Post on 16-Jan-2016
description
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Regional Environmental Center Regional Environmental Center for Central and Eastern Europe for Central and Eastern Europe
Đorđićeva 8a, 10000 Zagreb, CroatiaĐorđićeva 8a, 10000 Zagreb, CroatiaŽeljka MedvenŽeljka Medven, , Project ManagerProject Manager
E-mail: E-mail: zeljka@rec-croatia.hrzeljka@rec-croatia.hrTel: +385-1-4873-622Tel: +385-1-4873-622Fax: +385-1-4810-844Fax: +385-1-4810-844
Urban sustainability and energy efficiency in industry
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From global to local levelFrom global to local level
Urban sustainability and industryIndustry in CroatiaEnergy efficiency in small and medium
size enterprizes (SMEs) – Croatian case study
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Urban developmentUrban development
A path to a sustainable world?Environmental threats, social and economic distress
- agglomerations- wealth and income inequality
- consumption of natural resources and production of waste
- urban transportation system- industrial development and its pollution- inefficient energy consumption
Economic globalization lacks an effective model for sustainable local development.
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Key Factors in Urban Key Factors in Urban SustainabilitySustainability
ENERGY USE AND CONSERVATION:Oil problemPatterns of transport energy use
between cities and within citiesEnergy conservation and efficiency
in the built environment
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Where next?Where next?Situation
•Over 50% of the world's population, i.e. 3 billion people, lives in urban centres (cities and megacities)
•Around 80% of the European Union’s population lives in cities and towns
Solutions to-date
•Sustainable community initiatives - promote waste reduction, pollution prevention, forming of environmental industry economic development strategies
Drawbacks
•Incremental improvements
•Separate interests of stakeholders
Solution•communities as living systems (industrial metabolism)•industrial ecology as the new approach
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Industrial MetabolismIndustrial Metabolism
"metabolism" of industry, commerce, municipal operations, and households
community consumes material and energy inputs, processes them into usable forms, and eliminates the wastes from the process
possible public and private cost-savings and opportunities for new business development
Measures of sustainability:
The ratio of virgin to recycled materials Ratio of actual/potential recycled materials Ratio of renewable/fossil fuel sources Materials productivity: Energy productivity Resource input per unit of end-user service
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Industrial ecologyIndustrial ecology An industrial ecology (IE) perspective provides tools for understanding the
environmental impacts of a community's industry, commerce, infrastructure, and household behavior as a whole system.
addressing industry's needs in the transition to sustainable communities. The goal is to support business competitiveness and job creation through
strategies that also improve environmental protection and quality of life in all dimensions.
The benefits to communities of this holistic foundation for change include: Creation of common ground for all community stakeholders to plan
effective change; Increased efficiency of energy and material resource use; Increased competitiveness for businesses; Ability to target highest risks and opportunities for greatest improvement; Decreased pollution and damage to the health of citizens and the
environment; Opening of new local business and job development opportunities; Revitalization of existing industries; Improvements in the efficiency and extension of the life of municipal
infrastructure systems; and Restoration of the viability of local ecosystems.
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Industrial ecosystemIndustrial ecosystemAn industrial ecosystem is a community or network of companies and other organizations in a region who chose to interact by exchanging and making use of byproducts and/or energy in a way that provides one or more of the following benefits over traditional, non-linked operations:
Reduction in the use of virgin materials as resource inputs;
Reduction in pollution; Increased energy efficiency leading to reduced
energy use in the system as a whole; Reduction in the volume of waste products
requiring disposal (with the added benefit of preventing disposal-related pollution); and
Increase in the amount and types of process outputs that have market value.
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Industrial ecosystemIndustrial ecosystem– Kalundborg case study– Kalundborg case study
Kalundborg is a Denmark harbor town with buildings dating back to the 12th Century.
What happened over last 20 years? spontaneous but slow evolution of the "industrial symbiosis" development of network of materials and energy exchanges among
companies (and with the community)
Why it happened?to reduce costs by seeking income-producing uses for "waste" products
Five core partners: Asnaes Power Station Statoil Refinery Gyproc, a plasterboard factory Novo Nordisk, an international biotechnological company The City of Kalundborg, supplies district heating to the 20,000 residents, as
well as water to the homes and industries
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Industrial ecosystem – case Industrial ecosystem – case study...study...
Energy Flows
The power station - coal-fired, 40 percent thermal efficiency. Refinery flared off most of its gas by-product.
Then, starting in the early '70s, a series of deals were struck:
The refinery agreed to provide excess gas to a plasteboard factory Power station began to supply 3 new customers with stem
the city with its new district heating system (3,500 oil furnaces replaced) biotechnology company refinery
The power plant uses salt water, from the fjord (instead fresh lake water), for some of its cooling needs. The resulting by-product is hot salt water, a small portion of which is supplied to the fish farm's 57 ponds.
In 1992, the power plant began substituting fuels, using surplus refinery gas in place of some coal. This only became possible after refinery built a sulfur recovery unit to comply with regulations on sulfur emission; the gas was then clean enough to permit use at the power plant.
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Industrial ecosystem – case Industrial ecosystem – case study...study...
Materials Flows
In 1976 the biotechnology company started the pattern of materials flows, matching the evolving energy flows at Kalundborg.
Sludge from biotechnology processes and from the fish farm's
water treatment plant is used as fertilizer on nearby farm.
A cement company uses the power plant's desulfurized fly ash. Power plant reacts the SO2 in its stack gas with calcium carbonate, thereby making calcium sulfate (gypsum), which it sells to plasterboard company, supplying 2/3 of the latter's needs.
The refinery's desulfurization operation produces pure liquid
sulfur, which is trucked to sulfuric acid producer.
Surplus yeast from insulin production at biotechnology company goes to farmers as pig food.
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Industrial ecosystem – case Industrial ecosystem – case study...study...
Lessons from Kalundborg contracts negotiated bilateraly economically attractive for both
companies opportunities only within a company's
core businessminimizing risks independent evaluation of deals
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Industrial ecosystem – case Industrial ecosystem – case study...study...
Pre-conditions for development of a similar network of exchanges:
Industries different and yet fit each other. Arrangements commercially sound and profitable. Development voluntary, in close collaboration with
regulatory agencies. A short physical distance between the partners
necessary for economy of transportation (with heat and some materials).
At Kalundborg, the managers at different plants all know each other.
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Industrial ecology Industrial ecology - Municipal - Municipal infrastructureinfrastructure
community's energy and materials flows – mostly local energy, water, solid and liquid waste, and transportation systems
industrial ecology approach - "soft infrastructure" (finance, education, training, tax incentives, and other public programs) to achieve much higher efficiencies
An integrated strategy for extending the life of landfills would include: Analysis of the major elements in the waste stream Education and training in waste reduction A business development strategy targeting companies recycling and
reusing waste Selection among options to get highest value out of reused materials and
products; Development of information systems and businesses supporting the
exchange of waste materials and energy
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Industrial Ecology - Business Industrial Ecology - Business Development OpportunitiesDevelopment Opportunities
Entering new markets for existing goods and services By-product trading – opportunities for reprocessing and information
technologies and for service providers
Marketing emerging technologies, materials, and processes Consulting and information system opportunities services of management and environmental consulting companies,
training firms, print and electronic publishers, information system providers, and educational institutions.
Integrating technologies and methods into innovative new systems. larger corporations, or joint ventures an integrated home appliances
Supply and distribution services to sustainable farming greater need for education, training, consulting, telecommunications, and
electronic equipment
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Energy efficiency?Energy efficiency? Energy efficiency means using less energy to perform the same function.
Energy efficiency should reduce both use of resources and damage to the environment due to energy generation and consumption.
Demand Site Management programs are aimed at reducing the energy used by specific end - use devices and systems, typically without affecting the services provided. E.g. these programs reduce overall electricity consumption by substituting technologically more advanced equipment to produce the same level of end-use services (eg, lighting, heating, motor drive) with less electricity.
Examples include energy saving appliances and lighting programs, high-efficiency heating, ventilating and air conditioning (HVAC) systems or control modifications, efficient building design, advanced electric motor drives.
Energy audit is a systemized approach to measuring, recording, and evaluating the operating performance of a building or building system with the intention of improving the performance
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Energy efficiencyEnergy efficiencyin Croatiain Croatia
Socialist market - low level of the efficient use of energy old technologies lack of energy management inadequate energy policy
Transitional approach unorganised approach the lack of up-to-date knowledge missing information interchange
Emerging trends energy laws capacity building programs new financing possibilities - Fund for environmental protection and
energy efficieny
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Target groups Tipical activities
Industry
Key projects in sectors: wood and food processing Analysis of EE potential
Potentials for fuel replacement, use of wood waste, etc.
Benchmarking
Construction materials
Others
Hotels and other
Hotels and other tourist facilities Potentials for increasing EEDevelopment of financing modelsOthers
Public sector
Hospitals Development of energy auditsDevelopment of ESCO and similar
modelsSchools and kindergardens
Other (shops, admin.buildings,etc.)
Energy consumersEnergy consumersby sectorsby sectors
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Industry sector -networking
Industry sector missing:
Scientific approach to energy efficiency Global insight into economic and environmental aspects of the non-
rational energy consumption Relevant information on applicable savings Knowledge on general and technological development
Tipically:• Large enterprises have adequate knowledge• Smaller enterprises due to their size do not pay adequate
attention to energy efficiency
Networking:Network of industrial energy efficiency (MIEE)
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Sectors and processesSectors and processes Electricity consumption Heat consumption Water consumption etc.
Industry:
construction materials
food processing
chemical industry
glass and non-metals
paper
iron and steal
non-ferrous metals
other
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Energy consumption
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
Ele
ctri
city
, GW
h
Croatia totalIndustry
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
200000
Hea
t T
J
Croatia total
Industry
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Energy consumption - Energy consumption - industryindustry
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
TJ
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Industry - consumptionNatural gas
Coal and coke
Fuel oil
Steam and hot water
Electricity
In 2002:electricity: 2890 GWh (~23%)
heat: 41000 TJ (~38%)
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0
100
200
300
400
500
600
700
800
GW
h
Construction m
aterials
Chemical
Food processingPaper
Iron & steel
Glass & non-metallic
minerals
Nonferrous m
etalsOther
Industry - electricity consumption in 2002.
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0
2000
4000
6000
8000
10000
12000
14000
16000
18000
TJ
Construction m
aterials
Food processing
Chemical
Glass & non-meetallic
mibneralsPaper
Iron & steel
Nonferrous m
etalsOther
Industry - heat consumption in 2002.
Steam & hot water
Coal & coke
Natural gas
Liquid fuel
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Chemical industryChemical industry
0,0
2000,0
4000,0
6000,0
8000,0
10000,0
12000,0
14000,0
TJ
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Steam and hot water
Natural gas
Liquid fuel
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Chemical industryChemical industryCharacteristics:Heat consumption 4 times larger then electricityConsiderable steam and hot water consumptionNatural gas consumption increases
Applicable measures:Heat: process rationalization, waste heat recovery, boiler
improvement and other measures for heat Electricity: similar measures as in other industries, but it should
be emphasised that the broader application of efficient motors and variable speed drives, at pumps and other devices
Annual saving potentials:Annualy 200-300 TJ heat and 80-100 GWh electricity
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Construction materialsConstruction materials
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
TJ
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Steam and hotwater
Coal and coke
Natural gas
Liquid fuel
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Construction materialsConstruction materialsCharacteristics:Electricity consumption has reached its pre-war levels heat consumption has gone above 30% of that level largest part of consumption caused by the cement works
Applicable measures:waste heat utilizationfuel switchimprovement of machinery and technologyapplication of more efficient motors etc.
Annual saving potential:heat – about 800 TJ ;electricity - about 50-60 GWh
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Food processingFood processing
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
TJ
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Steam and hot water
Coal and coke
Natural gas
Liquid fuel
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Food processingFood processingCharacteristics:reached its pre-war energy consumption level relatively quick Electricity consumption – continuous increase from 1994 heat – heat and hot water up to 83%Sugar production – max heat consumerMeat industry – max electricity consumerApplicable measures:electricity: applying of efficient motors and el. consumers,
improvementof technology processes, machinery and other heat, process rationalisation, use of waste heat, condensate
and technology water re-use, and other measures Annual saving potential:700-800 TJ heat,50 GWh electricity
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MeasuresMeasuresacc. consumers groups and prioritiesacc. consumers groups and priorities
Priorities: 1 – high 2 – medium 3 -low
consu
mpti
on e
ffici
ency
ele
ktr
om
oto
r fa
cilit
ies
lighti
ng
HV
AC
syst
em
s
heati
ng
ele
ktr
oly
sis
an
d o
ther
pro
cess
es
heati
ng o
f p
rem
ises
heat
carr
iers
reuse
of
condensa
te
reuse
of
wast
e h
eat
indu
stri
al th
erm
al p
roce
sses
food p
roce
ssin
g
sanit
ary
hot
wate
r
heat
for
ab
sorp
tion
chill
ers
wate
r an
d o
ther
med
ia c
onsu
mpti
on
INDUSTRY 1 1 3 3 1 3 1 1 1 1 1
PUBLIC SECTOR
1 1 1 1 2 1 2 2 2 1 1 1 1
SERVICESECTOR
1 1 1 1 1 2 3 1 1 2 1
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Efficiency of electricity Efficiency of electricity consumptionconsumption
Electromotor facilities – largest energy consumers in industry
Potential in energy efficiency motors (EEM) and variable speed drivers (VSD)
Combined application of EEM and VSD implies 10% economic savings, and more then 15% in energy savings
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Efficiency of heatEfficiency of heatconsumptionconsumption
Similar share of high- and low-temperature consumption in industry
Low-temperature mainly in non-metal, chemistry, and food processing
Big potential in reuse of waste heat, and implementation of efficient technologies
High-temperature heat mainly in construction materials, paper, non-metal and chemical industry
Potential in BAT implementation, and increasing fuel efficiency
In steam consumption-usualy no recovery of condensate, or reuse of waste heat
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Cogeneration in industryCogeneration in industry
simultaneous production of electricity and heat
best locations are already available combustion facilities in industry
reconstruction needed for existing cogeneration plants
old boiler facilities should be modernized
potential in whole industry; specifically chemical, construction, meat procesing, pharmaceutical, wood procesing, textile, tobacco, paper, alcohol, beer, oil, etc.
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Energy eficiencyEnergy eficiencyin small and medium size enterprizesin small and medium size enterprizes
Training ProgramTraining Program
Donor: Donor:
Ministry of Environment and Territory, ItalyMinistry of Environment and Territory, Italythrough Italian Trust Fund (ITF), Januarythrough Italian Trust Fund (ITF), January 20042004
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BackgroundBackground•General: continuous increase in energy consumption in Croatia, paralel to the obligation of reducing the greenhouse gas emissions according to Kyoto protocol
•Specific: REC projects related to industry showed low priority for implementing energy efficiency measures
•PROHES (Program od Development and Organization of Croatian Energy Sector)
•MIEE (The Netwok of Industrial Energy Efficiency)
•Expert study in energy efficiency (FER – Faculty of Electrical Engineering and Computing, Norwegian Partners, EIHP – Energy Institute Hrvoje Pozar)
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Project ObjectivesProject Objectives Building capacity of SMEs for planning and
implementation of energy efficiency measures through interactive training activities
Presentation of technical, economical and financial feasibility of energy efficiency measures through identified case studies in SMEs
Promotion of energy efficiency and dissemination of project results in Croatia and abroad
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FrameworkFramework
REC - project manager Italian Partner: International Solar Energy
Society (ISES)/Pisa University Local Partners (Croatian Chamber of
Commerce, Energy Institute Hrvoje Pozar, Faculty of Electrical Engineering and Computing)
Beneficiaries: SMEs (up to 250 employees) Industry sectors: chemical, construction, food
processing, pharmaceutical, wood procesing, metal and plastic
Project duration: 1,5 year (January 2004-May 2005)
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ActivitiesActivities Short fact-finding mission in SMEs re. energy
management
Promotional half-day seminar
Interactive training (2 workshops+2 site-visits to companies); development of case studies
Review of financing possibilities for EE measures in Croatia
Presentation of project results
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OutcomesOutcomes Review of current energy management practices in
SMEs
Case studies developed in 8 companies
Pilot testing for training methodology
Increased capacity of local trainers for future educational activites
Increased capacity of SME employees for planning and implementation of energy efficiency measures
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Energy efficiency measuresEnergy efficiency measures
Human resources and implementation of energy mgmt. system
Knowledge on current energy consumption and benchmarking
Employees education (new technologies, , maintenance, new legislation, environmental fees)
Improvement of maintenance system Replacement of old and insufficient
technologies, fuel replacement
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...technical solutions...technical solutions
ELECTRICITY AND HEAT improving heating system improving lighting improving compressed air system peak-load mgmt.
ALTERNATIVE ENERGY renewable energy resources fuel replacement (especially in wood processing)
WATER development of modern water mgmt. system
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Case study - Wood industryCase study - Wood industryCroatiaCroatia
Basic data:
Joint venture for wood processing and construction materials.
Main product – massive parquet115 employees.private (100% small shareholders).1998 energy audit performedhard copy – data for electric energy and water acc. on a
monthly basis, and compared with the previous periodmotivation for EE measures
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Basic data – already implemented measures:Time delay in various processing lines for peak load
decrease.Heat from 1980 from waste woodPart of the steaming process is indirectImplemented frequency controllers in new drying chambersIn 2004. unproductive electric energy costs ~1.700 €,
problem solved after three monthsMore then 3.000.000 EUR invested through subsidized
loans
Case study - Wood industryCase study - Wood industryCroatiaCroatia
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Case study - Wood industryCase study - Wood industryCroatiaCroatia
51%
40%
9%
1
2
3
biomasselectricityfuel oil
Ratio of energy supply
46Energy costs are higher then net profit!!!
Case study - Wood industryCase study - Wood industryCroatiaCroatia
8%
10%
82%
waterfuel oil
electricity
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Wood industryWood industry
Fields for potential savings
Current state
Measures to be applied
Benefits
Improvements in compressed air system
manually operated compressors
Implementation of automatization and PLC monitoring system
Investment: 4.500 EUR
• Savings of losses in idle mood
• Savings: 2.500 EUR/year
• Payback period: 1,8 year
Boiler reconstruction, fuel replacement
Fuel oil produces steam in one of the steaming units
Boiler reconstruction from direct to indirect steaming, fuel oil replacement with wooden leftovers
• Investment: 21.700 EUR
• Savings of about 55.000 l of fuel oil and usage of wooden leftovers
• Savings: 19.800 EUR/year
• Payback period: 1,1 year
Implementation of water mangement system
Only one water meter at the entrance of the company, old internal water supply network
Monitoring equipment (for water losses)
• Investment: 3.200 EUR
• Savings of about 1.300 m3 water/year
• Savings: 1.800 EUR/year
• Payback period: 1,8 year
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Wood industryWood industryTotal costs of energy supply 200.000 EUR (including water
and wastewater)
Saving potential EUR
1. compressed air system 2.500
2. lighting 2.300
3. peak load management 2.300
4. water management system 1.800
5. reconstruction of steaming unit 19.800
Total 28.700
Potential for 15% economic savings!
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Measures and benefitsMeasures and benefits integral mgmt. of resources (energy, water, raw
materials!) – cleaner production! reducing energy consumption up to 30% best saving measures return investment in 1-2
years less emissions, pollution and environmental
fees better market position compliance with existing/future legislation
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Implementing partnersImplementing partnersNetworking ensures project success:business sector – SMEs, Croatian
Chamber of Commerceconsulting companiesacademic and scientific institutionsfinancing organisations (HEP ESCO,
Environmental and Energy Efficiency Fund)
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CooperationCooperation
EIHPHRVATSKA
GOSPODARSKA KOMORA
Sektor za industriju
HEP grupaHEP ESCO d.o.o.
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For more informationFor more information
www.indigodev.com/Sustain.html www.indigodev.com/Sustain.html
www.rec.org/REC/Programs/itf/Renewables-efficiency_full.html