Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation

Industrial water circuits (IWC) are frequently neglected as they are auxiliary circuits of industrial processes, leading to a missing awareness of their energy- and water-saving potential. Industrial sectors such as steel, chemicals, paper and food processing are notable in their water-related energ...

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Bibliographic Details
Published inEnergies (Basel) Vol. 12; no. 2; p. 223
Main Authors Iten, Muriel, Oliveira, Miguel, Costa, Diogo, Michels, Jochen
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 11.01.2019
Subjects
Air flow
Billets
Case studies
Circuits
Cold
Cooling
Cooling rate
Cooling towers
Economic analysis
Energy conservation
Energy consumption
Energy efficiency
Energy management
Energy requirements
Flow velocity
Flowmeters
Food processing
Food processing industry
Industrial water
industry
Microprocessors
Noise reduction
Object-oriented languages
OpenModelica
optimisation
Pipes
Power management
Process controls
Resistance thermometers
Signal processing
Steel
Temperature probes
Temperature sensors
water circuits
Water circulation
Water conservation
Water consumption
Water treatment
United Kingdom > UK
Portugal
Germany
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Summary:Industrial water circuits (IWC) are frequently neglected as they are auxiliary circuits of industrial processes, leading to a missing awareness of their energy- and water-saving potential. Industrial sectors such as steel, chemicals, paper and food processing are notable in their water-related energy requirements. Improvement of energy efficiency in industrial processes saves resources and reduces manufacturing costs. The paper presents a cooling IWC of a steel wire processing plant in which steel billets are transformed into wire. The circuit was built in object-oriented language in OpenModelica and validated with real plant data. Several improvement measures have been identified and an optimisation methodology has been proposed. A techno-economic analysis has been carried out to estimate the energy savings and payback time for the proposed improvement measures. The suggested measures allow energy savings up to 29% in less than 3 years’ payback time and water consumption savings of approximately 7.5%.
ISSN:1996-1073
1996-1073
DOI:10.3390/en12020223