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Industrial water circuits (IWC) are frequently neglected as they are auxiliary circuits of industrial processes, leading to a missing awareness of their energy- and water-saving potential. Industrial sectors such as steel, chemicals, paper and food processing are notable in their water-related energy requirements. Improvement of energy efficiency in industrial processes saves resources and reduces manufacturing costs. The paper presents a cooling IWC of a steel wire processing plant in which steel billets are transformed into wire. The circuit was built in object-oriented language in OpenModelica and validated with real plant data. Several improvement measures have been identified and an optimisation methodology has been proposed. A techno-economic analysis has been carried out to estimate the energy savings and payback time for the proposed improvement measures. The suggested measures allow energy savings up to 29% in less than 3 years’ payback time and water consumption savings of approximately 7.5%.

Water and Energy Efficiency Improvement of Steel Wire Manufacturing by Circuit Modelling and Optimisation