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Management of Natural Gas Consumption during the Manufacturing of Lead-Acid Batteries

Author

Listed:
  • Alexis Sagastume Gutiérrez

    (Energy Department, Universidad de la Costa, Calle 50 No. 55-66, PBX 336 22 00, Barranquilla 080002, Colombia)

  • Juan Jose Cabello Eras

    (Departamento de Ingeniería Mecánica, Universidad de Córdoba, Carrera 6 No. 77-305, Montería 230002, Colombia)

  • Jorge Mario Mendoza Fandiño

    (Departamento de Ingeniería Mecánica, Universidad de Córdoba, Carrera 6 No. 77-305, Montería 230002, Colombia)

  • Humberto Carlos Tavera Quiroz

    (Departamento de Ingeniería Mecánica, Universidad de Córdoba, Carrera 6 No. 77-305, Montería 230002, Colombia)

Abstract

The production of lead-acid batteries is an energy-intensive process where 28 to 35% of the energy is used in the form of heat, usually obtained from the combustion of fossil fuels. Regardless of the importance of heat consumption during battery manufacturing, there is no discussion available in the specialized literature that assesses heat during battery manufacturing. This study assessed natural gas consumption in a battery plant based on historical data, the thermographic evaluation of different equipment, and measurements of the combustion processes and combustion gases. Heat transfer models were used to calculate surface heat losses in the various assessed processes, while combustion theory was used to identify other saving potentials. Saving potentials equivalent to 16.6% of the plant’s total natural gas consumption were identified. Replacing the ingot casting system accounts for a potential saving equivalent to 13.6% of the plant gas consumption, improving the grid casting systems for 2.8%, and the leady oxide accounts for a low 0.1%. Implementing the saving measures related to surface heat loss and poor operational practice reduced natural gas consumption by an estimated 1.2% monthly. Savings could be increased to 3.2% by expanding the saving measures to the remaining grid casting systems. Overall, natural gas consumption was reduced by an estimated 777 m 3 /month, GHG emissions by 1.6 tCO 2eq. /month, and fuel costs by 1603 USD/month.

Suggested Citation

  • Alexis Sagastume Gutiérrez & Juan Jose Cabello Eras & Jorge Mario Mendoza Fandiño & Humberto Carlos Tavera Quiroz, 2023. "Management of Natural Gas Consumption during the Manufacturing of Lead-Acid Batteries," Sustainability, MDPI, vol. 15(15), pages 1-27, August.
    • Handle: RePEc:gam:jsusta:v:15:y:2023:i:15:p:12030-:d:1211325
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    References listed on IDEAS

    as
    1. Milen Balbis Morejon & Juan Jose Cabello Eras & Alexis Sagastume Gutierrez & Vladimir Sousa Santos & Yabiel Perez Gomez & Juan Gabriel Rueda Bayona, 2019. "Factors Affecting the Electricity Consumption and Productivity of the Lead Acid Battery Formation Process. The Case of a Battery Plant in Colombia," International Journal of Energy Economics and Policy, Econjournals, vol. 9(5), pages 103-112.
    2. Cabello Eras, Juan José & Sagastume Gutiérrez, Alexis & Sousa Santos, Vladimir & Cabello Ulloa, Mario Javier, 2020. "Energy management of compressed air systems. Assessing the production and use of compressed air in industry," Energy, Elsevier, vol. 213(C).
    3. Carpenter, Joseph & Woodbury, Keith A. & O'Neill, Zheng, 2018. "Using change-point and Gaussian process models to create baseline energy models in industrial facilities: A comparison," Applied Energy, Elsevier, vol. 213(C), pages 415-425.
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