The heat recovered from the condensers of the refrigeration units is used to heat domestic hot water. It is a refrigeration cycle that works by drawing heat from the evaporator and discharging it to the outside (condenser). The idea behind the project involves recovering this waste heat to preheat domestic hot water (DHW).
This technology is suitable for food businesses with refrigeration units (cold rooms, refrigerated units, air conditioning, etc.).
By installing this technology, which has been available on the market for more than 5 years, the company can save on its electricity bills and reduce its carbon footprint. However, implementing this measure can be complex with a medium-to-long-term return on investment, and requires the temporary shutdown of production during the technical installation stage
The project involves installing sun control window films on the exterior glazing, which can help reduce the amount of solar heat entering the building. In summer, air conditioning needs and associated energy consumption are reduced. In winter, the need for heating and associated energy consumption may increase slightly.
Sun control window films are suitable for commercial buildings, shop windows and existing businesses with large glazed areas which are likely to overheat inside and have increased air conditioning needs due to solar radiation.
By installing this technology, which has been available on the market for more than 5 years, the company can save on its electricity bills and reduce its carbon footprint, but above all improve comfort. This measure is relatively simple to implement, has a quick return on investment and does not require production shutdown during the technical installation.
There are different types of solar film that can be used to control the solar radiation according to need and season, guaranteeing protection and thermal optimisation in both winter and summer, without any loss of luminosity.
Adjustment of air exchange flow rates to actual needs using a CO2 sensor
The project aims to install one or more CO2 sensors on the air intake of air handling units (AHUs) in supermarkets and to adjust the flow rate of new air introduced into the shopping centre as needed. This way, the airflow is increased during busy periods and reduced the rest of the time.
Air handling units ensure the air exchange and heating/cooling of the commercial premises. The AHUs operate at a fixed flow rate over time slots programmed according to opening hours.
By installing this technology, which has been available on the market for more than 5 years, the company can achieve significant savings on its electricity bills and reduce its carbon footprint. This measure is relatively simple to implement, has a quick return on investment and does not require production shutdown during the technical installation.
Replacement of linear or vertical chillers and freezers
The project aims to replace old chillers and freezers with new generation refrigeration units that are closed, well insulated, fitted with more efficient fans and LED lighting. Defrosting is optimised and it is possible to increase the temperature regime of the evaporator circuit.
This system applies to supermarkets or grocery stores with chillers and freezers to store food in store. By installing this technology, which has been available on the market for more than 5 years, the company can save on its electricity bills and reduce its carbon footprint. However, implementing this measure can be complex and requires the temporary shutdown of production during the technical installation stage.
Installation of a transcritical CO2 refrigeration system
The project involves replacing an existing conventional, centralised, or direct expansion installation with a refrigeration system using CO2 as a fluid which is transferred in a transcritical or subcritical cycle (cascade or refrigerant) to the units diffusing the cold (refrigerated units, cold room evaporators, etc.) for a positive or negative application, or both.
This system applies to existing commercial buildings, particularly food distribution premises. This includes spaces intended for the display or self-service of fresh products for the public, such as hypermarkets, supermarkets, and small food stores. Drive-through facilities and click and collect points allowing the public to pick up their purchases without actually entering the store (the “drive-through” concept) as well as refrigerated warehouses.
Setting up this new technology will allow the company to save electricity, while reducing its carbon footprint. However, implementing this measure can be complex and requires the temporary shutdown of production during the technical installation stage.
Promoting self-consumption and electricity sharing within your company
Self-consumption refers to using the electricity that you generate on your own. This approach helps you become less reliant on the energy market and suppliers, insulating you from price fluctuations. For instance, by installing solar panels, you can produce renewable electricity that meets your company’s electrical needs, whether it’s for lighting, powering an EV-charging station, or running other appliances. Additionally, this self-produced energy can also be used to power larger systems like heat pumps.
The following article provides an overview of various self-consumption methods, highlighting their benefits and drawbacks, along with the necessary procedures, available subsidies, and relevant measures.
Founded in 1824, Brasserie Simon is a family-run business based in Wiltz. Well known for its high-quality beers, the brewery currently employs 24 people and is part of the food industry. With a long tradition and expertise in brewing, Brasserie Simon blends heritage and innovation to produce a varied range of beers that are appreciated throughout the country.
Idea
Lowering electricity costs
In response to today’s energy challenges and to improve its sustainability performance, Brasserie Simon made the decision to integrate a photovoltaic installation into its production process. The objective was to not only lower its electricity costs, but also to increase its energy independence and adopt a more environmentally-friendly business approach.
Design
Self-consumption for the cooling of beer
The project consists in the installation of a 190 kW photovoltaic system capable of covering the daytime electricity needs of production, as well as powering the 10 m³ cold store. The process of cooling the ice water, which is essential for beer production, has been redesigned to take full advantage of solar energy. Traditionally, this cooling was done at night to save on energy costs. However, by installing a new photovoltaic system, the brewery has inverted this pattern: chilled water is now produced during the day, when electricity production is at its peak.
Implementation
Participation in a call for projects
In terms of cost-effectiveness, the brewery applied to a call for projects to benefit from an investment subsidy. The call was conditional on the brewery self-consuming the generated electricity. Luxinnovation accompanied them in the application process. Once the Ministry had approved the bid, the project was immediately put into place.
An efficient control system is ensured by the technical service and enables optimum utilisation of the electricity generated for the cooling process of the 10 m³ cold store.
Results
Energie- und Geldersparnis
Senkung der Energiekosten: Durch die Integration von Solarenergie konnten etwa 40 % des Strombedarfs der Brauerei gedeckt werden, wodurch die Energierechnungen gesenkt wurden.
Investitionsrendite: Die Brauerei Simon schätzt, dass die Amortisationszeit ihrer Photovoltaikanlage etwa 8 Jahre beträgt. Diese Rendite ist das Ergebnis niedrigerer Energiekosten und einer verbesserten Gesamteffizienz ihrer Produktionsprozesse.
Additional measures
Within the framework of the national “Zesumme spueren – Zesummenhalen” campaign, Brasserie Simon increased its efforts to save energy and resources. Beyond the installation of solar panels, the brewery also introduced a number of additional measures to optimise the various production processes. Find out more in the video below.
The factory in Bissen is part of ArcelorMittal Europe Long Products – Bars & Rods, which employs more than 288 people on an area of around 50 hectares and produces more than 100,000 tonnes of industrial, fence and vineyard wire as well as metal fibres for the construction industry every year.
Idea
An effective lever for energy savings
The energy-saving measure focussed on a significant reduction in compressed air consumption at the ArcelorMittal plant in Bissen. Compressors are often energy-intensive machines that can sometimes operate inefficiently. A thorough analysis of compressed air consumption was carried out, followed by a study to identify potential savings.
Design
Planning an efficient compressed air network
In order to realise the concept of reducing compressed air consumption, various measures are being planned or have already been taken.
A study is currently being carried out to reduce the air pressure in the entire network. This approach aims to move from a paradigm of “we need pressure on the line” to a “how much pressure is really needed” by adjusting the general pressure in the network from 6 to 5 bar. This measure allows the factory to reduce energy consumption without affecting operations.
Project to identify consumers that can operate at lower pressure: A detailed analysis was carried out to determine which devices and processes can operate efficiently at lower pressure levels.
A systematic analysis of the air networks and production facilities revealed that many leaks can only be rectified when production is at a standstill.
Calculation of the savings potential for compressed air of approx. 10 % by repairing the leaks alone. In cooperation with a specialised company, a repair phase lasting several days with a production stop was planned.
Implementation
Introduction of a strategy to reduce compressed air leaks
ArcelorMittal has worked with a specialised company to detect leaks in the compressed air system. The initiative was carried out during the Christmas holidays. In a three-day operation, during which production was shut down, all leaks were identified and repaired.
Result
The improvements are clearly visible
As 60% of the leaks found were repaired during the three-day shutdown at the end of 2023 and around 65% of the remaining leaks have also been repaired since then, ArcelorMittal now estimates that they need around 7% less electricity to generate compressed air. Their goal is to eliminate at least 25% of the 35% of remaining leaks by the end of the year.
Implementation of a variable speed system on dust or fumes extractor fans
The project consists in setting up a speed regulation system on the extractor fan, activated by the machines in operation which actually require the extraction of sawdust or fumes. It involves the addition of valves and a speed variator on the extractor fan. The valves open only when the machine is operating and the fan flow rate adjusts according to the pressure.
Installing this technology, which has been available on the market for more than 5 years, the company can save significantly, up to 50%, on its electricity bills (depending on the baseline production regime) and reduce its carbon footprint. This measure is quite simple to implement, can show a rapid return on investment, and does not require a production shutdown during installation.
Use of high-performance, combination tools to reduce cycle time
The measure involves replacing simple machining tools, changing the production mode and avoiding shutdowns for unplanned maintenance and cleaning.
Use of high-performance machining tools to increase machining speeds.
Use of combination machining tools to reduce the operating time of machine tools.
Optimisation of production changes using the SMED method (Single Minute Exchange of Die – rapid tool change in less than 10 minutes).
By installing these technologies, which have been available on the market for over 5 years, companies can save up to 30% on electricity costs and reduce their carbon footprint. This measure is not simple to implement and would entail a medium-to-long term return on investment. This measure can be implemented with only a partial production shutdown during installation.
