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Development of a Methodology for Integral Energy Analysis of Industrial Processes and Plants

Iñigo Bonilla


  • DIRECTORS: Nerea Nieto and Luis del Portillo 


This thesis contextualises the energy consumption of the industrial sector whose processes show high production variability and dynamism in the consumption profile. These processes have not been evaluated as extensively as the continuous ones, and yet they have high margins of energy efficiency and savings potential.

After an exhaustive analysis of the state of the art on process modelling, an absence of methodologies oriented to this type of processes (usually with a high thermal component) is confirmed. Based on the analysed methodologies and on the studies of improvement of the energy efficiency of processes, a comprehensive methodology (multi-scale -operational, tactical and strategic- multi level -device, process, plant, environment-) is proposed for the identification, quantification and evaluation of measures to improve energy efficiency. The proposed methodology analyses the process from the energy and operational point of view and creates simulation models. All phenomena and events which affect the process under evaluation are identified and modelled (transcription of physical equations that govern the phenomenon or parameterisation). The methodology is implemented in a case study with real data and, then, the models are validated. In this way, several courses of action are identified and in-depth analysed. The identified measures are modelled and evaluated (energy economic and ecologically).

As a result, energy savings of up to 50% are obtained with PayBacks less than 24 months. Finally, the capabilities of the methodology, the conclusions and their results are discussed and compared.

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