How can we obtain an overview of all the consumption data required during ongoing production? The first step of energy management is effective energy controlling: Ongoing consumption must be monitored exactly: The cause must be researched wherever specific upturns are seen. Meter data is prepared to assign it exactly to the individual energy consumers. Energy management creates the prerequisites for responsible, conscientious and economical handling of energy, to continuously improve the ecological footprint of our metal production.
“We have always been conscious about our environment and costs” says Camille Kielwasser from Central Services at Diehl Metall in Röthenbach. “We basically never had open doors to the boiler room and we installed motion sensors on lamps that were always on. But that is not what we mean, when we talk of energy management. For example, we are working on reducing the energy expended and the material used in the individual processing stages of production.”
This means rethinking and optimizing the entire production process time and again. “The high number of over 100 different alloys and a wide spectrum of semi-finished product formats and dimensions make recording and accurate assignment to products very difficult. This is a giant task”, acknowledges Dr. Claus Heubeck, Manager for Energy and responsible for the purchase of energy for the entire Diehl Group. More and more meters were installed at Diehl Metall in Röthenbach for this purpose, which recorded the consumptions in real time and routed it to an evaluation system. This enables production heads to effectively monitor the energy consumption of their plants. Managing energy with continuously improving transparency, is the task.
"Time and again we find new adjusting screws which we must turn to improve a bit every year", Camille Kielwasser says. "This year we plan to reduce waste heat losses. The hot-water basin into which the brass rods are immersed after pickling will be provided with a flexible cover swimming in the basin during breaks in production. This will have two effects: water losses will be reduced and energy will be saved as the water temperature is maintained.
For more information on the careful handling of resources in brass manufacture, see Sustainability.