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Description
The project envisages the implementation of energy-saving measures and recommendations for energy savings. The measures provide for the replacement of three old lathes with one new lathe and two old machining centers with one new center. This will lead to expected savings of 254406 kWh of electricity. An element of the project is the utilization of waste heat from the working chambers of the metalworking machines, which reaches 60°C when the machines are in operation mode. The heated air is purified from mechanical particles and impurities from the evaporation of the coolant, and then it will be fed to heat the impregnation baking chamber. This will lead to using the waste heat, which will help the inlet air flow in at about 40°C higher temperatures and will save electricity. The project envisages the introduction of a system for monitoring the electricity needed. This will help with continuously registering and storing data regarding the needed electricity. Analyzing the information received from the electricity monitoring system will help make the right technological and managerial decisions leading to saving electricity.
Summary of project results
SPECIFIC GOALS of the project: - implementation of energy-saving measures including investments for improving the energy efficiency of industrial processes; - implementation of energy-saving measures for reuse of waste heat in the industrial processes; - implementation of measures for measuring and controlling energy consumption; - building an effective partnership in the implementation of energy efficiency measures, including also by the donor state (Norway).
Delivery and installation of machinery and equipment - Vertical 3-axis milling machine with CPC controller; Horizontal CNC lathe with CPC controller.
Implementation of energy-saving measures for reuse in the industrial processes of waste heat - Construction of air ducts to capture the output air from the working chambers of metalworking machines, which reaches 60°C when the machines are in operation mode. The output air is purified from mechanical particles and impurities from the evaporation of the coolant, and then fed to heat the impregnation chamber.
Introducing a system for monitoring the electricity needed - a system for optimization of the energy consumption and monitoring of consumed electricity in the production units of Almott Ltd. in the process of machining of details. The monitoring system provides the following basic functionality: • Remote infrastructure connectivity of electro-mechanical and industrial equipment to centralized IoT monitoring and management of electricity consumption • Bilateral communication with controllers (PLC) and industrial sensors through standardized industrial protocols • Primary processing of incoming data from industrial sensors •Normalization and validation of incoming data • Data transfer in the complex environment of existing Cloud-based IoT platforms for development of different monitoring software applications Area of application and function: • Monitoring of energy consumption in production units with electro-mechanical industrial equipment • Accumulation of historical data on energy consumption in production units • Analysis and optimization of the functioning of industrial equipment on the basis of the accumulated historical data on the energy consumption in the production units.
The achieved indicators: - Annual energy savings FES, kWh-254406; - Savings share criterion Y, %-66.52; - Saved CO2 emissions, t-300.199; - Criterion BGN/t CO2-979; - annual money savings, EUR/y - 43 315.11 contribute to achieving the objective of the procedure.