Energy-saving in steam systems: Case studies from the Moroccan industry - comparison and learned lessons

The industrial sector accounts for a significant share of global energy consumption and CO<inf xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</inf> emissions, with steam systems playing a critical role in process heating and power generation. This paper presents a comparative analysis of three case studies conducted in Morocco's pulp and paper, agri-food, and plastic industries, all of which are considered energy-intensive sectors. The objective is to assess the performance of these industries' steam systems using the Steam System Scoping Tool (SSST) and evaluate their system efficiencies. The study highlights energy-saving actions implemented in each case and demonstrates how simple maintenance measures, such as repairing steam leaks, controlling excess air, and improving insulation, can significantly enhance energy efficiency and reduce costs. By adopting a systems approach to steam optimization, the study proves that cost-effective actions with short payback periods can lead to substantial energy savings without requiring major capital investments. The annual cumulative financial savings across the three case studies amounted to $608,547, with energy savings of 40,987.65 GJ and an emissions reduction of 2,809.65 tons of CO<inf xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</inf>. Despite focusing on different industries, the findings are applicable to a broad range of sectors, as the core components of steam systems are widely shared. Additionally, this work supports the African Union's Agenda 2063 and the United Nations Sustainable Development Goals (SDGs) by providing practical insights and recommendations for improving industrial energy efficiency and reducing environmental impact.