Efficiency measures in the three REEMAIN case studies (textile, iron foundry and food) are now almost fully deployed. On the side of textile, BOSSA is currently working on different process phases and components. Some key improvements have been obtained by intervening on machine speeds for spinning and weaving. Interestingly, preliminary experiments for decreasing the process duration of dyeing and finishing showed that the total water consumption could possibly be reduced by one third without negatively affecting the quality. Significant savings could also be reached in the gas consumption for heat production, with preliminary analysis of punctual examples of the data collected on the waste heat recovery system showing a possible annual saving of around 280.000 cubic meters of natural gas.
Major advancements in the food case study at Gullón are expected through the new commissioning of an efficient free cooling control system, foreseen at the end of October. Additionally, a data acquisition system for visual management and energy management is to be set up in the factory. “The hardware devices will be installed in the electrical cabinet of the machines - says Carlos Zaballos Alonso, from the Gullón industrial department - we are working on the design point of view: screens, control, signals and alarms to be represented”. This new system should be operating by February 2017.
In Italy, the SCM foundry has been working on improving the compressed air distribution system, with a new configuration of the compressors area and with the choice of the compressor machines from German supplier BOGE. All this is leading to considerable economic gains, together with those expected from the usage of the new Plasmapour facility, installed during the summer, to manage more efficiently temperatures in the melting process. The flue gas pilot heat exchanger has also been the object of improvement, with a new unit installed and a new campaign started in May 2016, to collect data necessary to design the final system. Some concern has emerged on the side of measuring instruments (a thermocouple and the water flowmeter), issues that the company is confident to bring under control soon. SCM has also given a start to a measure for heat recovery from air compressors. Other interventions have focusses on installations for air destratification, due to the inhomogeneous distribution of heat in the different compartments and works for automating heat management, to enable the new regime when the low temperatures of advanced autumn will require the functioning of the heating system.