when energy costs are rising continuously and legal requirements are becoming ever stricter, the topic of energy data management (EDM) is becoming increasingly important. Particularly in energy-intensive industries such as electroplating, a professional EDM system opens up considerable potential for greater efficiency and cost reduction. But what exactly is an energy data management system? And how can it be used in a targeted manner to make optimum use of energy and resources? The example of a best practice from a company in the electroplating industry shows how such a system can be successfully implemented and what advantages it offers.
The importance of energy data management
Energy data management (EDM) involves more than simply measuring and monitoring energy consumption. Rather, it involves the systematic recording, analysis and use of energy data in order to optimize energy consumption and reduce costs in the long term. In the energy-intensive electroplating industry in particular, a professional EDM system offers considerable potential for increasing efficiency and complying with legal regulations.
A well-implemented EDM system makes unused energy potential visible and enables processes to be optimized. Through targeted measures, companies can not only significantly reduce their energy costs, but also achieve environmental targets and meet legal requirements. The introduction of such a system also ensures greater transparency and makes it easier to identify potential savings.
Advantages of an energy data management system
The implementation of a professional EDM system has numerous advantages:
- Cost reduction: identifying potential savings and implementing them can significantly reduce energy costs.
- Compliance with legal requirements: Companies can ensure that they meet all relevant legal requirements.
- Sustainability: By reducing energy consumption, companies contribute to the achievement of environmental goals and improve their ecological image.
Best practice: Step-by-step implementation of an EDM system
The successful implementation of an energy data management system requires careful planning and execution. Using the example of a medium-sized surface finishing and heat treatment company with around 100 employees, the steps for introducing an EDM system and the real savings are illustrated. These are real values and real savings. For this reason, the company will appear anonymously below as Galvanotechnik GmbH.
Like most companies in this sector, Galvanotechnik GmbH's production is very energy-intensive. The company had enormous energy costs due to its high energy consumption of 2,000,000 kWh/year of electricity and 2,700,000 kWh/year of gas. At the same time, the company is subject to the provisions of the Energy Efficiency Act (EnEfG) and the Building Energy Act (GEG) and must take efficiency measures.
The following seven key steps break down exactly what needs to be considered in order to comply with the law and where savings can be made in order to reduce energy and costs:
- Advice on potential savings
- Analysis of further savings potential
- Development of the measuring point concept
- Application for BAFA funding
- Installation of the EDM and energy optimization
- Training and initial instruction
- Utilization and implementation of real savings
1. advice on the potential savings
It now takes a lot of time and knowledge to keep track of the jungle of energy and electricity laws and to familiarize oneself with the current legislation. Galvanotechnik GmbH spared itself this effort and commissioned bwh-energy GmbH, a specialist in energy and subsidy consulting. In close cooperation, possible refunds, e.g. from electricity and energy taxes, were examined.
By applying for the following refunds, Galvanotechnik GmbH was able to save a total of around 46,900 euros in 2023:
- Electricity and energy tax refunds: approx. 33,000 euros
- Energy Financing Act: approx. 8,000 euros
- StromNEV levy: approx. 3,700 euros
- Exemption from the concession levy: approx. 2,200 euros
Electricity and energy tax refund
In principle, all companies in the manufacturing sector can benefit from the electricity and energy tax refund. Based on consumption values, partial refunds are possible under certain conditions in accordance with Section 9b of the German Electricity Tax Act (StromStG). In this case, the general electricity consumption on which the electricity tax was paid can be used, provided it is not allocated to a specific process.
For electricity used in various processes, such as powder coating, an application is made in accordance with Section 9a StromStG. In this case, it is possible to reclaim the electricity tax paid in full for the electricity used in the respective processes.
For the company's other energy consumption, in this case natural gas consumption, an application is made in accordance with Section 54 of the Energy Tax Act (EnergieStG). Here, the energy that was not used for specific process procedures can be applied for, which enables a partial refund of the energy tax paid.
Relief can be realized for the energy consumed in the process procedure in accordance with Section 51 of the Energy Tax Act. Analogous to Section 9a of the Electricity Tax Act, it is possible to reclaim the energy tax paid in full.
Thanks to the successful application, bwh-energy was able to realize a total of around 33,000 euros in refunds from electricity and energy taxes for Galvanotechnik GmbH.
Energy Financing Act
The Energy Financing Act (EnfG) offers a further savings opportunity. Under certain conditions, it is possible to reduce the levy from the Combined Heat and Power Generation Act (KWKG) and the offshore levy. The conditions include, for example, that the energy consumption must be at least 1,000,000 kWh and that the company must belong to one of the two industry lists. The company's energy efficiency in general and the implementation of an energy management system also play an important role.
bwh-energy examined this possibility and successfully submitted an application in 2024 for the 2025 limitation year on behalf of Galvanotechnik GmbH. This resulted in additional savings of around 8,000 euros.
§19 StromNEV levy
bwh-energy was also responsible for the allocation to the corresponding end consumer group in order to enable the reduction of the Section 19 Electricity Grid Charges Ordinance (NEV) levy. As shown in Table 1, the end consumers are divided into three groups. Galvanotechnik GmbH was successfully assigned to end consumer group B, resulting in additional savings of EUR 3,700.
Table 1: Final consumers are divided into three groups within the scope of the §19 electricity NEV levy
Individual grid charge
If a company behaves atypically during the peak load windows of its grid operator, it has the option of applying for a limitation of the grid fees. However, this option is subject to certain conditions, in particular the atypical grid usage behavior compared to other grid users.
The necessary criteria were reviewed by bwh-energy. In the specific case of Galvanotechnik GmbH, it was not possible to apply for an individual grid fee as not all the necessary requirements were met.
Concession fee
Another way to save costs is to be exempt from the concession fee. Unsurprisingly, certain conditions must also be met for this exemption. Firstly, the company's average electricity price must be below the published marginal price. This threshold price is determined and published by the Federal Statistical Office on the basis of the average revenue per kWh from electricity supplies to all special contract customers in Germany in the calendar year before last. In this specific case, a comprehensive review by bwh-energy resulted in an exemption for the customer, which led to additional savings of around EUR 2,200.
In addition to the tax savings, Galvanotechnik GmbH's goal was not only to reduce energy costs, but also to reduce energy consumption and comply with legal requirements in terms of energy consumption. Further potential savings were therefore analyzed.
2. analysis of further savings potential
In order to identify additional savings, a load profile analysis was carried out (Fig. 1). This analysis revealed that high power peaks occur at the start of work, when machines are started up and electroplating baths are preheated. These power peaks result from the highest average consumption in the measured quarter-hour values and significantly increase electricity costs. On average in the industry, power peaks account for 30-40% of the total costs in the electricity bill. Accordingly, the power charge was also a major cost item in the electricity bill at Galvanotechnik GmbH and could be specifically addressed by introducing control systems.
As part of the energy consultation, Galvanotechnik GmbH also learned that, due to its electricity and natural gas consumption of around 4.7 GWh, it is highly likely that it will soon be required to implement the Energy Efficiency Act (EnEfG). This central law in Germany aims to increase energy efficiency and reduce energy consumption in order to achieve climate targets. Companies that exceed certain consumption limits are obliged to carry out regular energy audits or implement an energy management system. They must also document the results and the measures implemented and submit them to the competent authority.
In view of the forthcoming amendments to the Energy Services Act (EDL-G) and the Energy Efficiency Act (EnEfG), it is expected that the audit obligation will come into force for companies with a final energy consumption of 2.77 GWh or more, regardless of whether they are small and medium-sized enterprises (SMEs) or large companies. Currently, this obligation only applies to large companies. Final energy consumption includes all energy consumption of a company, from electricity to district heating or fuel consumption of the vehicle fleet, as shown in Figure 2. The draft law is already in the Federal Council and adoption is planned for this year.
As energy audits for SMEs are currently still subsidized by BAFA, Galvanotechnik will carry out an audit in the near future.
Fig. 2: Final energy consumption includes all forms of energy: from electricity, gas, hydrogen and district heating to diesel fuels
3. development of the measuring point concept
In order to meet the legal requirements and turn the potential savings into real savings, Galvanotechnik GmbH commissioned KBR EnergyManagement GmbH, an expert in operational energy management, to carry out the technical planning and development. Thanks to the optimal interaction between bwh-energy and KBR, Galvanotechnik GmbH was already aware of the initial situation and was able to proceed directly to the detailed planning stage.
Based on the analyses, KBR GmbH developed an individual measuring point concept in collaboration with the company. This concept was necessary in order to successfully implement energy data management in the company and forms the basis for the application for funding and for further project development. For this purpose, all energy media and measuring points were recorded in detail as shown in Figure 3. Possible consumers that can be switched on and off, such as energy storage systems or charging stations, were also included in order to be able to control the power peaks.
Fig. 3: The technical elaboration includes the development of an individual measuring point concept
4. application for BAFA funding
Thanks to state subsidy programs to promote energy efficiency and renewable energies, such as the BAFA subsidy (Module 3: Measurement, control and regulation technology), the acquisition costs for the EDM system could be partially reimbursed. In addition to intelligent measurement technology and energy management software, the installation costs are also subsidized.
The amount of funding depends on the size of the company. Large companies receive up to 25% of the costs, medium-sized companies up to 35% and small companies even up to 45%, i.e. almost half of the investment costs. Due to its size, Galvanotechnik GmbH can be classified as a medium-sized company. With the help of bwh-energy, which supported the company from the application stage right through to final processing, the full 35% funding could be utilized. An additional advantage was that all measurement technology components and the visual energy software from KBR GmbH are officially classified as eligible for funding by BAFA.
5. installation of energy data management and energy optimization
Once the application for BAFA funding had been approved, the next step was to put the developed measuring point concept into practice. Galvanotechnik GmbH opted for the energy data management system from KBR GmbH, consisting of precise measurement technology and the visual energy software. After a workshop with a KBR service employee and the installation of the meters, the software was set up according to the requirements of Galvanotechnik GmbH and the first evaluations were created. The software made it possible to monitor energy consumption in detail and develop individual key figures (Fig. 4).
Fig. 4: Detailed monitoring and transparent visualization of energy consumption thanks to EDM software visual energy
For reporting to the management of Galvanotechnik GmbH, the energy manager set up a monthly energy report with clear diagrams and key energy figures. At the same time, a dashboard was set up with live analyses, including a heat map, level-time diagram and Sankey diagram, which graphically shows the energy flow quantities. The energy team at Galvanotechnik GmbH can now monitor energy consumption at a glance and uses the certified visual energy software as a central tool for meeting the ISO 50001 standard requirements.
The energy optimization system was also installed to avoid power peaks through time-controlled shutdowns. By using the multimax energy optimization system from KBR, all major energy consumers are now controlled individually and energy consumption and costs are reduced through automatic time control. Specifically, the system automatically switches the electroplating baths on and preheats them, taking into account weekend days, public holidays and production-free periods. During the peak heating phase, consumers that can be switched off, such as the e-charging stations, are also regulated so that no unnecessary power peaks occur and the set maximum value is not exceeded.
6 Training and initial instruction
After the system was installed, KBR GmbH provided training and instruction for the Galvanotechnik GmbH energy team. A detailed initial training session on site provided the employees with in-depth knowledge of how to use the software and measurement technology. In future, new metering points can be integrated independently and the energy data visualized. For more specific questions or requirements, the company's energy team has access to a wide range of services from KBR GmbH. Depending on the application, the hotline service or technical support can be accessed directly on site.
7 Utilization and implementation of real savings
With the implementation of the energy data management system, Galvanotechnik GmbH now records and monitors all energy data in compliance with the law. The software identifies optimization potential and also makes deviations immediately visible. For example, an unusually high water consumption at the weekend enabled a leak to be quickly identified and rectified. In addition, measures were identified that contribute to a sustainable reduction in energy consumption. The energy optimization system helps the company to avoid unnecessarily high power peaks and thus reduce energy costs in the long term.
Conclusion
The use of an energy data management system offers electroplating and other energy-intensive industries an effective way to optimize energy consumption, reduce costs and meet legal requirements. With professional advice, the use of state subsidies and targeted implementation, companies can benefit twice over - through lower energy costs and reduced investment expenditure.
The article is based on a presentation on September 13, 2024 at the Surface Days in Leipzig
