My presentation about energy efficiency in industry held at the workshop "Energy efficiency: where will it lead us" at the British embassy in Roma on 26 March 2014. Topics: statistics, comparison with energy efficiency gains and white certificates in industry, discounts for energy intensive industries, energy management systems, energy managers, international standards.
19. www.fire-italia.org
FIRE
The Italian Federation for the Rational use of Energy is a no-profit
association that promotes energy efficiency, supporting energy manager,
ESCOs and other companies dealing with energy.
!
Besides the activities directed to its nearly 500 members, FIRE operates
under an implementing agreement with the Ministry of Economic
Development to manage the Italian energy manager network since 1992.
!
In order to promote energy efficiency FIRE cooperates and deals with
public authorities, energy technology and service companies, consultants,
medium and large consumers, universities and associations to promote
best practices and improve the legislation.
www.fire-italia.org
EGE certification
Energy Management Experts
UNI CEI 11339
www.secem.eu Gestione Energia magazine
20. www.fire-italia.org
FIRE activities and projects
Besides to dedicated meetings, FIRE organizes the Enermanagement
conference, workshops, and training courses. It implements dissemination
campaigns, surveys, market analysis and studies.
Among the subjects with which FIRE has cooperated there are ENEA (national
energy agency), GSE (manager of incentive mechanisms), RSE, large
companies, universities, associations, agencies and trade fairs organizers.
www.hreii.eu/demo
www.esd-ca.eu
Among completed projects:
- www.soltec-project.eu
- www.enforce-een.eu
- www.ener-supply.eu
- www.e-quem.enea.it
- www.eu-greenlight.org
- Eurocontract
Whaves
Starting soon!
Enspol
Starting soon!
SME energy
check-up
Starting soon!
21. www.fire-italia.org
Framework
Energy managers
Tools for EE
Final energy consumption in industry
!4
!!!!! !1.000!! !2.000!! !3.000!! !4.000!! !5.000!! !6.000!! !7.000!! !8.000!!
Metallurgy!
Mechanical!
Chemical!
Construcon!materials!
Food!and!tobacco!
Paper!and!prinng!
Glass!and!ceramics!
Texles!and!clothing!
Other!manufacturing!
Petrolchemical!
Non!metalliferous!minerals!
Construcon!industry!
Mining!and!extracve!industry!
ktoe%%
Industrial%final%energy%consump5on%
Total%final%consump5on:%30.2%Mtoe%
Source:!FIRE!on!MSE!data!
22. www.fire-italia.org
Framework
Energy managers
Tools for EE
Final energy consumption in industry
!5
23,6%
13,3%
12,5%11,6%
9,0%
8,6%
7,8%
4,0%
3,2%
2,9% 2,5%
1%
0,4%
Industrial+final+energy+consump4on+
Total+final+consump4on:+30.2+Mtoe+
Metallurgy
Mechanical
Chemical
Construc?onmaterials
Foodandtobacco
Paperandprin?ng
Glassandceramics
Tex?lesandclothing
Othermanufacturing
Petrolchemical
Nonmetalliferousminerals
Construc?onindustry
Miningandextrac?veindustry
Source:FIREon
MSEdata
23. www.fire-italia.org
Framework
Energy managers
Tools for EE
Source: RAEE 2011 ENEA.
But only some sectors improved their energy efficiency
!6
RAEE 2011 – Executive Summary
Figura 8 - Efficienza energetica nell’industria manifatturiera (1990=100)
Fonte: elaborazione ENEA su dati MSE (ODYSSEE)
50
60
70
80
90
100
110
120
130
140
150
160
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
industria manifatturiera Siderurgia Metalli non ferrosi Meccanica
Alimentare Tessile Minerali non metalliferi cemento
Chimica Carta
Best performance for the chemical and steel sectors.
24. www.fire-italia.org
Framework
Energy managers
Tools for EE
White certificates and energy efficiency in industry: 2005-2012
!7
Source: FIRE on data from ENEA.
STEEL%
METALLURGICAL%
PETROCHEMICAL%
PHARMACEUTICAL%
CHEMISTRY%
BUILDING%MATERIALS%
AGRO4FOOD%
ENERGY%/%SERVICES%/%
WASTE%TREATMENT%
RESIDENTIAL%
COMMERCIAL%
GLASS%
PAPER%AND%PRINTING% ICT%
AUTOMOTIVE%
MECHANICS%WOOD%
TEXTILE%AND%
TANNING%
Sector'breakdown'for'number'of'PPPMs'
www.fire4italia.org%
25. www.fire-italia.org
Framework
Energy managers
Tools for EE
Final energy consumption in industry
!8
0,0#
1,0#
2,0#
3,0#
4,0#
5,0#
6,0#
7,0#
Chemical#
Construc9on#industry#
Construc9on#materials#
Food#and#tobacco#
Glass#and#ceramics#
Mechanical#
Metallurgy#
Mining#and#extrac9ve#
industry#
Non#metalliferous#minerals#
Other#manufacturing#
Paper#and#prin9ng#
Petrolchemical#
Tex9les#and#clothing#
Heat%to%electricity%ra,o%
Source:#FIRE#on#MSE#data#
26. www.fire-italia.org
Framework
Energy managers
Tools for EE
Source: H-Reii project.
The importance of heat recovery: Hreii project estimated potential
!9
7
catalyze investment in the energy efficiency market, helping to reach the objective of 20% reduction in energy
consumption. The figure 3 depicts the priority in the utilization of waste heat recovery. Moreover, during the
energy audit, special attention should be placed in the gas cooling - often compulsory before the waste gas
treatment – as it is possible to put heat exchanger(s) and a Rankine cycle instead of adding air to cool down.
This way, the electricity consumption of the waste treatment can be covered.
Figure 3: Waste heat recovery priority
8 M. Lowe, G. Gereffi, Recycling Industrial Waste Energy, Chapter 7. Report prepared for the Environmental Defense Fund (EDF),
Center on Globalization, Governance Competitiveness (CGGC), Duke University, 2009
Legend:
DHW: Domestic Hot Water
ORC: Organic Rankine Cycle
Typical cement production plants have a production capacity between 2.000 and 8.000 10 kg per day, with
energy consumption ranging from 3,5 to 5 GJ/103
kg of clinker produced (10–15% in the form of electricity).
The cement production process involves lime decarbonizing reactions (endothermic) and requires great amounts
of heat and high temperatures to take place.
The temperature of the gaseous sources after the internal use in the process (available for the recovery of heat) is
relatively low (about 250 - 350 ° C). The unused heat supplied for these reactions can be found in the
combustion gas – or kiln gas – (after the raw material pre-heating) and in the clinker cooler air flow. These flows
could, via thermal oil heat recovery circuits, be the heat sources feeding the ORC to generate power.
Gas from the kiln are characterized by a substantial content of dust (typically 10 to 50 g/Nm3
) nevertheless
several applications of heat recovery – with both steam turbine and ORC technology – in cement industry are
currently working: a clear proof of the feasibility of heat recovery.
Recovery potential of the cement industry in Italy
POTENTIALITY
plants to install (estimation) n 25
power to install MWelectric 30,3
energy to produce MWhelectric/year 196.950
ENVIRONMENTAL IMPACT
CO2 emissions avoided 10
3
kg/year 125.260
Electric energy saved MWhelectric/year 196.950
Primary energy saved toe/year 36.830
The estimation of the potential is still on going for non ferrous materials, oilgas, etc. The cumulative potential
of electricity generation from waste heat for the iron and steel, cement and glass, with an average value of 6.500
h/y at rated power, is estimated in over 800 GWhelectric/year (Figure 4) and the associated greenhouse gas savings
in 500.000*103
kgCO2/year (Figure 5).
Turboden s.r.l.
via Cernaia,10 25124 Brescia Italy
t. +390303552001 f. +390303552011
info@turboden.it www.turboden.it
C.F./P.I. 02582620981 capitale sociale Euro 1.800.000,00 i.v.
registro delle imprese C.C.I.A.A. di Brescia REA 461817
0
200.000
400.000
600.000
800.000
1.000.000
1.200.000
Glass
Cement Steel
Total
MWhelectric/year
Energy production
MIN MWh electric/year
MAX MWh electric/year
Turboden s.r.l.
via Cernaia,10 25124 Brescia Italy
t. +390303552001 f. +390303552011
info@turboden.it www.turboden.it
C.F./P.I. 02582620981 capitale sociale Euro 1.800.000,00 i.v.
registro delle imprese C.C.I.A.A. di Brescia REA 461817
0
200.000
400.000
600.000
800.000
1.000.000
1.200.000
Glass
Cement Steel
Total
MWhelectric/year
Energy production
MIN MWh electric/year
MAX MWh electric/year
Recovery potential of the cement industry in Italy
POTENTIALITY
plants to install (estimation) n 25
power to install MWelectric 30,3
energy to produce MWhelectric/year 196.950
ENVIRONMENTAL IMPACT
CO2 emissions avoided 10
3
kg/year 125.260
Electric energy saved MWhelectric/year 196.950
Primary energy saved toe/year 36.830
The estimation of the potential is still on going for non ferrous m
of electricity generation from waste heat for the iron and steel, c
h/y at rated power, is estimated in over 800 GWhelectric/year (Fig
in 500.000*103
kgCO2/year (Figure 5).
Figure 4 Italian potential of electricity generation from heat rec
Figure 5 Italian potential of CO savings due to electricity gene
via Cer
t. +39030
info@
C.F./P.I. 02582620981
registro delle impr
0
200.000
400.000
600.000
800.000
1.000.000
1.200.000
Glass
Cement Steel
Total
MWhelectric/year
Energy production
MIN MWh electric/year
MAX MWh electric/year
0
100.000
200.000
300.000
400.000
500.000
600.000
700.000
glass
cement
steel
103kg/year
CO2 saved
CO2 saved MIN
10^3kg/year
CO2 saved MAX
10^3kg/year
via Ce
t. +3903
info@
C.F./P.I. 0258262098
registro delle im
0
200.000
400.000
600.000
800.000
1.000.000
1.200.000
Glass
Cement Steel
Total
MWhelectric/year
Energy production
MIN MWh electric/year
MAX MWh electric/year
0
100.000
200.000
300.000
400.000
500.000
600.000
700.000
glass
cement
steel
Total
103kg/year
CO2 saved
CO2 saved MIN
10^3kg/year
CO2 saved MAX
10^3kg/year
27. www.fire-italia.org
Framework
Energy managers
Tools for EE
Even energy intensive sectors have non energy intensive users
!10
L'importanza dei dati…Distribuzione dell'incidenza dei Costi
Energetici sul fatturato delle Imprese Chimiche
Incidenza %
Costo Energia/
Fatturato
Incidenza
sul Fatturato
Incidenza sul
Fatturato al netto
rivendita prodotti
(20%)
6,4 8,0
Frequenza
Energy cost intensity in the chemical sector. Source: Federchimica.
Energy cost
intensity
Energy cost
intensity not
considering the
supply of energy
products
Energy cost
intensity
Frequency
28. www.fire-italia.org
Framework
Energy managers
Tools for EE
Energy is usually not the core business…
Low impact of energy costs on turnover of most of the companies.
!11
(Fonte: http://trend.cestec.eu)
Energy costs are
usually among 2-6%
of the turnover.
In Italy almost
3,000 industries are
in the energy intensive
list VS 425,000
companies in the
manufacturing
industry
29. www.fire-italia.org
Framework
Energy managers
Tools for EE
Discounts for energy intensive industries
!12
In Germany the “discount” for the energy intensive industry is:
53 €/MWh EEG levy exemption for ISO 50001 or EMAS organizations;
20,5 €/MWh electricity tax exemption for a list of energy intensive
companies plus ISO 50001 (audit for SMEs) and voluntary CO2 reduction
targets.
A much higher discount, but at least not given for free.
Requirements in Italy to access the discount:
2.4 GWh energy consumption;
energy cost intensity over 3%.
30. www.fire-italia.org
Framework
Energy managers
Tools for EE
Energy management system around the World
According to the result of a DIN survey on the implementation ISO
50001 certified energy management systems, there were in February
2014 more then 3,100 certified organizations and over 6,600 certified
sites.
!
!
!
!
!
!
!
!
!
The results in Italy are far from the German ones, but it should be also
considered the absence of incentives so far.
!13
!3.063!!
!937!!
!407!!
!338!!
!220!!
!198!!
!190!!
!138!!
!121!!
!107!!
!103!!
!91!!
!714!!
ISO$50001$cer+fied$sites$
February$2014$8$Source:$FIRE$based$on$DIN$data.$
Germany!
France!
Netherlands!
UK!
Italy!
Spain!
Sweden!
India!
Korea!
Turkey!
Taiwan!
Ireland!
www.fireGitalia.org!www.fireGitalia.org!
!1.640!!
!183!!
!154!!
!99!!
!85!!
!78!!
!73!!
!70!!
!68!!
!64!!
!57!!
!43!!
!508!!
ISO$50001$cer+fied$organiza+ons$
February$2014$;$Source:$FIRE$based$on$DIN$data.$
Germany!
Italy!
Spain!
India!
Sweden!
Turkey!
Taiwan!
UK!
France!
Austria!
Denmark!
Ireland!
Altri!www.fireFitalia.org!
31. www.fire-italia.org
Framework
Energy managers
Tools for EE
A lot of available projects with a good ROI
Examples extracted from enterprises in the chemical and the paper sectors.
!14
www.fire-italia.org
Premessa
Il sistema
L’efficienza
Strumenti
Interventi
Audit e Costi
Comunicazione
Unità di misura
130
Un’industria chimica. Fonte: Armstrong.
Individuazione degli interventi
“Expect many enjoyable experiences!”
David M. Armstrong
“Expect many enjoyable experiences!”
David M. Armstrong
3,0%
%diRisparmiosulbudgetAnnuodivapore
2,5%
2,0%
1,5%
1,0%
0,5%
0,0%
0 0,5 1 1,5 2 2,5 3 3,5
Tempi di Ammortamento (Anni)
Sintesi delle potenziali ottimizzazioni
6
Economizzatore
Acqua d'alimento
Recuperi di Calore
Progetti avanzati
alto livello d'Ingegnerizzazione
Investimenti Richiesti Alti
Progetti semplici
basso livello d'Ingegnerizzazione
Investimenti Richiesti Bassi
Riduzione BD
Perdite Vapore Varie
Coibentazione
Livelli Pressione
Scaricatori in perdita
Recupero Calore
da BD
Recupero vapori
di Flash
Condensazione
dei Vent
Controllo Automatico
Ossigeno
Recupero della Condensa
Progetti standard
Medio livello d'Ingegnerizzazione
Investimenti Richiesti Medi
Economizzatori
a condensazione
Caldaie in stand-by
Energy efficiency means three
actions:
avoiding losses and waste of energy;
using energy efficiency technologies;
adopting renewable energy sources.
32. www.fire-italia.org
Framework
Energy managers
Tools for EE
Source: Politecnico di Milano and ENEL Foundation.
And this is confirmed for horizontal technologies
!15
High penetration rate
Low penetration rate
Interesting
investment
Not interesting
investment
The
blue labels
are for the
industry
34. www.fire-italia.org
Framework
Energy managers
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Energy management issues
!17
The energy manager is a key figure for
managing energy efficiently in a company or an
institution. Until a few years ago these were the
typical problems to be faced... No energy policy
in the company
Lack of
management
There is no
energy manager
Lack of money or
other resources
Issue “0”
Issue 1
Issue 2
Issue 3
Source: FIRE.
35. www.fire-italia.org
Framework
Energy managers
Tools for EE
Energy manager: the origin and the Italian mandatory approach
The figure of the energy manager was born in the industry sector in the
the seventies, at the time of the first oil crisis.
!
Law 373/1977 is the first example of a national public regulation on
energy efficiency, integrated and followed by law 9 and 10 of 1991 and
the strong flow of new European regulations.
!
In the eighties the first voluntary associations were born:
AIGE (Italian Association of Energy managers)
The Energy Manager Club (EMC) for the State-owned industries
!
Law 308/1982 established the obligation for all industrial enterprises
with a consumption over 10.000 toe/year and with over 1.000
employees to appoint a person “in charge for the rational use of
energy”.
!
In 1987 AIGE and EMC merged in FIRE as founder members, together
with ENEA. !18
36. www.fire-italia.org
Framework
Energy managers
Tools for EE
The evolution of the role of the energy manager
Law 10/1991 extended the mandatory requirements appointment of
such “technician” (energy manager) to all the industrial enterprises over
10.000 toe/year and for the organizations of civil (residential and
services) and transportation sectors over 1.000 toe/year.
!
According to law 10/1991 the tasks of the energy manager are:
• identify actions, measures, procedures and whatever else is
needed to promote the rational use of energy;
• ensure the preparation of energy balances also in accord to the
economic parameters and the final energy uses;
• prepare energy data to verify the measures implemented with the
contribution of the State.
!
This role evolved with the opening of the energy markets, the
continuing evolution of the legislation on various levels (European,
national, local), technical standards and harmonized standards,
contracts increasingly complex (Energy performance contract, etc.),
markets increasingly competitive, the international context.
!19
37. www.fire-italia.org
Framework
Energy managers
Tools for EE
Energy manager: the Italian mandatory approach
These are the appointed energy managers according to the law 10/91,
whose obligation is unfortunately largely ignored by the public
administration.
!20
SECTORS SUBSECTORS)AND)NOTES EM))
Agriculture!(of!which!35!are!!land!reclamation!authorities) 41))))))))))))))))
Industria 587))))))))))))))
Extraction*of*minerals*from*quarries*and*mines 5******************
Manufacturing*activities 406**************
Supply*of*electricity,*gas,*steam*and*air*conditioning 94****************
Supply*of*water,*sewerage*networks,*management*activities*of*waste*rehabilitation 78****************
Constructions 4******************
Transport!(of!which!70!publicly!owned) 324))))))))))))))
Pubblic)Sector!(ministries,!central!government,!regions,!local!authorities,!etc.)! 144))))))))))))))
P.S.)enlarged 143))))))))))))))
Healthcar 110**************
University 19****************
Research 9******************
Territorial*utilities 5******************
Private)tertiary 223))))))))))))))
Energy)service 69))))))))))))))))
TOTAL)APPOINTED)E.M. 1.531)))))))))))
Energy)manager)(EM))appointed)in)2013)in)accordance)with)article)19)of)the)law)10/91
Source:!FIRE!data.!For!further!information:!www.fireEitalia.org
Note about appointments and appointed: the table shows only the data on obliged parties who have appointed an
energy manager according to the law, does not take into account any energy manager of multisite venues (399 local
EM), nominations received beyond the statutory deadline (143 EM, 17 local EM) and those from nonPobligated
parties*(530*EM,*102**local*EM).
38. www.fire-italia.org
Framework
Energy managers
Tools for EE
The work of the energy manager
FIRE periodically makes surveys on energy managers. Those are the
results on the typical efficiency/renewables measures implemented
according to the 2013 survey:
!
!21
led lighting, heat recovery, free cooling, HVAC with heat recovery,
condensing boilers, power factor correction, solar cooling, high
efficiency electric motors and variable speed drivers, piping
insulation, combined beat and power, trigeneration solar PV, use
of biomass, compressed air, UPS, energy distribution, macchine
ventilanti, optimization of wells water extraction, efficiency of the
production process (iron steel, cement, glass), heat pumps,
industrial automation, smart motor management, behavioral
change programs, measures on buildings envelope, energy
recovery on elevators, efficient lighting, energy management
software, fuel efficiency, building automation, data center
efficiency, ground water source heat pumps, recycle of scraps.
39. www.fire-italia.org
Framework
Energy managers
Tools for EE
SECEM: the first accredited body for the UNI CEI 11339 standard
The first body to be accredited to release a third party certification for energy
management experts was SECEM (within FIRE).
Since then other two bodies have been accredited by Accredia.
!
!
!
!
!
!
!
!
!
!
!
!
!
!
www.secem.eu
!22
30/05/13 11:17Home
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CERTIFICAZIONE
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BANDI E PROGRAMMI
DEGLI ESAMI
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ELENCO PROVE
D'ESAME
Sessione aprile 2013
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Pubblicata la nuova revisione del
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2013-05-08 Italian 293.9 KB 242
relativo alla sessione d'esame del 25 giugno 2013.
Pubblicato il Decreto Legislativo relativo al sistema
nazionale di certificazione delle competenze
Entra in vigore il 2 marzo 2013 il Decreto Legislativo n. 13/2013 (G.U. n. 39 del 15
febbraio 2013) che - in attuazione dell'articolo 4, commi 58 e 68, della Legge Fornero (L.
n. 92/2012) - disciplina l'attività di individuazione, validazione e certificazione delle
competenze acquisite dalla persona in contesti non formali e informali, ossia durante la
sua storia di vita, di studio e di lavoro.
Il provvedimento individua nei Ministeri dell'Istruzione, dell'Università e della Ricerca, del
Lavoro e delle Politiche sociali e dello Sviluppo economico e nelle Regioni, gli enti
pubblici titolari a regolamentare i servizi di individuazione, validazione e certificazione
delle competenze, e individua negli enti titolati i soggetti pubblici o privati che possono
erogare tali servizi.
E' specificato all'articolo 4, comma 5, che tali enti, nel caso in cui eroghino il servizio di
certificazione delle competenze in conformità alle norme tecniche UNI, dovranno essere in
possesso dell'accreditamento rilasciato da ACCREDIA.
Saranno oggetto di certificazione unicamente le competenze riferite a qualificazioni
ricomprese in un repertorio nazionale costituito da tutti i repertori codificati a livello
nazionale e regionale pubblicamente riconosciuti.
SECEM rientra tra i soggetti privati (ente titolato) che possono erogare tali servizi, come
definito dall'art. 2 comma 1) lettera g.
Questo provvedimento, che segue la Legge 4/2013 sulle professioni non organizzate,
apre la possibilità ad eventuali accordi di SECEM con tutti gli enti pubblici titolari.
Riconoscimento delle professioni non regolamentate
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40. www.fire-italia.org
Framework
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Directives and technical standards
!23Source: E. Piantoni revised by FIRE
Directive
2009/72/EU
E. Energy
Directive
2009/73//EU
Nat. Gas
Directive
2006/32/EU
E. Efficiency
Directive
2012//27/EU
E. Efficiency
Energy
Efficiency
Directive
2004/8/EU
Cogeneration
Directive
2009/28/EU
RED
Market
Liberalization
Directive
2009/125/EU
Ecodesign
Directive
2010/31/EU
Building
Energy
PerformanceClimate and
Energy
Package
20-20-20
Directive
2010//30/EU
Energy
labelling
ISO 14001
Environmental
Management
System
EN 16001
Energy
Management
Systems
EN 15900
Energy
Efficiency
Services
ISO 50001
Energy
Management
Systems
EN 16247
Energy Audit
EN 16231
Energy
Benchmarking
EN 16212
Energy Saving
Calculation
EN 16235
Guarantees of
origin for
electricity
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Building
efficiency
Renewable
Energy
Directive
2004/18/EU
Public
Procurement
Directive
2004/17/EU
Public
Procurement
Italian !
standards
UNI CEI 11339!
EGE
UNI CEI 11352!
ESCO
41. www.fire-italia.org
Framework
Energy managers
Tools for EE
Energy management issues: solved?
!24
The energy manager is a key figure for
managing energy efficiently in a company or an
institution. Until a few years ago these were the
typical problems to be faced... No energy policy
in the company
Lack of
management
There is no
energy manager
Lack of money or
other resources
Issue “0”
Issue 1
Issue 2
Issue 3
ISO 50001
ISO 50001
Business
models
ISO 50001
Source: FIRE.
42. www.fire-italia.org
Abbreviation list
DSO: Distribution System Organisation
ENEA: Italian National Agency for New Technologies, Energy and
Sustainable Economic Development.
CEI: Italian electrical standardization body
EN: European technical standard
ESCO: Energy Service Company
FIRE: Italian Federation for Rational use of Energy
GME: Electric Market Manager
GSE: Energy Service Manager
RSE: Research on Electric System
SSE: Energy service provider company
toe: ton of oil equivalent
UNI: Italian standardization body
WhC: White Certificate