Increasing the energy efficiency of a hot-dip galvanizing plant and reducing its environmental impact

  • Jacek Szymczyk Institute of Heat Engineering, Warsaw University of Technology,
  • Aldona Kluczek Institute for Organization of Production, Faculty of Production Engineering, Warsaw University of Technology,

Abstract

Most industrial plants prioritize efficient, uninterrupted production, with production costs coming in second even though they are no less important. Any commitment to boosting energy efficiency while cutting pollution and energy waste is treated as an after-thought. This article presents an in-depth analysis of energy efficiency and its related emissions reduction opportunities in the context of a hot-dip galvanizing plant. This paper describes the modernization of the galvanization process in terms of the current situation with the process and possible energy efficiency improvement actions (such as operating parameters and changes at system level), which affect the overall exhaust emissions without changing current production or the technology used. Results show that the energy requirement dropped by 23%, from 399.3 MJ/tonne at baseline to 307 MJ/tonne in the improvement scenario, while emission intensity NO dropped by 96%.

References

[1] K. Jordan-Korte, Government promotion of renewable energy technologies, Springer, 2011.

[2] M. A. Rosen, H. A. Kishawy, Sustainable manufacturing and design: Concepts, practices and needs, Sustainability 4 (2) (2012) 154-174.

[3] IEA (International Energy Agency), 2008. IEA Energy Policies Review. The European Union, Paris, France. URL (available at https://www.iea.org/publications/freepublications/publication/EU2008.pdf)

[4] J. Kroes, R. Subramanian, R. Subramanyam, Operational compliance levers, environmental performance, and firm performance under cap and trade regulation, Manufacturing & Service Operations Management 14 (2) (2012) 186–201.

[5] IEA(Energy Information Administration), 2015. Accelerating Energy Efficiency in Small and Medium-sized Enterprises. Powering SMEs to catalyse economic growth. URL (available at www.iea.org/publications/freepublications/publication/SME_2015. pdf)

[6] EC (European Commission), 2012. Directive 2012/27/EU on energy efficiency.

[7] S. T. Anderson, R. G. Newell, Information programs for technology adoption: the case of energy-efficiency audits, Resource and Energy Economics 26 (1) (2004) 27–50.

[8] C. Galitsky, L. Price, E. Worrell, Energy efficiency programs and policies in the industrial sector in industrialized countries, Lawrence Berkeley National Laboratory.

[9] P. Thollander, O. Kimura, M. Wakabayashi, P. Rohdin, A review of industrial energy and climate policies in japan and sweden with emphasis towards SMEs, Renewable and Sustainable Energy Reviews 50 (2015) 504–512.

[10] C. Drumm, J. Busch, W. Dietrich, J. Eickmans, A. Jupke, Structese–energy efficiency management for the process industry, Chemical Engineering and Processing: Process Intensification 67 (2013) 99–110.

[11] G. P. Barbetta, P. Canino, S. Cima, The impact of energy audits on energy efficiency investment of public owners. evidence from italy, Energy 93 (2015) 1199–1209.

[12] A. Kluczek, P. Olszewski, Energy audits in industrial processes, Journal of Cleaner Production 142 (2017) 3437–3453.

[13] E. Worrell, J. A. Laitner, M. Ruth, H. Finman, Productivity benefits of industrial energy efficiency measures, Energy 28 (11) (2003) 1081–1098.

[14] Brueske S., Sabouni R., Zach C., Andres H., 2012. U.S. Manufacturing energy use and greenhouse gas emissions analysis. ORNL/TM-
2012/504, Energetics Incorporated,. URL (available at http://energy.gov/sites/prod/files/2013/11/f4/ energy_use_and_loss_and_emissions.pdf)

[15] M. Noro, R. Lazzarin, Energy audit experiences in foundries, International Journal of Energy and Environmental Engineering 7 (4) (2016) 409–423.

[16] I. Dincer, The role of exergy in energy policy making, Energy policy 30 (2) (2002) 137–149.

[17] J. A. Moya, N. Pardo, The potential for improvements in energy efficiency and CO2 emissions in the EU27 iron and steel industry under different payback periods, Journal of Cleaner Production 52 (2013) 71–83.

[18] P. des Nations Unies pour l’environnement, Towards a green economy: Pathways to sustainable development and poverty eradication, United Nations Environment Programme, 2011.

[19] N. R. Council, et al., Real prospects for energy efficiency in the United States, National Academies Press, 2010.

[20] S. Backlund, P. Thollander, Impact after three years of the swedish energy audit program, Energy 82 (2015) 54–60.

[21] Y. Li, J. Li, Q. Qiu, Y. Xu, Energy auditing and energy conservation potential for glass works, Applied Energy 87 (8) (2010) 2438-2446.

[22] J. Petek, P. Glavic, A. Kostevšek, Comprehensive approach to increase energy efficiency based on versatile industrial practices, Journal of Cleaner Production 112 (2016) 2813–2821.

[23] J. Fresner, F. Morea, C. Krenn, J. A. Uson, F. Tomasi, Energy efficiency in small and medium enterprises: Lessons learned from 280 energy audits across europe, Journal of Cleaner Production 142 (2017) 1650–1660.

[24] M. Dörr, S.Wahren, T. Bauernhansl, Methodology for energy efficiency on process level, Procedia CIRP 7 (2013) 652–657.

[25] A. Kluczek, Assessing measures of energy efficiency improvement opportunities in the industry., LogForum 13 (1).

[26] K. Tanaka, Assessment of energy efficiency performance measures in industry and their application for policy, Energy policy 36 (8) (2008) 2887–2902.

[27] J. Szymczyk, P. Olszewski, Flameless combustion-state of art, Archivum Combustionis 36 (1) (2016) 13–36.

[28] V. Kuklik, Post on the issue of safety of steel structures of hot dip galvanized structural components, Procedia Engineering 40 (2012) 241–246.

[29] P. Bicao, W. Jianhua, S. Xuping, L. Zhi, Y. Fucheng, Effects of zinc bath temperature on the coatings of hot-dip galvanizing, Surface and Coatings Technology 202 (9) (2008) 1785–1788.

[30] Dallin G. W., 2012. Galvanizing - 2012. Continuous hot-dip galvanizing - process and products. Galvinfo Center - A program of the international zinc association. URL (available at http://www.galvinfo.com/GalvInfo_2012_Course_Docs/Galvanizing%2020120831.pdf)

[31] D. Che, Y. Liu, C. Gao, Evaluation of retrofitting a conventional natural gas fired boiler into a condensing boiler, Energy Conversion and Management 45 (20) (2004) 3251–3266.

[32] M. Habib, M. Elshafei, M. Dajani, Influence of combustion parameters on nox production in an industrial boiler, computers & fluids 37 (1)
(2008) 12–23.

[33] ORNL, 2008. Combined heat and Power. Effective Energy Solutions for a Sustainable Future. URL (available at http://info.ornl.gov/sites/ publications/files/Pub13655.pdf)
Published
2018-02-27
How to Cite
SZYMCZYK, Jacek; KLUCZEK, Aldona. Increasing the energy efficiency of a hot-dip galvanizing plant and reducing its environmental impact. Journal of Power Technologies, [S.l.], v. 97, n. 5, p. 349--358, feb. 2018. ISSN 2083-4195. Available at: <https://papers.itc.pw.edu.pl/index.php/JPT/article/view/1262>. Date accessed: 14 dec. 2024.
Section
Research and Development in Power Engineering 2017

Keywords

Energy efficiency; galvanizing; environmental impact; modernization

Most read articles by the same author(s)

Obs.: This plugin requires at least one statistics/report plugin to be enabled. If your statistics plugins provide more than one metric then please also select a main metric on the admin's site settings page and/or on the journal manager's settings pages.