OBJECTIVES

• Precisely monitor key energy consumption: gas, electricity, water, and thermal production.

• Build a traceable and continuous energy database to support continuous improvement.

• Detect inefficiencies and reduce energy usage in auxiliary processes.

• Prepare the plant for future phases of optimization involving industrial refrigeration and AI.

Methodology and Approach

• Implementation of a multi-energy monitoring system, measuring:

  • • Gas and thermal production: steam boiler, heating and DHW boilers, GNL and thermal meters.

    • Compressed air: three compressors monitored, air flow/volume, and electric consumption per unit.

    • Water consumption: sectorized metering by critical areas, leak detection, real-time data consolidation.

• Integration into the Energy Management System (EMS) using Modbus TCP.

• Periodic reports, alerts, and full traceability for ISO 50001 audits.

Problems Identified

• Unoptimized thermal cycles in boilers (excessive gas use).

• Leaks and oversizing in compressed air systems.

• High water usage in critical areas, previously unmonitored.

Results

• Estimated 9% reduction in thermal gas consumption.

• Improved efficiency in the compressed air system after loss corrections.

• Better water usage control, reducing unnecessary consumption.

• Availability of key energy indicators, enhancing technical and operational decisions.