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Energy Data Management: Case for Industry

Danai Manoli's picture

Innoven helped a recycling facility in Greece to save €15,000 / year and reduce their energy consumption by 6% - all with a single intervention.

With equipment at different stages of their life cycle, different types of machinery, two or three shift days and building additions and retrofits introduced as the plant grows, industrial factories can easily waste energy in a number of ways. In this case, Innoven helped a recycling facility in Greece to save €15,000 / year and reduce their energy consumption by 6% - all with a single intervention.

The client
With an annual energy consumption of 3.8 GWh, a yearly electricity bill exceeding €370,000 and a peak demand of 700 kW, energy efficiency is definitely a priority for this aluminum recycling facility in Voiotia, Greece. The three most energy consuming activities of the facility include the shredding equipment, the melting furnaces and the motor drive controlling air inflow in them, which at the time consumed almost 15% of the daily load.

The challenge
The factory’s management was looking for an integrated solution to monitor, manage and optimize its significant energy consumption, in order to achieve its strategic goal of a more sustainable energy usage. Operating 24/7 also meant that any proposed efficiency interventions would have to have a high reliability and a high Mean Time Between Failures so as not to cancel their savings out.

The solution
To pinpoint and evaluate the most effective solutions, Innoven designed a metering plan and installed several meters to create an accurate consumption profile of the facility and its various components.
Using the Building InSights application, Innoven’s engineers monitored each stage of the recycling process for two months while also logging the technical specifications of the factory’s equipment. After evaluating key energy loads and taking into account equipment upgrade costs, industry process and potential benefits, our engineers proposed an upgrading of the motor drive that controls air flow into the furnaces, as analysis indicated that this intervention would have a relatively low investment cost with quick returns.
More specifically, it was proposed to install a variable speed drive in the motor. The drive offered reduction of active and reactive energy, and reduced the speed of equipment degradation. The result? Energy savings reached 40% at that specific load and 6% of the overall energy use.
In addition, using the Thresholds and Alerts feature of the Building InSights application, our engineers set up real time alerts for the factory managers, in order to get notified about midday peaks so as to handle and reduce peak demand charges.
Currently, Innoven continues to monitor production line loads to identify more opportunities to improve energy efficiency in the factory.

Further details

How was the green solution financed?: 
Would you characterize the green solution as: 
High capital intensive investment (i.e. above €30,000)
Energy consumption description: 
230 MWh/year