Energy Saving in Industrial Process Based on the Equivalent Production Method to Calculate Energy Performance Indicators

Abstract

This paper presents the estimation and analysis of energy performance indicators based on the equivalent production method to improve the decisions and operational actions to reduce the energy consumption of a fertilizer company in Colombia, where the global consumption of natural gas in the plant is 4800 kcf per day for an equivalent production of 1,029 MT of NPK fertilizer 15-15-15, where the 63.4% of the energy is consumed by the complex fertilizers line, the 29.2% by equipment of the energy supply plant, and finally the 7.4% is consumed by the fertigation SoluNKP plant. Based on the standard ISO 50001 and the operational data for 2015, some energy performance indicators such as the baseline and goal line of consumption, the actual consumption rate compared to the theoretical consumption index, the efficiency Index Base 100 and finally the consumption trend accumulated (CUSUM) were calculated, allowing to identify energy saving potentials of 16.1% through good operational practices without technological changes, besides 25.6% for production planning. Finally, the natural gas potential savings identified have been achieved by the organization through the implementation of an Integrated Energy Management System.