Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry

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dc.contributor.advisorHibberd, Andrewen_ZA
dc.contributor.authorThiel, Dennisen_ZA
dc.date.accessioned2017-05-16T07:35:31Z
dc.date.available2017-05-16T07:35:31Z
dc.date.issued2016en_ZA
dc.description.abstractDue to lack of generation capacity and high energy intensities South Africa's electricity supplier is forced to shut down high energy users frequently. Power cuts as well as escalating electricity prices threaten the country's steel industry. The objective of this study was to identify cost-effective energy efficiency improvements for the South African foundry industry. A lack of research in South African foundries was identified as existing literature on the topic was analysed. A large foundry operating an induction furnace in the Western Cape served as subjects to investigate the topic specifically in South Africa. The aim was to identify the energy intensity, evaluate already implemented energy efficiency measures and identify further opportunities to reduce energy cost of the foundry. The method followed for the data collection was much orientated on an industry energy audit. Types of energy, amounts and cost of energy usage were determined. The energy consumption and energy intensity of the foundry were analysed, based on meter readings, electricity bills and where necessarily a "bottom-up" approach for estimation was used. Results of the energy audit have shown that the foundry under review consumes about 127,000 MWh annually with a maximum demand of 26,500 kVA. The already implemented energy saving measures decreased the company's energy usage by 5% resulting in a current energy intensity of 1,493ZAR/ton. Further proposed energy efficiency measures included the compressed air system, preheating of the charge material and the reduction of the holding furnaces were analysed. The results of all evaluated measures, namely lighting, load-shifting and maximum demand management were cost effective solutions. Furthermore the recommended energy efficiency measures, namely reduction of compressed air leaks, reduction of holding furnaces as well as preheating of charge material, showed in theoretical calculations a reduction of carbon emissions as well as cost savings. This study offers an insightful view on energy intensity and energy efficiency opportunities in South African foundries, especially the ones operating an induction furnace.en_ZA
dc.identifier.apacitationThiel, D. (2016). <i>Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry</i>. (Thesis). University of Cape Town ,Faculty of Engineering & the Built Environment ,Energy Research Centre. Retrieved from http://hdl.handle.net/11427/24288en_ZA
dc.identifier.chicagocitationThiel, Dennis. <i>"Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry."</i> Thesis., University of Cape Town ,Faculty of Engineering & the Built Environment ,Energy Research Centre, 2016. http://hdl.handle.net/11427/24288en_ZA
dc.identifier.citationThiel, D. 2016. Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry. University of Cape Town.en_ZA
dc.identifier.ris TY - Thesis / Dissertation AU - Thiel, Dennis AB - Due to lack of generation capacity and high energy intensities South Africa's electricity supplier is forced to shut down high energy users frequently. Power cuts as well as escalating electricity prices threaten the country's steel industry. The objective of this study was to identify cost-effective energy efficiency improvements for the South African foundry industry. A lack of research in South African foundries was identified as existing literature on the topic was analysed. A large foundry operating an induction furnace in the Western Cape served as subjects to investigate the topic specifically in South Africa. The aim was to identify the energy intensity, evaluate already implemented energy efficiency measures and identify further opportunities to reduce energy cost of the foundry. The method followed for the data collection was much orientated on an industry energy audit. Types of energy, amounts and cost of energy usage were determined. The energy consumption and energy intensity of the foundry were analysed, based on meter readings, electricity bills and where necessarily a "bottom-up" approach for estimation was used. Results of the energy audit have shown that the foundry under review consumes about 127,000 MWh annually with a maximum demand of 26,500 kVA. The already implemented energy saving measures decreased the company's energy usage by 5% resulting in a current energy intensity of 1,493ZAR/ton. Further proposed energy efficiency measures included the compressed air system, preheating of the charge material and the reduction of the holding furnaces were analysed. The results of all evaluated measures, namely lighting, load-shifting and maximum demand management were cost effective solutions. Furthermore the recommended energy efficiency measures, namely reduction of compressed air leaks, reduction of holding furnaces as well as preheating of charge material, showed in theoretical calculations a reduction of carbon emissions as well as cost savings. This study offers an insightful view on energy intensity and energy efficiency opportunities in South African foundries, especially the ones operating an induction furnace. DA - 2016 DB - OpenUCT DP - University of Cape Town LK - https://open.uct.ac.za PB - University of Cape Town PY - 2016 T1 - Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry TI - Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry UR - http://hdl.handle.net/11427/24288 ER - en_ZA
dc.identifier.urihttp://hdl.handle.net/11427/24288
dc.identifier.vancouvercitationThiel D. Reducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundry. [Thesis]. University of Cape Town ,Faculty of Engineering & the Built Environment ,Energy Research Centre, 2016 [cited yyyy month dd]. Available from: http://hdl.handle.net/11427/24288en_ZA
dc.language.isoengen_ZA
dc.publisher.departmentEnergy Research Centreen_ZA
dc.publisher.facultyFaculty of Engineering and the Built Environment
dc.publisher.institutionUniversity of Cape Town
dc.subject.otherSustainable Energy Engineeringen_ZA
dc.titleReducing industrial energy costs through energy efficiency measures in the South African foundry industry - evaluation and opportunities of a South African foundryen_ZA
dc.typeMaster Thesis
dc.type.qualificationlevelMasters
dc.type.qualificationnameMSc (Eng)en_ZA
uct.type.filetypeText
uct.type.filetypeImage
uct.type.publicationResearchen_ZA
uct.type.resourceThesisen_ZA
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