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Open AccessArticle

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

Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal
Departamento de Engenharia Química, Instituto Superior Técnico, 1049-001 Lisboa, Portugal
Departamento de Engenharia Mecânica, Faculdade de Engenharia da Universidade do Porto, 4200-465 Porto, Portugal
Dechema Research Institute, 60486 Frankfurt am Main, Germany
Author to whom correspondence should be addressed.
Energies 2019, 12(2), 223;
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)
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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MDPI and ACS Style

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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