Energy Efficiency in Industry and Technology
Energy efficiency measures and renewable energy applications implemented in industrial facilities can reduce operating costs, as energy is one of the most significant cost items for such facilities. Today, energy efficiency is becoming increasingly important both for reducing costs and improving environmental performance.
Industrial processes that use energy vary depending on the equipment and production lines required. Some processes use large amounts of heat, while others consume large amounts of electricity. In processes involving substantial heat transfer, insulation measures are particularly important. Where electricity consumption is high, energy efficiency measures should be tailored to the specific process components that consume electricity.
In some forms of production, different processes, such as baking, shaping and drying or melting, moulding, rolling and annealing, must be carried out sequentially to produce a single product. In others, similar steps are repeated across different production lines. Some processes, such as those in the glass and paper industries, involve continuous production or integrated production lines. Regardless of the production method, energy efficiency analysis should first consider the process as a whole and then assess each stage of the process separately.
Any energy efficiency opportunity identified at a particular stage of the production chain should be assessed by considering its effects on the entire chain. Where an improvement to a particular workstation, point, area or production line would cause disruption, reduce efficiency or otherwise negatively affect overall production, the opportunity should be disregarded. However, such situations are not generally common.
Evaluating a process from an energy efficiency perspective requires both expertise in energy and detailed knowledge of the process. Where possible, these analyses should be carried out by individuals who are competent in both areas. The sectoral energy audit guides developed by EVÇED are also recommended as a reference for these assessments.
Another important consideration is to assess the process together with the condition of auxiliary systems, including steam, fans, pumps, compressed air, motors and electrical systems. For example, the effects of proposed changes to steam or compressed air systems and distribution lines on the relevant process or processes should be examined. Similarly, the potential effects of an investment in process improvement on auxiliary systems should also be assessed.
Establishing an ISO 50001 Energy Management System within an organisation is critical for carrying out these analyses effectively and identifying potential areas for efficiency improvement. Analysing processes according to their energy loads within the framework of the Pareto principle is a useful approach for identifying priority areas for intervention.
Establishing the correlation between energy loads and production volumes, preferably using historical data covering an extended period, and carrying out single or multiple regression analyses can support the proper design of the initial steps. Ranking the efficiency opportunities identified through technical analyses according to the added value they are expected to create helps maintain a balance between potential savings and investment costs.
The specific measures required to improve energy efficiency in a process may vary depending on the type of process and the range of products. In some cases, the nature of the process may not allow production to be stopped or reduced.
Nevertheless, an Energy Management System developed within the framework of ISO 50001 can align production planning with energy management and support the continuous consideration of energy efficiency.
In some forms of production, different processes, such as baking, shaping and drying or melting, moulding, rolling and annealing, must be carried out sequentially to produce a single product. In others, similar steps are repeated across different production lines. Some processes, such as those in the glass and paper industries, involve continuous production or integrated production lines. Regardless of the production method, energy efficiency analysis should first consider the process as a whole and then assess each stage of the process separately.
Any energy efficiency opportunity identified at a particular stage of the production chain should be assessed by considering its effects on the entire chain. Where an improvement to a particular workstation, point, area or production line would cause disruption, reduce efficiency or otherwise negatively affect overall production, the opportunity should be disregarded. However, such situations are not generally common.
Evaluating a process from an energy efficiency perspective requires both expertise in energy and detailed knowledge of the process. Where possible, these analyses should be carried out by individuals who are competent in both areas. The sectoral energy audit guides developed by EVÇED are also recommended as a reference for these assessments.
Another important consideration is to assess the process together with the condition of auxiliary systems, including steam, fans, pumps, compressed air, motors and electrical systems. For example, the effects of proposed changes to steam or compressed air systems and distribution lines on the relevant process or processes should be examined. Similarly, the potential effects of an investment in process improvement on auxiliary systems should also be assessed.
Establishing an ISO 50001 Energy Management System within an organisation is critical for carrying out these analyses effectively and identifying potential areas for efficiency improvement. Analysing processes according to their energy loads within the framework of the Pareto principle is a useful approach for identifying priority areas for intervention.
Establishing the correlation between energy loads and production volumes, preferably using historical data covering an extended period, and carrying out single or multiple regression analyses can support the proper design of the initial steps. Ranking the efficiency opportunities identified through technical analyses according to the added value they are expected to create helps maintain a balance between potential savings and investment costs.
The specific measures required to improve energy efficiency in a process may vary depending on the type of process and the range of products. In some cases, the nature of the process may not allow production to be stopped or reduced.
Nevertheless, an Energy Management System developed within the framework of ISO 50001 can align production planning with energy management and support the continuous consideration of energy efficiency.
Steam is, by its nature, a highly flexible energy transfer medium that can be used both for process heating and power generation. For this reason, it is widely used in industry. Data indicate that average steam energy use in industry may account for 35–40% of a facility’s total energy consumption. It is therefore very important to optimise these systems and minimise operating costs.
Energy efficiency in industrial steam systems depends on pressure levels, the amount of steam used, the processes that use steam, such as heating, separation and drying, and the source of energy generation.
Energy efficiency in industrial steam systems depends on pressure levels, the amount of steam used, the processes that use steam, such as heating, separation and drying, and the source of energy generation.
In simple terms, fans are devices that create a pressure difference to enable airflow. The blades, which are the moving components of a fan, perform work on the air and provide it with static and kinetic energy. The ratio between the static and kinetic energy transferred to the air depends on the characteristics of the fan.
Fans are widely used in industry and consume significant amounts of energy. Motor systems account for 70% of electricity consumption in industrial facilities. Although fan system efficiency may reach 79% or more, it often falls below 50% and may even decrease to 15–20%. Assessing and optimising the performance of fan systems therefore offers significant energy efficiency opportunities.
Fans are widely used in industry and consume significant amounts of energy. Motor systems account for 70% of electricity consumption in industrial facilities. Although fan system efficiency may reach 79% or more, it often falls below 50% and may even decrease to 15–20%. Assessing and optimising the performance of fan systems therefore offers significant energy efficiency opportunities.
Pumps are used to transfer water and other liquids from one location to another. Research conducted by the European Commission has shown that pumping systems account for approximately 22% of global energy demand from electric motors.
Operating pumping systems at flow rates or heads higher than required causes inefficiency. The high energy consumption of pumping systems also means that they offer significant opportunities for improving energy efficiency.
Air compressors are machines that increase the pressure of air drawn from the atmosphere by compressing it. The air is compressed to a pressure above ambient or atmospheric pressure. The pressurised air is then transported through a distribution system consisting of pipework, and part of the energy used to compress the air is recovered to perform useful work.
Compressed air systems may operate inefficiently due to excessively high operating pressure, leaks, open drip legs and condensate drains, restricted pipework, unrecoverable pressure losses in filters and other components, and inefficient compressor control.
To optimise the performance of compressed air systems, it is necessary to understand how the system meets production related air demand, how waste can be prevented, how compressed air energy storage can be applied and how compressor control can be optimised.