Energy management system case study in refractory industry
Sinosteel Luoyang Refractories Research Institute is to collect and monitor electricity consumption information, establish the company’s energy consumption data center, and provide a data management platform for the company’s refined operations and reduction of production costs.
1. Project Files
Project Name: Energy Management Project Case of Sinosteel Luoyang Refractory Research Institute Co., Ltd.
Industry: Refractory industry
Project procurement related equipment: 1 set of energy management system, 1 communication management machine
II. Project Introduction
1. Project Introduction:
Sinosteel Luoyang Institute of Refractory Materials covers a total area of 290,000 square meters, with a total construction area of about 120,000 square meters. It has an industrial base with the National Engineering Research Center for Refractory Materials and the National High-tech Industrialization Special Refractory Materials Demonstration Project as its main body. The headquarters of the institute is located in Jianxi District, Luoyang City, and the production area is located in Luoxin Industrial Park. There are 18 production lines in ten categories, including composite materials, advanced oxides, metallurgical functions, and amorphous refractory materials. The annual output of medium and high-end refractory materials is more than 60,000 tons, and the product varieties are more than 200. They are mainly used in steel, nonferrous metals, petrochemicals, ceramics, building materials, cement, glass, electricity and other industries, and are sold to more than 40 countries and regions in the world, including America and Europe.
2. Customer needs:
A) The main goal of the smart energy system is to collect and monitor electricity consumption information, establish an energy consumption data center for the company, and provide a data management platform for the company’s refined operations and reduced production costs:
By collecting power data in real time and accurately, the task of collecting power data that was previously done manually has been solved; power consumption problems can be discovered in a timely manner through data analysis; and powerful decision-making data can be provided for the company’s production and operation through analysis of the trend of total energy consumption, deviation analysis of total power consumption, comparison of power consumption by equipment or region, and month- on-month analysis ; intelligent power consumption of equipment can be realized, power utilization rate can be improved, and energy-saving effects can be achieved; power consumption indicators of key work processes and unit product energy consumption indicators can be monitored, warning lines can be set for specified energy-saving targets, and automatic alarms, dynamic monitoring, and real-time monitoring can be performed for indicators that fail to reach the targets during the production process;
B) Water use monitoring
The real-time data of industrial water, domestic water, greening water, etc. of each factory area and workshop can be monitored by region on the factory map. The water use plan is displayed in real time to effectively supervise the water management of the entire factory area.
C) Gas usage monitoring
It can realize real-time monitoring of the energy consumption of natural gas, compressed air, high-temperature steam and other gases in the entire factory area and centralized management of their safe use, so as to effectively avoid waste and standardize operations.
D) Energy consumption analysis
Energy cost analysis and bill management; energy consumption statistical ledgers and reports ; providing a data platform to provide a data foundation for the company’s third-party systems.
3. Energy Management System Solutions
Sinosteel Luoyang Refractories Research Institute is divided into three lines: East, Central and Line. The original power monitoring equipment used in the three lines was mechanical power meters without remote transmission function; the water supply network of the water supply system had no water metering equipment, and it was impossible to evaluate the water use situation.
In view of such on-site situations, it is impossible to collect energy consumption data at the bottom layer, and it is even more impossible to carry out subsequent data transmission, storage, display and analysis. Therefore, the metering equipment of Xinguangse’s electricity and water systems is replaced and added to realize the remote transmission of equipment energy consumption data.
The communication management machine of the power system is placed in the East Cutting Mill Room of the East Line Power Distribution. The energy consumption monitoring data of the mill room is transmitted in a limited way. The energy consumption data of the system cutting mill room of the East Line Power Distribution is transmitted wirelessly via LoRa. The environment in the workshop is connected to the energy management system by connecting the video monitoring system to the energy management system, realizing the organic unity of energy management and environmental management.
The power distribution distance between the central and western lines is relatively short, and some equipment can share a communication management machine, thereby transmitting the energy consumption information of the central and western line equipment to the energy management system.
The communication management machine of the water supply system is arranged in the restaurant. The water consumption is transmitted to the management machine by wireless transmission, and the management machine transmits the information to the energy management system via optical fiber.
4. User Benefits
1. Short-term benefits
1) Security
Strengthen the specialization, standardization and regularization of operation and maintenance management of energy-consuming equipment to avoid electrical accidents and personal safety accidents caused by improper operation and management.
2) Decision support
After a short period of data collection and analysis, the energy consumption trends and flows of energy-consuming areas, energy-consuming media, and energy-consuming equipment are determined, providing data models for overall energy-saving transformation, equipment energy consumption anomaly analysis, and department and regional energy consumption performance assessment.
2. Mid-term benefits
1) Improve electricity sales transaction strategy
Calculate and analyze quarterly and annual year-on-year electricity consumption deviations, understand the dynamics of corporate electricity consumption, participate in free electricity sales transactions, reduce annual reported electricity consumption deviations, and reduce electricity unit price costs and overall electricity costs.
2) Extended equipment life
The system can be used to timely detect abnormal conditions of equipment, reduce equipment failure rate, and provide judgment basis for maintenance and overhaul. Through targeted maintenance and management, the operating life of equipment can be extended and the cost of equipment iteration can be saved.
3. Long-term benefits
1) Unmanned operation
Comprehensive control of energy-consuming equipment and energy-consuming media enables unmanned operation and helps operation and maintenance personnel improve operation and maintenance efficiency.
2) Apply for policy subsidies
The government is increasingly supporting the construction of energy management systems. Enterprises that have passed the energy management system construction and certification will receive different levels of policy funding subsidies according to different regional policies. At the same time, it is also conducive to the application of scientific and technological projects by enterprises in the later stage.
