Manufacturing information-based energy usage simulation for energy-intensive steel casting process

Abstract

Energy efficiency improvement in the industrial sector is critical in achieving carbon neutrality by 2050. A discrete-event-based dynamic energy simulation method is suggested to enhance the efficiency of energy-intensive manufacturing processes. The statistical characteristics of an actual manufacturing site were reflected in the simulation using data from the factory energy management system (FEMS) and manufacturing execution system (MES). The proposed method integrates discrete event simulation (DES) and transient thermal analysis. The dynamic behavior resulting from the interaction between sub-processes is simulated in DES. The energy conversion and detailed heat loss occurring at the facilities were modeled in the transient thermal analysis. The concept of process loss was suggested for the analysis to account for the energy that could have been not wasted at the factory level. The simulation results provided three key performance indicators (KPIs) representing the energy usage, production, and product quality of a manufacturing site. Investigation of these KPIs under various operating conditions found that the specific energy consumption could be reduced by 12.6% with a better operating strategy. We expect that the integrated simulation method can provide a practical solution for improving the energy efficiency of manufacturing sites equipped with a FEMS.