Company profile
The factory in Bissen is part of ArcelorMittal Europe Long Products – Bars & Rods, which employs more than 288 people on an area of around 50 hectares and produces more than 100,000 tonnes of industrial, fence and vineyard wire as well as metal fibres for the construction industry every year.
Idea
An effective lever for energy savings
The energy-saving measure focussed on a significant reduction in compressed air consumption at the ArcelorMittal plant in Bissen. Compressors are often energy-intensive machines that can sometimes operate inefficiently. A thorough analysis of compressed air consumption was carried out, followed by a study to identify potential savings.
Design
Planning an efficient compressed air network
In order to realise the concept of reducing compressed air consumption, various measures are being planned or have already been taken.
- A study is currently being carried out to reduce the air pressure in the entire network. This approach aims to move from a paradigm of “we need pressure on the line” to a “how much pressure is really needed” by adjusting the general pressure in the network from 6 to 5 bar. This measure allows the factory to reduce energy consumption without affecting operations.
- Project to identify consumers that can operate at lower pressure: A detailed analysis was carried out to determine which devices and processes can operate efficiently at lower pressure levels.
- A systematic analysis of the air networks and production facilities revealed that many leaks can only be rectified when production is at a standstill.
- Calculation of the savings potential for compressed air of approx. 10 % by repairing the leaks alone. In cooperation with a specialised company, a repair phase lasting several days with a production stop was planned.
Implementation
Introduction of a strategy to reduce compressed air leaks
ArcelorMittal has worked with a specialised company to detect leaks in the compressed air system. The initiative was carried out during the Christmas holidays. In a three-day operation, during which production was shut down, all leaks were identified and repaired.
Result
The improvements are clearly visible
As 60% of the leaks found were repaired during the three-day shutdown at the end of 2023 and around 65% of the remaining leaks have also been repaired since then, ArcelorMittal now estimates that they need around 7% less electricity to generate compressed air. Their goal is to eliminate at least 25% of the 35% of remaining leaks by the end of the year.
