From showering at the gym to turning on the heating once a month, many people have gone to extreme lengths to cut back on energy costs at home. However, businesses affected by the same crisis can face even higher costs, particularly if they are in energy-intensive industries like recycling or manufacturing. In this article, Steve Hughes, managing director of power quality specialist, REO UK explains how businesses can unconsciously over-consume electricity and what can be done to limit this.
The energy crisis that the UK is facing affects us all in different ways. According to MAKE UK in September 2022, 42 per cent of manufacturers surveyed said their electricity bills increased by 100 per cent in the past 12 months and 60 per cent said that increased energy costs are now business-threatening. The businesses most affected will be energy intensive manufacturers in industries like recycling, petrochemical and metal production and processing.
For example, aluminium production requires constant levels of high power. From the mining of the bauxite to the working of the finished aluminium, the industry is highly reliant on energy. The smelting process typically requires 300 kA of electrical current in order to break the ionic bond between the oxygen and aluminium in order for it to be processed.
So, what can we do?
For businesses to reduce the impact of the energy crisis on themselves, they will need to tighten up on faults and inefficiencies. According to The Water Services Regulation Authority (OFWAT), the UK water industry sees over 2900 million litres lost each day to leaks and inefficiencies.
The electrical generation, supply and distribution network is similar, though not as easy to quantify. Power can be lost in a variety of ways, largely in the equipment we use. Leaks can be found in complicated control electronics or small conductor diameters that have been purchased in order to save money. Alternatively, you may have out of date equipment, like motors or lighting systems, that aren’t built to the latest international efficiency (IE) classes.
Electricity overconsumption also goes hand in hand with an increase in harmonic currents. The electrical loads become non-linear, as the voltage and current are neither sinusoidal, in phase or both. This means that much of the current present in an installation cannot be used efficiently but it still flows in the circuits, contributing to the heating of conductors, switchgears and fuses. If it continues to worsen, there is the risk of failure or even fire.
One of the ways that REO can help reduce harmonics and energy overconsumption is through passive solutions. For example, a REO mains or line choke can be used in a circuit, typically where variable speed drives are used. These can reduce the distortion of the current waveform and increase efficiency, resulting in a potential reduction of supplied current by over 15 per cent. Alternatively, the REOWAVE passive filter can give an even bigger reduction of over 30 per cent. This electricity can then be used elsewhere or stored for another day.
Energy-intensive businesses can reduce their energy consumption and level of harmonics by ensuring they have the correct, up-to-date electrical equipment. Not only can this save costs, it can also help protect your own electrical infrastructure.
To find out more about energy-saving solutions from REO, visit www.reo.co.uk.
