Reducing energy consumption in industry: levers, methods and tools

French industry has played a key role in reducing its energy consumption by 9% in 2020 compared with 2019. This decline demonstrates the importance of industry in the energy transition.

With a reduction target of 35% by 2035, action to optimize energy and adopt low-carbon solutions is becoming crucial. Energy audits are essential to identify potential savings.

Heating, ventilation and air conditioning (HVAC) systems, which consume over half the energy in industrial buildings, offer significant potential for improvement.

The recovery of waste heat, which represented a potential of 109.5 TWh in France in 2017, is another avenue for increasing energy efficiency. The "France 2030" plan, with its investment of 54 billion euros, actively supports this decarbonization of industry.

Understanding energy issues in industry

Why industry is a major lever in the energy transition

French industry reduced its energy consumption by 9% in 2020, demonstrating its ability to improve energy efficiency. This sector plays a key role in the reduction of greenhouse gas emissions and the energy transition.

A 35% reduction in industrial energy consumption is possible by 2035. This underlines the importance of ongoing efforts to optimize usage and integrate renewable solutions.

Energy audits show that HVAC (heating, ventilation and air conditioning) systems account for more than half the energy consumed in industrial buildings.

Optimizing these systems can therefore lead to significant savings and lower costs. By undertaking work to improve energy efficiency, industrial companies are making a direct contribution to reducing their overall environmental impact and moving towards carbon neutrality.

The main sources of energy consumption: heating, processes, compressed air, etc.

In industry, energy consumption is divided mainly between several key items. Heating, ventilation and air-conditioning systems account for over 50% of an industrial site's total energy consumption.

Next come electricity generation and natural gas, which account for 38% and 34% respectively. Oil is not to be outdone, accounting for 9%.

Compressed air production is also significant, and is very costly in terms of energy, as 90% is converted into heat.

Unused waste heat from industrial processes had a potential of 109.5 TWh in France in 2017.

Energy losses in utilities such as steam, electricity and compressed air are also important factors. Particular attention must therefore be paid to optimizing these consumptions.

Precise analysis of where and how energy is used on our sites can identify substantial savings opportunities. Energy efficiency requires this detailed analysis and commitment to a process of continuous improvement to reduce energy bills while supporting the transition to a more sustainable industry.

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Primary energy, final energy, conversion factor: definitions

Primary energy is that which is found in nature before any transformation. Examples include crude oil, natural gas and solar energy. Factories often use this energy to run their machines or heat their premises.

Final energy, on the other hand, is the energy available to the user after conversion and transportation. For example, the electricity that powers a company computer is a form of final energy.

The conversion factor makes it possible to switch from one to the other, taking into account losses during conversion and transport. Understanding these differences helps factories optimize their consumption and undertake energy-saving work.

This includes installing heat pumps or replacing old equipment with high-performance systems.

Diagnose consumption to take better action

An energy audit is an essential tool for diagnosing energy consumption in industry. It helps to identify high-consumption areas and any shortcomings that need to be corrected.

Companies with over 250 employees or sales in excess of €50 million are required to carry out an energy audit. This process helps to measure the energy performance of all equipment, and to identify solutions for reducing expenditure.

Statutory energy audits: for whom, how and when?

Energy audits are essential for large companies. It is aimed at companies with over 250 employees or sales in excess of €50 million.

1. The audit begins by identifying energy consumption items. In-house teams can carry out this task using an energy audit guide.
2. Deficiencies must be corrected quickly. This improves the energy efficiency of the installations.
3. Accurate analysis of energy consumption is crucial. A detailed assessment helps identify potential sources of savings.
4. Heating, ventilation and air conditioning (HVAC) systems account for over 50% of a building's energy consumption. Optimizing these systems is therefore essential.
5. Regular maintenance of equipment helps to keep installations running smoothly. It also limits energy losses.
6. The legal frequency of audits must meet the requirements of the French Energy Code and ADEME recommendations. This ensures compliance with current regulations.
7. These assessments are carried out every four years for the companies concerned, ensuring ongoing monitoring of their energy efficiency.
8. Practices such as installing smart thermostats and switching to LED lighting are recommended following the audits to reduce electricity consumption.
9. Rigorous monitoring also enables proactive management of usage levels during critical periods, especially in winter when demand rises.

These steps facilitate the transition to energy sobriety in industry, while reducing the carbon footprint and controlling the costs associated with rising energy prices.

Measure and track consumption with metering tools

Measuring energy consumption is essential for optimizing costs. Metering tools help to track energy in real time.

1. Smart meters provide precise data on electricity consumption. They make it easier to identify peaks in energy demand.
2. Sub-metering enables consumption to be tracked by zone or appliance. This tool helps locate energy-hungry equipment, such as HVAC systems.
3. Software such as Energy Star Portfolio Manager manages and analyzes energy data. They provide a useful overview for planning improvements.
4. An EMS (Energy Management System) also collects relevant data on gas and electricity consumption. This provides a clear energy balance sheet, enabling you to take more effective action.
5. Measuring steam, flow and temperature with sensors helps to optimize industrial processes, especially in certain industries.
6. Using solutions such as Schneider Electric or Siemens provides better visibility of a site's overall consumption.
7. Regular measurement helps to monitor energy performance and detect any anomalies quickly.
8. Analyzing this data also improves efficiency in real time and guides towards sustainable savings.

These tools enable companies to commit to a responsible and efficient energy policy, while reducing their ecological footprint on a daily basis.

Identify sources of savings: heat loss, waste, inefficient cycles, etc.

Analyzing energy consumption is crucial. Paying particular attention to losses can generate significant savings.

• Heat losses often occur in compressed air networks. These systems use up to 90% of their energy in the form of heat, resulting in significant wastage.
• Poor management of energy networks increases production costs. It also leads to losses in the form of heat, reducing overall efficiency.
• Inefficient production cycles also affect consumption. For example, a motor operating outside its optimum range consumes more energy to produce the same amount.
• Plant optimization plays a major role. Installing more efficient equipment reduces energy costs and improves energy efficiency.
• Precise analysis of energy consumption helps identify sources of savings. Energy audits help identify weak points and implement appropriate solutions.
• Raising staff awareness of eco-gestures also helps to limit energy wastage. For example, turning off unnecessary lights or optimizing heating use makes a real difference.

By identifying and acting on these savings opportunities, French industry can effectively reduce its energy consumption.

Optimizing existing uses without heavy investment

Optimizing existing processes can reduce energy consumption without high capital outlay. There are many simple and effective solutions available to companies.

• Adjusting temperature settings improves comfort and reduces energy costs. The right temperature setting can make a big difference.
• Scheduling machine operation during off-peak hours reduces consumption without investment. It also means significant savings on bills.
• Installing presence detectors for lighting allows lights to be switched off automatically in unoccupied offices. This simple action has a direct impact on reducing energy use.
• Automating the switching off of appliances outside working hours facilitates energy management. Employees can concentrate on other tasks while saving energy.
• Implementing awareness-raising initiatives helps to develop a culture of eco-actions within teams. Staff commitment contributes to overall energy efficiency.
• Regular maintenance of equipment prevents breakdowns and maintains optimum performance. Good maintenance can extend the life of machines while reducing their energy consumption.
• Replacing conventional light bulbs with LED lighting offers an immediate reduction in power consumption. This simple change offers a rapid return on investment thanks to the savings made.

These methods demonstrate that it is possible to make better use of energy without excessive expenditure, while boosting competitiveness and optimizing operating costs.

Temperature settings, schedules, automatic switch-off

Maintaining the right temperature settings saves energy. Automatically switching off lights in unoccupied rooms further optimizes consumption.

1. Set workshop temperatures between 16 and 19°C. This reduces heating requirements without compromising comfort.
2. Set office temperatures at 19-21°C. This range balances energy efficiency and employee well-being.
3. Set schedules for heating and lighting. Limit their operation during unoccupied periods.
4. Install occupancy sensors in offices. This turns off lights automatically when no one is in the room.
5. Use a programmable thermostat for better heat management. This system adapts to the occupancy schedule of each section.
6. Encourage your team to report any excessive or irregular temperature variations in the premises.
7. Train your teams in the importance of optimizing energy consumption through simple gestures.
8. Replace old bulbs with efficient LED lighting to significantly reduce your electricity bill.

These simple actions can improve energy efficiency without requiring a large budget, while contributing to sustainable development in your company.

Behavioral savings: raising team awareness, eco-gestures

The impact of human behavior on energy consumption is crucial. Every gesture counts. Raising team awareness can lead to significant savings. For example, turning off lights in unoccupied offices or ensuring that LED lighting is used can reduce costs.

Putting up visible signs reminds everyone of the importance of these eco-gestures. Simple tips, such as using the stairs rather than the elevator, encourage positive change.

Encouraging carpooling for business trips also reduces fuel consumption. These easy and effective actions help to reduce energy intensity within companies.

Maintenance and preventive maintenance of equipment

Regular maintenance of HVAC systems plays a key role in energy optimization. Good maintenance helps to ensure equipment efficiency and avoid energy drift.

Simple checks such as filter cleaning or duct inspection can significantly reduce energy consumption. What's more, a precise energy audit identifies sources of waste and helps to target actions to be taken.

Preventive maintenance of equipment also contributes to optimizing energy costs. Replacing old equipment with more efficient systems, such as heat pumps, further improves efficiency.

These actions not only save energy, but also meet the requirements of the Ministry of Transition. Companies must therefore integrate these practices into their strategy to reduce energy consumption.

Take action on industrial processes and technical equipment

Optimize industrial processes to reduce energy consumption. Insulating networks and lagging considerably reduces heat loss. Heating, ventilation and air conditioning (HVAC) systems consume over 50% of an industrial building's energy.

Improve their efficiency to cut your energy costs.

Recovering waste heat from equipment can also generate savings. Optimize compressors, motors and boilers to boost their performance. Automation and variable speed control provide precise energy control.

Integrating these solutions helps you reduce your carbon footprint while cutting costs.

Network insulation and lagging

Network insulation and lagging are essential for reducing heat loss in industry. These techniques keep heat where it's needed.

Good insulation prevents energy loss, reducing production costs. By improving energy efficiency, companies can make significant savings on their bills.

For example, insulating pipes can reduce heat loss by 80%.

The usual return on investment for such work is between 1 and 3 years. Inadequate management of energy networks leads to significant losses and high costs.

Investing in these solutions contributes to more responsible and sustainable consumption.

Waste heat recovery

The recovery of waste heat represents significant potential for businesses. In France, this potential reached 109.5 TWh in 2017. This method involves capturing the heat emitted by industrial processes, such as furnaces or compressed air systems.

In the case of compressed air, 90% of the energy used is transformed into heat. This heat can be reused to heat hot water or for other energy needs.

Companies can install systems to recover this wasted energy. For example, they can connect heat exchangers to compressors. This reduces overall energy consumption and keeps costs down, especially in times of energy crisis.

Such initiatives fit perfectly into an energy efficiency strategy and contribute to energy savings.

Optimizing compressors, motors and boilers

Optimizing compressors, motors and boilers is crucial to reducing energy consumption in industry. This equipment often wastes energy. In fact, 90% of the energy used to produce compressed air is transformed into useless heat.

Simple adjustments can be made to improve performance. Frequency variation can be used to adjust motor speed. This results in significant savings.

Proper combustion control maximizes boiler efficiency. Regular measurements of fuel consumption help monitor energy efficiency.

Actions such as preventive maintenance keep equipment running smoothly. They also help reduce operating costs. Adopting these practices can transform a company's energy performance.

Automation, variable speed control and industrial BMS

Automation and building management systems (BMS) play a crucial role in reducing energy consumption. These systems automatically adjust equipment operations according to actual needs.

For example, a factory can reduce energy consumption by using variable-speed motors. This allows the power used to be adapted according to demand.

The savings measured in some industries are impressive. In some cases, reductions of up to 30% in energy costs have been observed. These results show that the combination of automation and a well-thought-out energy strategy is transforming the industrial landscape.

Companies can better manage their resources while reducing their carbon footprint.

Integrating renewable and recovered energies

The integration of renewable and recovered energies is essential. It helps reduce energy consumption and greenhouse gas emissions in industry.

Solutions such as thermal and photovoltaic solar panels make it possible to use solar energy for clean applications. Industrial biomass and geothermal energy also offer interesting options.

Cogeneration increases efficiency by producing both electricity and heat. By using these energy sources, companies reduce their dependence on fossil fuels.

They thus contribute to a more sustainable energy mix. In France, industry accounts for 9% of total energy consumption. Investments in these technologies amount to 8.4 billion euros to encourage innovative projects.

Thermal and photovoltaic solar power for clean applications

Solar thermal and photovoltaic technologies are proving extremely useful for clean industrial applications. These technologies enable the preparation of hot water and self-consumption of energy.

Thanks to them, companies can reduce their energy costs. Solar solutions also improve energy efficiency.

The level of technological maturity is high. Systems are reliable and widely adopted. Installing heat pumps in conjunction with these solutions boosts savings even further.

By integrating renewable energies, companies reinforce their brand image in terms of sustainability.

Industrial biomass, geothermal energy, cogeneration

Industrial biomass, geothermal energy and cogeneration offer effective solutions for reducing energy consumption in industry. These technologies encourage the use of renewable energies.

They reduce energy costs and greenhouse gas emissions. To implement these systems, companies need to assess their energy requirements and available resources.

Lack of information and expertise can hinder their adoption.

Cogeneration enables companies to produce green energy more efficiently. It uses the heat generated by industrial processes to produce electricity.

Energy audits can include analyses of the use of biomass and geothermal energy to optimize consumption. Energy metering solutions precisely measure these improvements, contributing to better cost management.

Local heat loops or waste heat recovery

Local heat loops use heat generated by industrial facilities. They convert waste heat into energy for other uses. This system reduces energy requirements.

It also reduces energy consumption.

Waste heat recovery can be used to heat buildings, particularly in the residential and commercial sectors. These solutions improve France's energy efficiency.

They also support energy renovation while optimizing available resources.

Digitization and intelligent energy management

Digitization is transforming energy management in industry. IoT sensors collect data in real time. These sensors enable companies to accurately monitor their energy consumption.

DeltaConso Expert software makes it easy to monitor the energy performance of construction sites.

Artificial intelligence analyzes this data to anticipate needs. This helps optimize costs and reduce consumption. Connected maintenance improves operational efficiency.

With these digital tools, industries can better manage their environmental impact while reducing their energy expenditure.

IoT sensors and energy management platforms

IoT sensors play a key role in energy data collection. They measure the energy consumption of utilities such as steam, electricity and fuel.

These devices enable real-time analysis of energy use. Thanks to this information, companies can identify sources of savings and optimize their energy efficiency.

Energy management platforms complement these sensors. They process the data collected and propose corrective actions. In this way, these tools help to reduce leaks and improve the insulation of industrial facilities.

By adopting these solutions, industries reduce their energy costs and environmental impact.

Artificial intelligence and predictive analysis

Artificial intelligence (AI) plays a key role in industrial energy management. It analyzes consumption data to detect anomalies and forecast future needs.

For example, a plant can use AI to anticipate a peak in consumption during a ramp-up. This makes it possible to adjust energy distribution in real time and reduce losses.

In this way, AI optimizes the operation of equipment, particularly in compressed air networks, improving their efficiency.

Predictive analysis also identifies opportunities for energy savings. By predicting variations in demand, it helps to better manage energy supply.

This technological tool reduces the environmental impact of plants. Companies can then integrate more renewable energies and reduce their dependence on fossil fuels.

Solutions such as industrial biomass and geothermal energy become more accessible thanks to these innovations.

Connected maintenance and real-time efficiency

Connected maintenance improves efficiency in real time. IoT sensors monitor industrial equipment. These devices send data on machine status.

Thanks to this data, companies can quickly identify problems. As a result, they can avoid unexpected breakdowns and limit energy losses.

Predictive analysis helps anticipate maintenance needs. Regular monitoring helps optimize equipment operation. This reduces energy consumption and lowers operating costs.

Companies carry out a consumption audit to better understand their maintenance needs.

Financing your energy efficiency project

Manufacturers can benefit from financial assistance for their energy-saving projects. The government offers subsidies and specific funds, such as the Certificats d'Économie d'Énergie (CEE).

These grants encourage companies to carry out an energy audit. This process helps identify sources of excessive consumption.

In 2023, 8.4 billion euros were invested in innovative projects to reduce energy consumption. These opportunities represent an effective way of financing renovation work and improving energy performance in France.

Energy Savings Certificates (CEE) and specific windows

Certificats d'Économie d'Énergie (CEE) offer valuable assistance to companies seeking to improve their energy efficiency. These incentives encourage investment in energy-saving solutions.

• CEE are financial incentives for work that reduces energy consumption. These certificates can be obtained after efficient projects have been carried out.
• A good example is an energy audit that highlights potential savings. Companies carrying out this type of audit can sell these certificates.
• ADEME and BPI France provide useful advice on obtaining CEE. These organizations also provide guidance on how to maximize the impact of projects.
• Two-thirds of industrial energy bills come from gas and electricity. CEE helps to reduce these costs by making installations more efficient.
• The "guichets spécifiques" offer personalized support for each company. They help establish a precise diagnosis of energy consumption.
• Every industry, whatever its size, can benefit from these certificates. The common objective is to reduce the total cost of energy consumption by 9%.
• To achieve effective optimization, a precise analysis of consumption is essential. This enables us to identify potential savings on the various processes used.

For more information, visit the official ADEME website: www.ademe.fr.

Support from ADEME, BPI France, local authorities

ADEME, BPI France and local authorities play a key role in financing energy efficiency projects. These organizations support industrial companies in their energy transition.

• ADEME offers subsidies for mandatory energy audits. This helps to identify the energy savings required.
• BPI France finances innovative renewable energy projects. Companies can apply for loans to purchase new equipment.
• Local authorities facilitate access to local grants. They often offer advice on maximizing return on investment.
• The average amount of support varies according to the project. An audit can be financed up to 70% of its cost by these schemes.
• Specific initiatives, such as Energy Savings Certificates (CEE), encourage the reduction of energy consumption.
• Funded projects include thermal optimization and waste heat recovery. These actions considerably reduce energy bills.
• The grants help to boost the competitiveness of industrial companies by reducing their operating costs.
• The implementation of renewable energies thanks to this financing becomes a key solution for reducing dependence on gas prices.

These schemes encourage industries to adopt sustainable and efficient strategies. By integrating these aids, they improve not only their performance, but also their environmental impact.

Financing models: third-party investment, energy performance contracting

Financing models provide effective solutions for improving energy efficiency. They offer interesting options for SMEs and ETIs.

• Third-party investment allows companies to finance their projects without any up-front costs. An investor assumes the cost of energy improvement work. The company then repays the investment from the savings it makes on its energy bills.
• Energy performance contracts guarantee measurable savings. A company undertakes to achieve precise results in terms of energy savings. If the results are not achieved, the service provider makes up the difference.
• These options reduce the financial barrier associated with heavy investment. They also allow for rapid upgrading of obsolete equipment, while respecting tight budgets.
• SMEs and SMIs can benefit from specialized advice and support for their energy projects. This ensures that their specific needs are taken into account.
• Such strategies make it possible to replace old equipment with modern, more efficient solutions. They also encourage a cultural shift towards eco-responsibility within the company.
• By integrating these models, companies improve their image and become more competitive in the marketplace. Adopting a sustainable approach often attracts customers and partners concerned about their environmental impact.
• Appropriate financing also strengthens the ability to innovate, with a focus on digitalization and energy optimization. The data generated by these new technologies helps to constantly refine energy performance in industry.

Part of a global, sustainable strategy

France aims to reduce industrial energy consumption by 35% by 2035. This ambition underlines the importance of a sustainable strategy. Companies must draw up a multi-year action plan to achieve this goal.

Adopting ISO 50001 standards facilitates continuous improvement in energy performance.

Training teams is also a major challenge. Appointing an energy coordinator helps to coordinate the efforts of each member of staff. Good training helps to integrate eco-responsible behavior within teams.

This contributes to better overall, sustainable performance.

Setting up a multi-year action plan

A multi-year action plan helps structure efforts to save energy in industry. First of all, it is essential to carry out a complete diagnosis of current consumption.

This step helps identify the main contributors to energy waste, such as HVAC systems, which account for over 50% of an industrial building's consumption.

The next step is to prioritize the actions to be taken. Some solutions can be implemented quickly, without the need for heavy investment. For example, planning machine operating times can reduce energy consumption.

Finally, establishing a precise timetable for each stage ensures follow-up and guarantees tangible results. An ambitious target is to reduce energy consumption by 35% by 2035.

ISO 50001 standards and continuous improvement processes

The ISO 50001 standard guides companies in their quest for energy efficiency. It promotes systematic energy management. By adopting this standard, industries can significantly reduce their energy consumption.

This improves their competitiveness.

Continuous improvement processes reinforce this efficiency. They enable weaknesses to be identified and practices adjusted. For example, optimizing HVAC systems can reduce energy costs.

These systems consume over 50% of an industrial building's energy. Integrating these standards and methods can transform a plant into a model of sustainability.

Train your teams and appoint an energy coordinator

Training your teams is essential to reducing energy consumption in industry. Well-trained employees understand the importance of eco-gestures. This reduces waste and optimizes usage.

What's more, appointing an energy coordinator helps oversee these efforts. This person acts as a guide for the teams. They ensure that everyone complies with energy-saving standards.

Thanks to this approach, energy savings increase a company's competitiveness. An audit and analysis of consumption is necessary to identify any discrepancies.

Regular monitoring also enables better use of energy resources.

Conclusion

Reducing energy consumption brings economic, ecological and strategic benefits. Companies need to act quickly. A good place to start is with an energy audit.

This helps identify potential savings. By integrating renewable energies and optimizing processes, every industry can make a difference.

FAQ

1. What does it mean to reduce energy consumption in industry?

Reducing energy consumption in industry means implementing strategies to reduce energy use in France and around the world.

2. What are the levers, methods and tools for reducing energy consumption in industry?

Levers include mobility and IT, while methods can include an in-depth study of current practices. Tools can include energy management software.

3. How can mobility help reduce energy consumption in industry?

Mobility, such as the use of electric cars, can help reduce energy consumption by replacing gasoline-powered vehicles with greener alternatives.

4. How can a study contribute to reducing energy consumption?

A study can help identify areas where energy is being wasted and implement strategies to reduce this consumption.