Evaluation of Electrical Energy Conservation Opportunities: A Case Study on SABIC Facilities

Abstract

Electrical energy conservation in industrial research facilities is challenging due to continuous operation, stringent environmental control requirements, and variable process loads. This study examines opportunities for electrical energy conservation at the SABIC Research and Technology Centre in Bangalore, identifying technically feasible and economically viable measures to reduce electricity consumption while supporting SABIC’s sustainability goals. The facility has an average monthly electrical consumption of approximately 650,000 kWh, and the study aims to achieve a minimum 10% reduction in energy usage by 2026. A structured two-phase methodology was adopted. The first phase involved a detailed assessment of electrical energy, including load profiling, equipment-level measurements, and performance analysis of major energy-consuming systems, such as HVAC, laboratory ventilation, air compressors, chillers, cooling towers, and lighting. The second phase focused on optimization planning, during which identified inefficiencies were translated into prioritized energy conservation measures based on their energy-saving potential and economic feasibility. The analysis revealed that HVAC and laboratory ventilation systems account for the majority of electrical energy consumption. Retrofitting Air Handling Units with electronically commutated fans proved to be the most effective measure, providing annual energy savings exceeding 1.2 million kWh and a payback period of approximately 1.66 years. Additional improvements, including IoT-based laboratory monitoring, variable-speed drives for compressors, optimised transformer loading, and chiller sequencing, further enhanced efficiency. The novelty of this research lies in its integrated, data-driven optimisation framework that combines real-time operational analysis, economic evaluation, and climatespecific considerations. This study offers a replicable model for sustainable energy management in industrial R&D facilities without compromising operational performance.