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How to reduce the operating costs of industrial installations?

Energy savings allow companies to increase their competitiveness and create new room for manoeuvre. The potential for savings is often poorly exploited, while the gains to be made are rapid and significant.
Auditing, measuring and analysing the consumption of utilities (steam, fuel, electricity, cooling and air) is an essential step in order to optimise costs.

The weight energy consumption in industry

The weight energy consumption in industry

The industrial sector is the world's largest consumer of energy resources. It accounts for 37% of global final energy consumption. This consumption is expected to increase by 1.2% annually by 2025 at a cost of 700 billions of dollars.

Every company manager seeks to optimize his processes in order to minimize his financial losses.
What are the main energy consuming sources in the industrial sector?

 

 

The main sources of energy loss in industry

Inadequate use of utilities leads to over-consumption, reduced equipment availability and production capacity, increased excessive heat, breakdowns and curative maintenance.
The same applies to networks: poor management leads to higher costs, inadequate energy supply, inadequate electricity distribution and consequently lower energy efficiency.
As a result, energies are neither valorised nor redirected in an optimal way within the company. This results in a reduction in the life span of the production tool, an extension of the effective working time and a decrease in product quality and yield.

Best practices for optimizing operating costs in industry

A large proportion of energy losses in industry concerns utilities (steam, fuel, electricity, electricity, refrigeration and air): inaccurate or non-existent measurement of the process, failure to detect anomalies, insufficient or non-existent recovery, etc.
The reduction of utility costs requires the ability to measure, visualize and monitor consumption.

The virtuous circle of energy optimisation

The virtuous circle of energy optimisation

  1. Energy audit of the installation: inventory of the industrial site, setting of energy and financial savings objectives
  2. Measure the energies consumed: in particular the utilities (steam, fuel, electricity, cold and air)
  3. Set up a monitoring of the constants and analyse the data collected
  4. Optimization of energy efficiency: Implement corrective actions, reinforce existing good practices
  5. Service and metrology: measuring the results of the actions implemented

 

The importance of utility measurement

A precise analysis of consumption associated with relevant actions makes it possible to optimize utilities as follows

steam

The measurement of saturated or superheated steam, the pressure and/or temperature corrected flow rate is essential in industrial sectors such as food processing, chemistry-petrochemistry or energy.
It allows:

  • Reduction of leaks
  • Improved purging
  • Isolation of out-of-service networks
  • Maintenance of purge system
  • Improved control and use
  • Reduced heat losses

fuel

In the majority of industrial companies, gas and fuel oil are used to produce heat in processes. Hydrocarbons are used as raw materials, particularly in the chemical-petrochemical industry.
Proper measurement of fuels allows:

  • Optimization of combustion
  • Precise calculation of returns
  • Increased monitoring of consumption

Electricity

Whatever the sector of activity, electricity is probably the most essential utility for the operation of your production equipment.
Its optimization allows:

  • Improvement of network settings
  • Load distribution
  • Optimisation of sources of consumption
  • Modernisation of equipment, motors, inverters, etc.

cold

Although the food industry is the main consumer of energy for cold chain conservation, other sectors such as pharmaceuticals and chemicals also use it (process cooling systems, data centres, public buildings, etc.)
Accurate measurement of cold consumption allows:

  • monitor of clogging
  • monitor of thermal exchange
  • monitor the COP (coefficient of performance)
  • optimize process performance

Air

11% of the electricity production for industry is dedicated to the manufacture of compressed air. For these industries, relevant management of the compressed air networks is essential.
Collecting, analysing and exploiting precise data on these consumptions, choosing and implementing relevant performance indicators can generate between 15 and 30% gains by:

  • Monitoring leaks
  • Optimisation air network maintenance (monitoring level of clogging of the filters, etc.)
  • Maintenance of the lowest possible pressure level

Saving and optimizing energy consumption is finally within the reach of every industrial company. All that is required is to put in place the right procedures and use the right measuring instruments.

Fuji Electric France can help you to install monitoring systems that will effectively measure and collect energy usage data. Our solutions are based on normative guidelines (ISO 5167, MID, ISO 50001, etc.).

To implement these processes in your industry, do not hesitate to download our detailed catalogue:

energy optimisation catalogue
 

Download the catalogue


Contact our energy metering experts now to help you audit, measure and analyse your utility consumption!