Energy Management System in the Steel Industry
SOLVERA LYNX CASE STUDY
ENERGY MANAGEMENT SYSTEM IN THE STEEL INDUSTRY
The company is one of the largest steel producers in Europe. It manufactures a wide range of more than 200 different steel grades, dimensions, and forms – from carbon and alloy structural steels to tool and specialty steels – in the form of rolled and forged products.
The company decided to implement an energy management project with the following objectives:
- real-time monitoring and analysis of energy consumption,
- definition and analysis of key energy performance indicators,
- implementation of an energy management system,
- development of benchmarking and savings calculation methodologies,
- introduction of energy cost allocation and billing,
- reduction of energy consumption as a result of active energy management.
KEY FACTS
RESOURCE CONSUMPTION
Electricity, natural gas, compressed air, oxygen, heat, water, argon, nitrogen
MEASUREMENT POINTS
340× electricity, 78× natural gas, 10× compressed air, 10× oxygen, 9× cooling water, 31× heating, 2× argon, 1× nitrogen, 42× potable water
CONSUMPTION
Electricity Consumption
12 GWh/month
Natural Gas Consumption
3 million Nm³ per month
Heat Consumption
800 MWh per month
Technical Gases Consumption
870,000 kg per month
- Oxygen: 700,000 kg/month
- Nitrogen: 150,000 kg/month
- Argon: 20,000 kg/month
Compressed Air Consumption
3 million Sm³ per month
Water Consumption
300,000 m³ per month
OUR SOLUTIONS AND PROJECT RESULTS: GEMALOGIC
Core Tools: general overview, real-time data monitoring, historical data analysis, alarms (SMS, email), user-generated reports, geolocation features.
Energy Efficiency Tools: load profile visualization, specific consumption indicators (KPIs), benchmarking, time-based comparisons, target-based energy monitoring, M&T and CUSUM analysis, energy cost allocation and billing across different suppliers, buildings, metering points, and energy products.
OUR SOLUTIONS
Energy Consumption Monitoring
Electricity, natural gas, compressed air, oxygen, heat, water, argon, nitrogen
Energy Efficiency Analysis and Forecasting
Energy performance indicators
Correlation between energy consumption and production output
Energy Performance and Target Management
Target energy consumption volumes and costs
Deviation alerts for abnormal consumption or cost levels
CO₂ Emissions Accounting
PROJECT RESULTS
BENEFITS OF PROJECT IMPLEMENTATION
CONSUMPTION REDUCTION
The implementation of the energy management system resulted in a significant reduction in resource consumption across various production processes. Electricity consumption was reduced by 3% through distribution network optimization and improved efficiency of the Electric Arc Furnace (EAF). Natural gas consumption decreased by 5–7% due to furnace optimization and enhanced process flows. In addition, industrial gases, heat, water, and compressed air recorded a combined reduction of 7%, primarily as a result of improved leak detection and continuous system monitoring.
These reductions not only delivered substantial financial savings but also significantly reduced the company’s environmental footprint.
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