One of India’s oldest industries is the chemical one. Since the country’s early years of independence, the chemical industry in India has advanced significantly. In India, the chemical industry is the backbone of both industrial and agricultural growth, and it also supplies raw materials for downstream sectors. This sector significantly contributes to India’s overall economic expansion. The amount of energy being consumed must be known in order to determine the extent of energy waste. The purpose of an energy audit is to check, assess, and analyze energy flows in order to find ways to save energy without degrading the system’s output. The energy audit is the foundational tool for Energy Management Case Studies decision-making.
Foundry Energy Management Program Foundry Energy Audit (EMP):
- Audit of Foundry Energy
- Setup of the Foundry EMP
- Recognize Foundry EMOs
- Impacts of Foundry EMOs being evaluated
- Projects for Foundry EMO are prioritized
- Creating EMP
- EMP implementation
Energy management system monitoring:
An essential procedure that allows for a comparative evaluation of potential future energy efficiency improvements is energy auditing. An organized audit makes sure that every opportunity to benefit from project synergies is investigated in energy-saving projects.
Foundry Energy Management Program Foundry Energy Audit (EMP):
Audit of Foundry Energy
Setup of the Foundry EMP
Recognize Foundry EMOs
Impacts of Foundry EMOs being evaluated
Projects for Foundry EMO are prioritized
Creating EMP
EMP implementation
Energy management system monitoring:
An essential procedure that allows for a comparative evaluation of potential future energy efficiency improvements is energy auditing. An organized audit makes sure that every opportunity to benefit from project synergies is investigated in energy-saving projects.
(I) Stepwise Energy Audit Process
An audit has four significant steps:
- First, starting the audit
The stages involved in this are as follows: a) Audit Objective and Scope The top management establishes the audit’s purpose. It involves determining the depth, or the organizational and physical bounds of the audit, as well as the breadth, or the level of details necessary for energy consumption.
By analyzing the energy activity in terms of outflow, inflow, and within the box, the scope of the audit establishes the boundary or a “black box” that will serve as the audit region to be concentrated on. The foundry as a whole or a single operation could be covered by the black box. The number of the foundry’s workforce, their skills, their availability, the skills of the outside consultant, and last time and financial factors will all affect the scope.
b) The Auditors’ Selection
To function successfully, the chosen auditor should ideally have qualities like sound judgment, high personal integrity, great communication, and strong people management skills.
Depending on the budget, the auditor may be a foundry employee or an outside consultant. However, it’s crucial to consider things like interference with ordinary tasks, the learning curve involved, and the possibility of prejudice in specific circumstances when hiring internal workers.
c) Budget and time estimation
The budget is computed using person-days and weeks while taking into account the scope, goals, level of difficulty, available resources, and timing variables.
II) Audit Planning
The following are aspects of audit preparation:
a) Timing
In order to provide precise assessments of energy losses and inefficiencies, the audit was organized in conjunction with the foundry management. A suitable time period is chosen while taking into account the best production window and removing distortions.
(b) Establishing the Production Baseline
A comparison benchmark for estimating energy consumption levels should be included in the audit to make future Energy Management Case Studies duties easier.
c) Capturing data that is available.
Identification of the main end customers is aided by historical data already available. Data on the price of gasoline, the cost of raw materials, labor statistics, etc., are readily available. The calculation of material and energy balances depends heavily on this data.
d) Purchasing the Equipment
All monitoring devices used in the foundry, with the exception of those controlled by specific utility providers, must be checked for calibration and consistency during an audit. Process mapping, simulations, spreadsheets, natural gas distribution diagrams, etc. are a few often used auditing tools.
(III) Conducting the Audit
A thorough examination of foundry practices and procedures is necessary before beginning the audit. To get reliable information, it is helpful to watch the staff members at work or conduct interviews with them.
It’s crucial to establish material and energy balances. Balances show the impact of development plans and energy conservation initiatives. They could be for the efficiency of the boiler or one of the essential operations, such as the efficiency of the melting furnace.
The audit’s goal is to draw attention to locations, particularly those where energy is utilized most heavily, where there are chances for energy efficiency. It also places emphasis on regions where energy is either underutilized or overpaid for, allowing for the implementation of corrective measures to reduce these issues. The auditor must carefully examine the manufacturing procedures and machinery that have a significant impact on energy efficiency. It’s crucial to assess how scrap is used and examine the cast yield ratio, which relates to energy utilization.
IV) An audit report
The audit is finished when the results are reported in the appropriate format. There are two parts:
- a) a verbal report delivered at the end of the audit stressing significant findings, and
- b) a written report delivered after meticulous completion and analysis of audit results.
The format of an audit report typically includes the following sections:
a) Objective and Scope;
b) Location and Duration of the Audit;
c) Personnel and Resource Information;
d) Foundry Operation Conditions at the Audit;
e) General Observations
f) Energy Usage Data, Calculations, and Balances.
g) Conclusions and Evaluations, and finally.
h) Recommendations.
Various aspects of Energy Management
Let’s now examine many facets of energy management, namely how it benefits sectors like building facilities, logistics, industrial production, machine maintenance, the energy procurement process, and your personal life.
1. Facility Management
Facility management includes energy management.
Energy Management Case Studies in commercial settings entail taking measures to lower electrical energy consumption expenses without sacrificing work quality.
As we already mentioned, installing Energy Management Case Studies can help you save up to 29% of your overall energy bills.
2. Energy Management in Logistics Operations
Choosing the best modes of transportation, and routes, optimizing loads, employing fuel-efficient vehicles, and choosing clean fuels are all part of energy management in logistics.
The usage of roads for transportation accounts for 15% of global CO2 emissions. Therefore, employing Energy Management Case Studies in this situation will not only reduce transportation costs but also fight climate change and environmental harm.
3. Energy Management in Manufacturing Industries
The potential for energy improvement in the industry is likewise significant. Ensuring optimum energy practices in industries will result in significant cost savings, increased productivity, and a safe working environment.
4. Energy Management in the Process of Purchasing Energy
Energy is procured through the sale and purchase of energy units.
A company’s energy costs could go up as a result of this bad strategy and transactional choices.
5. Personal Energy Management
For a better and healthier existence, personal Energy Management Case Studies involve controlling your physical activity, mental exertion, and emotional mood throughout the day.
