LAUSR

Abstract In this research, three industrial plants (hot rolling mill for steel, injection molding plant, rinsing in a galvanizing workshop), were studied regarding their potential for the reduction of energy consumption and water consumption using a novel approach. This approach follows the TRIZ method. As a first step, the main function of the process was identified, consequently the theoretical minimum consumption to perform the process was determined. Then, the relevant additional sources of consumption were characterized (non-ideal realization of the process in practical equipment, non-continuous process, consumption for the supply of utilities to support the infrastructure of the factory). In the three studied processes, the theoretical minimum consumption was a fraction of the actually observed consumption. The sources for additional consumption were identified together with the corresponding loss, represented in a simple model showing also potential remedies. For the three enterprises, working programs were elaborated. The implementation of the working programs is underway. It will result in reducing energy consumption per ton of hot rolled wire by 50%, the energy consumption per ton of plastic by 50% and the water consumption per m2 of rinsed surface by more than 80%. The approach of supporting classical benchmarking by calculating the ideal minimum consumption is recommended therefore as a support to conventional benchmarking as guidance for engineers.