With these steps you can achieve energy savings in industrial processes

Industry is facing an unprecedented energy crisis, costs are rising dramatically and, in addition to businesses, many households are also concerned about energy consumption. 40 percent of the energy in the Netherlands and Belgium goes to industry and 70 percent of that goes to electrically powered systems. Analyzing energy consumption is therefore becoming increasingly important. But how exactly do you do this? Thomas Vermeir, Offer Marketeer Drives & Drive Systems at Schneider Electric, explains the next concrete steps.

Step 1: Examine the engines in your factory

The engine is known as the workhorse of industry and therefore a major user of electricity. An electric motor converts electrical power into mechanical power and the extent to which this happens is called the motor efficiency. Motors can be classified into four efficiency standards: standard IE1, high IE2, premium IE3 and super premium IE4 and the latter standard IE5, which is at least 20 % more efficient than IE4. The fewer motor losses, the higher the efficiency standard and the less energy the motor consumes.

Step 2: See if you can apply speed variation

When an electric motor is energized, it runs at a fixed speed. However, without an aid, this speed cannot be controlled and energy can be wasted. After all, the application runs at full power, while 30% may require less power. The most efficient tool for adjusting the speed in the electric motor is a frequency controller. By using the frequency controller, you ensure that speed variation is possible. You can therefore lower the speed and this is beneficial if you want to save energy.

Step 3: Measuring is knowing

Measurement data are crucial when analyzing energy consumption. By digitally connecting equipment, all energy data can be centralized. The collected data can be processed into visualizations and provide unique insights in an overview, available to stakeholders. These give the user an idea of the total and partial consumption of industrial installations. This can provide an initial indication that encourages savings.

'It is not necessary to focus on using all possible sensors and analyzing all types of consumption from the start.'

Step 4: Analyze your energy consumption

It analyze energy consumption is a step that seems complicated, but it is actually quite simple. By linking acquired energy data to production parameters, even more in-depth insights can be created. It is not necessary to focus on using all possible sensors and analyzing all types of consumption from the start. Using software that analyzes different types of consumption, such as gas, electricity, steam and water, can provide initial indications of simple savings.

The mix and the connection makes the difference

Ultimately, it is a mix of hardware and software that makes energy savings possible. Hardware is all about effective energy savings: motor efficiency and speed variation. Software collects and analyzes all energy data and provides insights into consumption. The combination and digital connection of the two ensure that an industrial installation is ready for the future and that it becomes resistant to energy price shocks.

Tip: our Altivar process frequency controllers contain all the necessary sensors to measure energy consumption, which are very easy to connect to our Ecostruxure power monitoring software, which gives you direct insight into your consumption through our clear dashboards.

More information?

Then watch Schneider Electric's On Demand webinar about energy saving in industrial processes, or contact me directly:

Thomas Vermeir; thomas.vermeir@se.com.