energy audit case study for steel industry

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Detailed Energy Audit of an Industrial Firm. A Case Study of Zuqualla Steel Rolling Mill (Zusrom) Factory Located in Debre Zeit Town, Ethiopia

2020, Journal of critical reviews

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adebimpe abiodun , MGES Journals

In this paper, analysis of the energy audit of Food processing industry and Distillation and Bottling Company in Ota, Nigeria has been carried out. A walk-through energy audit of these industries was undertaken to identify the major sources of energy in use, identifying the lapses in energy usage, identifying areas to improve energy usage, determining the level of consumption of the energy sources and recommending policy measures that will enhance energy savings in the industries and Nigerian industries at large. The study observed that among a wide variation of end-use electricity consuming equipment, electric motors were the major consumer of electrical energy, accounting for 40-47% of total electric energy. Also from the identified energy use sources in the two industries, it was observed that fuel energy expended in operating the generating set, boilers or heaters in the industries had the highest value of energy use accounting for more than 65% of the total energy used. It was observed that none of the companies under review sufficiently utilized their energy as they all have their energy used ratio far below 1. This was as a result of some factors that contributed to energy waste and energy use inefficiency in the companies. Among these factors are: Poor in housekeeping of air-condition and refrigeration equipments and electric motors that dissipate much heat, use of electric motors that are weak and generate excessive noise because they have been rewound more than twice, improper lagging of boilers that lead to losing much heat, switching on of the lighting points in the day time and generation of electrical energy more than needed in the industry by some electric generator. The study concluded that energy is not sufficiently utilized in these companies and recommendations for efficient energy usage in the industries were proposed in this study.

International Journal Of Scientific Advances

cyril ocheri

The research work focuses on the need to perform an energy audit in a metallurgical industry concerning the operations of the Foundry Shop of the Ajaokuta Steel Company Limited. Some basic components for performing the energy audits were discussed. The foundry processes and operations are based on the production of components for other basic industries where their components are used for manufacturing processes like the quarry industries, battery industries, manufacturing, and other process industries. To produce the desired components that the vessel used for the production processes like the Electric Arc Furnaces, the Induction furnace, the crucible furnace, and centrifugal furnaces must be utilized for the effective and optimal production processes tHrough constant monitoring and sustenance of the energy used during the production process. To achieve these production processes, there is always a need to perform energy audits of the facilities used. One method is to design methods...

American Journal of Modern Energy

Bashir Kunya

RSIS International

Now a days, in the development of any nation, the availability of Electrical Energy plays an important role. Energy crisis is increasing day by day. The major consumer of electrical energy is industry and in most of industrial units, a big portion of electrical energy is wasted because of improper and unplanned consumption. The energy which has been wasted by these industries is also paid. One of the solutions to overcome the energy crisis problem is energy conservation that can be achieved by auditing of energy. Implementation of energy audit can improve the plant efficiency and thereby reduce the energy wastages. So, there should be an energy saving cell in every industrial unit for continuous survey and to provide remedial steps for energy conservation. The present research work aims at analysis, evaluation and implementation of Energy Audit in the industry which will help in avoiding the energy wastage. The work presented in the thesis explores the possibilities to identify and then to minimize the energy wastages area in the industry. In case study of Vardhman Special Steels, in which the major electrical energy is consumed in motors, furnaces, compressed air system etc. study of instantaneous load analysis of motor has been done. The study shows the loading status of the motor, which helps in keeping a check as to which motors are consuming more power than they ought to be consuming. Hence the loop holes for higher power consumption have been pointed out and steps are recommended to avoid them. The work presented here also pertains to explore the possibilities of electrical energy saving in compressors, furnaces. It was observed that there is a potential for energy saving for which corrective measures have been suggested. Similarly, other energy porous related to various component of the industrial unit viz transformers, capacitors, water pumps etc. are considered. The analysis of each of these factors has been done and recommendations have been given accordingly. If suggestions and recommendations in this thesis are applied properly, the unit will save a large amount of electrical energy and hence electrical bills can be cut to certain amount.

transstellar

TJPRC Publication

India is a developing country and electrical energy consumption byindustries is about 60% of the total energy consumption. The industrial development in the country is progressing at a fast pace due to the increase in the number of industries, the gap between demand and supply of electricity is also increasing day by day. To minimize this gap the best solution is to conductan energy audit of all industries on regular bases. The energy audit will determine energy wastage and losses, and provide techniques and ways to minimize the losses. The energy consumption techniques suggested by the energy audit will not only minimize the losses but also reduce monthly electricity bill. This paper suggests ways and means to conduct an energy audit in an industry

American Journal of Electrical Power and Energy Systems

Jamilu Ya'u Muhammad

Olawale M Sanusi

Energy is one of the major inputs for the economic development of any country. In the case of the developing countries, the energy sector assumes a critical importance in view of the ever-increasing energy needs requiring huge investments to meet them. Energy audit will determine energy wastage and losses, and provide techniques and ways to minimize the losses. The payback period of the energy audit programmed for the industry was found to be 14 months. The energy consumption techniques suggested by the energy audit will not only minimize the losses but also reduce monthly electricity bill. The objective of Energy Management is to achieve and maintain optimum energy procurement and utilization, throughout the organization as to minimize energy costs and wastage without affecting production and quality. Energy Audit is the key to a systematic approach for decision-making in the area of energy management. It attempts to balance the total energy inputs with its use, and serves to identify all the energy streams in a facility.

MOHAMMED SHU'AIBU ABUBAKAR

A study was conducted on the evaluation of energy use patterns in two flour mills (Maiduguri and Yobe). Energy use and production data in the two agro-allied industries for seven years (1998-2004) were collected through the administration of a structured questionnaire. Results show that three energy sources manpower, electricity and diesel fuel were used. For Yobe Flour Mills, manual energy consumed accounted for 0.1%, electrical energy accounted for 7% while diesel fuel consumed accounted for 92.9% of the total energy inputs over the years under review. Maiduguri Flour Mills, manual energy accounted for 0.1% while diesel fuel energy consumed accounted for 99.9%. The minimum and maximum values of energy use ratios for Yobe Flour Mills were 0.12:1 and 0.16:1 in 2003 and 2002 respectively. The mean energy use ratio was 0.15:1. The mean energy use ratio for Maiduguri Flour Mills was 0.36:1 while the minimum and maximum values were 0.33:1 and 0.40:1 in 2003 and 2004 respectively. For Yobe State Flour Mills Company there was linear relationship between energy inputs and outputs with R2 values of 0.87. For Maiduguri Flour Mills, energy input and output relationships was best described by polynomial equation with R2 values of 0.99. Comparing the data of the two flour mills using t-test at 0.05 level of significance, it was found that there is a significant difference between their mean total energy inputs as well as their mean total energy outputs. The energy use ratios obtained show that neither of the flour mills efficiently used energy. Some energy use lapses were identified in the course of the study, which include malfunctioning of some electric motors and other auxiliary equipment and general wastage. Manufacture, Transport and Repair (MTR) energy was not evaluated due to insufficient data on the masses of machines available in the industries and on their usage. Thus, the results of energy use obtained from the industries are incomplete because the MTR energy plays a significant role in energy use analysis.

Luqman Audu

IRJET Journal

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Implementation of energy audit in the Chinese steel industry : case studies of integrated steel plants

• X. Wang , Chuan Wang , +1 author J. Dahl
• Published 2008
• Environmental Science, Engineering

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Wang, Chuan

Grip, carl-erik, abstract [en].

Steel production is one of the energy intensive industries in the world. Energy saving measures are of increasing interest to Chinese steel industry in recent years. One of the technical instruments of energy saving is energy audit. This paper presents the energy audit analysis of integrate steel plants in China as a case study. The analysis is useful to determine the actual consumption, reveal the anomalies and suggest corrective measures. These will provide clear indication on the pattern of energy losses and will aid in decision support for evolution of energy saving measures. The paper will show the achievements of Chinese steel plants during these years of energy saving activities proposed by government and the potential for energy efficient renovation. Some suggestion has been made in order to widely use this analytical diagnostic tool in Chinese steel industry.

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Industrial Energy Audit Guidebook: Guidelines for Conducting an Energy Audit in Industrial Facilities

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Various studies in different countries have shown that significant energy-efficiency improvement opportunities exist in the industrial sector, many of which are cost-effective. These energy-efficiency options include both cross-cutting as well as sector-specific measures. However, industrial plants are not always aware of energy-efficiency improvement potentials. Conducting an energy audit is one of the first steps in identifying these potentials. Even so,many plants do not have the capacity to conduct an effective energy audit. In some countries, government policies and programs aim to assist industry to improve competitiveness through increased energy efficiency. However, usually only limited technical and financial resources for improving energy efficiency are available, especially for small and medium-sized enterprises. Information on energy auditing and practices should, therefore, be prepared and disseminated to industrial plants. This guidebook provides guidelines for energy auditors regarding the key elements for preparing for an energy audit, conducting an inventory and measuring energy use, analyzing energy bills, benchmarking, analyzing energy use patterns,opportunities, conducting cost-benefit analysis, preparing energy audit reports, and undertaking post-audit activities. The purpose of this guidebook is to assist energy auditors and engineers in the plant to conduct a well-structured and effective energy audit.

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Analysis of energy audits results and impacts: case of small and medium enterprises in Lithuania

• Review Article
• Published: 03 September 2022
• Volume 15 , article number  48 , ( 2022 )

Cite this article

• Aurimas Lisauskas   ORCID: orcid.org/0000-0003-0678-4240 1 ,
• Vaclovas Kveselis 1 ,
• Eugenija Farida Dzenajavičienė 1 ,
• Sigitas Masaitis 1 &
• Eugenijus Perednis 1  

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Efficient energy use in industry is an important issue capable of reducing the overall energy consumption. Large enterprises in the European Union countries are obliged to conduct regular energy audits or implement energy management systems, while for small and medium enterprises, energy audits are voluntary. However, governments implementing their energy and environmental policy goals support energy audits in small and medium enterprises through national support programs. Another driving factor is compulsory energy audit for companies seeking financial support for their modernization and implementation of renewable energy projects. The article presents an overview of findings from energy audits of 18 small and medium enterprises in Lithuania, starting with energy management and accounting issues and their energy consumption profiles, followed by proposed energy-saving measures, estimated energy savings, and avoided greenhouse gas emissions. Buildings, technological processes, and transport are the main energy consumption sectors in audited companies. The relatively short pay-off time required by industrial small and medium enterprises limits the amount of investment and achievable energy savings. Audit recommendations containing opportunities to introduce renewable energy installations expand the environmental benefits of auditing. The cost of energy savings resulted from recommended energy efficiency measures compared with energy prices and availability of resources is one of the strongest economic arguments for accepting audit recommendations.

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Lisauskas, A., Kveselis, V., Dzenajavičienė, E.F. et al. Analysis of energy audits results and impacts: case of small and medium enterprises in Lithuania. Energy Efficiency 15 , 48 (2022). https://doi.org/10.1007/s12053-022-10052-x

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