1. Analyse
Boiler-efficiency data and the factory gas KPI were analysed across the four boilers.
Reducing steam demand through condition relaxation
When strict environmental conditions drive avoidable gas consumption
Customer Scenario
A manufacturing site found that 60 to 70% of its steam consumption could not initially be accounted for. Cotopaxi analysed how steam demand changed across production and non-production periods to identify the source of this unexplained consumption.
What our energy experts revealed
Steam use extended beyond the main production demand
The analysis found that 60–70% of site steam consumption was unaccounted for, with air washers, HVAC and unit heaters among the major users.
Environmental conditioning created avoidable baseload
Air washers continued operating during non-production periods and unit heaters remained on longer than required.
Operational changes reduced demand without capital investment
The site relaxed environmental conditions, shut down air washers during non-production and switched off unit heaters earlier.
From insight to action
2. Interpret
Engineering analysis identified the efficiency gap between Boilers 1, 2 and 3 and Boiler 4.
3. Improve
The boiler sequence was changed to prioritise the more-efficient units during normal operation.
4. Acheive
The boiler sequence was changed to prioritise the more-efficient units during normal operation.
Why conditioning demand matters
Environmental conditioning systems can create substantial steam demand even when production is reduced or stopped. Separating process demand from HVAC, air-washer and unit-heater demand helps reveal where operating conditions and schedules can be adjusted. These changes can reduce gas consumption using existing assets and controls.
Could environmental conditioning be driving unnecessary steam demand?
Talk to our energy experts to identify unaccounted steam use and assess lower-energy operating conditions.
Talk to an expert