Our engineers performed a thorough walk-thru audit, surveying the existing equipment and measuring the key energy loads. By integrating DTWISE data analytics platform we unified the independent systems of the production line and furthermore we managed to have access in real-time multi-dimensional data, defining the absolute energy profile.
The load profile analysis identified the shredding equipment and the melting furnaces as the main energy consumers. The motor drive which controls the air inflow in the melting furnace was accountable for the 15% of the daily general load. We proposed a variable speed drive control (inverter) for the motor in order to achieve reduction of active and reactive energy.
With an annual energy consumption of more than 4.2 GWh and a 24/7 peak demand of 900 kVA the proposed intervention had a high impact on the energy consumption reduction. The impact was 40% reduction of the specific load and 6% on the overall factory consumption.
Additionally, major part of the production line equipment's booting was not fully controlled, leading to a random load pattern with several peaks. Our energy engineers proposed a substantial power arbitrage system to smoothen and optimize the load demand curve, which furtherly reduced energy consumption by 12%.