How to improve the energy utilization of steel structure plant?

2025-03-27 15:35:18

In a new energy battery factory in the Yangtze River Delta, the annual power generation of the integrated photovoltaic roof reaches 28 million kWh; an automobile parts base in the Pearl River Delta saves 38% energy through the waste heat recovery system; an intelligent warehousing center in Chengdu-Chongqing area realizes the energy consumption per unit of output value of 0.05 tons of standard coal per ten thousand yuan... These practices reveal that modern steel plants are building an intelligent energy system covering “source-network-load-storage” through systematic technological innovation.

I. Optimization of energy saving of building body

Envelope structure performance upgrade

Sandwich insulation board: 0.4mm aluminum-zinc-plated board + 100mm rock wool (λ=0.038W/m-K) + 0.5mm liner board, heat transfer coefficient ≤ 0.25W/(㎡-K)

Practical data: annual air conditioning energy saving of 420,000kWh for a 30,000m2 plant, energy saving of 35% compared with the traditional structure.

Airtightness treatment: EPDM sealing strip + polyurethane foam, the number of air changes ≤ 0.5 times / h

Intelligent lighting system

Light guide tube (Φ600mm) + LED compensation lighting

The effect of a factory in Dongguan: 75% of natural lighting during daytime, 68% reduction of lighting energy consumption.

Light sensor control: 5000 lighting points to realize 0.1lux level illumination adjustment.

New energy system integration

BIPV photovoltaic roof

Double-glass module (power 410W/㎡) + Steel Structure integrated installation

Suzhou project data: annual power generation of 5.5 million kWh from 50,000 square meters of roof, accounting for 32% of electricity consumption.

Innovative technology: removable fixture installation, maintenance efficiency increased by 3 times

Wind-solar complementary system

Vertical axis wind turbine (5kW/unit) + building-integrated photovoltaics

Inner Mongolia plant case: annual power generation increased to 1.8 times that of a single PV system

Intelligent scheduling: 5G+edge computing realizes minute-level output prediction

Energy-saving transformation of process equipment

Air compressor group control system

Frequency conversion control + dew point tracking technology

Shenzhen project results: specific power reduced to 5.8kW/(m³/min), annual power savings of 1.2 million kWh

Waste heat recovery: 80℃ hot water is used for process cleaning, heat recovery efficiency ≥72%.

Energy-saving transformation of injection molding machine

Servo motor replaces traditional hydraulic system

Ningbo case: unit energy consumption decreased from 0.45kWh/kg to 0.28kWh/kg.

Intelligent temperature control: mold temperature fluctuation is controlled at ±0.5℃.

Waste energy recycling system

Flue gas waste heat gradient utilization

400℃ flue gas → waste heat boiler (producing 0.8MPa steam) → lithium bromide refrigeration

Chemical plant practice: annual heat recovery equivalent to 3800 tons of standard coal

Intelligent regulation: PLC control of steam production fluctuations of ≤ 3%

Air conditioning energy saving optimization

Maglev chiller (COP6.8) + cooling tower free cooling

Guangzhou project data: annual operating costs reduced by 45%, maintenance costs reduced by 60

Intelligent group control: dynamic host start-stop strategy based on load prediction

V. Intelligent Energy Management System

Digital twin energy efficiency platform

1:1 three-dimensional modeling + 100,000 data points / second collection

Practical effect: an electronic factory identified 23% of energy waste points

Prediction algorithm: LSTM model realizes 24-hour load prediction error ≤5%.

Demand Intelligent Control

Energy storage system (2MWh) + flexible load regulation

Jiangsu project results: 28% reduction in basic electricity costs, 500,000 RMB annual increase in demand response revenue

Dynamic optimization: adjust equipment operation combination every 15 minutes.