Anonymous South Asian Steel Manufacturer

A major steel producer in South Asia with 18 million tonnes per annum capacity faced energy costs impacting financial profitability. Facility management needed to reduce energy costs and consumption, reduce gas flaring, and achieve a quick ROI from the investment.

Rockwell Automation deployed an Energy Intelligence System using the FactoryTalk software suite to automatically collect, analyze, and report on data with actionable information, enabling operators to make real-time process changes and manage access to automation assets.

Energy costs were reduced by 3% annually and electricity consumption by 3%. The bottom line was boosted by 1.35%, overall fuel consumption reduced by 2%, and full ROI was achieved in six months.

• Automated real-time energy intelligence systems deliver faster ROI than periodic manual energy audits • Contextualizing energy data with production data reveals efficiency opportunities invisible in raw consumption figures • 6-month ROI is achievable for energy management systems in large-scale, energy-intensive steel operations