result of baseline study of selected sector industries to assess the potentials for more efficient...
DESCRIPTION
Nepalese industries offer a huge potential to cut production cost by using energy more efficiently. It is estimated that around 15% of electrical and 30% of thermal energy could be saved in eight energy intensive industrial sector. This presentation contains the result of a study conducted by German Development Cooperation (GIZ) among 200 Nepalese industries in 2012.TRANSCRIPT
Result of Baseline Study of Selected Sector Industries to assess the Potentials
for more Efficient use of Energy
Gyanendra P. UpadhyayLocal Long Term Expert, Energy Efficiency
Background Scope for efficient use of energy in Nepalese
industries.
GON and GOG signed agreement for NEEP to promote efficient use of energy
GIZ and WECS as implementing agencies – FNCCI has established EEC
Consulting Company awarded by GIZ to conduct a baseline study of industries comprising eight sectors of industries namely Cement, Pulp & Paper, Food, Metal, Soap & chemicals, Hotel, Brick, and Cold storage
Selection
S. No. Sector of Industry Population Sample size
1 Cement 35 26
2 Pulp & Paper 7 5
3 Food 139 51
4 Metal 64 21
5 Soap & Chemicals 38 19
6 Hotel 188 39
7 Brick 435 27
8 Cold Storage 23 12
Total 929 200
Summary of all sectors
Saving potential of 8 energy-intensive sectors
No Sector
Nepal
National Production
Energy Saving PotentialEmission Savings
Electrical Thermal Money CO2Q MWh GJ NPR kg
1Cement 2,642,521 t 1,488,829,349 85,853
Clinker-based 1,933,518 t 45,854 - 383,938,427 5,486Limestone-based 709,003 t 35,390 1,598,359 1,104,890,923 80,367
2 Pulp & Paper 39,372t 919 136,848 33,663,972 9,940
3
Food total 783,680,733 12,835Beverage 2,000,000 kl 23,075 177,635 430,210,534 1,161
Biscuit 18,000 t 1,551 12,835 18,988,796 791Dairy 1,556,000 kl 7,584 192,145 257,647,474 1,068
Noodle 42,840 t 478 52,577 15,298,110 2,353Sugar 190,650 t 1,900 5,080 21,020,412 491
Vegetable Oil & Ghee 194,319 t 1,911 124,337 40,515,407 6,9714 Metal 600,000 t 5,522 202,695 281,870,090 9,4905 Soap & Chemical 112,000 t 1,210 149,334 42,087,972 10,2266 Hotel 15,021 rooms 29,445 97,056 360,432,716 1,951
7
Brick 3,374,780,735 6,535FC-BTK 3,984,000,000
bricks0 5,329,804
3,374,019,929 6,524
VSBK 16,000,000 bricks
0 1,214/760,806 12
8 Cold Storage 60,900 t 1,838 - 13,191,798 108Total 156,676 8,079,920 6,378,537,366 136,938
Cement Sector
Observations
Two types of cement plants Limestone based Clinker based
Limestone based plants use electrical as well as thermal energy (coal) as fuel for Sintering process
Clinker based plants use electrical energy Motors used are old, rewound and of standard efficiency NEA supply is from 66/33/11 kV with TOD metering Capacitor banks are installed to improve P.F. Face problem of voltage fluctuation and low voltage supply Production hampered by load shedding
Pulp & Paper Sector
Observations Electrical as well as thermal energy from rice
husk in boiler
Capacitor banks used to improve power factor more than 0.9
Combustion efficiency is not checked for boilers
Steam leakages observed
Insulation not satisfactory
Frequent non-scheduled power cuts result in production loss
High cost of Generated electrical energy
Food Sector
Food Sector
Sub-sectors
Beverage
Biscuit
Dairy
Noodle
Sugar
Vegetable oil & Ghee
Observations
Food industries consume both electrical and thermal energy.
Diesel boiler used most for backup.
Use of inefficient motors.
Steam leakages are observed.
Improper Insulation
Power factor not manage well.
Potential saving as per ESPS standard
Total Electrical (MWh)
Electrical saving (MWh)
Total Thermal
(GJ)
Thermal saving (GJ)
Beverage 1,530 139 55,623 10,707
Biscuit 3,571 1,052 56,584 8,702
Dairy 7,996 505 91,913 12,785
Noodles 3,956 243 235,382 26,786
Sugar 5,386 783 10,106 2,095
Veg. oil & ghee
21,863 1,200 705,371 78,084
Metal Sector
Observations
Iron and Steel industries are installed with heavy motors and electrical energy is mainly used for the drives of rolling mill, billet sharing, pumps, compressor, blowers and wire plant motors
Motors are old and re-winded
Capacitor banks are used to improve power factor
Furnace is used mainly with coal, FO and diesel and workplace is warm/hot indicating insufficient insulation
Frequent power cuts affect production
Soap & Chemical Sector
Observations Laundry soap is the main product
Small scale pan boiling units use firewood medium and large units use rice husk fired boiler
Only few industries uses capacitor bank
Combustion efficiency is not checked
Leakages are seen
Insulation not adequate – pipes, flanges and valves are not insulated
Brick Sector
Observations
Majority of brick industries are BTK (fixed chimney)
Energy use in brick kiln is coal and coal is imported from India
Electricity is used for lighting and drives
No significant disturbance in production by load shedding
Insulation inefficient
Inefficient coal feeding practice
Cold Storage Sector
Observations
Potatoes and fruits are the main products stored
They consume only electrical energy for cooling process
The rate of electricity charge is subsidized 50% by NEA
All units have DG for backup.
Motor loadings are not checked
Power factor is low – none used capacitor banks
Many incandescent lamps are used
Air curtains are not used
Energy Intensity regional VS Baseline
Sector Electrical Intensity
Regional (kWh/MT) Baseline (kWh/MT)
CementLimestone Base
105 148.5
Cement Clinker Base
35 48.68
Pulp & Paper 1175 937.49
Metal 200 149.17
Soap & Chemical - 111.25
Brick (BTK Fixed - 21.27 kWh/1000 pcs
Cold Storage - 283.53
Energy Intensity regional VS Baseline
Sector Thermal Intensity
Regional (MJ/MT) Baseline (MJ/MT)
CementLimestone Base
3,138 5,411.26
Cement Clinker Base
- -
Pulp & Paper 16,412 15,434
Metal 1,500 1,470
Soap & Chemical - 3,378
Brick (BTK Fixed 2,215 MJ/1000 pcs 3,951 MJ/1000 pcs
Cold Storage - -
Areas of Potential Savings Efficient motors Power factor improvement Improvement in insulation of the cold pipelines,
storage room walls and ceiling More efficient belt and pulleys Partition of cooling areas, installation and
effective use of air curtains Regular cleaning and maintenance of condenser
pipes Replacement of incandescent lamps Minimization of leakages of compressed
ammonia gas
Recommendations Energy audits must be carried out
periodically in all the industries so that opportunities are known and understood
Awareness & training about EE
Financing for the implementation of energy saving options – mobilize financial institutes and banks
Keeping the record of data and monitoring
Recommendations
Institutionalizing energy audit expertise
Focus on best practices and best available technology on energy
Policy with mandatory periodic energy audits and reporting
Involve educational institutions for offer course on EE
Competition and award for improvement in EE by sector
Thank you