Optimization of the Energy Monitoring System for Continuous-Process Industrial Enterprises

Abstract

In the context of growing demand for efficiency, resilience, and sustainability in industrial energy usage, optimizing monitoring systems has become a critical priority. This paper develops and tests a data-driven approach to enhance energy monitoring in continuous-process industries, with a case study of a large-scale water supply enterprise in the Khorezm region of Uzbekistan. The proposed methodology integrates statistical distribution analysis, correlation mapping, and logical process modeling to capture both quantitative relationships and the physical dynamics of operations. Unlike traditional systems that rely on isolated parameters or manual interpretation, the new model embeds process logic into digital platforms, thereby reducing human dependency, minimizing error, and improving response time. The results demonstrate that the modular framework enables more accurate identification of key parameter interdependencies, supports predictive forecasting of energy consumption, and allows for real-time adjustment through ensemble machine learning submodules. In the water supply case, the system successfully differentiated between operational and idle energy usage, optimized pump loads, and provided early detection of anomalies. These improvements translate into enhanced energy efficiency, reduced operational costs, and greater reliability of supply. The study concludes that integrating physical process logic with statistical modeling not only improves monitoring accuracy but also supports the deployment of digital twins and adaptive control systems aligned with Industry 4.0. Policy implications highlight the potential for broader adoption of such models across industrial sectors, particularly in contexts where energy sustainability and infrastructure resilience are national priorities. This approach offers a scalable pathway toward smarter, more sustainable industrial energy management.