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 Corus is a leading player in an energy intensive, high temperature process industry. As such there is significant expertise available within the company aimed at minimising the costs associated with energy consumption. Energy audits may be carried out in any industry, over a specific works unit or process line. Audits typically aim to analyse the total energy consumption of the works or site over a period of time in terms of the major fuel types, for example natural gas, fuel oil, coal, coke, electricity. The distribution of this consumption by items of process plant and services is then analysed. This operation helps to identify the major users and targets areas where the greatest savings may be made. Further analysis may include identification of temporal trends, which can highlight, for example, excessive consumption during non-production periods resulting from inappropriate design or operation, poor control or ‘housekeeping’. The relative benefits of changing to different supply tariffs can also be established at this stage. Calculation of the specific energy consumption of particular processes, that is the energy consumed per unit product manufactured, may be carried out. The variation with production rate can then be studied to establish whether the no production load is excessive, for example due to poorly maintained or designed refractories or air:fuel ratio control systems. Knowledge of the specific energy consumption establishes a benchmark for the process, which can be compared against known world best practice. It also establishes a target for consumption against which performance can be monitored as part of an energy ‘monitoring and targeting’ system and where the causes of anomalous trends can be identified. Following the above initial data collection and analysis exercise, particular items of plant may be singled out as being worthy of further investigation, particularly if they are major consumers of energy or if inefficient operation has been highlighted. Typical examples in the steel industry may include:
On-site measurements are carried out by experts in the specific process. These facilitate the formation of energy balances which act to identify where the energy consumed by the process is transferred, for example into the product, waste combustion stream, cooling water or through the refractory structures. This allows a detailed assessment of the plant operation to be obtained, from which the potential impact of changes in operating practice or the implementation of energy savings schemes. These could include:
Energy audit consultancy from Corus has included such clients as the UK Government’s Energy Technology Support Unit (ETSU), Steel industries in Western Europe, Eastern Europe, India and Africa. Benefits include:
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