Energy Consumption Optimization in a Metallurgical Industrial Facility: A Case Study

Optimizing energy consumption in industrial facilities is essential for reducing costs and improving efficiency. This study examines a metallurgical plant producing ferroalloys, casting inoculants, wire cords, and high-purity magnesium ingots, characterized by high energy use and low power factor from continuous operation of heavy equipment. Energy consumption, demand patterns, three-phase current imbalance, power factor, and reactive power requirements were analyzed. The investigation employed sub-metering, load monitoring, and statistical analysis. Optimization measures, including smart load management, variable frequency drives (VFD), LED lighting, and automatic capacitor banks, were proposed. Results indicate potential energy savings of ۲۵-۴۰% and power factor improvement above ۰.۹۱, reducing costs and extending equipment life.

Keywords:

Energy Optimization , Industrial Electricity , Power Factor Correction , Smart Load Management , Reactive Power Compensation