Energy efficiency in industry is a key point for the sector. On a national level, the industry is responsible for 41% of the total energy consumed in Brazil, according to the National Confederation of Industry (CNI).
Some good news is that in 2022 the industrial sector showed a 1.5% reduction in energy consumption, according to the Quarterly Bulletin of Electricity Consumption, linked to the Energy Research Company (EPE), a federal agency responsible for energy planning.
Although in the commercial and residential sectors the EPE Bulletin has registered an increase of 0.6% in energy consumption in the first quarter of the year, the industrial segment went against this result and has been demonstrating a good potential in terms of energy efficiency.
This is due in part to the environmental awareness of managers with regard to sustainable construction and intelligent systems in the production line. Thus, it is possible to save energy without sacrificing productivity in the industrial chain. This is what we will talk about in this content, showing how to achieve energy efficiency from more modern and sustainable practices.
What is the role of industry in e nergetic efficiency?
Generally speaking, the industrial sector represents a scenario of attention when it comes to energy efficiency. After all, the production chains are extensive and cannot stop, which ends up driving high consumption.
Generally speaking, the industrial sector represents a scenario of attention when it comes to energy efficiency. After all, the production chains are extensive and cannot stop, which ends up driving high consumption.
When an industry positions itself as a sustainable and energy efficient company, its image in the market improves and profitability is also much higher. However, according to data from Epbr, a specialized media in the energy market, energy efficiency is still lagging behind in Brazil in all segments.
Identificar os grandes vilões do cenário é o primeiro passo para se conscientizar a esse respeito. Em resumo, os principais fatores que contribuem com a manutenção deste panorama são:
- increase in world population;
- emergence of new enterprises and industries;
- growth in demand for electric energy;
- the high cost of electricity.
The search for energy efficiency is the great means of overcoming this scenario and making it more optimistic. This process is the result of a global effort of energy transition, i.e., that aims to replace an energy generation matrix in which the use of fossil fuels predominates by a sustainable chain, based on renewable sources and with low emission rates of pollutants such as CO2.
The rational use of electrical energy is also a decisive aspect in this process, in order to contain greenhouse gas emissions and at the same time reduce operating costs in the industry. Energy efficiency is therefore an environmental and, at the same time, an economic issue. This is why investments in sustainable solutions are so important. We will talk more about these solutions throughout the content.
What are the main villains of energy efficiency?
Before we talk about sustainable systems for industry and think about efficient methods of using energy, we have to start from an analysis of waste. According to the National Program for Conservation of Electrical Energy (Procel), the annual waste of energy reaches 22 million kW, which is equivalent to 1.54 billion dollars. This when we consider industries, residences, and commerce.
It is clear, then, that there is still much work to be done in the search for energy efficiency in industry and other segments. The following are the main villains that undermine this quest in industrial plants in general.
Electric Motors
It is estimated that in Brazilian factories about 20% of the motors installed are more than 25 years old. As is well known, old machinery is one of the things that consumes the most energy in industries, since they are outdated technologies. It is no coincidence that approximately 70% of a factory's energy expenditure comes from these motors.
The best alternative in this case is to replace the old motors with new, high-efficiency solutions. Although they require a high initial investment, the return comes in the medium to long term with energy savings.
Another alternative is to use adjustable speed drives in older machines. This makes it possible to adapt the system to varying workloads. This way also contributes to reducing energy waste.
Compressed Air Systems
Negligently maintained compressed air systems can generate a great deal of wasted energy, mainly due to internal leakage. This problem is usually due to wear on piston rings or valves. This produces less air than the compressor's rated capacity. This is why proper maintenance is so important.
In addition, when it comes to the distribution and use of gas in industries, it is important to check whether there is any pressure loss between the reservoirs and the points of use. Making use of low-pressure fans and compressors can help in the quest for energy efficiency in industry - especially when used in places where compressed air is not needed as much.
Air-conditioning and ventilation
The improper use of air conditioning directly influences the consumption of electricity. Therefore, using it in the appropriate temperature ranges for the environment and installing air curtains are some important measures to avoid waste on a daily basis. More than that, preventive maintenance should always be considered (cleaning the filters, checking for gas leaks, etc.);
How to achieve energy efficiency in industry?
One of the main ways to achieve energy efficiency in industry is to invest in renewable sources and other sustainable solutions. The installation of photovoltaic panels to generate energy from sunlight is a good example, although the system requires a high initial cost.
Another alternative, with lower costs, is the use of LED lamps, which combine maximum luminous efficiency with minimum energy consumption. In addition, the useful life of LEDs is very extensive. A system that combines daylighting and dimmable LEDs represents the most innovative aspect of this proposal.
Besides helping in the search for energy efficiency in the industry, these sustainable solutions make the company more competitive in the market. After all, working in an ecologically correct manner reveals a positive brand image.
Replace conventional light bulbs with LEDs
The exchange of incandescent and fluorescent lamps for LED models is the most recurrent example when it comes to reducing energy costs, combining maximum performance with minimum consumption. In addition, LED lamps are recyclable and can be dimmed, which allows even greater control in their use.
The ideal is to install automatic sensors to ensure that the lamps will remain off whenever necessary. Especially in factories and industrial parks, it is also recommended to invest in a complementary way to LED lamps in solutions that prioritize natural lighting, so as to also favor thermal comfort in the shed.
Replace old equipment
Many industries operate with old machines that, although they are within their useful life, are not economical from an energy point of view, as we mentioned before. Replacing them with more modern versions is a viable solution that brings results even in the short term. In fact, this is one of the most common practices in industrial retrofit projects.
There is a range of efficient equipment available on the market, with higher yield and lower consumption compared to the older versions. Another alternative is to install transformers so that the older appliances work in the nominal power range compatible with the performance of the machinery.
Use industrial air conditioners
The industrial air conditioner has a number of advantages over conventional air conditioners, particularly with regard to energy efficiency. In addition to significantly reducing energy consumption, this type of air conditioner is easier to install and requires little maintenance.
The installation of industrial blinds is also a very efficient solution when it comes to favoring thermal comfort and reducing electricity costs. The blinds work as a natural ventilation mechanism, allowing continuous air flow and preventing workers from being exposed to sudden temperature changes, besides preventing the accumulation of contaminants in the air.
Bet on natural lighting and ventilation
Throughout this content, we have already given some clues about the importance of natural lighting and ventilation systems for industry. Now we will go into more detail about them. These sustainable solutions bring quick payback and are more affordable than other alternatives. Among the systems of natural lighting and ventilation that operate at zero energy cost, we can mention domes, shutters and industrial louvers.
The lighting conditions can be considerably improved with the installation of linear domes. This structure favors the entrance of natural light in the right measure for the shed, which will be well illuminated during most of the workday. Thus, it is not necessary to resort to artificial lamps for about eight hours of work.
Another advantage is that the domes help control the internal temperature and have protection against UV rays, making the place more pleasant. When the subject is thermal comfort, the champion solutions are the shutters and the industrial louvers. If used together, the effect of constant air renewal in the shed is further enhanced.
Thus, the accumulation of stale air, dust and eventual toxic gases in suspension in the environment is avoided. These particles are eliminated by the exhaustion process that takes place at the entrances and exits of the lanterns, as a result of the Venturi and chimney effects.
Because ventilation is permanent and air exchange is constant, there will be no need to use air-conditioning units. The air quality, in turn, will be the best possible, which also helps to create a healthier corporate environment. In other words, besides gaining energy efficiency in the industry, you also gain more quality of life in the workplace.
So if you are looking for intelligent solutions with guaranteed return for your factory, you already know where to start. Invest in natural lighting and ventilation systems and elevate your industry to a more economical, modern, and sustainable level.
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