Comparative analysis of specific energy consumption and energy consumption benchmarking in galvanising plants

Abstract

The inadequacy of sustainable energy is endlessly posing major challenges globally. The issue of energy optimisation is indispensable for manufacturing sector, particularly for a hot-dip galvanising process where galvanising furnaces are the significant energy users. This study is aimed at comparative analysis of specific energy consumption and energy consumption benchmarking in four galvanising plants with the view to necessitate the identification of best practices. Energy baselines were used as quantitative reference points to compare energy performance indicators and quantify fluctuations in energy performance during the baseline and reporting periods. A quantitative analysis was also conducted to benchmark four galvanising facilities on factors that included the electricity/zinc ratio, electricity /dips ratio and product tonnage/zinc used ratio. The results revealed improved performance for plant 4 over time relative to the baseline consumption when compared to plants 1, 2 and 3. Plant 4 also outperformed other facilities after the energy efficiency interventions in terms of electricity/zinc ratio and electricity/ product tonnage ratio. Given the disparity between the results of specific energy consumption (SEC) for the four plants, it was concluded that SEC alone should not be used as an energy performance indicator.