Energy audit of a tire manufacturer

SOLVERA LYNX CASE STUDY

ENERGY AUDIT OF TIRE MANUFACTURER

The company is one of the leading tire manufacturers in Central Europe, with an annual production of approximately eight million tires. It conducted a comprehensive energy audit with the objective of implementing measures to improve energy efficiency and reduce CO₂ emissions.

The audit covered six locations with a total area of 75,050 m², including the main production site, testing facility, boiler house, compressor station, and water supply system.

Facility Scope

6 locations with a total area of 75,050 m²

Resource Consumption

Electricity, natural gas, water, heat, nitrogen

Production Volume

8 million tires per year

PROCESS

The energy audit, conducted in accordance with standard audit methodologies, included a comprehensive analysis of current energy consumption and the energy management system. Potential energy efficiency measures were identified, followed by the preparation of a detailed report outlining findings and recommended actions.

1. Current State Analysis

Review of energy consumption during the reference period 2020–2023

2. Identification of Measures

Definition of measures for improving energy efficiency

3. Review and Evaluation

Assessment of proposed measures and their technical and financial feasibility

4. Reporting and Presentation

Preparation of documentation and presentation of findings

KEY CONSUMERS

Main energy consumers

  • Electricity: ≈ 4,500 MWh/year
  • Heat: ≈ 1,400 MWh/year
  • Natural gas: 13,800 MWh/year
  • Water: ≈ 75,000 m³/year

Audit Scope

The reference period for analyzing the current energy performance was 2020–2023. The calculations were based on average prices of electricity, natural gas, and heat.

PROPOSED MEASURES AND SAVINGS

Steam Boiler Gasket Replacement

  • Annual savings: 1,508 MWh / 36,225 EUR
  • Investment: 130,000 EUR
  • Payback period: 3 years

Heating Station Refurbishment (Location 1)

  • Annual savings: 519 MWh / 13,785 EUR
  • Investment: 105,000 EUR
  • Payback period: 5 years

Improved Waste Heat Utilization

  • Annual savings: 680 MWh / 23,800 EUR
  • Investment: 30,000 EUR
  • Payback period: 1 year

Installation of Dry Coolers

  • Annual savings: 75 MWh / 72,585 EUR
  • Investment: 193,600 EUR
  • Payback period: 2 years

265 kW

unused waste heat

Potential to utilize 80% or more of waste heat from compressors

23.458 EUR

lighting savings

Annual savings through lighting system improvements

3 %+

with an energy management system

Additional savings through ISO 50001 implementation

Additional Optimization Measures

  • Implementation of ISO 50001 energy management standard
  • Reactive power compensation
  • Thermal insulation for steam and hot water distribution systems
  • Refurbishment of heating stations at multiple locations with various implementation options

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