Energy Consumption
Energy Consumption
Energy efficiency is key, both environmentally and economically.
In 2023, Aciturri advanced towards implementing energy-saving measures to reduce the electricity demand.
Specifically, in March 2023, the operating permit was received for the El Puerto de Santa María photovoltaic installation, completed in December 2022, with a plant's total power rating of 800 kW and a peak power of 994.1 kW. Since obtaining the authorisation, the plant has self-consumed 1,218 MWh, representing 30% of the plant's total electricity consumption and an economic saving of 101,000 €.
The second phase of installing rooftop photovoltaic panels has been concluded in Boecillo. The panels will incorporate an additional 250kW of installed power in addition to the 1000 kW already installed in 2022.
The Aerópolis facility (Seville) started up in April 2023; the installation of a 75kW variable compressor to cover facility demand to replace the 132 kW fixed compressors, which only come into action when the high flow rate required by the lungs of the compressed air installation of the facility's autoclaves is needed. A sequencer was also installed, managing the compressors in the room (both the variable and the existing fixed compressors) so that it dynamically selects the most efficient compressor or combination of compressors according to the energy consumed and the compressed air demand and prioritizes the operation of the variable compressor to minimize the energy wasted due to the idle operation of the fixed compressors.
At Boecillo, the second phase of rooftop photovoltaic panel installation has been completed, adding an additional 250 kW of installed capacity, which complements the 1000 kW already installed in 2022.
ENERGY CONSUMPTION
2021 | 2022 | 2023 | 2023 | 2023 | 2023 |
|
|---|---|---|---|---|---|---|
|
ELECTRICITY (KWH)
|
24,821,676
|
27,592,944
|
40,464,958 22
|
3,030 23
|
7,701,727 24
|
48,169,714
|
|
Electricity Generated (kWh)25
|
-
|
-
|
3,310,483
|
0
|
-
|
3,310,483
|
|
GAS (kWh)26
|
9,962,149
|
9,013,497
|
14,483,755
|
0
|
205,683
|
14,689,438
|
|
diesel oil (L)
|
74,093
|
54,726
|
52,276
|
0
|
2,281
|
54,557
|
|
Total (GJ)27
|
130,001
|
133,901
|
209,522
|
0
|
28,548
|
238,070
|
|
Energy intensity ratio (GJ/k€) 28
|
0.87
|
0.64
|
-
|
-
|
-
|
0.54
|
22. The share of renewable energy from Endesa, the electricity supplier for all facilities in Spain, is 40.5%, according to the CNMV report published for 2023.
23.The share of renewable energy of EDP, the electricity supplier in Brazil, is 50%, according to the power purchase agreement with the company.
24. The share of renewable energy of EDF, the electricity supplier in France, is 13.7%, according to its website.
25. Electricity generated comes from Boecillo, Tres Cantos and Puerto de Santa María facilities.
26. Including natural gas and propane.
27. The conversion factors used are as follows: 1 kWh = 0.0036 GJ; diesel oil density = 832 kg/m3; diesel oil NCV = 43 GJ/t.
28. The ratio has been calculated based on the total energy consumed within the company against the turnover.
total ENERGY CONSUMPTION (GJ)
total ENERGY CONSUMPTION IN 2023 BY COUNTRIES (GJ)
Mechanisms have been established to inform plant managers about the monitoring of electricity, gas, and nitrogen consumption, with the aim of tracking possible deviations from consumption forecasts.
Furthermore, a monitoring system has been installed in the plant's compressor room so that the operation can be supervised and managed and possible alarms can be alerted.
The consumption reduction resulting from implementing this new variable compressor in the facility was assessed by auditing the operation of the current compressors and was estimated at 365,000 kWh/year.
Since the commissioning of this compressor, the facility's energy consumption has been reduced concerning the previous year's figure and the estimated consumption in operating expenses for 2023, with a saving of 9% of total consumption. The same initiative will be rolled out to the Puerto Real and El Puerto de Santa María facilities in 2024.
Both Aerópolis and Mairena have automated the switching on and off the plant compressors, depending on the work shifts. The lighting switch in the production areas and outside the facilities has also been automated so that it is not on when no employees are on the premises.
In addition, at Aerópolis, the air conditioning in the offices has been programmed to switch off automatically depending on the working hours.
The Tres Cantos facility's outdoor lighting has been upgraded to LEDs, reducing electricity consumption and improving safety conditions near the manufacturing facilities.
Also, as a savings measure, mechanisms have been established to inform plant managers about monitoring electricity, gas and nitrogen consumption, track possible deviations from the consumption forecasts established in operating expenses and consumption in the previous year, propose savings measures and control the implementation status of these measures.
In Brazil, energy-intensive luminaires in the workshop and office areas have been replaced with LEDs, and presence sensors have been installed at the cleanroom entrances. Air-conditioning equipment in the workshop has been programmed to be switched off during non-working hours, and insulation improvements have been made by folding the roofs of all the facilities. In-plant air extractors have been installed to reduce the incidence of heat on the electronic equipment. Also, a single central unit has replaced office air-conditioning units, and variable frequency drives have been installed.
The electricity contracting model has been changed from the captive market to the free energy market.
The Rochefort facility has renovated all windows to improve insulation, and the office heaters have been replaced with more energy-efficient ones.