Energy efficiency measurement in industrial processes

Although the meaning of energy efficiency is clear, different definitions exist and important issues relating to its implementation still need to be addressed. It is now recognised that complicating factors – such as complex industrial sites and energy flows, multiple products and fuels, and the influence of production rate on energy efficiency – render it necessary to adopt a structured framework to define and measure energy efficiency more precisely. In this paper, a methodology is proposed to build such a framework. The whole energy system of a site is represented using a single matrix equation, which expresses the relationship between imported energies and energy drivers. The elements of the matrix are the specific energy consumptions of each single process. Mathematical process modelling, through statistical analysis of energy consumption data, is used to quantify the specific energy consumption as a function of the output. The results of this structured approach are relevant for energy benchmarking, budgeting and targeting purposes. Furthermore, this approach is suitable for implementation in an energy management system standard (e.g. EN 16001, ISO 50001) or LCA standard (e.g. ISO 14044). Glass and cast iron melting processes are presented in order to illustrate the application of the method.

► A structured framework for energy efficiency in industrial processes is proposed.
► Two energy efficiency indicators are revised to take into account a variable output.
► The whole energy system of a factory can be represented by a single matrix equation.
► Mathematical modelling is used to characterise the energy consumption of a process.
► The results are relevant for energy benchmarking, budgeting and energy targeting.