| Abstract [eng] |
In industrial facilities, water-cooling systems represent an energy intensive part of the infrastructure. Large volumes of recirculated water, fluctuating heat loads, and outdated equipment lead to high electricity consumption. With rising energy prices and stricter environmental requirements, assessing modernization options and identifying effective energy saving solutions has become essential. The study aimed to evaluate how the efficiency of an industrial water-cooling system could be improved by analysing technical upgrades, control strategies, and economic factors. The key problem was that traditional fixed-speed pump systems do not respond to real production load variations, causing excessive energy use and hydraulic losses. The research plan included several stages – analysing the efficiency of pumps used in industry and the applicability of variable-frequency drives, developing a numerical model of the existing cooling system using real operating data and enhancing the model with more efficient pumps and variable speed drives to determine the impact on hydraulics and energy use. An economic evaluation was then performed to estimate potential savings and payback time. The results showed that combining new pumps with variable speed drives significantly reduces electricity consumption across all operating modes: low-flow, medium-flow, and high-flow conditions. Modelling also revealed reduced pressure fluctuations, improved hydraulic stability, and pump efficiency consistently above 85% in the upgraded configuration. The economic analysis indicated that modernization could lower annual energy costs, with a payback period of roughly 2.5 years. Moreover, the modernized system would reduce CO2 emissions, supporting both corporate and national environmental goals. Additionally, based on the research results, conclusions and recommendations were provided to guide the modernization and efficiency improvement of the systems. Overall, the study demonstrates that integrating hydraulic improvements with advanced control solutions provides a strong foundation for long-term energy efficiency, lower operating costs, and more sustainable industrial development. |
