Energy consumption optimization

How much is your energy consumption per unit? Is natural gas cheap in your region? Is the calculation of your electricity based on the agricultural tariffs? Are you in an industrial town, and it is hard for you to treat residue?

Which of the existing devices and methods do you use for air conditioning of industrial halls, and why? How many hours per day is your collection’s steam boiler is on? Is the electricity distribution system works optimally? Is the depreciation of your electronic equipment high?

These questions are those every employer has faced while walking in their collection. What should we do to optimize energy consumption? The answer is the accurate utilization of “physics.”
In a production hall with a specific area, to have the desired amount of light, we must first have an accurate definition of the “desired” amount. The “desired” amount has a specific and standard number in different industries so that the lighting standard of the production hall differs from the packaging hall. Besides, the lighting of the plant production factory with textiles production factory and the hall with 20 employees with a hall whose number of employees has been reduced to 5 by the automation level differ. Moreover, we face the same issues in all kinds of fluid distribution, such as water. Among the factors involved in selecting a pump is the local distance to which water should be supplied, the vertical and horizontal distance that fluid should travel, fluid output flow, and other physical features. It may be necessary to modify your piping system before purchasing a new pump. Calculations regarding optimization and controlling the energy in factories categorize into four large groups in the Sur mechanism. It is critical to have a factory plan in all four groups; otherwise, you must prepare before the calculations. Since there are four consumption factors in most factories and workshops, electricity, gas, water, and steam, we examine each of these factors separately.

۱. Electricity consumption optimization
Generally, improper halls design and inappropriate layout of production lines lead to excessive electricity utilization in factories and workshops. For instance, the cooling systems will work for more hours if the existing heating factor of the hall is not appropriately isolated. Also, more ventilation fans should be on. In this case, you can select the hall with a lower height to improve the lighting and allocate the hall with a higher height to the storehouse. Furthermore, you can create more windows. The reason for many electric heaters in winter or water coolers in Summer may be that the doors of the halls open and close too much for unnecessary and unpredicted movements. Are the steam boilers’ torches always working and consuming much electricity?

Correct the structure. Another important note is to select the proper cross-section of wires and cables. Examine the size of wires and cables by accurately calculating the consumer power and its distance to the electricity source. If cables and wires are not standard and their material is not good, it will waste much electricity and convert into heat. The ventilation systems of the hall are usually one of the electricity-intensive equipment. You can optimize the power consumption of your ventilation system by calculating the produced heat energy in the hall and the ideal temperature that is proper for all conditions. There may not be a need for large centrifugal fans, which impose high electricity costs and make much noise. Fundamental actions for electricity consumption optimization include designing the appropriate ventilation system, fans’ required pressure to move a specific amount of air, types of used fans, and hood design. However, we must review the production and storage processes, change the structure to achieve the optimal state, and eliminate non-standard factors.

۲. Natural gas consumption optimization
Natural gas is usually consumed to generate heat. It may be a melting furnace utilized for the cooking operations with the direct flame to generate the required steam of the steam boiler. There are gas generators in some factories. Thereby, the importance of examining the accurate operation of generators is prominent. In any of these mentioned cases, one of the essential measures for optimizing gas consumption is principle isolation. Definition of “principle isolation” is the utilization of proper isolation material and regular isolation system inspection. Is the gas distribution line is standard in your collection? What is the basis of collectors and the number of regulators calculation in your collection? The answer to these questions is also structure design. How many cubic meters are required to maintain a 300-meter hall with 10-meters height at the standard temperature? The first question is, is this a standard hall at all? The second question is, how optimal is the design of your heating devices for this amount of consumption?

۳. Water consumption optimization
Appropriate recycling water equipment installation is essential in industries that use water for washing and keeping the equipment cool. The design of the residue collection system should
be able to treat residue in some steps to utilize the least energy for recycling. Multi-step filtration can dramatically reduce the supplying cost of sediment formation material in treatment tankers. Furthermore, water hardness should be controlled in the cooling tower regularly. Consequently, the formation of sediment reduces around the wall. You can use high-pressure water pumps that turn water into droplets for washing halls and equipment. It is critical to install electronic water valves wherever water can transfer. Sometimes, the weakness of washing planning leads to wastage of water that needs to be addressed. Sometimes, water heaters in toilets can not optimize the water temperature, and valves stay open for a long time to get hot water out of the valves. Therefore, you should review the raw material washing system, particularly in the food industry. Minimizing the water required for washing systems can be done by changing production lines and structure devices. Water coolers are also water-intensive, so you can reduce their water consumption by optimizing cooling pads. Besides, condensed water in steam pipes can be reused in steam boilers. The structure principle design is also critical here. You can install water recycling before construction to minimize costs.

۴. Steam consumption optimization
The problem of the steam supply in industries that utilize steam boilers is the unprincipled design of the steam distribution system. Factors that should be examined in the principle isolation of steam pipes include: pipes diameter, consumer distance from steam boiler, heater pressure is needed for the consumer. The thickness of the sheets must be examined for steam consumers like double-walled tanks, autoclaves, and other devices that can not be isolated in the usual way. You should review the metal’s thermal conduction, which composes the large cross-section of devices’ components. But the main point is the steam boiler. Notably, you can significantly reduce the depreciation of the steam boiler by designing and implementing the condensed water recovery system from output traps toward the steam boiler, as the distilled water recovers to the steam boiler at 80 degrees temperature. So it converts to steam faster. Besides, it leaves the least sediment in the steam boiler as its hardness is around zero. Consequently, the steam production efficiency will remain constant, and the steam boiler costs of repair and maintenance will reduce dramatically. The implementation of the mentioned system, like all the above, requires the standard design of the factory structure.

As seen, the defective structure influences everything. The defective structure leads to more worn out of devices, the constant concern of technical and engineering section regarding repairs and troubleshooting, reduce the concentration of human resources for performing their tasks and duties following the continuous stops of line. Eventually, all of the mentioned cases will decrease your product quality. In many cases, the restructuring costs may be even greater than the electricity consumption or wasted water over 20 years. Hence, employers become hesitant to continue the present method or reform the structure. Finally, they accept restructuring by observing the depreciation of their assets and the positive psychological impacts of their workspace. It is worth noting that any cost to maintain the product quality is more important than other costs. Moreover, if you optimize your collection in terms of energy consumption, environmental concerns will be reduced.

All rights reserved for surmechanism™© ۲۰۲۲