A Novel Set of Analysis Tools Integrated with the Energy Gap Method for Energy Accounting Center Diagnosis in Polymer Production

Energy and production efficiency are critical for achieving sustainability and competitiveness in polymer processing plants. A system with high energy efficiency and performance enhances productivity while reducing greenhouse gas emissions. While Monitoring and Targeting (M&T) methodologies are widely used for energy control in Energy Accounting Centers (EACs), they do not provide a diagnostic framework. The Energy Gap Method (EGM), introduced in 2018, addresses this gap by identifying the origin and magnitude of energy inefficiencies through a hierarchical model that defines six levels of specific energy consumption (SEC). Inspired by M&T strategies, the EGM has led to the development of diagnostic tools, including the Performance Characteristic Line for Diagnostics (PCLD), the Activity-Based Target from Diagnostics (ABTD), and the Performance Characteristic Curve for Diagnostics (PCCD). These tools enable manufacturers to determine optimal production batch sizes, establish minimum productivity requirements, identify molds and product references requiring intervention, and support the design of energy-efficient components. By integrating these tools, manufacturers can optimize energy consumption, achieve cost savings, and enhance environmental sustainability. This paper presents the methodology and two case studies demonstrating the analytical capabilities of the developed tools in improving energy efficiency within polymer production processes.