The use of water in domestic purposes is occasionally overlooked within industrial companies. For this large company, savings associated with introducing water conservation devices for domestic use reached 3% of the total company water consumption.
Solid waste from this fiberglass pipe manufacturing company was not utilized, and was originally sent to landfills. Knowing that the waste had binding material in its constituents, the waste was mixed with other non-binding material and used to produce artificial marble. The binding properties of that waste was a main success factor for this prototype.
For this glass manufacturing company, the lights represented almost 3% of their electricity consumption. After preparing a light inventory, it was decided to replace the conventional lamps with LED lamps. Moreover, the company agreed to adopt some management practices including the utilization of transparent sheets allowing for sunlight, and installation of motion sensors to switch on the lights only when needed. These actions together can save up to 80% of the light consumption.
This company had three superheated boilers operating in parallel. For safety reasons, the three boilers were always running, yet operating at the low end of their load factor. From the walkthrough, steam leaks were observed at several locations, thus a steam mapping was prepared to define the exact demand and supply from steam. Based on the mapping results, it was concluded that a better steam management system supplemented with a computer aided software can tremendously reduce the steam leaks, and safely switch off one boiler, saving 4% of the water consumption, and 5% of the natural gas.
This fiberglass pipes manufacturing company had losses of material that are spilled during the production process. This spilled material is not suitable for reuse in the production. Installing a pyrolysis plant can utilize that spilled material to produce pyrolysis oil, carbon black, and recover small portion of the material.
A plastic recylcing company practices setting the temperature of the contamination removal steps at limits exceeding the optimum setting. Resetting the set points to the supplier’s recommended setting saved 5% of the energy, and improved the product quality.
To recycle PET plastic material, the raw material has to be cleaned of dirt, labels and caps. The production line starts with a grinding and washing process, followed by sorting stations to remove all undesirable contamination.
Installing a pre-sorting station prior to raw material feed to the washing line, served in increasing the production throughput. That pre-sorting station served to remove the sand, dust, fine particles, and partially remove the labels from the input material.
In a tableware glass manufacturing facility, the furnace flue gases are directed to a recuperator type chimney, which serves to preheat the combustion air.
Measurements showed that the chimney insulation is detiorated at several locations, and the temerature of flue gases exiting the chimney is relatively high. Maintaining and fixing the chimney insulation serves in increasing the efficiency of the recuperator to preheat the combustion air, leading to increase in the combustion efficiency, saving on energy consumption.