CO2 reduction through targeted energy optimization

About the Project

Conventional sand drying systems are used to efficiently dry moist sand by applying heat in a rotating drum. For a client in the construction industry, targeted energy optimization measures were implemented to reduce energy consumption and significantly lower CO₂ emissions.

As part of the project, Rey Technology handled the planning and implementation of a comprehensive plant optimization. In addition to creating the electrical schematic with new measurement points, a PLC solution based on the SIMATIC S7-1500 was implemented to capture all relevant data points. The existing conventional system was connected via PROFIBUS to a new system component, which operates under PROFINET. A detailed system analysis and thermodynamic modeling of the entire system formed the basis for the targeted interventions. The thermal section of the plant was equipped with appropriate sensors for temperature, humidity, and flow rate. The recorded KPIs are visualized in an ERIQ dashboard, enabling seamless monitoring of the plant. Precise measurement series provided the necessary data for accurate system modeling as the basis for optimization.

Benefits for the customer

• Energy-optimized system with additional identified potential for improvement
• Reduction in CO₂ emissions from the system, which was conventionally powered by natural gas
• Digitized plant section with alerts for process-critical humidity levels
• Five-figure savings per year with the same plant output
• Significant economic benefits while contributing to sustainability goals

KPIs

• Over 10% reduction in fossil fuel consumption
• Nearly 70 tons of CO₂ savings per year
• Five-figure savings while maintaining the same plant output
• Significant economic benefits while contributing to sustainability goals