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Energies 2019, 12(2), 223; https://doi.org/10.3390/en12020223

Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation

1
Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal
2
Departamento de Engenharia Química, Instituto Superior Técnico, 1049-001 Lisboa, Portugal
3
Departamento de Engenharia Mecânica, Faculdade de Engenharia da Universidade do Porto, 4200-465 Porto, Portugal
4
Dechema Research Institute, 60486 Frankfurt am Main, Germany
*
Author to whom correspondence should be addressed.
Received: 29 November 2018 / Revised: 2 January 2019 / Accepted: 3 January 2019 / Published: 11 January 2019
(This article belongs to the Special Issue Energy Efficiency in Electric Devices, Machines and Drives)
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Abstract

Industrial water circuits (IWC) are frequently neglected as they are auxiliary circuits of industrial processes, leading to a missing awareness of their energy- and water-saving potential. Industrial sectors such as steel, chemicals, paper and food processing are notable in their water-related energy requirements. Improvement of energy efficiency in industrial processes saves resources and reduces manufacturing costs. The paper presents a cooling IWC of a steel wire processing plant in which steel billets are transformed into wire. The circuit was built in object-oriented language in OpenModelica and validated with real plant data. Several improvement measures have been identified and an optimisation methodology has been proposed. A techno-economic analysis has been carried out to estimate the energy savings and payback time for the proposed improvement measures. The suggested measures allow energy savings up to 29% in less than 3 years’ payback time and water consumption savings of approximately 7.5%. View Full-Text
Keywords: energy efficiency; industry; water circuits; OpenModelica; optimisation energy efficiency; industry; water circuits; OpenModelica; optimisation
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Iten, M.; Oliveira, M.; Costa, D.; Michels, J. Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation. Energies 2019, 12, 223.

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