Utilisation of waste heat from a concrete block factory

Location: Brovary
Programme: SUDH
Project status: Pre-implementation
Investment: EUR 7 million
Payback period: 3.5 years
Reduced gas consumption: 8.6 mln m3/year


19,000 tonnes/year

The city of Brovary

Brovary is located about 25 km east of Kyiv. The city has an official status as a city of oblast significance. Brovary is home to 108,000 citizens, 6% of the total population of Kyiv oblast. It is the third largest city in Kyiv oblast.

Brovary was selected as a location for the SUDH programme based on an application from the city and its DH company. Read more here.

The Brovary DH company and its long-term strategy

The Brovary DH company (BrovaryTeploVodoEnerhiya) was established in 1991. It is owned by the Brovary community and is subordinated to Brovary City Council. The company provides DH, DHW, water supply and wastewater collection services and is responsible for the maintenance of internal networks.

The DH Company supplies heat to 70,400 people in the city, and almost the entire population (about 98%) are customers; the share of budget institutions is 0.6% and other customers 1.3%. For the last five years, DHW has only been provided during the heating season. This situation is the result of high DHW tariffs, leading customers to start using their own boilers instead.

The long-term strategy for the municipal DH Company in Brovary is to transform the current production-driven DH system into a demand-driven, customer-oriented DH system, providing high-quality heating services to its customers with a reduced environmental impact. To enable such a transformation, the DH company plans to interconnect small DH networks into larger DH systems.

Ultimately, this should lead to the creation of a single citywide heat supply system that provides a DH baseload from more sustainable heat sources. Such heat sources could include waste heat from nearby industries, such as solid waste from the city and region, or renewables, like sustainable biomass, providing a Waste-to-Energy solution. Brovary’s long-term DH strategy also includes restoring year-round DHW supply to all customers, as well as reducing disruptions to the heat supply resulting from malfunctions and accidents at boiler houses or with DH networks.

SUDH project

The SUDH project covers the first steps of the long-term strategy by integrating existing individual DH systems, restoring DHW services and using industrial waste heat resources to provide a baseload heat supply.

The project area covers the central part of the city and is generally limited by the main road and railway.

SUDH project components

Investment Component 1: Using waste heat from the concrete block factory

The use of waste heat from the concrete block factory LLC Orientyr-Budelement to supply baseload throughout the year, including DHW during summer, has been proposed.

The industry produces excess heat in the form of hot condensate, which currently is cooled in cooling towers. The SUDH project proposal includes plans to pump the condensate to the largest boiler house, located at Nezalezhnosti Blvd, 26/1. Heat exchangers will be used to separate the condensate circuit from the DH circuit.

Investment Component 2: Interconnecting existing networks and upgrading CHS

The installation of interconnecting pipes in the central part of the city will link the separate DH networks to make one system. This will provide greater flexibility and increase the capacity for utilising waste heat throughout the year.

The proposed measures will interconnect all the networks in the central part of the city and allow three existing boiler houses to be decommissioned. Combined with the installation of new frequency-controlled pumps, the measures will lead to a future transition to a fully demand-driven system.

Investment Component 3: Installing flue gas condensers at the boiler house at Yaroslava Mudrogo str 96

The installation of flue gas condensers in the boiler house at Yaroslava Mudrogo str 96 to increase the efficiency of the existing gas boilers and utilise the heat from flue gases has been proposed.

The boiler house has three gas boilers, up to two of these are in operation at any time, depending on heat demand. The proposal is to install two flue gas condensers to be used with any two of the three boilers interchangeably.

Investment Component 4: Installing IHS in selected buildings

There are 256 buildings connected directly to the main pipes (not after CHS). About 90 of them are blocks of flats with more than nine storeys. The introduction of IHS in these buildings would bring two benefits:

  1. Bring the system closer to being fully demand-driven, which would provide electricity savings.
  2. Enable a reduction in the static pressure across the whole system. Using IHS with heat exchangers for the space-heating systems will make the systems in the buildings independent of the external DH network.

Table: Estimated savings per year

Investment component Gas savings, 1,000 m3 Electricity savings, MWh CO2 savings, tonnes
Waste heat 3,856 -734 6,912
Interconnection+CHS 2,309 2,451 6,452
FGC 457 -130 784
IHS 2,026 972 4,718
Total 8,648 2,559 18,867

Positive impact

The proposed investment project will contribute to improving the environmental situation in Brovary. The use of waste heat and installation of modern and efficient equipment will lead to considerable savings of gas and electricity and thereby reduce carbon dioxide and nitrogen oxide emissions.

The social benefits will include improvements in quality and reliability of DH and DHW services for the population.

The proposed investment project will benefit about 60,000 citizens in Brovary.

Financing the project

The project will be financed in accordance with the conditions of the SUDH programme:

  • EUR 5 million loan from Nefco;
  • EUR 1.5 million grant from Sweden;
  • EUR 860,000 contribution from Brovary.

With estimated yearly savings of 2 MEUR from implementing the project, the expected payback for the investment is just 3.5 years.

Current status

The feasibility study has been approved by the Nefco Board of Directors, as well as by Brovary DH Company and Brovary City Council. The city council will now consider the issue of a municipal guarantee to secure the Nefco loan to the DH Company for the implementation of the SUDH project. The municipal guarantee must then be approved by the Ministry of Finance of Ukraine and the Anti-Monopoly Committee of Ukraine, after which Nefco, BrovaryTeploVodoEnerhiya and Brovary City Council will be able to sign the relevant legal agreements for the project’s financing, allowing the implementation phase to begin.