Investigation of energy efficiency in a pilot aluminum extrusion manufacturing plant

Aim of this study was to achieve the highest possible heat energy efficiency and to decrease the total energy demand without any decrease in the production quality and quantity in Aluminum extrusion facilities. For this purpose, machines with the highest heat loss were determined. Measurements were made via a thermal camera for each machine. The results obtained by the thermal camera were processed in a software and the parts causing heat loss were detected. Various isolation and mechanical repair suggestions were made depending on the location of the heat loss. After the revisions made in accordance with the recommendations, thermal camera measurements were repeated. The energy losses for all machines were calculated before and after the revisions and the ultimate energy saving obtained after revisions were determined. Revision costs for mechanical repair and isolation were also calculated. The economic input caused by the heat loss of each machine were compared to the revision costs to determine the pay-off period of each revision. In addition, measurements were also performed for machines that did not undergo any revision to calculate the amount of the energy loss experienced the two measurements in these machines. According to the results obtained in the study, 33240,5 kWh / Month heat losses and the corresponding cost of 8510 TL / Month were prevented in the machines revised for increased energy efficiency.