Industrial energy management
Tyrolit Neuenrade
87% less electricity · 65% less CO₂A holistic energy and resource concept connects electricity, heat, cooling and building infrastructure – measurably reducing consumption, emissions and operating costs.
The starting point
Using reconstruction as an opportunity for fundamental change
After a fire in the electroplating area, Tyrolit used the reconstruction to rethink its production rooms, technical infrastructure and energy supply. The objective went beyond replacing damaged equipment: energy consumption, environmental impact and ongoing costs had to be reduced permanently.
Instead of optimizing isolated equipment, an overarching concept for production and buildings was developed. This allowed generation, distribution and consumption to be considered together.
The system scope
Electricity, heat and cooling as one connected system
PV, grid and CHP
Energy management
Electricity
Heat
Cooling
Production and buildings
The concept comprises modernized building infrastructure, new lighting, on-site power and heat supply with a combined heat and power unit, optimized heating and cooling systems, energy-efficient climate control and rooftop photovoltaics.
Overall project and xNet's contribution
Four interlocking building blocks
The energy modernization comprised four coordinated building blocks. xNet was responsible for the fourth: the overarching energy management system and centralized room-heating control.
Rebuild the infrastructure
Production rooms, lighting and building infrastructure were realigned for energy efficiency during reconstruction.
Integrate generation
The CHP unit and photovoltaics were incorporated into the plant-wide electricity and heat supply.
Centralize cooling
Numerous individual cooling circuits were replaced by a central ring system, connecting them technically and energetically.
Manage operations transparently
Energy management connects the equipment, monitors grid purchase and feed-in, and supports central room heating control in the office areas.
The xNet solution
Energy management for the entire plant
Overall system
Connect energy flows
Electricity, heat and cooling are not treated separately. The overall concept reveals interactions and provides the basis for efficient plant operation.
Operations
Monitor purchase and feed-in
Grid consumption, on-site generation and feed-in are recorded centrally and made available for technical operations.
Buildings
Control room heating centrally
Individual room control in the office building is also integrated into the overarching heat management system.
The results
Measurably combining economic value and resource conservation
Energy and emissions
Electricity consumption fell by 87 percent and CO₂ emissions by 65 percent.
Water and chemicals
The new concept reduced wastewater by 97 percent and avoided the use of special chemicals.
Economic value
With an investment of approximately €2.14 million, the calculated savings potential from energy and maintenance costs is around €480,000 per year.
Tyrolit demonstrates how an industrial master concept can improve energy efficiency, environmental impact and operating costs at the same time.
The complete technical system