How to reduce the operating costs of industrial installations

A significant portion of energy wastage in industrial settings pertains to utilities such as steam, fuel, electricity, refrigeration, and air conditioning. This is often attributed to inaccuracies or absence of process measurement, failure to detect anomalies, inadequate or nonexistent recovery methods, among other factors. Lowering utility expenses necessitates the capability to accurately measure, visualize, and monitor consumption. Thoroughly analyzing consumption and implementing appropriate measures allows for the optimization of utilities in the following manner:

Steam
In various industrial sectors like food processing, petrochemistry, and energy, accurate measurement of saturated or superheated steam, along with pressure and/or temperature-corrected flow rate, is vital. This facilitates: Minimization of leaks, Enhancement of thermal insulation, Isolation of out-of-service networks, and Maintenance of purge systems.

Fuel
Gas and fuel oil are commonly utilized in industrial operations for heat production, with hydrocarbons serving as essential raw materials, especially in the chemical-petrochemical sector. Accurate fuel measurement facilitates: Optimization of combustion, Accurate yield calculation, and Enhanced monitoring of consumption.

Electricity
Irrespective of your industry, electricity likely stands as the most crucial utility for operating your production equipment. Metering and optimizing electricity usage can aid in: Enhancing network parameters, Optimizing load distribution, Streamlining consumption patterns, and Modernizing equipment, motors, drives, etc.

Refrigeration
While the food industry remains the primary energy consumer for cold chain preservation, sectors like pharmaceuticals and chemicals also utilize refrigeration (for process cooling systems, data centers, public buildings, etc.). Precise measurement of refrigeration consumption enables: Strategic power consumption planning, COP (coefficient of performance) monitoring, and Enhanced process performance optimization

Air
11% of industrial electricity production is allocated to compressed air manufacturing. For these industries, proficient management of air networks is imperative. Gathering, analyzing, and leveraging accurate consumption data, as well as selecting and deploying compressed air meters and relevant performance metrics, can yield savings ranging from 15 to 30% in: Detecting and rectifying leaks, optimizing air network maintenance (e.g., monitoring filter clogging levels), and maintaining pressure levels as low as feasible.

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