Green Industry: Energy Efficiency Improvement of Steam Generation in a Moroccan Plastic Recycling Industry

Abstract

Steam systems in industry represent a substantial share of industrial energy consumption. Therefore, improving the energy efficiency of these systems is necessary to reduce fossil fuel consumption and greenhouse gas emissions in the context of energy transition. This improvement not only leads to environmental benefits but also enhances financial gains, thereby increasing industrial competitiveness. The objective of this study is to identify energy-saving opportunities in a plastic recycling plant in Morocco while adopting a system approach based on thermodynamics fundamentals. After conducting a benchmark analysis based on a scoping tool questionnaire, the steam generation section is diagnosed to quantify major losses. Subsequently, an action plan is suggested for more efficient thermal energy use. The assessments focus on energy loss reductions along with waste heat recovery. The implementation of these actions results in a potential saving of 22%, achieving an energy gain of 5574 GJ/y, a financial benefit of 96 884 $/y, and a reduction in CO₂ emissions by 332.15 tons annually. The global payback period does not exceed one year. The study conducted encourages the adoption of cost-effective energy efficiency measures by industry stakeholders, in line with the Sustainable Development Goals. Furthermore, it benefits all industries utilizing boilers in their steam production systems, regardless of the diversity of industrial systems.