Application of Modeling and Calibration in Optimization of Industrial Water Distribution Networks: A Case Study of the Kavir Tire Factory

Document Type : Case Study

Authors

1 Faculty of Engineering, University of Birjand, Birjand, Iran

2 Department of Civil Engineering, Faculty of Engineering, University of Birjand, Birjand, Iran

3 Energy Consultant, Kavir Tire Company, Birjand, Iran

10.22067/jwsd.v13i1.2601-1494
Abstract
Industrial water distribution networks are vital components of manufacturing plants, annually supplying billions of cubic meters of water for process cooling, HVAC systems, and sanitation. Due to gradual expansions of production lines and changes in equipment specifications, these systems often deviate from their optimal hydraulic performance, leading to increased water and energy losses. This paper presents the hydraulic modeling and optimization of the industrial water distribution network at the Kavir Tire Plant. The network is primarily designed to supply cooling water for equipment and processes but suffers from pressure imbalance in several production sections. A detailed hydraulic model was developed using WaterGEMS software and calibrated with a combination of the Darwin Calibrator (genetic algorithm), direct field measurements, and volumetric balancing. Calibration revealed that pipes with high hydraulic losses and excessive pressure are the main weaknesses. Proposed optimization strategies—including the installation of pressure-reducing valves and replacement of undersized or deteriorated pipes—reduced pump energy consumption by 12% and brought pressure within acceptable limits at 85% of the nodes. Field surveys and sensitivity analyses were also conducted to refine network maps and improve model accuracy. The study demonstrates practical solutions for enhancing industrial water network efficiency and recommends the establishment of a digital database and continuous monitoring system. An approximate annual saving of 280,000 m³ of water and 650 million Tomans in operational costs is anticipated, with a payback period of about 11 months.

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Articles in Press, Accepted Manuscript
Available Online from 17 October 2026

  • Receive Date 31 January 2026
  • Revise Date 05 May 2026
  • Accept Date 16 September 2026