Reduce Energy Costs in Industrial Plants

 

Energy costs can be an enormous expense for industrial plants of all shapes and sizes. Different manufacturing processes require massive amounts of energy to keep up the production- cooling, heating, drying, lighting, and more. Finding out ways to save energy in your industrial plant can save you a huge amount. If you do not have a strategy in place to reduce energy costs, it is time for action.

An energy audit is important as it helps in identifying ways for improvement. During the audit, HVAC, lighting systems, and production line machinery are inspected and assessed. Some manufacturers even have an internal team who conduct an assessment. However, if you do not have such a team, you may consult energy experts. Whatever you wish to choose, here are few techniques to reduce energy costs in your industrial plant to make your facility more energy-efficient and less expensive to run.

1) Evaluate Air Compressors for Leaks

Air compressors are to blame for the massive amount of energy consumption and wastage. Some are designed poorly, while others aren’t maintained properly. Leaks can lead to almost 20 to 30% loss of a compressor’s output. They can even lessen the effectiveness of equipment.

Undertaking air leak surveys is one way to determine if your system has any leaks. Some common causes for leaks include loose hoses and tubes, worn materials missing seals or welds. Depending on the cause, repairing leaks can be as easy as tightening up fittings or changing minor parts.

2) Conduct an Equipment Audit

Keeping industrial equipment in good working condition is crucial to becoming energy efficient. Retro-commissioning methodically looks for equipment in the facility operating below optimum standards. While retro-fitting is about replacing inefficient or outdated equipment.

However, do not associate this with only the major pieces of equipment like HVAC systems. But, savings from upgrading aging equipment including industrial wall fans, ceiling fans, motors, and also computers can tally up in the long run. Implement a schedule to evaluate and maintain all equipment—not only the major ones.

3) Schedule Floor Shut-Downs and Start-Ups

Scheduled floor shutdowns where all machinery is powered off for a while, maybe during off-shift periods or weekends, can considerably lower energy costs. Similarly, powering up all machinery at once may create a large spike in the energy demand. Staggered start-up of equipment can help reduce this spike.

4) Improve Process Heating

Process heating is essential to manufacture most industrial and consumer goods, and it can be liable for over one-third of a plant’s energy usage. Manufacturers can save energy by setting up waste heat recovery systems, automatic blowdown control systems, controlling exhaust gases, and confirming proper furnace installation.

5) Schedule Machinery Use Strategically

Identify when and which processes require the most energy? Is there a chance to reschedule? If possible, schedule operating hours of this machinery other than the peak hours. Electrical rates vary depending on the timing, thus avoiding peak period rates can save a lot of energy costs.

To support your industry needs like cooling systems, ventilation systems, or air problems, Riseecovent is the name. We offer industrial exhaust fans, roof ventilators, wind turbine ventilators, and much more for all types of industrial plants. Reach out to us for a customized solution and get started in a new direction.