Increasing Energy Efficiency in Industrial Facilities: AI-Based Smart Solutions

Energy costs are constantly rising, and sustainability goals demand greater emphasis on energy efficiency. Striking the right balance between the cost and environmental impact is a challenge for industrial systems.

Is it possible to reduce costs while also lowering carbon emissions through AI-based smart solutions?

At SmartOpt, we seek to answer this question through cutting-edge research and implementations in various industrial systems.

Energy management in industrial systems is crucial, especially in sectors where production processes require large amounts of energy in their operations. Most of these systems require energy in different forms such as electricity and heat (mainly steam as the energy carrier).  Main equipment in steam generation includes burners and boilers and their operation and control are one of the main determinants of energy efficiency.  Inefficient operation of these systems can lead to wasted energy, increased costs, and carbon emissions. At SmartOpt, with our ForecastOpt^® and Energy Optimization solutions, we help industrial facilities achieve energy savings, reduce their carbon footprint, and improve operational efficiency.

SmartOpt has been conducting research on the use of cutting-edge AI-based methods for energy efficiency of industrial systems.  Our aspiration is to make energy efficiency from cost and emission perspectives one of the top priorities in industrial systems.  Our two-stage approach involves ML for the development of the digital twin that continuously updates itself by considering the real-time feed from different sensors and Reinforcement Learning for optimal operation.

One of the key projects we carried out was with the industrial giant Tofaş, focusing on optimizing the operation of boilers and burners that supply hot water to production facilities. In this project, we aim to make heating center management more efficient by accurately forecasting the facility’s hot water demand and optimizing boiler operations accordingly. As a result, we reduce energy consumption while preventing any interruptions in production processes. With this system, we have been to provide up to 15% energy savings across the entire facility.

Our energy optimization projects are not limited to the automotive sector. We offer scalable solutions that can be applied to various industries. One of the areas we are working on is the management of paint shop burners in large production facilities, such as BSH. Since temperature fluctuations during the painting process can impact product quality, we use Reinforcement Learning (RL) algorithms to optimize burner operations and temperature values. This ensures both energy savings and improved product quality.

Another significant area for energy optimization in industrial facilities is steam boilers. Steam is a vital component of production processes in industries such as chemicals and textiles. Currently, we are working with SASA, a major industrial player, on optimizing steam boilers. This project is still in the preparation phase. Our goal is to make combustion processes more efficient and adjust steam production according to the dynamic needs of the production line, thereby minimizing energy consumption. These types of optimizations not only reduce production costs but also contribute to lowering carbon emissions in facilities.

In our energy optimization projects, we analyze the past energy consumption data of facilities and create forward-looking forecasting models by taking production processes into account. With our ForecastOpt^® and Energy Optimization solutions, industrial facilities can monitor and optimize their energy consumption in real time. These systems can be applied not only to boiler and burner management but also to cement kilns, cooling systems, and reactors in various industries.

The need for energy optimization in industrial facilities is becoming increasingly critical. Rising energy costs and sustainability targets push facilities to invest in more efficient energy management systems. At SmartOpt, we contribute to the industrial sector by providing solutions to meet these needs. The results of our energy optimization projects do not only reduce energy costs but also pave the way for more sustainable production processes.

In the future, energy efficiency and carbon emission reduction will become even more important in the industrial sector. At SmartOpt, we continue to make a difference in the industry with our pioneering projects in this field. If you think your facility needs energy optimization, get in touch with us, and let’s embark on your energy efficiency journey together!