Using energy efficiently in industry

The set of binding measures to help the EU reach its 20% energy efficiency target by 2020

Let’s get down to business: with the new European Energy Directive to be implemented in all EU member states, it is high time to really start thinking about how to improve energy efficiency at all stages of the energy chain – including and especially in industrial production. Manufacturing and production account for a substantial portion of total energy consumption, which also means that any savings have a correspondingly substantial impact on total energy savings. In order to produce something, you need energy, but the specific challenge is to use energy as efficiently as possible – as much as necessary, as little as possible.

Energy is also an important driver of production costs, especially in energy-intensive industries such as the chemical, metals processing, and cement industries. For example, energy costs constitute 20% to 40% of the total cost of cement production. Consequently, energy efficiency is a major lever to improve competitiveness. It really pays to take a closer look at how to improve energy efficiency in industry.

Detecting energy drains

In a publication on the potential of energy efficiency, the National Academy of Engineering (NAE) stated that improvements in energy efficiency could reduce energy use in industry by 14% to 22%. But just where are the energy drains in your production? Is it leaks in compressed air systems, over- or underdimensioned heat exchangers, a lack of awareness and training of your staff, outdated drive systems, insufficient controllability in your systems, or even inadequate insulation of buildings or equipment?

Where should you start, and what should you do? The answers to these questions may not be easy to find. In fact, the situation is so complicated that there are even dedicated energy-efficiency training factories where production managers can learn how to tackle the issue of improving energy efficiency. No matter what your business, though, improving energy efficiency should follow a three-step process:

Identifying how much energy is consumed where and how.

Evaluating the savings potential and identifying the resources required to exploit it.

Realizing the appropriate measures.

A comprehensive solution for improving energy efficiency

The “right” answer to the question of how to improve energy efficiency can be very different in each case – ranging, for example, from installing individual components that have a higher efficiency rating to implementing new systems to redesigning your process or plant. In addition to energy-efficient products and solutions, the right expertise and energy management software should be part of your energy optimization toolkit. This will allow you to prove that what you intend to do will reduce energy costs and improve your productivity and competitive edge.

And in the end, everybody will be happy: environmentalists, state officials, senior management, and investors. You see, even serious businesspeople can turn into tree huggers when given good enough cause.