Energy efficiency is a key agenda item for manufacturers; being as it is one of their most significant costs – often over and above their raw materials costs. Because energy costs are not totally in the user’s control the whole topic becomes an inevitable ‘elephant in the room’ at management meetings. Unfortunately this ‘elephant in the room’ has the capability to seriously trample manufacturing profits and ride roughshod over environmental obligations unless it is tamed.
Modern day plants are increasingly sophisticated in their instrumentation, DCS and SCADA systems and level of advanced control and equipment monitoring. These systems are capable of generating large quantities of data regarding the plant operation all of which can be utilised for product quality management, predictive maintenance, process optimisation and better energy management.
In many cases much of the data accumulated is laid dormant due to the company’s incapability or lack of appropriate data analysis software to analyse the information or as is often the case the incentive to do so. However Hosokawa Micron appreciates the value of stored data such as process flows, pressures, pressure differentials, temperatures and energy usage all of which it can utilise to pinpoint areas for improved energy efficiency or even other performance improvement strategies.
Today we discuss how combining engineering know how and sophisticated analysis software can set manufacturers on an energy efficiency course that keeps track with changing production parameters, helping them to create a unique energy efficiency strategy for tomorrow.
Understanding your plant
An essential part of energy efficiency is understanding individual plant operations and the complex interactions of multiple activities. To do this Hosokawa Micron process engineers start with an Overall Equipment Effectiveness survey to identify and benchmark underperforming operations that allow us to recognise new opportunities for lowering energy consumption and reduce emissions as part of a focus on environmental factors surrounding energy use.
Quantify the potential benefits from optimisation of powder processing equipment
At this stage customers are able to make valued judgements on the benefits of making the changes with the opportunity to weigh up for themselves any costs involved versus the energy cost savings resulting from remedial actions.
24/7 Birds Eye Overview
The system keeps a watch on your plant by 24/7 monitoring and measuring activities against pre-set parameters. It is this knowledge of your operations that Hosokawa engineers use to diagnose operating problems, energy peaks, excessive energy use machinery etc.
Proactive diagnostics for trouble shooting and best practice settings
Hosokawa Micron engineers using the system can pinpoint areas of inconsistent power consumption across similar equipment, time periods, individual processing activities identifying how best to implement plant operation changes to positively address energy efficiency.
Intelligent control systems
Hosokawa Micron’s intelligent control system can keep your plant working in pre-set operational ‘best fit’ or optimised setting to meet your energy efficient operating requirements. The system offers model-based multivariate control – identifying not only independent process variables but also dependent variables and the dynamic between them.