Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation

Iten, Muriel; Oliveira, Miguel Castro; Costa, Diogo; Michels, Jochen

doi:10.3390/en12020223

“…In this section, firstly improvement measures will be identified for each case study (Section 5.1). This is followed by its introduction into the modeling, according to an optimization methodology presented by Iten et al [47]. The optimization methodology considers the operational requirements of the industrial plants by solving of optimization problems.…”

Section: Resultsmentioning

confidence: 99%

“…Table 5 summarizes the details of each case-study (designated CS). The eleven case studies have been assembled in OpenModelica applying the WaterWatt library developed by the authors and presented in Iten et al [47]. Following the previously introduced procedure, the current energy and water consumption have been estimated for all case studies and presented in Table 5.…”

Section: Description Of Case-studiesmentioning

confidence: 99%

“…5-15% typical increase in efficiency [41] In addition to these measures, Iten et al [47] also investigates the replacement of sand filters, commonly found in the water treatment units of the IWC. The principle behind the application of this measure is the decrease of the pressure loss along a circuit, which decreases the head demand of the pumps and consequently the power demand.…”

Section: Refurbishment Of Pumps Eem4mentioning

confidence: 99%

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Water–Energy Nexus in Typical Industrial Water Circuits

Oliveira

¹

,

Iten

²

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Matos

³

et al. 2019

Water

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Water–energy nexus has been recognized as an important and challenging issue, namely in industry. This is due to industry reforms, increasing demand, and climate change. This concept focuses on the link between energy and water infrastructure. Overall, there is limited understanding of the nature of this link, as it is assumed that water is not a threat to the energy sector or an influence of the electricity to the water resources. This work aims to present and evaluate case studies related to typical industrial water circuits. These circuits represent some of the most relevant industrial sectors in terms of water–energy nexus such as: steel industry, chemical industry, paper and pulp industry, and food industry. Moreover, these sectors also cover typical industrial water circuits, namely: cooling circuit, gas washing circuit, water treatment circuit, transportation circuit, and quenching circuit. The circuits have firstly been assembled in OpenModelica software considering the equipment and physical layout of each circuit. According to their actual operation conditions, the energy and water consumption have been estimated. Furthermore, water and energy efficiency improvement measures have been proposed and implemented into the assembled models. This enabled a techno-economic assessment based on the implementation of the improvement measures. In order to contextualise these results into the industrial trends, the achieved water and energy savings are projected into potential national and sectorial savings considering the current levels of water and energy demand for each sector.

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“…Regarding the energy balance, it is to note that appreciable economic savings are possibly to be obtained in the case that the economic savings produced by the fuel [13]) the conceptualized project may be considered reasonably viable, while in comparison to solar water heating projects (considering an acceptable payback time of less than 20 years [24]) the economic viability is highly ensured.…”

Section: Economic Assessmentmentioning

confidence: 99%

“…Numerical modelling may be applied in a multiscale perspective in order to either develop models for single unit operations in a plant or a building or the whole system which encompasses a set of processes. The Modelica language has been used to develop models and study the implementation of several types of measures [12][13][14][15]. Several open source libraries have been developed in Modelica for the simulation of several systems.…”

Section: Introductionmentioning

confidence: 99%

Modelling of A Solar Thermal Energy System For Energy Efficiency Improvement In A Ceramic Plant

Oliveira

¹

,

Iten

²

2021

Renew. Energy Environ. Sustain.

Self Cite

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The thermal energy use in the manufacturing plants is the most representative parcel of the total energy consumption within the European industry. Such is mainly attributed to the operation of high energy intensive thermal processes such as furnaces and boilers. The implementation of heat recovery technologies is a solution with a great potential to improve the operation of these processes and improve the overall energy efficiency in a plant. On the other hand, the use of renewable energy resources such as solar energy is highly relevant measure to decrease the use of fossil fuels, such as natural gas. This paper presents the modelling of a solar thermal energy system (STES) established by a water circuit and solar thermal collector for the heat supply to two boilers installed in a ceramic plant. Such system has been conceptualised in the scope of industrial practices, proposing solar heat for industrial processes (SHIP). The practical work in this paper aims to the development of a customised simulation tool for the modelling of heat recovery networks and thermal processes in manufacturing industry plants using the Modelica language. The system model has been developed using existing and newly developed equipment models. The simulation results were validated with measured data in the industrial plant, being consistent with the real values (e.g. highest deviation of about 0.01%). In addition to the boilers, the performed simulation allowed to achieve the sizing of the components of the water circuit, in particular for the pumping system (with a required supply of 0.747 kW of electric energy). A techno-economic assessment has been performed to evaluate the viability of the cproposed solution, showing a payback time of approximately 3 years, a total annual economic savings of about 25209 € and associated reduction of equivalent carbon dioxide emissions of about 170 ton/year.

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Modelling of a Solar Thermal Energy System for Energy Efficiency Improvement in a Ceramic Plant

Oliveira

¹

,

Iten

²

,

Fernandes

³

2022

Innovative Renewable Energy

View full text Add to dashboard Cite

The thermal energy use in the manufacturing plants is the most representative parcel of the total energy consumption within the European industry. Such is mainly attributed to the operation of high energy intensive thermal processes such as furnaces and boilers. The implementation of heat recovery technologies is a solution with a great potential to improve the operation of these processes and improve the overall energy efficiency in a plant. On the other hand, the use of renewable energy resources such as solar energy is highly relevant measure to decrease the use of fossil fuels, such as natural gas. This paper presents the modelling of a solar thermal energy system (STES) established by a water circuit and solar thermal collector for the heat supply to two boilers installed in a ceramic plant. Such system has been conceptualised in the scope of industrial practices, proposing solar heat for industrial processes (SHIP). The practical work in this paper aims to the development of a customised simulation tool for the modelling of heat recovery networks and thermal processes in manufacturing industry plants using the Modelica language. The system model has been developed using existing and newly developed equipment models. The simulation results were validated with measured data in the industrial plant, being consistent with the real values (e.g. highest deviation of about 0.01%). In addition to the boilers, the performed simulation allowed to achieve the sizing of the components of the water circuit, in particular for the pumping system (with a required supply of 0.747 kW of electric energy). A techno-economic assessment has been performed to evaluate the viability of the cproposed solution, showing a payback time of approximately 3 years, a total annual economic savings of about 25209 € and associated reduction of equivalent carbon dioxide emissions of about 170 ton/year.

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Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation

Cited by 8 publications

References 7 publications

Water–Energy Nexus in Typical Industrial Water Circuits

Water–Energy Nexus in Typical Industrial Water Circuits

Modelling of A Solar Thermal Energy System For Energy Efficiency Improvement In A Ceramic Plant

Modelling of a Solar Thermal Energy System for Energy Efficiency Improvement in a Ceramic Plant

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