Energy Savings in Industrial Processes: The Influence of Electricity Emission Factor and Financial Parameters on the Evaluation of Long-Term Economics and Carbon Savings
Abstract
1. Introduction
Aim of the Work and Novelty
- scenarios of high inflation rate for energy vectors and sources;
- plausible evolution of carbon dioxide emission factors in electricity conversion.
2. Materials and Methods
2.1. Economic and Financial Parameters
2.2. Emission Factor
- e0 is the emission factor of the first year of operation;
- r is the initial linear growth rate, which is assumed here to be r = 0;
- m is the decay parameter.
- with e0 = initial value of the historical series (e(1990)), least squares approximation on m only, called “model opt(e0 = e(1990))”;
- least squares approximation on both e0 and m, called “model opt”.
2.3. The Case Studies
- A.
- isolation of the intervention with measurement of the main parameters;
- B.
- isolation of the intervention with measurement of all parameters;
- C.
- assessment of the entire plant or structure based on pre- and post-intervention measurements;
- D.
- assessment of the entire plant or structure based on post-intervention measurements combined with a calibrated pre-intervention simulation.
- Case 1. A company operating in the wooden office furniture sector, located in the Province of Padova (North-East Italy). The analysis focuses on the energy savings achieved through a substantial modification of the production processes. In particular, the assembly line was restructured by replacing both the die-cutting machine (Figure 5) and the packaging line (Figure 6), representing an intervention that combined technological upgrading with managerial reorganization. The project was implemented within the framework of the POR FESR 2014–2020 regional funding program (Veneto Region), specifically under the call addressing the “replacement of production cycles with cycles that demonstrably reduce electrical and/or thermal consumption compared to the pre-intervention situation, including per unit of product.” As the company did not have a detailed energy monitoring system in place, IPMVP® Option C was selected for the determination of savings, relying on pre- and post-intervention energy consumption data at the level of the entire plant. The pre-intervention baseline period was defined as the entire year 2019, while the reporting period for the calculation of savings corresponded to the entire year 2021. Two energy audits were carried out according to the ENEA protocol pursuant to Legislative Decree 102/2014 [16], one referring to the baseline year (2019) and the other to the reporting year (2021). The energy data used in the analysis derive from the processing and results of these two audits.
- Case 2. A company that operates in the sheet metal cutting and bending, in the same Province of Padova. The analysis focuses on the reduction in electricity consumption due to the installation of a new laser-cut machine that replaces two different machines for metal cutting and punching, which can be seen in Figure 7. The energy efficiency project is developed under the Italian national framework Industry 5.0 for industrial automation and energy saving. Also this second company is not equipped with energy monitoring, but IPMVP® Option A was selected for the determination of savings, relaying on field measurement of the old machines and the new machine consumption when the same production schedule runs in parallel.
3. Results and Discussion
3.1. Evaluation of Savings—Case 1
- 0.187 × 10−3 toe/kWhe;
- 8.250 × 10−7 toe/Sm3;
- 11,630 kWh/toe.
3.2. Evaluation of Savings—Case 2
3.3. The Impact of Variation in Economic Parameters
- (i)
- to what extent a sustained increase in energy prices amplifies the calculated economic savings; and
- (ii)
- to what extent inflation (Figure 9) affects the actual profitability of energy efficiency investments.
- -
- the type of subject undertaking the investment (e.g., private individual, public administration, company with high or low profit margins);
- -
- the source of capital;
- -
- the company’s financial strategy and profit expectations.
- -
- O (Optimistic): 9% per year;
- -
- ML (Most Likely): 6.7% per year, corresponding to the average electricity price inflation observed between 2005 and 2015;
- -
- P (Pessimistic): 4% per year.
- -
- the case characterized by low inflation and high interest (b = 3%, im = 20%) leads to a marked reduction in the present value of future cash flows;
- -
- the case with moderate inflation and low interest (b = 8%, im = 4%), corresponding to a negative real interest rate, yields a substantially higher NPV;
- -
- the pairs (b = 3%, im = 4%) and (b = 15%, im = 20%), while numerically proportional, produce similar but not identical results due to the nonlinear relationship between nominal interest, inflation, and the derived real interest rate.
3.4. The Impact of the Evolution of the Electricity Emission Factor
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
| Symbol | Meaning | Unit |
| b | Inflation rate | - |
| E | Electrical energy consumed | kWhe |
| e | Emission factor | kgCO2 kWhe−1 |
| i | Interest rate | - |
| m | Decay parameter | - |
| Q | Quantity of product | - |
| r | Initial linear growth rate | - |
| S | Energy savings | kWhe |
| SC | Specific consumption | kWhe item−1 |
| t | Time | h or y |
| Subscript | Meaning | |
| 0 | Initial value | |
| e | Electricity | |
| m | Monetary | |
| new | New machine | |
| old | Old machine | |
| p | Primary energy | |
| product | Product | |
| r | Real | |
| ref | Reference period | |
| rep | Reporting period | |
| tot | Total | |
| Acronym | Meaning | Unit |
| ENEA | Agenzia nazionale per le nuove tecnologie, l’energia e lo sviluppo economico sostenibile (Italian National Agency for New Technologies, Energy and Sustainable Economic Development) | - |
| EPC | Energy Performance Contract | - |
| EU | European Union | - |
| GDP | Gross Domestic Product | EUR |
| GHG | GreenHouse Gases | - |
| IPMVP | International Performance Measurement and Verification Protocol | - |
| MARR | Minimum Attractive Rate of Return | - |
| ML | Most Likely | - |
| NPV | Net Present Value | EUR |
| O | Optimistic | - |
| P | Pessimistic | - |
| PUN | Prezzo Unico Nazionale (National Single Price) | EUR kWhe−1 |
| WACC | Weighted Average Cost of Capital | - |
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| Fit | e0 (kgCO2/MWhe) | m | R2 |
|---|---|---|---|
| Model opt (e0 = e(1990)) | 593.03 | 0.0613249 | 94.9% |
| Model opt | 575.84 | 0.0588657 | 92.0% |
| Before Intervention | After Intervention, Reporting | After Intervention, Backcasting | Absolute Savings-Backcasting | Relative Savings-Backcasting | |
|---|---|---|---|---|---|
| Year | 2019 | 2021 | 2021 | ||
| Electric energy (kWhe) | 1,629,828 | 1,476,319 | 702,362 | 927,466 | 57% |
| Natural Gas (Sm3) | 117,730 | 128,455 | 61,113 | 56,617 | 48% |
| Quantity of production (kg) | 2,334,090 | 4,906,103 | 2,334,090 | ||
| Non-renewable primary energy (kWhp) | 4,674,804 | 4,514,766 | 2,147,911 | 2,526,893 | 54% |
| Non-renewable primary energy (toe) | 402 | 388 | 185 | 217 | 54% |
| Time Beginning | Time Ending | Items (#) | Electric Consumption (kWhe) | SC (kWhe/Item) | |
|---|---|---|---|---|---|
| Old machines | 9:49 | 18:09 | 337 | 101.54 | 0.30131 |
| New laser cut machine | 10:42 | 20:02 | 337 | 50.97 | 0.15125 |
| b | 3% | 8% | 15% | |
|---|---|---|---|---|
| im | 4% | 2,423,396 | 3,242,639 | 4,899,349 |
| 20% | 1,124,410 | 1,423,410 | 2,001,205 |
| b | 3% | 8% | 15% | |
|---|---|---|---|---|
| im | 4% | 12,402 | 15,436 | 21,217 |
| 20% | 7156 | 8434 | 10,772 |
| Case | Scenario S0 e(t) Fixed | Scenario S1 e(1990) = 575.84 | Scenario S2 e(1990) = 593.03 | Difference S1-S0 (%) | Difference S2-S0 (%) |
|---|---|---|---|---|---|
| Case 1 | 7,785,415 tCO2 | 4,539,093 tCO2 | 4,343,782 tCO2 | −41.7% | −44.2% |
| Case 2 | 26,463 kgCO2 | 17,390 kgCO2 | 16,539 kgCO2 | −34.3% | −37.5% |
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Busato, F.; Noro, M. Energy Savings in Industrial Processes: The Influence of Electricity Emission Factor and Financial Parameters on the Evaluation of Long-Term Economics and Carbon Savings. Appl. Sci. 2025, 15, 11852. https://doi.org/10.3390/app152211852
Busato F, Noro M. Energy Savings in Industrial Processes: The Influence of Electricity Emission Factor and Financial Parameters on the Evaluation of Long-Term Economics and Carbon Savings. Applied Sciences. 2025; 15(22):11852. https://doi.org/10.3390/app152211852
Chicago/Turabian StyleBusato, Filippo, and Marco Noro. 2025. "Energy Savings in Industrial Processes: The Influence of Electricity Emission Factor and Financial Parameters on the Evaluation of Long-Term Economics and Carbon Savings" Applied Sciences 15, no. 22: 11852. https://doi.org/10.3390/app152211852
APA StyleBusato, F., & Noro, M. (2025). Energy Savings in Industrial Processes: The Influence of Electricity Emission Factor and Financial Parameters on the Evaluation of Long-Term Economics and Carbon Savings. Applied Sciences, 15(22), 11852. https://doi.org/10.3390/app152211852
