OBJECTIVES

• • Improve energy efficiency through real-time monitoring and control.

  • Digitize the plant’s energy system, with an initial focus on refrigeration and critical auxiliary consumption.

  • Reduce unnecessary consumption of energy, water, and compressed air.

  • Establish a data-driven foundation for audits and ISO 50001 certifications.

  • Prepare for future AI-based optimization (Cirrus AI).

Methodology and Approach

• Implementation of the PilotE² Permafrost system to monitor:

  • Industrial ammonia-based refrigeration compressors

  • Thermal parameters (temperatures, pressures, COP)

  • Operation times and thermal loads

• Data integration via Modbus TCP protocols with Carel and Omron PLCs.

• Cross-cutting monitoring of auxiliary consumption:

  • Steam boilers and thermal energy production

  • Compressed air (electricity, flow rate, volume)

  • Water (sectorized metering, leak detection, overuse)

• Centralized data integration into the plant’s Energy Management System (EMS).

Problems Identified

• Oversizing in air compressors during off-peak hours, causing inefficiencies.

• Excessive water consumption in wet services.

• Lack of energy traceability prior to system implementation.

• Need for more precise thermal control in boilers (gas-to-steam/ACS ratio not optimized).

Results Achieved

• Full energy visibility of the industrial refrigeration system.

• Over 12% reduction in mains water consumption.

• Identified 15–18% energy savings potential in compressed air.

• Improved thermal efficiency and control of boilers (gas vs. steam/ACS).

• Automated reporting and monthly traceability of key performance indicators (KPIs).

• Solid technological foundation for future optimization with AI (Cirrus AI), enabling:

  • Predictive control

  • Dynamic adjustment of setpoints

  • Energy coordination with actual demand