Case Study: Reducing Energy Costs and Fuel Expenses through Demand Forecasting of Electricity and Steam
Achieved demand forecasting for electricity and heat and automatic control, optimizing the operation of the cogeneration system. Reduced energy costs by approximately 21 million yen annually.
Related Products: MainGATE/PPA MainGATE/PPA (Process Performance Analysis) is an energy management and analysis tool based on a manufacturing execution system. It analyzes and visualizes factors that hinder operational efficiency from integrated data on energy and manufacturing management, achieving energy savings improvements of 3-5% (with a maximum recorded improvement of 27%).
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basic information
A case study of the introduction of an energy management and analysis tool based on a manufacturing execution system for the pulp and paper industry. Prior to the implementation, there were issues with reverse flow and costs associated with gas turbine full operation, steam, and boiler fuel. Therefore, it enabled demand forecasting for electricity and steam, achieved optimal operation of the cogeneration system, reduced the amount of electricity received, and lowered fuel costs for exhaust gas boilers and auxiliary boilers.
Applications/Examples of results
- Implementing Company: Manufacturing Industry (Pulp and Paper) - Implemented Products: MainGATE/PPA, MainGATE/MSPC [Challenges Before Implementation] - Power Reverse Flow Issue: Reverse flow occurs during full operation of gas turbines when demand decreases. - Waste of Steam: Release of surplus steam due to constant load operation. - Inefficient Fuel Consumption: Fuel loss during auxiliary boiler operation when steam is insufficient. [Effects After Implementation] - Annual cost reduction of 6 million yen due to reduction in received electricity consumption. - Annual cost reduction of 7 million yen due to reduced fuel costs for exhaust gas boilers. - Annual cost reduction of 8 million yen due to reduced fuel costs for auxiliary boilers.
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Case Study: Reducing Energy Costs and Fuel Expenses through Demand Forecasting of Electricity and Steam
Current Status and Challenges of Manufacturing Industries Working on Energy Visualization for the Food and Chemical Industries
Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools