Energy Audit as a Tool for Improving Overal Energy Efficiency in
Serbian Industrial Sector
Mirjana Stamenić, Goran Jankes, Nikola Tanasić, Marta Trninić, Tomislav Simonović
University of Belgrade
Faculty of Mechanical Engineering
Belgrade, Serbia
mstamenic@mas.bg.ac.rs
Abstract—The paper presents caracteristics of energy
consumption in industrial sector of Serbia, the methodology
and results of energy audits (EA) performed in industrial sites
and potentials for energy efficiency (EE) improvements. The
present state of industrial energy in Serbia could be
characterized by significant technological out-of–date, low EE
and low level of environmental protection. Presented analysis
of the results of conducted EAs in selected industrial
companies in previous period has shown the significant
potentials for EE improvements in Serbian industrial sector
(upgrading or replacement of equipment in the industrial
energy sources and processes, introduction of energy
management, improvement of steam supply and condensate
return systems, the waste heat utilization, introduction of EE
technology, improvement of EE in electrical equipment, usage
of waste materials etc).
Keywords-Energy Audit; Industrial sector; Energy
Efficiency.
I. INTRODUCTION
Serbia is a country highly dependent on energy import,
with limited domestic energy sources. The most significant
characteristics of Serbian energy system are out-of-date, low
level of efficiency and high negative impact on
environment. Inadequate operation of the energy system in
Serbia and losses due to poor efficiency of transformation in
energy production, transmission and end-use, are so large
that improvement of energy efficiency (EE) is the best,
fastest and most powerful method to decrease primary and
final energy consumption, as well as to increase of
efficiency of industrial production. Significant energy
savings that can lead to the better competitiveness of
industry on a world market can be achieved by low level of
investments in upgrading of efficiency of existing
technology, better choice of energy sources, implementation
of energy management system, and introduction of energy
efficient and environmental friendly equipment.
All activities in the field of energy efficiency have been
deeply influenced by the following: a) the lack of
understanding of the importance of EE by the management
in the companies, b) the lack of stimulant economic
measures and financial sources for the investments in EE
projects and c) the lack of properly prepared EE project
proposals [1].
Recent introducing of the legal framework has created
new and more stimulant economic and financial
environment in Serbian energy sector. Serbian Parliament
adopted The Energy Law in 2004 and the Strategy of
Development of Energy Sector in Republic Serbia up to
2015 was adopted in May 2005. Further activities have
covered the acceptance of the Program for Implementation
of Energy Sector Development Strategy for the period from
2007-2012 in Serbia, National Strategy of Introduction of
Cleaner Production in Serbia, National Strategy for the
implementation of a Clean Development Mechanism of the
Kyoto Protocol in Serbian Energy Sector, Strategy and
priorities for the future activities of the National Energy
Efficiency Program (NEEP) of the Ministry of Science and
Technology of Serbia (2005). The final draft of the Law on
Rational Use of Energy (Law on RUE) is prepared and
Energy Efficiency Fund should be established soon after the
Law on RUE is accepted. In the mean time, South-East
European countries have signed the Energy Community
Treaty with the aim to create energy market for electricity
and gas and to accept all documents and directives related to
energy and energy efficiency of the European Community
and Kyoto Protocol. Responsibilities included in those
documents, especially in the Energy Community Treaty, and
responsibilities that Serbia will take over in the process of
association and joining to the European Community make
objectives in the field of energy efficiency and use of
renewable energy sources clearer and more obligated with
precisely defined time table [1]. The prolongation of the
acceptance of the Law on RUE and establishment of Energy
Efficiency Fund for several years (First Draft of Law on
RUE had been written in 2005) have made the serious
negative effects and the delay in the realization of the
energy efficiency improvements in all sectors of final
energy use, especially in industrial sector.
Specific Energy Consumption (SEC) and Energy
Intensity (EI) in Serbian industry are very high. Comparing
to the countries in Western Europe, EI in Serbian industry in
1990, was four times higher. In Serbia, in 2002 EI has been
increased for 25% comparing to 1990. SEC has been
increased in industrial sector in 90s, but share of energy
consumption in industry in final energy consumption
decreased due to usage of low capacity of industrial plants,
old equipment and inadequate equipment maintenance [1].
The share of final energy consumption per sectors in
2009 in Serbia is shown in Fig.1. Industry sector consumes
26.64% (85,668 TJ) of total final energy consumption
(321,582 TJ). The share of different fuels/energy sources in
industry sector is presented in Fig.2.
Figure 1. Share of final energy consumption per sector in Serbia in 2009
[4]
Figure 2. Share of energy fuels in Serbian industry sector in 2009 [4]
II. ENERGY AUDIT
The essential step to the energy efficiency improvements
is the performance of an energy audit. Energy audit is a
procedure that helps to analyze the use of energy in an
enterprise/building. The energy audit serves to identify how
a plant facility uses energy and to determine the energy
conservation opportunities. The energy audit can assist in:
evaluating energy efficiency, identifying energy saving
opportunities and establishing a plan to implement energy
saving projects.
An energy audit consists of comprehensive collection of
data on energy use. It is a procedure that requires the use of
auditing equipment and experienced personnel (energy
auditors). Through the energy audit the administration of the
site can: assess the energy cost and its effect to the total
production cost; identify financially and technically viable
options for reducing energy usage; identify possible ways to
improve productivity through interventions in areas not
directly linked to energy consumption, i.e. better manpower
utilization, reduction of the usage of raw material in
production, improved product quality.
There are several "levels" of energy audits, which can
include simple or detailed data surveys, often followed by
detailed examinations of existing data and/or special plant
test runs. The time taken to conduct any audit depends on
the size and type of facilities, but priority should be given to
the departments or sections of the plant of highest energy
consumption.
A. The type of audits
Short audits: This type of audits aims to assess present
energy consumption levels and relative costs based on
existing documentation and a short visit at the site.
Eventually good housekeeping measures and low cost/short
payback measures for energy efficiency are proposed. A list
of medium to high cost measures is also indicated without
major justifications as well as the specific points, which
must be tackled within a detailed energy audit. Short energy
audits belong to the scanning audit models, and according to
the Energy Efficiency BREF (published in March 2008),
there are two main examples of short energy audits: walk-
through energy audits and preliminary energy audits. A
walk-through energy audit is suitable for small and medium
sized industrial sites and preliminary energy audit is suitable
for larger sites.
Detailed energy audit: This type of audits requires a
comprehensive recording and analysis of energy
consumption data, split into various sectors within the site
(steam/hot water production, compressed air, electricity,
HVAC etc.). In this frame, different parameters that
determine each type of energy use are presented and
analyzed (e.g. production capacity, climate conditions, raw
materials etc.). Eventually, a list with potential energy
saving measures requiring investment capital is presented
together with a cost-benefit analysis for each proposed
measure.
B. The methodology
The methodology is based on the standard methodology
for short energy audits and it includes the following: (1)
Preparation of questionnaires on energy consumption,
company production rate, the list of energy systems and
energy consumers, etc.; (2) Determination of energy
indicators for the company; (3) Visit of the selected sites (an
initial audit normally requires a few days for a small to
medium-sized location; for large industrial facilities, such as
refineries or steel plants, it may take more than one week
and up to two weeks to complete); (4) Determination of
energy losses and calculation of energy balance and energy
flows; (5) Evaluation of energy efficiency and conservation
potentials; (6) Identification of energy efficiency measures
and applicable Energy Efficiency and Conservation (EE&C)
technology and evaluation of EE&C potentials in the sector;
(7) Evaluation of implementing capacities of the sites for
EMS introduction; (8) Reporting on results of energy audits.
 III. OVERVIEW OF COLLECTED DATA AND ANALYSIS TABLE I. LIST OF SURVEYED INDUSTRY SITES AND RESULTS OF
SHORT ENERGY AUDITS
In the period between November 2009 and September
Possibility of
2010 several domestic and international institutions Total energy introduction
implemented the Project “Fact Finding Survey on a Local Industry
Company consumption of EE
Level of Sites and Initial Energy Assessment for Northern subsector
of FE, GWh technologies
Serbia within the Study for Introduction of Energy and EMS
Management System in Energy Consumption Sectors in the “Soko-Nada
Confectionary 31.224 High
Republic of Serbia”. In order to accomplish the objectives Štark”
“Galeb Metal Metal
of the Project, two kinds of activities were performed: Pack” processing
6.905 High
− A fact-finding survey by questionnaires and “Zvezda Paintings and
interviews to assess local level of the sites considering 4.014 Medium-High
Helios” varnishes
introduction of Energy Management System (EMS). “Sojaprotein”
Food
106.057 High
− The initial energy assessment via Energy Audits on processing
Cardboard
the selected sites to identify EE&C potential and applicable “Umka”
processing
168.488 High
EE&C technology in industrial sectors. “Veterinarski Animal food
For the purpose of collection of data on energy zavod” and pharm. 12.275 Medium
consumption, specific questionnaires were developed and Subotica products
distributed in 9 industrial sites and 6 sites of public/state and “Hipol” Chemicals 88.387 High
commercial buildings. The aim was to collect the following PVC and
data: ”Tarkett” wooden floor 72.147 High
proc.
− Basic characteristics of the sites, Eatable oil
− Data availability (energy consumption) for EMS, “Victoria oil” 64.204 High
processing
− Capacity/possibility to deal with EMS (energy
audit experience, candidates for future Energy Managers TABLE II. SHARE OF HEAT AND ELECTRICITY CONSUMPTION PER
INDUSTRIAL SITE
etc.),
− Technological level of sites and Company
Heat consumption, Electricity
− Detailed data on energy consumption and % consumption, %
“Soko-Nada Štark” 60.27 39.73
equipment of utility systems. “Galeb Metal Pack” 49.02 50.98
The list of surveyed industrial sites and summarized data “Zvezda Helios” 49.29 50.71
on energy consumption and estimations of introduction of “Sojaprotein” 73.71 26.29
EE technologies and EMS based on short energy audits are “Umka” 75.60 24.40
presented in Table I. “Veterinarski zavod”
77.8 22.20
The potentials for energy savings and introduction of EE Subotica
technologies in all audited sites are recognized as “high”. “Hipol” 72.65 27.35
”Tarkett” 59.84 40.16
Considering proposed threshold level of 2,500 toe of total
“Victoria oil” 74.23 25.77
yearly energy consumption for the site that will be
designated for introduction of EMS, seven of nine industrial
sites accomplished above-mentioned criteria. The share of There are several obstacles for implementation and
heat/electricity consumption per each site is shown in table incentives for EE measures: low knowledge of top
II. management of the benefits of EE improvements, low
Potentials for energy savings in industrial sites can be financing possibilities, the lack of states mechanisms for the
estimated in range of 20 to 35% with low and medium support of the implementation of EE measures (e.g. legal
amount of investments and with simple pay back periods of framework and EE fund).
less than 4 years [3]. Possibility of introduction of EMS in the selected
The industrial sites (where audits were performed) are industrial sites is generally high, mostly because of the
knowledge of technical staff of the benefits of introduction
owned by successful companies with strong teams of
of EMS. Some of them have already participated in the
engineers who are competent in their fields. The knowledge
courses for capacity building in the field of EE&EC or
of these engineers, in general, is on the average level that is
Cleaner Production projects. The action plans for
required for introduction of EMS.
introduction of EE measures already exist in most of the
The potentials for introduction of EE technologies are
companies. The benefits of introduction of EMS are still not
high. Process and energy technologies of all sites are old
clear to the top management of the companies. In general,
and there is need of introduction of energy efficient and
there is no commitment of the top management to the
environmental friendly technologies. Most of the companies
introduction of EMS. There are no energy managers or
are already in the process of EE improvements of their
persons in charge for EE in the companies. The obligation
production and/or energy technologies. There is a strong
given by Law on RUE, which is in preparatory phase, as
will of technical staff to reduce energy consumption and to
well as the support of the state, can change the situation.
introduce energy efficiency measures.
This has to be accompanied by the huge information
campaign, education and capacity building with the aim to
raise the understanding of importance of EE and EMS. The
serious problem is technical support of EMS in the
companies, as the proper energy monitoring systems do not
exist, even in the large size companies.
IV. RESULTS OF ENERGY AUDITS IN SERBIAN INDUSTRY
Energy consumption in industry is deeply dependant on
the change of the structure of industrial production. The rise
of the share of industrial subsectors with low energy
intensity is very important, but that depends on the strategic
decissions of the Government based on the overall strategy
of the economic development of the country. Existing
information are not enough for the conclusions on the
possible trends. However, the low energy efficiency of
Serbian industry reflects in big difference of specific energy
consumption values of Serbian industry compared to those
in developed countries. Based on some previous researches,
these differences varie according to the specific industry
sector and there are from 30 % to more than 200 % [1]. For
more reliable potential estimates, it is essential to introduce
proper energy statistics of industrial sector which is still of
the low level in Serbia.
Generally, EE improvement measures for industry can
be divided in two main groups: (1) Energy efficiency
improvements of energy sources in industry (heat
production and electricity in heat and power plants in
industry) and (2) Energy efficiency improvements of
industrial production processes.
In EE improvements of energy sources in industry,
two groups of measures are recognized: (a) Programs and
measures of modernization, revitalization and reconstruction
of existing objects, equipment or energy technologies of
energy sources in industry and (b) Programs and projects of
building of new plants or units, or replacement of old units
with new energy efficient units (boiler units or CHP units)
in industrial heat and power plants. The effects of measures
and programs of EE improvements of energy sources in
industry are estimated approximately to 20% of
reduction of total energy consumption in industry. Programs
and projects of building of new plants or units, or
replacement of old units can be applied to almost 2/3 of all
installed industrial boilers in Serbia. It is essential to use the
highest standards of EE in design and construction of the
new boiler houses, or new CHP plants in case of the
replacement of existing boilers.
Programs and measures of EE improvements of
industrial production processes are in the second of
mentioned group of measures. The process equipment in
Serbian industry is out of date and of a high (SEC) rate. For
example, in paper industry, installation of a new state of the
art paper machine could reduce SEC up to 50% [1].
Referent BREFF documents for each industrial sector
recommend application of specific process equipment
referring the potential for EE improvements.
Introduction of EMS in industrial companies can
contribute to the reduction of energy consumption 10-15%
at company level in general, but the results of energy audit
has shown that it is over 15% in Serbian process industry
[3].
Significant potentials are in upgrading of steam and
condense return systems (the rate of condensate return in
Serbian industrial plants is in average 25-50%). It is
estimated that the potential of this measure is 6% reduction
of energy used for heat production in industry of Serbia [1].
The big share of electricity consumption in industry
takes electro drives and lightening system, which in
Serbia, are on the technical level of eighties. Electricity
consumption at the company level highly depends on the
efficiency of compressed air and cooling systems. The
biggest part of used electricity in these systems is
transformed to the waste heat and this waste heat is not used
in Serbian industrial sites. In general, the share of waste heat
to the total heat consumption in industrial processes is 10 -
60% [1]. There are no detailed studies on the sectorial level,
but it can be estimated that total EE potentials of the use of
waste heat in industry are 10-20% of total energy consumed
in industry [1]. The improvements of production processes
by the use of waste heat and introduction of new energy
efficient equipment and technologies, use of recycled waste
materials and renewables are the big potentials, but also the
challenges for the management of Serbian industrial
companies.
The estimations based on the experience in energy
efficiency improvements in EU countries and knowledge of
Serbian industry show that it is possible to reach over 25%
of reduction in total energy consumption in industry by the
consequent application of mentioned EE measures [1]. By
the year 2020, the consumption of energy in Serbian
industrial sectors need to show a stronger declining
tendency in order to overcome the huge differences in
specific energy consumption between Serbia and EU
countries.
The Serbian Law on RUE and all by-law regulations,
which are in preparatory phase, should be the legal
framework for the introduction of EMS in all energy
consumption sectors. The establishment of Energy
Efficiency Fund should be the support for implementation
of recognized EE measures, including financing regular
energy audits in industrial companies. The important issue
is to establish system for implementation of EE measures in
industry, as well as the system for monitoring, verification
and evaluation through regular energy audit schemes.
V. CONCLUSIONS
The present state of energy systems in Serbian industry
could be characterized by significant technological out-of-
date, low EE and low level of environmental protection.
Energy audit is a procedure that helps to analyze the use of
energy in an enterprise or building. The energy audit serves
the purpose of identifying how a plant facility uses energy
and of analyzing the energy conservation opportunities.
Within the Project “Fact finding survey on a local level
of sites and initial energy assessment for Northern Serbia”
nine short energy audits in selected industrial companies
were performed.
 The results of EA show:
- The potentials for introduction of EE technologies
is high, most of the companies are already in the process of
identification and implementation of EE improvements of
their production and/or energy technologies.
- The potential of EE measures implemented within
energy sources in industry are estimated to be 20% of total
energy consumption in industry.
- The potential of upgrading of steam and condense
return systems is estimated to contribute with 6% reduction
of energy used in boilers in industry of Serbia.
- Potential of EE measures in industrial production
process is highly dependent on industrial sector and
selection and application of specific process equipment. By
introducing the new technology in some industrial sectors
(e.g. paper processing), it is possible to reduce SEC up to
50%.
- Total EE potentials of the use of waste heat in
industry are 10-20% of total energy consumed in industry.
- Introduction of EMS in industrial companies can
contribute to the reduction of energy consumption 10-15%
at company level.
ACKNOWLEDGMENT
The Project “Fact Finding Survey on a Local Level of
Sites and Initial Energy Assessment for Northern Serbia
within the Study for Introduction of Energy Management
System in Energy Consumption Sectors in the Republic of
Serbia” was realized by consortium of three organization –
Serbian Industrial Energy Efficiency Network (SIEEN) of
the Innovative Center of Faculty of Mechanical
Engineering, Belgrade, Regional Energy Efficiency Center
of the Faculty of Mechanical Engineering, University of
Belgrade and Provincial Energy Efficiency Center of
Faculty of Technical Science, University of Novi Sad. The
project was supported and financed by JICA (Japan
International Cooperation Agency).
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