Model-based Real-time Energy Consumption Monitoring System In Process Industry

In process industries, production cost accounts for a large proportion in the total product cost, among which energy consumption, such as water, electricity, steam, etc., is the most important. Caused by some parameters (temperature, pressure, reaction, finished product yield, etc.), the energy consumption is constantly in flux with the features of multi-variable, strong coupling, nonlinear and so on. Traditional energy consumption accounting only allowed to be settled by a certain period of time (usually by month), which is not able to get real time information of product cost. So it would be a post behavior to check the cost and energy consumption accounting would always lag behind the use of energy.In order to monitor the energy consumption information in each process of production, a system has been developed in this paper. In this system, a process mathematical model can be established through a friendly graphical interface based on Input-output Theory, which takes the full advantage of all kinds of real-time data sources in MES and tracks the energy consumption in any moment. Any energy-related measurement, calculation and report will be accomplished automatically and any data collection, transmission, processing and distribution will based on any time rather than traditional accounting period. This system has enabled a real-time and online energy consumption tracking and accounting, and made benefits for managers to draft production plans. Users can easily check the energy consumption, analyze and find the reason of the difference between actual and theoretical value, then propose a control program.Process industry is a typical high-energy-intensive industry. In order to promote production efficiency while improving growth mode to develop recycling economy and achieve sustainable development for process industry, we must make the most of the establishment of information management platform to strictly control energy consumption, by which a process industry factory can survive in a highly competitive and rapidly changing market. With such a system, decision-makers can timely adjust the production program to response to the market changes.