How Can Energy Efficiency Be Improved In Industry?
Energy efficiency is critically important for industry. Industrial plants account for nearly a third of all energy used worldwide, so implementing energy efficiency measures can lead to substantial cost savings and reductions in greenhouse gas emissions (“The Importance Of Energy Efficiency For Industry”). There are many ways industries can improve their energy efficiency, including process optimization, installing heat recovery systems, utilizing combined heat and power, improving insulation, conducting energy audits, improving maintenance practices, engaging staff, and transitioning to renewable energy sources. This article will provide an overview of these key strategies industries can leverage to reduce their energy usage and costs.
Process Optimization
One of the most effective ways for industry to improve energy efficiency is through optimizing manufacturing and operational processes. This involves analyzing each step of a process to identify areas of waste and inefficiency in order to streamline operations (Energy and Process Optimization for the Process Industries). Some key ways to optimize industrial processes include:
Streamlining production workflows and layouts to eliminate any unnecessary movement or transportation of materials. This may involve reconfiguring factory floors or production lines to have a more linear flow (https://www.wiley.com/en-hk/Energy+and+Process+Optimization+for+the+Process+Industries-p-9781118101162). Process simulation and value stream mapping can help identify optimization opportunities.
Upgrading to more energy efficient equipment and machinery, such as boilers, motors, pumps and fans. Installing variable frequency drives and sizing equipment properly can provide significant efficiency gains (https://www.linkedin.com/pulse/top-5-solutions-optimizing-energy-efficiency/).
Implementing lean manufacturing principles to reduce excess inventory, overproduction and waste. Techniques like Total Productive Maintenance and Overall Equipment Effectiveness help improve productivity and energy performance.
Tuning and maintaining equipment to operate at optimal levels. Regular maintenance and testing ensures machines run efficiently over time.
Utilizing automation and process controls to maximize efficiency by reducing human error and unplanned downtime. Sensors, meters and software can help monitor and regulate systems.
By taking a holistic view of manufacturing operations and targeting the most energy-intensive processes, companies can achieve 10-20% energy savings through optimization (https://www.sciencedirect.com/science/article/abs/pii/S0360544219321759).
Heat Recovery Systems
Heat recovery systems allow industries to capture waste heat that would otherwise be lost and reuse it for heating or generating electricity (Sigmathermal.com, 2022). There are several types of industrial heat recovery systems:
Waste heat recovery units (WHRUs) use waste heat from hot exhaust gases to produce steam, hot water, or hot air. WHRUs can recover 50-90% of available waste heat (Enerquip.com, 2020). Common applications include capturing heat from turbines, engines, incinerators, and industrial processes.
Regenerators recover heat from process gas streams. They alternate flow directions to preheat incoming gases with outgoing hot gases. Regenerators are often used in steel heating furnaces, ceramic kilns, and glass furnaces (Globalfinishing.com, 2022).
Recuperators are gas-to-gas heat exchangers that recover heat from hot exhaust gases to preheat combustion air. This improves boiler efficiency. Recuperators are commonly used in industrial furnaces, ovens, and boilers (Sigmathermal.com, 2022).
Economizers capture waste heat from boiler flue gases. The recovered heat preheats boiler feedwater to improve steam generation efficiency. Economizers can improve boiler efficiency by 5-10% (Enerquip.com, 2020).
Combined Heat and Power
Combined heat and power (CHP), also known as cogeneration, is an efficient method for generating electricity while also capturing usable heat that would otherwise be wasted. As the EPA explains, CHP systems generate electricity at the point of use and recover heat that is then used for space heating, domestic or industrial hot water, or process heating. This allows CHP systems to achieve fuel efficiencies of 60% or higher, compared to about 45% for conventional separate heat and power generation.
There are several key benefits of implementing CHP systems in industrial facilities:
- Higher overall efficiency – By utilizing heat that would otherwise be wasted, less fuel is needed to produce the same amount of energy.
- Reduced energy costs – The improved efficiency of CHP systems lowers fuel consumption and energy costs.
- Increased reliability – Onsite power generation reduces reliance on the grid.
- Lower emissions – Less fuel usage results in lower greenhouse gas emissions.
- Increased competitiveness – Lower operating costs can give facilities a competitive advantage.
According to the Department of Energy, CHP systems are well-suited for facilities with continuous thermal energy demands, such as manufacturing plants, hospitals, universities, and commercial buildings. Implementing CHP can help these facilities boost efficiency, cut costs, and support sustainability goals.
Insulation
Adding insulation is one of the most effective ways to improve energy efficiency in industrial facilities. Insulation helps reduce heat loss from pipes, tanks, equipment, and building envelopes. By preventing heat transfer, insulation conserves energy that would otherwise be wasted heating the surroundings.
According to the Benefits of Industrial Insulation, “Increasing efficiency and using less fuel means fewer emissions, including harmful pollutants such as carbon monoxide, sulfur dioxide, and nitrogen oxides.”1 Properly insulating an industrial facility can reduce energy consumption for heating by 25-60%.
The return on investment for insulation can be quite high. As noted in Exploring the Benefits of Sustainable Industrial Insulation, “Effective insulation will improve energy efficiency for machinery and equipment, leading to reduced consumption.”2 The energy savings usually pay back the upfront cost of insulation within 1-2 years. After that, the savings continue year after year.
Overall, adding insulation is one of the most cost-effective ways for industrial facilities to improve energy efficiency and reduce operating costs.
Energy Audits
Conducting professional energy audits is a key strategy for identifying opportunities to improve efficiency in industry. Energy audits provide a detailed analysis of how a facility uses energy and where waste and inefficiency occur. According to Bernhard.com, “An energy audit is an assessment of how much energy a building uses. The audit looks at a building’s energy-consuming systems, like HVAC and lighting.”
Industrial facilities can benefit greatly from partnering with an energy audit company to perform a comprehensive audit. Alliant Energy explains that “During the Energy Audit, we will study your building’s operational characteristics, identify and analyze energy-saving opportunities, and pinpoint strategies to optimize energy usage while reducing operating costs.” Implementing the recommendations from a professional energy audit can significantly reduce energy usage and costs.
The audit will analyze all energy-consuming systems and identify ways to maximize efficiency. This includes examining heating, ventilation, air conditioning, lighting, compressed air systems, motors, pumps, and more. The auditor will look for issues like leaks, waste, improper operations, and areas to add insulation or controls. They will then provide a detailed report with recommendations to implement energy-saving measures.
By carefully following through on the suggestions from an energy audit, industrial facilities can achieve substantial reductions in energy use. The investment in an energy audit delivers significant long-term savings and shorter payback times for efficiency projects. Regular audits help ensure plants stay on track with energy-saving best practices.
Maintenance
Proper maintenance of equipment is crucial for maintaining energy efficiency in industry. Studies show that lack of maintenance accounts for 5-15% of industrial energy waste (https://iopscience.iop.org/article/10.1088/1757-899X/530/1/012047/meta). Keeping equipment properly maintained ensures it runs at optimal efficiency. Air compressors, pumps, motors, steam traps, HVAC systems, and other equipment should be regularly inspected and maintained per the manufacturer’s recommendations. Worn or loose parts, leaky compressed air lines, build up and corrosion can degrade performance. A good maintenance program will detect issues early before they impact efficiency.
Maintenance staff should be trained to spot signs of energy waste as they service equipment. Examples include hot spots on motors indicating increased friction, leaking steam traps allowing steam to escape, compressed air leaks wasting pressure, and excess vibration or noise indicating wear. When energy waste is detected, it should trigger corrective maintenance. Software can track maintenance tasks and energy use to identify poorly performing assets.
Staff Engagement
Engaging employees in energy efficiency efforts is a key way for industrial facilities to reduce energy usage. According to a report from Energy5, “Key steps to engage employees include raising awareness, providing training, incentivizing energy-saving efforts, involving employees in decision-making, and recognizing achievements” (Energy5). Providing training on energy-saving best practices allows staff to learn specific ways they can help reduce energy consumption as part of their daily workflows. For example, ensuring equipment and lights are turned off when not in use, reporting leaks or malfunctioning equipment, and following energy-efficient operating procedures. Offering incentives or rewards for energy conservation gives employees motivation to actively participate in efficiency efforts. This could involve individual rewards for saving energy or group rewards if a department meets targets. Getting staff engaged with energy-saving as a team effort is key.
Renewable Energy
Installing renewable energy systems on-site at industrial facilities is one strategy to increase energy efficiency and reduce reliance on fossil fuels. Many industrial operations require significant electricity and heat, making them good candidates for on-site solar panels, wind turbines, biomass systems, and other renewable sources. According to Deloitte, the renewable energy industry is projected to continue rapid growth, with 25 major utilities committed to 80% carbon reduction or clean energy by 2030.
There are several types of renewable energy systems well-suited for industrial facilities:
- Solar photovoltaic (PV) panels to generate electricity
- Concentrated solar power systems that produce heat for industrial processes
- Wind turbines to produce electricity
- Bioenergy systems that use organic matter like wood, crops, or waste as fuel
- Geothermal energy using heat from beneath the earth’s surface
- Low-impact hydroelectric power from streams or small dams
Choosing the right renewable energy technology depends on the facility’s needs, climate, available resources, and goals. Proper sizing, siting, and integration with existing systems are also key for successful on-site renewable energy. With the right strategy, industrial facilities can significantly increase their energy efficiency and sustainability.
Conclusion
In summary, industrial facilities have several effective ways to improve their energy efficiency, including process optimization, installing heat recovery systems, implementing combined heat and power, improving insulation, conducting energy audits, and focusing on proper maintenance. Engaging staff to be energy conscious can also lead to major efficiency gains. Transitioning to onsite renewable energy, where feasible, helps to further reduce environmental impact and energy costs.
Continued efforts to optimize energy use are crucial for both cost savings and meeting environmental goals. Industrial energy efficiency helps companies remain competitive while also reducing greenhouse gas emissions. New technologies, government incentives, and evolving best practices provide expanding opportunities for efficiency gains. Companies that make energy efficiency an ongoing priority through measures like staff training, energy monitoring, and investment in efficiency infrastructure can continuously improve their energy productivity.
