Qualitative and quantitative modelling to build a conceptual framework to identify energy saving options: case study of a wire producing company.

Energy management systems are considered as appropriate instruments to identify and realize energy efficiency potentials in industrial plants. Studies point out a largely untapped potential for energy efficiency in industry through the adoption of systematic energy management. We suggest introducing qualitative and quantitative modelling tools into energy management to facilitate a focused process to set priorities and identify effective measures. This paper describes the case of voestalpine Austria Draht GmbH, an Austrian wire rolling mill. voestalpine Austria Draht GmbH at present is implementing a knowledge based energy management system. Within the work described in this paper, first an overview of energy flows using Sankey diagrams was elaborated. Then a qualitative systems analysis was developed for the plant and a gap analysis done for priority areas. Subsequently physical input–output models for several energy intensive units were prepared. The paper describes the models for the cooling water system and product cooling. This study revealed a significant potential to save electricity by optimizing the control of cooling water pumps along the milling train and to recover heat from the final products. 2 GWh of electricity can be saved annually. The biggest single energy loss in the mill is the heat from air cooling the products on hook conveyors. These heat flows contain about 30–50 % of the energy input for heating up the billets. Following a theoretical analysis of the potential, a demonstration plant was developed and pilot tests were run to characterize the realistic potential of heat recovery on the hook conveyor. Based on the test results, feasibility studies for large scale plants were carried out. As a result, 0.8 GWh of heat can be recovered annually. The method was found useful because it helped to structure the existing information with a reasonable effort mostly by the operators themselves in their work and to build a conceptual model of energy flows and energy efficiency of the total plant. [ABSTRACT FROM AUTHOR]