Electrical Energy Audit of Walia Steel Industry
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Date
2020-11
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Addis Ababa University
Abstract
As the energy demands rise and the pollution levels grow, it becomes imperative to save the energy in all fields in which it is used therefore the subject of energy conservation is a big concern for industries in general and steel industries in particular where energy is intensively used but not properly managed.
And when it comes to the energy usage of Walia Steel Industry the inefficient energy usage of the factory can be seen from the average power factor value of 0.48, from its poor monthly average load factor of 31.80%, high specific energy consumptions as compared with international benchmarks, under-loaded motors, transformer, and cable losses, oversized installed capacities of distribution transformers and from the monthly average penalties for maximum demand and power factor which is of 81,564.67ETB.
Hence the purpose of this thesis is to address the energy inefficiency problems of the industry through conducting detailed energy audits of the factory and recommend energy conserving measures to alleviate the identified inefficiency reasons for the factory.
Accordingly, the energy audit of the major energy-consuming systems of the factory has been done and for the analysis of the audit historical data of energy consumption and production data of 23 months, measurement data of motors, power distribution lines data has been collected for analysis, modeling, and simulation work using motor master+ international and ETAP 16.0.0 software packages.
From the detailed audit by replacing the under loaded motors with proper sizes of motors can save 705,210.25ETB annually, and by correcting the power factor of the system and reconfiguring the network the energy loss has decreased by 69.1% and the annual cost saving of 167,690.43ETB can be gained from the avoided loss, from avoided demand charge is of 84,253.80ETB and from the avoided power factor penalty is 2,835,000.00ETB.
Finally to mitigate the energy inefficiency of the factory resizing the motors and installing power factor correctors in the power system of the factory has been recommended.
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Keywords
Energy Audit, energy Conserving Measures, Inefficient energy usage, motor loading