2005 Achievement Report

International Project for Increasing

the Efficient Use of Energy
International Project for Improving Infrastructure
for the Efficient Use of Energy
(Programs for Promotion of Energy Conservation
in ajor In!ustries in A"EA# Countries$
Report on the Results
arch% 200&
'he Energy Conservation Center% (apan
Preface
Recently, efforts to prevent global warming have been recognized as a challenge to be shared by
all humankind, while sustainable development of economy has been sought for. Mankind is
facing with the challenge of overcoming the two different conditions entirely conflicting each
other.
In order to get over these severe conditions, what are required are technical innovations such as
technologies to use energy efficiently with as little burden on the environment as possible and the
development of energy having little impact on the environment, etc.
In order to contribute to the balanced development of economy and environment in developing
countries, it is necessary to render support that is adoptable and appropriate to the respective
countries concerned based on the understanding of the actual condition of their energy use and
environmental measures and on the results of in-depth surveys on the progress in development of
infrastructure, living habits, etc.
nder these circumstances, we advanced to and worked on a new stage in this pro!ect as the
second year followed by "##$ that aimed to strengthen the infrastructure for implementing and
promoting energy audits and improvement plans, on the strength of the achievements of the
energy audits and energy audit skills transfer programs that we implemented in %# &'(&)
counties regarding one selected industry per country during the past $ years, "###*"##+.
,or an effective tool to help achieve such an aim, we carried on to create the -echnical
.irectory and .atabase/0enchmarks/1uidelines by business category.
In the meanwhile, as the activities to strengthen the infrastructure for the mentioned
implementation and promotion, we conducted follow-up surveys on the factories that were
sub!ect to energy audit in the past to check the progress in the practice of the recommended
improvement plans and also walk through energy audits in other factories to ensure the transfer
of energy audit skills. In "##2, the factories that received our follow-up survey and walk
through energy audit included that of the garment factories in 3ambodia, the steel factories in
4hilippines, a pulp 5 paper and a te6tile factory in Indonesia and a cement and beverage factory
in 0runei .arussalam. ,urthermore, we held seminar and workshop in each country, inviting
people from the government agency or factories of different categories of industries in countries
other than the host country to make a report on their successful energy conservation cases so
that information could be shared in the &'(&) region and the foundation of promotion
activities could be provided. In the seminars and workshops, the concept and development
policy regarding the creation of the -echnical .irectory and particularly database by category of
industry were discussed, and a concrete e6ample as a part was shown off.
7e believe it is very meaningful that as the result of the activities for the second year in the
pro!ect, we could achieve the above ob!ectives and create steadily the bases of the promotion of
energy conservation in the new stage.
7e hope that this pro!ect will contribute to energy conservation in the industrial sector and
environmental protection in the respective &'(&) countries so that they can eventually achieve
environment-friendly and sustainable development in economy and also that this pro!ect will
serve as a bridge of technical e6change and friendship between 8apan and the countries
concerned.
March, "##9
-he (nergy 3onservation 3enter, 8apan
Contents
4reface
'ummary
&bbreviation :ist
I. 4urpose and 0ackground of the 4ro!ect......................................................................-%
II. 3ambodia ;1arment Industry<...................................................................................-%
%. =utline of &ctivities..................................................................................................-%
". ,ollow-up 'urvey of the 1arment ,actory of 3ompany &.........................................-$
".% =utline of ,actory of 3ompany &.........................................................................-$
"." =utline of the Results of 4revious (nergy &udit on 1arment ,actory
=wned by 3ompany &.........................................................................................-9
".+ ,ollow-up (nergy &udit.......................................................................................->
".$ Results and .iscussion of the Investigation..........................................................-?
+. 7alk-through (nergy &udit of the 1arment ,actory of 3ompany 0........................-%9
+.% @isit of the 1arment ,actory of 3ompany 0.......................................................-%9
+." &dvice and Recommendations for ((53 &ctivities...........................................-%>
$. ,ollow-up 'urvey of the 1arment ,actory of M5@ International
Manufacturing :td.............................................................................................-%?
$.% =utline of ,actory of 1arment ,actory of M5@ International
Manufacturing :td.............................................................................................-%?
$." =utline of the Results of 4revious (nergy &udit on M5@+ 1arment ,actory
1arment ;Anitting< ,actory................................................................................-"#
$.+ ,ollow-up (nergy &udit.....................................................................................-"#
$.$ Results and .iscussion of the Investigation.........................................................-""
2. 'eminar and 7orkshop............................................................................................-"9
2.% 'ummary............................................................................................................-"9
2." Results of the 'eminar 7orkshop.......................................................................-">
. 4hilippines ;'teel Industry<.........................................................................................-%
%. =utline of the &ctivities.............................................................................................-%
". ,ollow-up 'urvey of Rolling Mill ,actory of 3ompany 3.........................................-$
".% =utline of the Rollimg Mill ,actory of 3ompany 3..............................................-$
"." =utline of the Results of the 4revious (nergy &udit on 3ompany 3.....................-2
".+ ,ollow-up (nergy &udit.......................................................................................-?
".$ Results and .iscussion of the Investigation.........................................................-%$
+. (nergy &udit of Rolling Mill ,actory of the =rimary 'teel 3orporation..................-%>
+.% =utline of ,actory of Rolling Mill ,actory of the 4lymary 'teel 3o...................-%>
+." 'uggested (nergy 3onservation Measures for the Rolling Mill ,actory.............-%B
+.+ ,ollow-up (nergy &udit.....................................................................................-"#
+.$ Results and .iscussion of the Investigation.........................................................-"%
$. 'eminar and 7orkshop............................................................................................-"B
$.% 'ummary............................................................................................................-"B
i
$." Results of the 'eminar 7orkshop.......................................................................-+#
. Indonesia ;4aper/pulp and -e6tile industry<................................................................-%
%. =utline of the &ctivities.............................................................................................-%
". ,ollow-up 'urvey of the 4ulp and 4aper Mill of 4- A(R-&' :(3('......................-+
".% =utline of 4ulp and 4aper Mill of 4- A(R-&' :(3('.......................................-+
"." 'ummary of the Results of the 4revious (nergy &udit of
4- A(R-&' :(3(' 4ulp and 4aper Mill...........................................................-2
".+ ,ollow-up (nergy &udit.....................................................................................-%+
".$ -echnical .iscussion and Recommendations.......................................................-%B
+. 7alk-through (nergy &udit at the 4atal 1rati 'pinning Mill of
Industri 'andang )usantara..............................................................................................-+%
+.% @isit to the 4atal 1rati 'pinning Mill..................................................................-+%
+." &dvice and Recommendations for ((53 &ctivities...........................................-+$
+.+ Recommendations for Improvement and (6pected (ffects..................................-+2
$. 'eminar and 7orkshop............................................................................................-$#
$.% 'ummary............................................................................................................-$#
$." Results of the 'eminar 7orkshop.......................................................................-$%
. 0urnei ;3ement Industry and ,ood 4rocessing Industry<.............................................-%
%. =utline of &ctivities..................................................................................................-%
". ,ollow-up 'urvey of the 3ement ,actory of 0utra Ceidelberg
3ement ;0C3<...................................................................................................................-+
".% =utline of the 3ement ,actory of 0utra Ceidelberg 3ement ;0C3<......................-+
"." =utline of the Results of the 4revious (nergy &udit of 0C3 3ement ,actory.....-$
".+ ,ollow-up (nergy &udit.......................................................................................-9
".$ Results and .iscussion of the Investigation...........................................................->
".2 'tatus of Implementation by 0C3.......................................................................-%?
+. 7alk-through (nergy &udit of the 0everage ,actory
of Aingston 0everage 5 3reamery 'dn. 0hd....................................................................-"#
+.% =utline pf the 0everage ,actory of Aingston 0everage
5 3reamery 'dn. 0hd....................................................................................-"#
+." =n-site 7alk-through (nergy &udit...................................................................-"%
+.+ &dvice and Recommendations for ((53 &ctivities...........................................-""
$. 'eminar and 7orkshop............................................................................................-+%
$.% 'ummary............................................................................................................-+%
$." Results of the 'eminar and 7orkshop.................................................................-+"
. &ctivities and (fforts as &'(&)................................................................................-%
%. =utline of 'ummary 7orkshop and 4ost 7orkshop .iscussions...............................-%
". 'ummary 7orkshop related Ma!or Industry..............................................................-+
+. 4ost 7orkshop .iscussions.....................................................................................-%"
. Reference Material......................................................................................................-%
(338 activity schedules
ii
Duestionnaires and answers of audited factories
'eminar-7orkshop programs and presented materials at $ countries
Materials for the 'ummary/4ost 7orkshop
iii
Summary
&'(&) counties are continuing to achieve dramatic economic development and their energy
consumption is anticipated to increase rapidly from now on. It will become vital to use energy
more efficiently and to give sufficient consideration to prevention of global warming.
-his pro!ect has entered its 9th year. &'(&) 3enter for (nergy ;&3(<, our &'(&) counterpart
and people concerned of the respective &'(&) countries are engaged in more and more
enhanced and substantial energy conservation activities, thereby contributing to gradually
spread change in the consciousness of the people in &'(&) countries toward the reduction of
energy consumption, particularly with the increases in energy price resulting from the recent
soaring crude oil prices and the Ayoto 4rotocol put into force in the background.
-he current year was positioned as the second year of the "nd stage for making serious efforts to
put into practice and disseminate the results we have made to date by combining all the
achievements we made in the pro!ects of the phase-%, past $ years and making further
self-supporting efforts. In other words, the "nd stage aims to establish the infrastructure for
implementing and promoting practical improvements centered on improvement plans discussed
and proposed in the respective countries in the past, based on the achievements and results of
energy audits conducted on factories of %# different types of businesses in all &'(&) countries
over the past $ years.
'pecifically, the following activities were developed in $ countriesE 3ambodia ;garment
industry<, 4hilippines ;steel industry<, Indonesia ;pulp/paper and te6tile industries< and 0runei
.arussalam ;cement and food processing industries<.
F ,ollow-up survey on the factories that underwent an energy audit in the past and walk
through energy audits on newly chosen factories
Intended for understanding of the problems lying in carrying out, promoting improvement
plans and the development of improvement measures
F 3reation of -echnical .irectory
Intended to introduce effective technologies usable in garment/steel/pulp 5 paper/cement
industries in &'(&) countries and also successful cases of the utilization of the respective
technologies for the purpose of information-sharing and enhancing the possibility of
implementation and dissemination of these technologies
F .evelopment of databases/benchmarks/guidelines
Intended to establish a scheme for setting numerical targets to advance energy conservation
activities and providing guide lines to achieve such goals
&s an immediate task, the development of databases in $ categories of businessesE
1arment/steel/pulp 5 paper/cement, is essential.
In the above mentioned countries, surveys including energy audits and seminars/workshops
were conducted. In the survey conducted in each country, guidance was given to the local
people concerned on the site again while the progress in their acquisition of energy audit skills
- % -
transferred from 8apanese specialists in the past was confirmed so that technology transfer could be
further ensured. In addition, as it was found in the survey that some factories had not
practiced improvements as instructed, factors seemingly constituting impediments to the
implementation as well as solutions were discussed, which lead to create the clue for the
implementation and progress in the future.
In the seminar/workshop held in each country, in addition to the aforesaid discussions, people from
the governments and the factories including those of different categories of industry in
other &'(&) countries ;including people of the factories undergoing energy audit in the past< were
invited to !oin with the people of the factories of the countries concerned to report on their
respective activities and the cases of practicing improvement plans. -he seminar and workshop held
in each country had a large number of participants each, playing an important role in terms of
information sharing and dissemination.
=n-site activities of the pro!ect of the current year were commenced with Inception 7orkshop
held in late 8une "##2 ;'ame as the one for both 0uilding and (nergy Management
Infrastructure .evelopment 4ro!ects<.
In the Inception 7orkshop, for the purpose of smooth launching of the pro!ect, the action plan
was e6plained and finalized, and preparations for the activities at site were confirmed among the
participants. ,ollowing that, surveys and workshops in $ countries were smoothly completed by
.ecember "##2, and topped off by 'ummary /4ost 7orkshops conducted in late 8anuary "##9
;common with 0uilding and (nergy Management Infrastructure .evelopment 4ro!ects<.
In 'ummary 7orkshop/4ost 7orkshop where delegates from &'(&) countries ;,ocal 4oints<
were present, reports on the activities and the results in the $ countries, including those on the
&'(&) 0enchmarking activities and the results, were made with the view to knowledge- and
information-sharing, and discussions regarding the creation of -echnical .irectory and the
development of database/benchmark/guideline for each country were held. ,inally, the policy
for action plans for the pro!ect ne6t year and in the future was discussed.
'pecific details of activities of the ma!or industry pro!ect for this year are as followsE
&ugust ""-'eptember ", "##2 ;-ripG &ugust "%-'eptember +<
=n-site activities in 3ambodia and 4hilippines ;4rimary survey<
%. ,ollow-up survey on garment factories ;3ambodia< and a steel factory ;4hilippines<
surveyed in the past, and a walk through energy audit of a newly selected factories of
garment/3ambodia and steel/4hilippines
'urveys on the factories were conducted and reporting of the results and discussions were
made in each factory.
". 'eminar-workshop in each country
$#-9# people participated in each country and were engaged in active information e6change
through vigorous discussions. -he policy for creation of -echnical .irectory and the action
policy regarding the development of database/benchmark/guideline proposed by 8apan were
- " -
approved in principle from the participants. -he seminar- workshop was concluded
successfully.
;%< (nergy conservation policy and program ;each country and 8apan<
;"< Report on energy conservation cases by people concerned in ma!or industries in each
host country and other &'(&) countries
;+< .iscussions on the policy regarding the creation of -echnical .irectory
;$< .iscussions on the action policy regarding the development of database in each host
country
.ecember 2-%> "##2 ;-ripG .ecember +-%B<E
=n-site activities in Indonesia and 0runei .arussalam ;'econdary survey<
%. ,ollow-up surveys on a pulp/paper factory ;Indonesia< and a cement factory ;0runei
.arussalam< surveyed in the past and a walk through energy audit of a newly selected
factories of te6tile/Indonesia and food processing/0runei .arussalam
'urveys on the factories were conducted and reporting of the results and discussions were
made in each factory.
". 'eminar-workshop in each country
9#-%## people participated in each country and were engaged in active information
e6change through vigorous discussions. -he policy for creation of -echnical .irectory and the
action policy regarding the development of database/benchmark/guideline proposed by 8apan
were approved in principle from the participants. -he seminar- workshop was
concluded successfully.
;%< (nergy conservation policy and program ;each country and 8apan<
;"< Report on energy conservation cases by people concerned in ma!or industries in each
host country and other &'(&) countries
;+< .iscussions on the policy regarding the creation of -echnical .irectory
;$< .iscussions on the action policy regarding the development of database in each host
country
8anuary "9-">, "##9 ;-ripG 8anuary "2-"B<
'ummary 7orkshop /4ost 7orkshop
4articipated in H'ummary 7orkshop and 4ost 7orkshop on 4romotion of (nergy (fficiency and
3onservation ;4R=M((3< ;Ma!or Industry, 0uilding and (nergy management<,
'=M(-M(-- 7ork 4rogram "##2-"##9I ;@enueG 0andung, Indonesia, same as the one for
building and energy management infrastructure development<
&lthough delegates from Myanmar, 'ingapore and @ietnam were absent, about "" people
including delegates of &'(&) countries and members of &'(&) 3enter for (nergy ;&3(< and
(nergy 3onservation 3enter, 8apan ;(338< participated and had comprehensive discussions on
the items given below. &fter reports of local activities at $ countries by (338 and evaluation
and future improvement of local activities prepared by $ countries we visited this time and on
- + -
the policy regarding and the progress in the development of .atabase/0enchmark/1uideline in
each country were made, lively and active discussions were held.
&lthough we confirmed that it remained our future challenge to make more efforts to improve
mutual understanding of the specific ways of advancing these practical works, we could earn
high evaluations from &'(&) countries on the results of our activities for this year and also
gain agreement in principle on the policy for advancing the pro!ect in the years to come.
=pening address ;.elegates of the countries surveyed and the organizations concerned<
'ummary 7orkshop
'ession %G Ma!or industries
- &ctivity report of this year/results and evaluations
- (valuation and future improvement of local activities
- 3ountry initiatives towards the preparation of -. and status / plan of .atabase
preparation
- 'tatus of preparation for -. and .atabase for ma!or industries in &'(&)
- 4olicy for approaches to be taken after ne6t year.
'ession "G 0uildings
'ession +G (nergy management
4ost 7orkshop
'ession %G 'ummary of discussions held in 'ummary 7orkshop for each pro!ect
'ession "G 0asic implementation plan for years after ne6t
In the current fiscal year, with an aim to support &'(&) countries in the establishment of a
firm foundation for developing continuous energy conservation activities, we improved the level
of our activities, requesting them to further make self-help efforts. &s we could gain cooperation
in our activities from all the participating countries, we successfully made significant results. =n
the other hand, we recognized the necessity to gain further understanding of our improved
activities and build a system in each country so that they could fully respond to us. -hus, our
future task was clarified. &t the same time, we appreciate such identification of our future issue
as a step forward in our activities, because it looked emerging when our pro!ect made
substantial advance and results.
,inally, we hereby would like to thank all those at &3( along with the organizations and
companies concerned in each country for their all-out cooperation.
- $ -
&bbreviation list
((53 (nergy (fficiency and 3onservation
-. -echnical .irectory
.0/0M/1: .atabase / 0enchmark / 1uideline
&3( &'(&) 3enter for (nergy
M(-I Ministry of (conomy, -rade and Industry
(338 -he (nergy 3onservation 3enter, 8apan
3ambodia
MIM( Ministry of Industry, Mines and (nergy, 3ambodia
((5' =ffice (nergy (fficiency and 'tandard =ffice
(.3 (lectricite du 3ambodge
.(- .epartment of (nergy -echnique
4hilippines
.=( .epartment of (nergy
.='- .epartment of 'cience and -echnology
R( Renewal (nergy
M(R&:3= Manila (lectric 3ompany ;=ld )ameG Manila (lectric Railroad and :ight
3ompany<
(34C -raining course of (nergy 3onservation for the 4hilippines held at 8une, "##2 in
8apan
,&' ,actory &utomation 'ystem
7('M 7holesale (lectricity 'pot Market
Indonesia
M(MR Ministry of (nergy and Mineral Resources
.I4 .e-Inking 4lant
0I= 0iotechnology
4M 4aper Machine
4:) 4erusahaan :istric )egara 4(R'(R= ;Indonesia (lectricity 3orporation<
A=)(0& 4- Aonservasi (nergi &badi ;4ersero<
0runei .arussalam
.(' .epartment of (lectrical 'ervices, 4rime MinisterJs =ffice
0C3 0utra Ceidelberg 3ement
Malaysia
4-M 4usat -enaga MalaysiaMalaysia (nergy 3enter
1
. 4urpose and 0ackground of the 4ro!ect
-his pro!ect generally aims to contribute to the promotion of energy conservation and
environmental protection in 'outheast &sian countries by helping promote energy
conservation measures in the ma!or industries in the countries concerned through providing
support for activities on the &'(&) with the view to promote and disseminate technologies for
the efficient use of energy in the ma!or industrial fields.
-his pro!ect was set up in "### with &'(&) 3enter for (nergy as the core organization,
with the aim of reducing ever-increasing energy consumption in the industrial sectors in the
&'(&) region. &'(&) call this pro!ect 4R=M((3 ;Ma!or Industries<. 4R=M((3 is an
abbreviation of H4romotion of (nergy (fficiency and 3onservationI and a cooperative
pro!ect with Ministry of (conomy, -rade and Industry certified by the conference of
ministers of energy-related ministries of %# &'(&) countries. 7e are providing support for
the promotion of energy conservation in the industrial sectors of &'(&) countries in the
aspects of technology and management through the activities of the pro!ect.
-he pro!ect has the following ob!ectivesE
%. -o deepen and strengthen the cooperative relation between &'(&) countries and 8apan
in the energy field
". -o promote energy efficiency and energy conservation in the ma!or industries in
&'(&) countries.
+. -o promote transfer of energy-related technologies of 8apan and the introduction of
good practice cases of energy conservation.
$. -o raise the quality level of &'(&) countries through energy audits and =8- for energy
audit
2. -o create .atabase/0enchmark/1uideline for energy audit in &'(&) countries.
-he current year is positioned as a second year of the activities to be developed in the
second stage, with the understanding that this cooperative pro!ect are advanced in the +
stages based on the discussions held to date with &'(&) countries including &3(.
-hrough the activities we developed in all &'(&) countries by March "##$ in the first stage,
we could build a foundation for developing energy conservation activities on an equal footing
with &'(&) countries.
%st stageG -ransfer of technologies and e6periences from 8apan to &'(&) countries
;3ompleted in "##+<
"nd stageG 8apan-&'(&) !oint implementation of improvement plans in each country and
promotion in other countries
+rd stageG 4romotion of energy conservation with independent efforts by &'(&) countries
'tarting in last year, we began to create a basis for advancing implementation and
dissemination of energy conservation based on the prepared foundation. In short, our
I-%
activities are centered at follow-up surveys on the factories that underwent energy audit in
the past, the creation of -echnical .irectory and the development of .atabase/ 0enchmark
/1uideline for each category of industry. In the current fiscal year, we developed such
activities mentioned above targeting the garment industry in 3ambodia, the steel industry in
4hilippines, the pulp 5 paper industry in Indonesia and the 3ement Industry in 0runei
.arussalam.
In the respective countries, we conducted follow-up surveys on the factories that underwent
an energy audit in the past to grasp the progress and the issues lying in the implementation
of improvement plans and also =8--based walk through energy audits of newly selected
factories !ointly with local people involved. In addition, we held seminar- workshop in
which we invited instructors from a government agency or factories of several categories of
business in the host country and other countries to introduce successful cases of
implemented improvement plans and cases of cutting-edge energy conservation technology
to further raise the awareness of energy conservation among &'(&) countries. -he concept
for promoting the creation of -echnical .irectory and .atabase/0enchmark/1uideline for
the use of each country and practical preparation activities were discussed and the future
direction was determined. -hese activities are intended to serve as the core work for
establishing the foundation for promoting energy conservation in the respective countries
sub!ect to the survey and to establish networks to promote it to other countries.
In the end, we held 'ummary 7orkshop bringing together delegates of the respective
countries to share the results and achievements of the activities made in the respective
countries and to discuss the basic plan for future activities.
I-"
. 3ambodia ;1arment Industry<
%. =utline of the &ctivities
-he follow-up energy audits of the companies that had performed energy audits in 4hase I ;.ec.
"##" and ,eb. "##+< were conducted, and the 'eminar-7orkshop was held in 4hnom 4enh
;3ambodia<, which involved the results of follow-up energy audits and the presentations on
practical e6amples for energy conservation in various industries.
-his time, the energy audits were carried out in two garment factories as a follow-up and newly walk
through energy audit in one garment factory.
In the inception workshop held in 8une "##2, it was agreed that, starting this fiscal year, the
MIM( should play a leading role in conducting follow-ups and reporting the results. Cowever, the
(338 eventually had to have an initiative instead. ,urthermore, the problems were that, when
we visited two garment factories, questionnaires, which had been sent to the MIM( via the &3(
prior to the visit, had not reached two factories. -herefore, it took long time obtaining and
confirmation of the answers.
Cere, we describe two garment companies as H3ompany &I and H3ompany 0I according to
demand of these companies.
%.% Implementation 4eriod
&ug. "" * &ug. "9, "##2
%." 'ite of Implementation
,ollow-up energy auditG 1arment factories of 3ompany & and M 5 @ International
Manufacturing :td. ;in 4hnom 4enh<
7alk through energy audit of a new factoryG 1arment factory, 3ompany 0 ;in 4hnom
4enh<
'eminar-7orkshopG 4hnom 4enh Cotel ;in 4hnom 4enh<
%.+ 'chedule ;Material )o. .-%#%(<
&ug. "" ;Mon.<G ,ollow-up energy audit of the garment factory, 3ompany &
&ug. "+ ;-ue.<G ,ollow-up energy audit of the garment factory, 3ompany &, and
walk through energy audit of a new garment factory, 3ompany 0
&ug. "$ ;7ed.<G ,ollow-up energy audit of the garment factory, M5@
International Manufacturing :td.
&ug. "2 ;-hu.<G ,ollow-up energy audit of the garment factory, M5@
International Manufacturing :td.
- 1
&ug. "9 ;,ri.<G 'eminar-7orkshop
%.$ Relevant 4ersons
&3( ;&'(&) 3enter for (nergy<G
Mr. 3hristopher 1. KamoraG Manager
Mr. Ivan IsmedG 4ro!ect =fficer
3ambodiaG Ministry of Industry, Mines and (nergy ;MIM(<
Mr. :ieng @uthy, .eputy .irector, .epJt of (nergy -echnique ;.(-<
Mr. Ceang 0ora, Cead of (nergy (fficiency and 'tandard ;((5'< =ffice, .(-
;3ambodia ,ocal 4oint<
Mr. :y 3hamroeun, @ice 3hief =fficer, ((5' =ffice Mr.
)ong 3hhavyvann, ((5' =ffice, .(-
Mr. 3houn -eiea, ((5' =ffice, .(-
8apanG International (ngineering .epartment, (338
Mr. ,umio =gawa, -echnical e6pert
Mr. Cisashi &mano, -echnical e6pert
Mr. Cideyuki -anaka, -echnical e6pert
- 2
'ituation of 3ambodia
;%< 1eneral circumstances
- &reaG %?%,### km
"
;less than half of 8apan<
- 4opulationG %+.99% million ;"##2<
- ReligionG Mainly 0uddhism
- 1overnmentG 3onstitutional monarchy
- (conomyG Aey industriesG
1.4G
1.4 per capitaG
3urrencyG
-rade ;"##"<G
(6portG
ImportG
(nergy/1.4G
&griculture, forestry and fisheries ;++.$L of 1.4<
Industries ;"9.+L of 1.4< ;.ata from the Ministry of
4lanning, "##"<
'M$.2billion ;"##$<
'M++# ;"##$<
Riel, %'M N appro6. $,### riel ;as of "##$<
1arment products, meats, vegetables, natural rubber, and
rubber goods to the .'., 1ermany, A, 'ingapore and
8apan. ;(6portsG 'M %.>$ billion<
1arment fabrics, machinery, vehicles, fuel from
-hailand, 'ingapore, Cong Aong and 3hina.
;ImportsG 'M ".$? billion<
+2k7h/per capita
- 1eneral economic conditionsG .ecrease in foreign investments and proceeds of tourism
due to the &sian economic crisis, which slowed the economic growth rate temporarily.
&fter that, the country maintained steady growth rate ranging from over 2.2L to >L
range. -he third coalition government, which started in 8uly "##$, has continuously
considered economic growth and industrial development to be the most important policy
goals. Cow to invite foreign direct investment may be a key to achieve the target in the
future.
;"< 3urrent state of energy in 3ambodia
In 3ambodia, the hydro power in addition to the renewal energy is availableE however all of oil
products are imported.
(lectrification rate was %>L, electricity e6pense is 'M#.%2/k7h, gasoline price was
appro6imate +,2##Riel/: and diesel oil was appro6imate ",?##Riel/: at the time of follow up
energy audit in "##2.
- 3
". ,ollow-up 'urvey of the 1arment ,actory of 3ompany &
".% =utline of 1arment ,actory of 3ompany &
;%< 3ompany profile
4roductsG 3asual wearMain product--shirts
4roductionG %.%> million dozens ;results of "##%<,
%.9B million .ozens ;the actual results of "##$<
4ayrollG $,+B+ persons ;)ov. +#, "##"<, appro6. 2,### ;&ug. "##2<
7orking shiftG >.2 hours in two-shift system
;9G%2-%$G%2 ;>.2 hours<, %$G%2-""G%2 ;>.2 hours<
;"< Manufacturing process and energy consumption of the garment factory
-he following are the previous situation of the factory and the follow-up resultsG
%< =utline of operation
3ompany & manufactures casual products, mainly --shirts, under the management of the
headquarters located in Malaysia. -his company founded in %BB" and started operation in
%BB$, e6porting all of the sewn products to the .', ( and &ustralia.
(nergy sources are electricity and oil products. -he company has purchased electricity
generated by a diesel electric generator of Independent 4ower 4roducer ;I44< installed in its
own factory and in "##% began to purchase electricity from 3ambodian government-owned
company ;(.3< as well. -he factory consumes electricity from I44 from %$G%2 to ""G%2,
while it uses electricity from the (.3 in another time zone. 'uch a method has been still
adopted at the time of investigation. 7hat were changed are the use of tap water and steam
drain for water supply to a boiler, and use of blended oil of H.iesel 5 heavy fuel oilI
instead of only .iesel oil.
,igure -"-% shows a flow chart of the manufacturing process and utilization of energy in a
typical garment factory. 3ompany & has adopted a similar manufacturing process.
- 4
)riginal cloth
Paper matri*
Cutting "e+ing
,irst Putting on
inspection -uttons
fasteners
.ighting
"econ!
Ironing
inspection
.a-els /
Pac0ing
Compresse!
"team
air
"hipping
Electricity
1ater ,uel oil
,igure -"-% ,low chart of the manufacturing process and
utilization of energy in a typical garment factory
"< ,acilities
0oilersG )o.% boilerG =nce-through boiler >?+kg/h
)o."boilerG =nce-through boiler 2##kg/h ;suspended<
)o.+ boilerG =nce-through boiler +##kg/h ;suspended<
)o.$ boilerG =nce-through boiler >?+kg/h ;in operation<
4ower receiving equipmentG ""k@ ;-ransformerG ""k@/$##-"+#@, %2##k@&,
one transformer<
&ir compressorsG
=ther facilitiesG
+< (nergy consumption
)o. % compressor N %".B2m
+
/minO?2.Bk7, reservoir tank %m
+
)o.
" and )o. + compressors were removed.
)o.$ compressor ;)ew< N >2k7 plus a reservoir tank #.+m
+
3utters, sewing machines, steam irons, lighting fi6tures, air
conditioners, etc.
-able -"-% shows the production and each type of energy consumption of "##% and "##$.
- 5
-able -"-% (nergy consumption ;"##% and "##$<
Items "##% "##$ Improvement
;"##$/"##%<
4roduction 3asual wear %,%>#,### ",%%#,###O#.?N%,9??,###
;.ozens/y< ;0y subcontractG "#L< ;%.$$+<
(nergy ,uel for .iesel =ilG .iesel =ilG +#,###
consumption 0oilers %B?,### ,uel =ilG %>%,###
;:/y< ;-otal N "#%,###< ;%.#%2<
(lectricity I44G %,9>9,### I44G %,+29,###
;k7h< (.3G ",%>#,### (.3G +,2$B,###
;-otalN+,?$9,###< ;-otal N $,B#2,###< ;%.">2<
4rimary energy
unit
Improved
skills
,uel
(lectricity
7orkers )o.
=utput per
person
#.%9B:/.ozen #.%%B:/.ozen
+."?>k7h/.ozen ".B#9k7h/.ozen
$,$## 2,###
"99 ++?
.ozens/person/y .ozens/person/y
#.>#$
#.??$
;%.%+9<
%.">
(nergy 4rice ,uel .iesel oil .iesel oil ;%.>%<
'M#.+2/: 'M#.9#/:
(lectricity 'M#.%""/k7h 'M#.%2/k7h ;%."+<
"." =utline of the Results of 4revious (nergy &udit on 1arment ,actory owned by 3ompany &
-he items suggested for improvement at the previous audit were as followsG
;%< tilize recycled drain from ironing process for water supply to boiler or for heating.
-he recycled drain from the ironing process had not been effectively utilized, but !ust
disposed. (ffective utilization of the drain will contribute to saving about > k:/y of fuel
oil.
;"< Ceat insulation of the bare piping lay between boilers, steam headers and the factory.
0inding a 9#m bare $#& pipes with a +#mm thick heat insulator can save about >." k:/y of
fuel oil.
;+< (nergy conservation by introducing a device controlling the number of air compressors in
service
=f the three air compressors ;>2k7G % unit, +> k7G " units<, >2k7 type has always been in
operation and repeating a cycle of loading and unloading. -herefore, we suggested an
introduction of a system to control =n/=ff operation of multiple air compressors through the
- 6
use of the pressure of a newly installed reservoir tank. It was estimated to reduce about
%%+M7h/y.
;$< (nergy conservation by relocating lighting fi6tures
-he cutting and sewing rooms are provided with both ceiling and pendant fluorescent lights. 0y
lowering the position of those pendant lights, the number of fluorescent lights can be
reduced. Reduction of about $>M7h per year is possible.
".+ ,ollow-up (nergy &udit
-he energy audit team visited the garment factory for two consecutive days to conduct a
follow-up energy audit of the improvement based on the previous guidance, and to e6amine
their new activities.
;%< .ate of energy auditG
&ugust "" ;Monday< "##2 at BG## a.m. - %9G## a.m.
"+ ;-uesday< "##2 at BG## a.m. - %"G## a.m.
;"< &udit team membersG
3ambodiaG .epartment of (nergy -echnique ;.(-<, MIM(
Mr. :ieng @uthy, .eputy .irector ;only paid our respects in the morning of
&ug. ""<
Mr. Ceang 0ora, Cead of (((5' =ffice, .(-, MIM(
Mr. :y 3hamroeun, @ice 3hief =fficer, ((5' =ffice, MIM( Mr.
)ong 3hhavyvann, ((5' =ffice, MIM(
Mr. 3houn -eiea, ((5' =ffice, MIM(
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical
(6perts
;+< &ttendees from the factoryG
&dministration Manager ;only paid their respects in the morning of &ug.
""<
&ccount 5 4ayroll Manager, 3ounterpart for audit team
Maintenance 'upervisor
;$< =utline of the follow-up investigation
7hen the energy audit team visited the factory of 3ompany &, a questionnaire (338 had
- 7
sent to the MIM( prior to the visit, had not reached the factory. &lthough the factory was very
cooperative to the investigation, the investigation efficiency was poor because they had no time
to prepare their answers to the questionnaire. -he team conducted a walk through energy audit
of the factory in the morning, &ug. "", and made question-and-answer in the afternoon about
production and energy consumption etc. -he team agreed that some data would be received
ne6t day because it took time. In the morning of &ug. "+, &udit team visited there again to
receive the answers, audited again the checkpoints on !ob site and measured the temperature
and illumination, etc.
3ompared with the previous investigation of the factory ;.ecember "##" and ,ebruary
"##+<, the production process ;receiving te6tile stuff, cutting, sewing, ironing, packing and
shipping< as well as operational methods were basically unchanged, but the production in
quantity over $#L, and partial improvements ;renewal of air compressors, improved air
conditioning system, recycling of steam drain, etc.< have already been made. &s a result,
primary fuel/electricity units significantly decreased, appro6imately +#L and %"L down,
respectively.
&s for recycling of steam drain, they seem to have followed previous suggestion. ,ollowing the
suggestion about air compressors, they adopted a high-efficiency model. -he steam pipes
have been partially insulated, but the lighting fi6tures have been untouched.
Relevant technical e6planations on this matter are shown in an attached document )o. .-
%%9 H,ollow up of (nergy &udit ((53 &ctivities in 1arment Industries, 3ambodiaI. In addition,
there were not any documents received from 3ompany &.
".$ Results and .iscussion of the Investigation
;%< 4roduction status and energy intensity ;Material )o. .-%#+(<
-able -"-% shows data, while ,igure -"-", -"-+ and -"-$ indicate the comparison
between "##% and "##$. 4roduction greatly increased from three years before, while the
consumption of fuels and electricity moderately increased, as a result, the energy intensity
was dramatically improved. -he 3ounter part ;3/4< of 3ompany & pointed out the
following reasonsG
- -echnical capabilities of employees were so improved that the production efficiency
increased, leading to a large growth in production. .uring the last three years, the
production per person increased by %">L.
- Renewal of sewing machines every four to five years contributes to energy conservation and
efficient production
- Investment for energy conservation began to have effect as mentioned later.
- 8
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,igure -"-" 3hange in production ;3omparison between "##% and "##$
"2#
"##
%2#
%## %B?
2#
# #
"##% Pear
Ceavy oil
.iesel oil
%>%
+#
"##$
(.3
9,### I44
2,###
$,###
+,### +,2$B
",%>#
",###
%,### %,9>9 %,+29
#
"##% Pear "##$
,igure -"-+ 3hange in fuel consumption and electricity consumption
;3omparison between "##% and "##$<
#."##
#.%2#
#.%##
#.#2#
#.###
"##%
$.###
+.###
".###
(lectricity
,uel %.###
#.###
Pear "##$
,igure -"-$ 3hange in primary energy unit ;3omparison between "##% and "##$<
;"< (nergy management
3/4 of 3ompany &, in charge of accounting, well understood the importance of energy
conservation. Cowever, the personnel in the factory as a whole were generally less aware of
its importance and did not grasp data sufficiently. =n the other hand, production per group
was shown on a white board. -his suggests that a small group activity appeared to have
- 9
started.
-he energy audit team highly evaluated 3/4Js understanding of the importance of energy
conservation. It is e6pected him to set up a measurement system and develop persuasive
activities based on quantitative data.
-he energy audit team obtained the results shown in -able -"-" through questions and
answers as well as on-site investigation to grasp each type of electricity consumption. In the
factory, the team checked specifications and the number of equipment, readout electric
power and consumption indicated by the electric switchboard, the control panel, etc., and
estimated the consumption by taking into account the information obtained from the D5&
sessions. -he estimation would be helpful for participants in the MIM( and 3/4 of
3ompany &.
In the future, it is necessary to grasp the kaleidoscopic changes quantitatively.
3onsequently, the point at issue will become clear, and they must be able to take measures,
more easily.
-able -"-" (lectricity consumption by purpose
(quipment (stimation 4ower Ratio
3onsumption
% 'ewing ;%$$# units<O;#.22k7<O#.2 N +B9k7 +B9k7 $BL
Machines -otal )o.G +9# piecesO$ factories
=peration Ratio N 2#L
" :ightings %B"9 unitsO#.#?7 N %2$k7 %2$k7 %BL
-otal )o.G +"% piecesO9 factories
+ &ir 9$ piecesO%.2k7 N B9k7 B9k7 %"L
3onditioners
$ &ir % pieceO>2k7 N >2k7 >2k7 BL
3ompressors =ne operating, one stand-by
2 &ir 3ooling ,an $# piecesO#.>2k7 N +#k7 $+k7 9L
'ystem 4ump 9 piecesO"."k7 N %+."k7
9 =thers $#k7 ;=ffice, (levator, 0oiler pumps, etc.< $#k7 2L
-otal ?#$k7 %##L
;=n the other hand, the total power consumption by readings of meters
on panel was ?$#k7.<
;+< &ir compressors
In addition to )o.% compressor ;0room7ade, >2k7<, 'crew 3ompressor ;CI'3R(7 >2,
>2k7< manufactured by Citachi :td. was newly purchased and installed about three months
ago and both were operated alternatively. -he latter reduces required power by varying the
number of revolution according to the change in loading. It operated steadily at the outlet
- 1 0
pressure of about #.2M4a at the time of energy audit. )o. % and )o. " compressors had
been removed. ,igure -"-2 shows the present configuration of air compressors.
No.1 Compressor
BROOM WADE,
Screw type 100Hp R.T
85.9kW (Input) (75kW) 1.0m
No.4 Compressor (New)
HITACHI, Japan
HISCREW75 100Hp R.T
Inverter control (75kW) 0.3m
3
,igure -"-2 3onfiguration of air compressors
New factory
Old factory
-he compressed air was sent to the sewing process ;the four sewing sectionsG each section
had about 2## sewing machines, half of which were those which feed thread cut by the
compressed air. &t the inlet of each sewing machine, there was a regulator controlling the
outlet pressure at the setting of about #.$M4a. &lthough (338 e6perts had suggested
improvements previously, the audit team again placed an emphasis on the following
mattersG
%< .ecreasing the outlet pressure
-he pressure of the regulator seemed higher than necessary, so we suggested that they
should perform a test to find whether or not decreasing the pressure of the regulator would
create a problem. If the regulator pressure is decreased, the outlet pressure of the air
compressor can be decreased. -his will lead to energy conservation. ,or e6ample, when
the outlet pressure is lowered from #.2M4a

to #.$2M4a, the electricity consumption will
be decreased about 9L.
"< :ooped piping
If the ends of the branched piping are connected in a loop to decrease the loss of piping
pressure, the distribution of the pressure in the factory can be leveled out and piping
pressure loss can also been reduced.
+< 4revention of air leakage
3heck air leakage and repair a leaking place. -he team insisted that it was difficult to
decrease the amount of leakage to less than 2L, but possible to decrease it to 2L easily.
.ecreasing the amount of leakage directly reflects electricity conservation. 3/4 of
3ompany & said that his superior had instructed him to consider the modification of the
piping of the compressor outlets
- 11
;$< :ighting fi6tures
%< Improvement of the illumination in the workplace
(338 suggested that the position of lighting fi6tures should be lowered in the workplace
at the previous investigation but they have not done it yet this time. =perations using
sewing machines belong to detail work, so insufficient illumination negatively affects
operation efficiency and reduces yield. -he measurement of illumination at a considerably
dark place indicates $##:u6, which was a little low from the viewpoint of the 8apanese
Industrial 'tandards ;8I'<. 3omparing with the standards, desirable illumination is about
?##:u6.
-he illumination is inversely proportional to the square of the distance. If the position of
pendant lamps is lowered by 2## mm as we suggested, the distance decreases from %,?## mm
to %,+## mm, and the illumination becomes as followsG
;%?##%+##<
"
O$##:Q%.B%>O$##:Q>9>:Q
-his value almost satisfies the abovementioned standard. -his should be considered
continuously. In contrast, in the rooms where additional fluorescent lights were installed at a
lower position, the ceiling lights might be turned out. In addition, we thought it was
brighter than necessary near the windows, in the warehouses, and packaging and shipping
rooms. Cowever, 3/4 of 3ompany & e6plained such high illumination was necessary for
33.-type surveillance -@ cameras.
"< Installing refractors
0y installing aluminum mirror refractors and specially coated refractors, actual
illumination can be improved. ,igure -"-9 shows the e6amples of improved reflectance.
In this case, a %.2-times improved reflectance is obtained. @arious types of refractors
attached to lighting fi6tures are available and some of them are directly attached to
fluorescent lamps.
+< &dopting high-efficiency fluorescent lights at the time of replacement
,or fluorescent lights, the use of the Cf ;high-frequency lighting lamps< enables further
energy conservation. -hrough the use of high-frequency lamps, various illumination
ad!ustment functions can be added.
- 1 2
1hite painting refractor
Aluminum mirror refractor
Improve! mirror refractor

light

,igure -"-9 (6amples of improved reflectance of lighting
$< Maintenance management of lighting fi6tures
7ith the increase in light-up time, the light beam ;brightness< decreases. ,or fluorescent
lights, lighting for 2,### hours decreases the illumination to ?9L ;?#L after the
%#,###-hour lighting<. ,urthermore, soiling causes a decrease in light beam. :ight beam is
reported to decrease to ?2L after one-year lighting under ordinary conditions. ,luorescent
lights decreases to >+L ;N #.?9O#.?2< in brightness after lighting for 2,### hours in a year.
-herefore, you should clean fluorescent lights at least once a year and replace old lights
with new ones.
;2< 4ower of sewing machines
Many of sewing machines were made in 8apan, and each consumption power was 22#7. 3/4
of 3ompany & e6plained that they were replaced every $ to 2 years and more effective
machines are introduced every time.
It was difficult to estimate the distribution as to how many percent of sewing machines
operate simultaneously, so we assumed that the distribution rate was 2#L based on the
above calculation.
;9< &ir conditioning facilities
&ir conditioners in the shop floor were replaced with new ones adopting a new cold air
ventilation system about one and half years ago. -he system works as followsG (6haust fans
;$# units, #.>2k7 each< are installed on the walls, and heat e6changers incorporating paper
corrugated plates ;made in the .'.< are installed on the air inlet side, or opposite side of the
wall to drip water from the upper side, so that its evaporation latent heat directly cools the
air. -he dripped water is recycled through the return pipes and circulated again with water
pumps ;9 units, %.92k7 each<. 7e thought that this system was economical as a cooling
system for a large room, but the working place did not produce comfortable environment
- 1 3
when considering the number of the workforce in the room.
=n the other hand, there were air conditioners ;9$ units, %.2k7 each< in each room of the
office. 7e suggested that they should increase the preset temperature ;"#<.
;>< 0oilers and steam piping
)o.$ boiler ;%,>"2 :b/h<, whose installation had been reported in the previous report, was
operating.
-hey are adopting two-boiler system with )o.$ and )o.% ;manufactured by ,:-=)<. -he
recycle of drain, which was advised at the previous investigation, was already performed by
newly installing a drain tank about one and half a year before. -he energy audit team found
that steam was rising around the descending drain pipes at the top portion of the tank and,
sometimes, water was overflowing and running down on the wall of the tank. =n the other
hand, the valve for the piping to make up fresh water was manually shut. -he temperature
on the wall of the tank was ?# or more at the top part and 9# or more at the lower part.
It was confirmed that the difference between these temperatures and the outside-air
temperature was bigE therefore the device had effect. nder these circumstances, the team
advised as followsG
a. 4revent steam leakage by using a steam trap.
b. &utomatically control supply of fresh water with level ad!ustment of the tank.
c. Insulate the whole boiler, the steam header, and the bare part of the piping.
d. 4erform combustion control ;(specially, the control of air ratio<.
e. 3onsider heat recovery from e6haust gases.
;?< Management of the usage of electricity
-he team e6plained confirmation of the installation of condensers for improving the power
factor of electricity and discussed for grasping power consumption.
In the electric distribution system in the garment factory of 3ompany &, 7att-hour Meters
are installed in each principal workplace. -he team recommended that they grasp the
electricity consumption using these meters. &t the predetermined times, they get a reading
of an integrating wattmeter and calculate the day-to-day difference so that they can grasp
the electricity consumption in each department everyday. 0ased on these data, a load curve
;graph< per day is obtainable as shown in ,igure -"->. Referring to -able -"-" as well, the
electricity amount to be reduced can be determined by analyzing the data. (specially, a
decrease in nighttime consumption and peak consumption of electricity is cost-effective.
Instantaneous power can be found by the rotation speed of the disk in the 7att-hour Meter.
- 1 4
P
o
+
e
r

-hrough these measures, they will know how to challenge other issues for energy
conservation.
250
200
350
300
250
200
450
400
50
0
0 2 2 & 5 40 42 42 4& 45 20 22 22
'ime h
,igure -"-> :oad curve ;graph< per day of electricity consumption
;B< 'ummary of energy conservation activities for the past three years through follow-up
investigation
,or the four improvements for which (338 made suggestions at the previous investigation,
mentioned in ".", -able -"-+ shows the survey results at this follow-up.
-able -"-+ Results of energy conservation activities performed on the items suggested for
improvement at the previous survey
Recommended -echnology/4ractice Implementation 'tatus of Implementation
;%< .rain recovery from the Pes Installing of water tank for drain
ironing process recovery.
;"< Ceat insulation for boilers, )o Re-recommendation
steam header and bare piping
;+< Introduction of control for Pes Installation of new compressor
number of compressors in controlled by inverter.
operation
;$< Improvement in lighting, )o - Much investment cost
changing the position of the - Recommended to fi6 reflectors
lighting fi6tures
- 1 5
+. 7alk-through (nergy &udit of the 1arment ,actory of 3ompany 0
&t the meeting in the morning of &ug. "+, the counterpart of 3ompany & made a sudden
request, saying HPour advice and recommendations are very helpful. & new factory of another
company that belongs to the same group has started operation. 'o, would you kindly pay a
short visit there and tell us any points to be improvedRI 7e discussed it with the MIM( and
accepted the request.
7e stayed the factory for a little more than one hour. ,irst, we toured the factory and then
e6plained the items to be improved for energy conservation.
+.% @isit of the 1arment ,actory of 3ompany 0
;%< =utline of our visit
3ompany 0 is a sister company of 3ompany &.
:ocationG 4hnom 4enh, 3ambodia
.ay of visitG &ug. "+ ;-uesday<, "##2, %"G+#-%+G$2
@isitors MIM( Mr. Ceang 0ora ;,4 of 3ambodia<
8une -e6tiles Mr. :.A. 'hyan ;&ccounting 5 4ayroll<
(338 Messrs. ,umio =gawa, Cisashi &mano and Cideyuki
-anaka ;-echnical (6perts<
4erson in charge in 3ompany 0G ,actory Manager
;"< =utline of the factory
-he new factory of 3ompany 0 located about a +# minute drive from the factory of
3ompany & or about $ km from 4hnom 4enh airport, is built in a considerably large area of a
vast industrial park. -he factory built for the first term has already started operation about three
months earlier. -he factory appeared to be designed aiming at high efficiency and high
productivity based on the e6periences of 3ompany &. 7orking environment was far more
e6cellent than in 3ompany &.
&s the first term, the factory started operation with half of its capacity. -he number of
workers is presently ",### with two working shifts and will double to ?,###, and will
employ %#,### in total including indirect department and other kinds of staff.
In 3ambodia, there is another bigger factory owned by a company in Cong Aong. -hey said that
among a total of "## garments manufacturing companies, this group is ranked within the
nationJs five largest groups.
%< 'ewing process
In a huge building ;about 2#mO>#m< with an appearance of the newest factory, it was a
grand sight that a large number of female workers were all working with sewing machines.
- 1 6
-he ceiling seemed to be about two stories high and for the air cooling system, Hthe air
cooling draft system by dripping waterI, the same as that of 3ompany &, was introduced.
-ransparent vinyl sheets were hanging from the ceiling at intervals of ten meters, so the
airflow was limited within some meters above the floor of the working place. 7e felt the
airflow and found that it produced comfortable environment.
"< Ironing process
:ike the factory of 3ompany &, two pipes for supplying and returning steam were installed, to
which two fle6ible pipes with small diameter from each ironing machine were connected. 7e
could not find how drain recovery was performed, but the effective use of drain was not
conducted at present.
+< &ir compressors
&lso like the factory of 3ompany &, 'crew compressors manufactured by Citachi 3o., :td. have
been installed. -he outlet pressure was set at about #.9>M4a, a little high value.
$< 0oilers
,uel oils were used ;there were the tanks marked as 4etronas, a petroleum company in
Malaysia<. -he heat insulator was attached only to the bodies of the boilers but heat
recovery drain has not been performed. Ceaders were arranged in the near the boilers, and the
drain from the lower part of the boiler was discharged to the nearby street via the steam trap, and
a cloud of steam was rising.
+. " &dvice and Recommendations for ((53 &ctivities
;%< -he working environment was very good because of the high ceiling and the air was
flowing etc. 7e felt that the air-cooling draft system worked well there.
;"< -he fluorescent lights installed on the high ceiling of the warehouse were not appropriate in
terms of the characteristics of light distribution. 7e recommend replacement of them with
CI. type ones.
;+< -he air filters for intake of air compressors seemed to be frequently cleaned. 7e recommend
installation of intake duct to intake fresh air. -he discharge pressure was a little high.
;$< 3oncerning boilers and steam piping etc., we made the same e6planations as we made for in
3ompany &. (specially, we recommended early improvement in manual supply of water to
the tanks and effective use of drain.
- 1 7
$,ollow-up 'urvey of the 1arment ,actory of M5@ International Manufacturing :td.
$.% =utline of the 1arment ,actory of M5@ International Manufacturing :td.
;%< 3ompany profile
3ompany nameG M5@ International Manufacturing :td. ;CeadquartersG Macao,
3hina.
,actory nameG M5@ International Manufacturing :td.
M5@ has four factories in 3ambodia. -his is the third factory ;M@+<.
&ddressG )o. %9"+ 3hac &ngre Araum, 4hnom 4enh, 3ambodia
-elG ;?22< "+-$"2 #$%
4roductsG Anitwear ;sweaters<
4roductionG 2.% million ;achieved in "##%<, ?.+ million ;achieved in "##$<
(mployeesG +,### ;)ov. "##"<, about +,"## ;&ug. "##2<
7orking shiftG ? hours in one shift ;>G## - %%G## and %"G+# - %9G+#<
;"< Manufacturing process of the sewing ;knitting< factory and energy consumption
-he results of this follow-up visit are described compared with those at the previous
e6amination as followsG
%< =utline of operations
-he factory ;M@+< manufactures only sweaters under the management of the headquarters
located in Macao, 3hina. -he M@+ did not have detailed data as previous investigation
because the headquarters control the organizations for production and the factory only
manufactured under the order of the headquarters.
M5@ International Manufacturing :td. was established in %BB$ and the M@+ factory
started operation in %BB>. -he annual production increased from 2.% million ;"##%< to ?.+
million ;"##$<. -he production is mainly winter clothes, so production decreases in the
winter. &ll of the manufactured products are e6ported to the .'.&., (, etc.
(nergy sources are electricity and oil products, and self-generated electricity by a diesel
generator is mainly used. (lectricity for nighttime lighting etc. is purchased from the (.3
;(lectricite du 3ambodge, a 3ambodian government-owned company<. ,or the boilers, river
water and heavy oil are used. -he above-mentioned state hardly changed compared with that
of the previous investigation three years ago.
,igure-$-% shows a flow chart of manufacturing process of the sewing ;knitting< factory and
of energy used.
- 1 8
)riginal cloth
(6nitting yarn$
7ying /
1ashing
6nitting
/
.in0ing
,irst
inspection
1ashing
/ 7rying Putting on Ironing
-uttons
fasteners
.ighting
"team
"econ!
inspection
/ Repair
Ironing
.a-els /
Pac0ing
"hipping
7iesel oil
Electricity
1ater ,uel oil
,igure -$-% ,low chat of manufacturing process of the sewing ;knitting< factory
and of energy used
"< ,acilities
0oilersG )o. % boiler horizontal fire-tube boiler $,"##kg/h
)o. " boiler once-through boiler %,29#kg/h
)o. + boiler once-through boiler >?+kg/h
)o. $ boiler horizontal fire-tube boiler 9,###kg/h
1eneratorsG =f three generators, )o. "5+ .iesel generators were operating
>"#k@&/unit
4ower receiving equipmentG +?#@ ;no transmitter<
-he facilities of the sewing ;knitting< factory consists of dyeing equipment, washing
machines, dryers, sewing machines, knitting machines, irons, lighting fi6tures, air
conditioners, and water treatment facilities, etc.
+< (nergy consumption
-able -$-% shows each type of energy consumption in "##".
- 1 9
-able -$-% (nergy consumption ;"##%- "##$<
Pear "##% "##+ "##$
4roduction 2.%# ;%##< 9.2# ;%">< ?.+# ;%92<
million pieces/y, and ;ratio<
(nergy consumption
Ceavy oil ;for boilers< k:/y B"? %,#$$ %,%2"
:ight oil ;for generation< k:/y $?# 2+9 2B"
(lectricity ;purchased power< M7h/y "%$ unknown unknown
4rimary energy unit
Ceavy oil ;for boilers< :/piece ;ratio< #.%?" ;%##< #.%9% ;?B< #.%+B ;>9.+<
:ight oil ;for generation< :/piece ;ratio< #.#B$ ;%##< #.#?" ;?>< #.#>% ;>2.?<
nit price of energy
Ceavy oil ;for boilers< 'M#."2/:
:ight oil ;for generation< 'M#.+2/: 'M#.9#/:
(lectricity ;purchased power< 'M#.%2"/k7h
$." =utline of the Results of the 4revious (nergy &udit on M5@+ 1arment ;Anitting< ,actory
-he items suggested for improvement at the previous energy audit were as followsG
;%< Ceat recovery from e6haust gas of diesel engines
Install heat e6changers in the e6haust gas ducts of )o. " and + diesel engines to generate
low-pressure steam ;co-generation<, which reduces the load on boilers, and fuels. -his will
save about "? k:/y of fuel oils.
;"< (nhanced heat insulation of bare parts of the steam piping
Installing a heat insulator to about 9#m-long "2& bare pipes will save about +.%k:/y of fuel
oils.
;+< (nergy conservation by changing the installed position of lighting fi6tures
In the cutting and sewing rooms, both fluorescent ceiling lights and pendant lights were
installed. 7e recommended that the ceiling lights be turned off because the turning off
hardly had effect on illumination. It was estimated to bring out a saving of +"M7h/y.
$.+ ,ollow-up (nergy &udit
In order to conduct a follow-up to investigate whether the problems pointed out at the
previous audits had been improved or not, and what kind of new activities had been
promoted, we visited the sewing ;knitting< factory for two days.
- 2 0
7e thought the M57+ factory was not cooperative in the investigation, probably due to
busyness. & technical engineer who accompanied us spoke only 3hinese, while a person in
charge of general affairs translated in (nglish, Ahmer and 3hinese, but did not know much
about technical terms, so the efficiency in communication was bad.
-his factory did not receive the questionnaire either that we had sent to the MI)( via &3(
prior to the investigation, so we could not obtain sufficient data in spite of our request. 7e
were told that only the headquarters in 3hina grasped the statistic data. 3onsequently, we only
confirmed the production and consumption of fuels in "##+ and "##$. ,urthermore, we were
prohibited from entering more areas than at the previous investigation. 7e only saw the
generators, boilers and passed by the yard for packaging and ironing. 7e !ust conducted a
simple follow-up audit investigation for a short time.
;%< .ate of the energy auditG
&ug. "$ ;7ed.<, "##2, at BG%2 a.m. - %#G+# a.m.
&ug. "2 ;-hu.< "##2, at BG## a.m. - %"G## a.m.
;"< &udit team membersG
3ambodiaG .epartment of (nergy -echnique ;.(-<, MIM(
Mr. :ieng @uthy, .eputy .irector
Mr. Ceang 0ora, Cead of (nergy (fficiency and 'tandard ;((5'< =ffice Mr.
:y 3hamroeun, @ice 3hief =fficer, ((5' =ffice
Mr. )ong 3hhavyvann, ((5' =ffice
Mr. 3houn -(I(&, ((5' =ffice
&3( ;&'(&) 3enter for (nergy<G
Mr. 3hristopher 1. Kamora, Manager
Mr. Ivan Ismed, 4ro!ect =fficer
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
;+< &ttendees from the factory ;M5@+<G
Mr. 'hu 8in ,a, Maintenance Manager
Ms. 7en Ping ,ang, 3.=.3
;$< =utline of the follow-up investigation
-he main product of the factory is knitwear, mainly sweaters, in which there was no
difference both at the previous visits ;.ec. "##" and ,eb. "##+< and this visit. &t the
- 2 1
4
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previous visit, we obtained data of "##% and, this time, data of "##+ and "##$. -hese data
showed that production steadily increased, which was the main cause of a large decrease in
the primary energy unit. -hey didnJt seem to invest e6clusively for energy conservation.
-he number of enrolled employees was +,### in "##% and presently +,"##, which showed
no big difference.
$.$ Results and .iscussion of the Investigation ;Material )o. .-%#$<
;%< 'tatus of production and primary energy unit
-able II-$-%, ,igure II-$-" and II-$-+ show energy consumption of the factory. ,uels ;heavy
oil< are used for boilers. (lectricity consists of self-generated one by diesel generators with
light oil ;the generation amount is proportional to the consumption of light oil for
self-generation< and received electricity ;purchased one< from the (.3 ;3ambodian
government-owned company<. .uring daytime, electricity necessary for production is self-
generated, and only electricity consumed for the safety purpose during nighttime ;BG## p.m. - >G##
a.m.< is purchased from the (.3.
-he primary energy unit of both fuels and electricity significantly decreased, about "$L, and it
is mainly due to drastic growth of production.
Ceavy oil
%#,###
?,###
9,###
$,###
",###
#
"##% "##+
Pear
%,2## .iesel oil
%,###
2##
#
"##$ "##% "##+ "##$
Pear
,igure II-$-" 3hange in production and consumption of fuels ;"##%-"##$<
#."##
#.%2#
#.%##
#.#2#
#.###
"##%
.iesel oil
Ceavy oil
"##+ "##$
Pear
#.%##
#.#?#
#.#9#
#.#$#
#.#"#
#.###
,igure II-$-+ 3hange in primary energy unit ;"##%-"##$<
- 2 2
;"< Management of energy
.ue to an increase in production, the primary energy unit has been greatly improved as
mentioned above, but we had no impression that the factoryJs system of energy
management was e6cellent. Cowever, for electricity consumption, it seemed that the
instantaneous value of a control board meter was obtained several times a day as mentioned
below, but due to lack of e6planation, it was unknown how they analyzed and used the
measurements. Relevant items are described below.
%< 'easonal change
-he products are e6ported mainly to the .'., etc.E accordingly demand varies with
seasons. -he production changes proportionally. -he peak production period is from &pril
through =ctober and other period is off-peak production period. 'ince there is a big gap
between the peak and off-peak periods ;the number of employees in clock hours varies
with the number of enrolled employees<, therefore, it is impossible to grasp the data
throughout the year only by obtaining instantaneous values of electricity consumption.
"< 3hange in electricity consumption during a day
It was in the peak consumption period. ,or e6ample, the time-series values of electricity
measured yesterday ;&ug. "$< varied as follows ;-he production was +#,###pieces.<G
#>G## - %%G## 9+#k7 ;full operation< self-generation
%%G## - %"G+# +?#k7 ;during lunch time< ditto
%"G+# - %9G+# 9+#k7 ;full operation< ditto
%9G+# - "%G## $>#k7 ;operation< ditto
"%G## - #>G## ;(lectricity consumed for the safety purpose,
purchased power<
,igure II-$-$ shows a daily load curve ;graph< based on the values read by this wattmeter.
-his graph will enable to grasp general tendency of electricity consumption.
- 2 3
P
o
+
e
r

800
&00
500
200
300
200
400
0
0 2 2 & 5 40 42 42 4& 45 20 22 22
'ime h
,igure II-$-$ .aily load curve ;graph< of electricity consumption
+< ,uel price
3ompared with data in "##%, the price of fuels has increased. ,or the price of electricity, the
present price of light oil is 'M#.9/:. If % liter of light oil could generate $k7h of
electricity, it costs 'M#.%2 per %k7h.
;+< Ceat recovery from e6haust gases of diesel engines
-his heat recovery was not performed in the factory. 7e talked about the importance of heat
recovery to them this time, too, but their understanding was insufficient, so we had no
productive discussion. 7e told them that that was a challenge to be reviewed later.
,or diesel engines, heat recovery is possible from e6haust gases as well as engine coolants.
-he amount of heat recovery is almost equal to that of output. =peration of two generators
produces about 9##k7 of electricityE consequently 9##k7h ;",%9##M8< of heat output is
obtained. If the efficiency of a boiler is estimated to be ?2L, it is equal to conservation of
B2:/h ;N "%?k:/y<.
;$< 0oilers and steam piping
-here were four boilers of &, 0, 3 and . as mentioned in the previous report. -he main
bodies were insulated. &lmost all of the steam headers and pipes were already insulated.
'ome valves and flanges were bareE therefore perfect insulation is desired.
HRecovery of drainI has been implemented previously, however whether they utilize it or not is
unknown.
-he outlet pressure of steam was about #.>M4a, and it may be necessary to determine
adequate pressure and temperature for the consumption side. & radiation thermometer read
- 2 4
%#B on the surface of the e6ternal wall of pipes for e6haust gases.
;2< -urning off the ceiling lights ;general<
:ights were not turned off in the ironing rooms, etc. =n the other hand, the illumination on
the desks in the packaging process was +?#:u6. It was a little dark but not an e6tremely low
level. 7e had heard at the previous investigation that they were attempting to turn off lights
during an intermission, and unnecessary lights. -his time, we investigated only part of the
factory during operational hours. -herefore, the actual state in other parts of the factory was
unknown.
;9< 'ummary of the results of the follow-up investigation of energy conservation in the past
three years
-able II-$-" indicates the follow-up investigation results of the three items of 2." whose
improvement was suggested at the previous audits.
-able II-$-" Results of energy conservation activities performed in order to resolve the items
suggested for improvement at the previous audits
Recommended -echnology/4ractice Implementation 'tatus of Implementation
;%< Ceat recovery from e6haust )o Recommended again
gas of diesel engines
;"< Ceat insulation for boilers, Pes @alves and flanges need to be
steam header and bare pipes insulated.
;+< :ighting off the ceiling ;Pes< Maybe =A
lights in all shops
- 2 5
2. 'eminar and 7orkshop
2. % 'ummary
-he seminar and workshop was held on &ug. "9 ;,riday<, "##2.
.r. 'at 'amy, nder 'ecretary of 'tate of 3ambodia delivered an opening address, while Mr.
-un :ean, .irector 1eneral, 1eneral .epartment of (nergy, MIM( ;Ministry of
Industry, Mines and (nergy< gave a closing address. :ess than 9# serious people took part in
the seminar and workshop. -he fruitful meeting ended successfully.
;%< .ate and -ime
&ug. "9 ;,riday< ?G+# to %9G2#.
;"< @enue
4hnom 4enh Cotel, %, 3rystal 0all Room, 4hnom 4enh, 3ambodia
;+< Reports presented on the 'eminar and 7orkshop
& program attached separately shows the content of presentations. -he participants of
3ambodia reported on the ((53 activities performed by the MI)(. -he participants from
&'(&) countries made four presentations. ,or questions and answers, in-house translators of
the MI)( served between (nglish and Ahmer. ;Material )o. .-%#B<
;$< 4articipants ;:ist was not circulated<
3ambodia
.r. 'at 'amy, nder 'ecretary of 'tate
Mr. -un :ean, .irector 1eneral, 1eneral .epartment of (nergy, MIM(
Mr. 3han 'ocheat, .irector, .epartment of (nergy -echnique ;.(-<, MIM( Mr.
:ieng @uthy, .eputy .irector, .(-, MIM(
Mr. Ceang 0ora, Cead of (nergy (fficiency and 'tandard =ffice, .(-, MIM( Ms.
3hum 'opha, Cead of Research =ffice, .(-, MIM(
Mr. :y 3hamroeun, @ice 3hief =fficer of (nergy (fficiency and 'tandard, .(-,
MIM(
Mr. )ong 3hhavyvann, 'taff, .(-, MIM(
Mr. 3houn -eiea, 'taff, .(-, MIM(
Rank-and-file 2? participants of 3ambodia including ones from the 1arment Industry,
and teachers and students of colleges ;as told by Mr. @uthy<G 7e asked them to send
- 2 6
us a list of participants as an electronic file within one week, but have not received it
yet.
&3( ;&'(&) 3enter for (nergy<G
Mr. 3hristopher Kamora, 4ro!ect Manager
Mr. Ivan Ismed, 4ro!ect =fficer
MalaysiaG
Mr. )or Cisham 'abran, -echnical &ssistant, (nergy Industry 5 'ustainable
.evelopment, .ivision - MI((4, 4usat -enaga Malaysia ;4-M<
:ao 4.RG
Mr. @anthong Ahamloonvylayvong, .eputy Manager of )am )gum Cydropower
4lant, (lectricite du :aos ;(.:<
IndonesiaG
Mr. 'ubagyo, 'upervisor, 4encana dan (valuasi 4roduksi, 4- Aertas :eces ;4ersero<
@ietnamG
Mr. :e -uan 4hong, =fficial on (nergy and (nvironment, Ministry of Industry,
'cience and -echnology .epartment
8apanG International (ngineering .epartment, (338
Messrs. Mr. ,umio =gawa, Mr. Cisashi &mano and Cideyuki -anaka,
-echnical (6perts
2. " Results of the 'eminar and 7orkshop
;%< =pening ceremony ;speeches<
%< &3(
Mr. 3. Kamora read the address of .r. 7eerawat, (6ecutive .irector of the &3(. .r.
7eerawat emphasized that energy conservation was becoming more important in terms of
that the price of crude oil recently reached an all-time high. &lso, he talked about the
activities of the &3( under the 4R=M((3 pro!ect for ma!or industries and building energy
control ;including public recognition of an e6cellent case of energy conservation in a
building< and told that 3ambodia was the first country that worked on energy conservation
especially in the ma!or industries in the four countries in this fiscal year.
"< (338
Mr. -anaka, -echnical e6pert, made a speech on behalf of the M(-I and (338, 8apan. Ce
e6plained the meaning of this pro!ect, outline, resent state and 8apanJs cooperation and
contribution to &'(&).
+< MIM(
- 2 7
.r. 'at 'amy, nder 'ecretary of 'tate, gave a speech in Ahmer. Ce emphasized reduction of
the rising cost of oil by means of energy conservation to achieve competitiveness, and
necessity of further energy conservation and measures against global warming, by gaining and
utilizing new knowledge through a seminar. ;(nglish version was distributed.<
-his ceremony was covered and filmed by the -@A ;3ambodian -@< and the 3ambodia
.aily ;an (nglish newspaper<. &fter that, photographs were taken.
;"< -he energy conservation plan and report on the activities
%< =verview of ((53 &ctivities in 3ambodia- Mr. @uthy, MIM( ;Material )o. .-%%+<
Materials were written in (nglish but e6plained in Ahmer. 0arriers pointed out four items
including lack of consciousness and unclear policies. 7e understood economic difficulties in
3ambodia concerning power generation using e6pensive imported oil and urgent
necessity of international cooperation.
"< 3ase 'tudy % - 1lass Industry, Malaysia - Mr. )or 'abran ;Material )o. .-%%$<
& staff member of the 4-M made a presentation instead of a technical engineer of the glass
factory. 7e saw the pride and capabilities of the 4-M.
+< 3ase 'tudy " - Cydropower 4lant, :ao 4.R - Mr. @anthong ;Material )o. .-%+#<
'ome new data was added to the content presented last year. 7e were impressed by that the data
since %B>" was shown in a graph in the documents.
$< 3ase 'tudy + - 4ulp 5 4aper Industry, Indonesia - Mr. 'ubagyo ;Material )o. .-%%2<
&udience seemed to be interested in e6planation of fuel conversion ;from heavy oil to
natural gas, and further to coal<. Cowever, the price of fuels deeply depends on the
governmentJs policy ;subsidies or ta6<. It is needed to pay attention to differences in
situation among countries.
2< 3ase 'tudy $ - 4orcelain ;3eramics< Industry, @ietnam- Mr. 4hong ;Material )o. .-%"2<
pdated data presented by the (338 last yearG It was found that some of the items, which
were pointed out or recommended again at the follow-up of last year, have been
implemented.
;+< Results of the follow-up audits
%< ,ollow-up (nergy &udit ,indings at 1arment ,actories - Mr. 0ora, Mr. &mano ;Material
)o. .-%%9<
7e had previously agreed that the members of the host country would play a leading role in
conducting a follow-up and make a presentation at the workshop. Cowever, for 3ambodia,
it was difficult in terms of the willingness and capabilities of the MI)(. -herefore, (338
- 2 8
prepared Materials for this theme and asked Mr. 0ora of the MIM( to make a presentation of
the first part ;three sheets of slides< ;Ce e6plained it in Ahmer<. Mr. &mano made a
presentation of the remaining.
,or the presentation of the follow-up, 3ompany & asked us Hnot to reveal the name and details
of the company.I 'o, concerning 3ompany & and M5@, we were forced to make a vague
e6pression, such as H-hese things generally apply to garment factories in 3ambodia.I -he
audience ;including many in the same trade< was greatly interested in this topic and we thought
the presentation sufficiently satisfied their interest.
"< 0arriers and Measures to implement ((53 - Mr. =gawa ;Material )o. .-%%><
sing the last yearJs documents, he e6plained the topic, based on garment industries in
3ambodia as well as quoting the presentations made by other persons on the day.
;$< 7orkshop
%< -echnical .irectory - Mr. -anaka ;Material )o. .-%%?<
Ce e6plained the purpose of -., its preparation and format, etc. and presented e6amples in order
to give better understanding. Mr. Ivan was newly employed, so Mr. Kamora told H&3( will
be in charge of this matter from now on.I
"< .atabase/0enchmark/1uideline for Industry - Mr. =gawa ;Material )o. .-%%B<
Ce made a brief e6planation on this topic because its priority was lower than -. and the
garment industry in 3ambodia was not well developed yet.
;2< D5& 'ession
&t the ends of 'ession % and 'ession ", a question-and-answer session was held. Many
questions were presented actively, but some of them were not appropriate for the workshop.
,ollowings are typical questions and answersG
DG 7hich should cover a leading part, provider or user, in responsibility for promoting
energy conservation ;(3<R
&G 0oth. In 3ambodia, it is practical that the user side of energy makes efforts to reduce the
consumption of energy.
DG 7hat are the criteria when choosing the equipment for (3R
&G -he technical directory ;-.< will help you choose the equipment in the future, not
presently. It is because the -. is based on the usersJ e6periences, which is different from
a manufacturerJs catalogue.
;9< 3losing speech
- 2 9
-he workshop ended after Mr. -un :ean, .irector 1eneral of 1eneral .epartment of
(nergy, the MIM(, delivered a closing speech in (nglish. ;-he handout was provided to the
audience.<
- 3 0
. 4hilippines ;'teel Industry<
%. =utline of the &ctivities
7e have held seminar and workshop that included follow-up energy conservation audit of
3ompany 3, with whom we have conducted 4hase I ;,eb %#-%$, "##+<, follow-up of ,eb "##$ and ,eb
"##2 8(-R=-8(Q'& energy audit of 4rimary 'teel 3o. and presentation of e6amples of energy
conservation efforts in various industries in the Metro Manila, 4hilippines.
&ctually, we will describe one company name as H3ompany 3I according to the agreement at
4hase I.
.epartment of (nergy ;.=(< of the 4hilippine 1overnment was to mandated to take the initiative in
conducting follow-up energy audit and assessment reporting at Inception 7orkshop at
4hilippines, 8une "##2, however, (338 had to have initiatives instead.
%.% Implementation 4eriod
&ug "B - 'ep ", "##2
%." 'ite of IMprementation
,ollow-up surveyG Rolling mills of 3ompany 3 and 4rimary 'teel 3orp ;Metro
Manila area<
'eminar and workshopG Makati 3ity ;Metro Manila<
%.+ 'chedule ;Material )o. .-%#%(<
&ug. "? ;Mon<G
"B ;-ue<G
+# ;7ed<G
'ep. % ;-hu<G
" ;,ri<G
%.$ Relevant 4ersons
,ollow-up energy audit ;3ompany 3<
,ollow-up energy audit ;3ompany 3<, .=( visitation
,ollow-up energy audit ;4rimary 'teel 3orp<
,ollow-up energy audit ;4rimary 'teel 3orp<, .=( visitation
'eminar and workshop
&3( ;&'(&) 3enter for (nergy<G
Mr. 3hristopher 1. KamoraG Manager
Mr. Ivan IsmedG 4ro!ect =fficer
4hilippine 1overnmentG
.epartment of (nergy ;.=(<
1
Mr. Marlon R.. .omingo, 'r. 'cience Research 'pecialist, (nergy (fficiency .ivision
-he ,ocal 4oint in the 4hilippines
Mr. Michel (strada, (nergy (fficiency .ivision
.epartment of 'cience and -echnology ;.='-<
Mr. =scarlito Malvar, 'cience Research 'pecialist, ,uels and (nergy .ivision Ms.
Rochell, ,uels and (nergy .avison
8apanG International (ngineering .epartment, (338
Mr. ,umio =gawa, -echnical (6pert
Mr. Cisashi &mano, -echnical (6perts
Mr. Cideyuki -anaka, -echnical (6pert
2
3urrent 'ituations of 4hilippines
;%< 1eneral
- &reaG "BB,$#$km
"
;?#L of total area of 8apan<G 3omprised of >,%#B islands
- 4opulationG ?%.2 million ;"##+ 7orld 0ank data<
- ReligionG Roman 3atholics ?+L, =ther 3hristian 'ects %#L, Islamic 2L
- 3onstitutionE 3onstitutional Republican ,orm of 1overnment
- (conomyG Ma!or IndustriesG &griculture and ,isheries ;&ppro6. +>L of the entire work
force<
1.4 per 3apitaG %,#2# ' dollars ;"##+<
(conomic 1rowthG $.2L ;"##+<
3urrencyG 4hilippine 4eso, appro6. " yen ;8une "##2<
-rade ;"##+<G
(6portG (lectronic, electric machinery and tools, transportation
equipment to ', 8apan, and the )etherlandsG (6port value
+2.>2 billion ' dollars.
ImportG 3ommunications and electric machinery and tools,
electronic parts, heavy electric equipment for generation,
etc. imported from 8apan, ' and AoreaG Import value
+>.$2 billion ' dollars
- (conomic 3onditionG In gradual recovery since &sian currency crisis. Recorded 1.4
growth rate of $.2L in "##+G 1overnment =b!ective of $." - 2."L was met. -o
sustain growth, economic structural reform, elimination of budget deficit,
disposal of bad debts, and restoration of civil order are necessary to secure
public/international confidence in 4hilippine economy.
;"< (nergy 'ituations
-he self-supplied primary energy in 4hilippines was 29L, such as the renewable energy
;R(<, geothermal energy, hydropower and natural gases. Import of oil and gas was $$L. -he
energy consumption in industry sector was "9.2Mtoe/y, +%L of total ;"##+<.
-he electricity price, varying in region, was 'M#.%"/k7h in Metro Manila in "##2. -he
prices of gasoline and light oil were 'M#.2>/: and 'M#.2"/: each.
3
". ,ollow-up 'urvey of Rolling Mill ,actory of 3ompany 3
".% =utline of the Rolling Mill ,actory of 3ompany 3
;%< 3ompany profile
(stablished in %B99, and the rolling mill began operation with annual steel rod production
capability of +# thousand tons, and later increased production capability to B# thousand tons in
the old plant, M-II. 4lanning for a new mill on the present site ;ad!oining to the M-II site< of
+9#-thousand ton capacity was put in place in %BB$ and production operation began in %BB9. It
is one of ma!or steel bar production companies in 4hilippines and all of its products are
consumed domestically.
4resented below are conditions at the time of the 4hase I energy audit including the status at the
time of the follow-up visit.
)ame of the 3ompanyG 3ompany 3
:ocationG )orth of Metro Manila, about % hour by automobile
4roductsG .oes not use electric furnaceE only rolling of purchased raw material
'teel bars ;.iameterG %#%"%9"#"2"?+"+9$#2#mm<
(mployeesG $2# ;of whom technical personnel 29<
=perationsG -hree shifts, ?-hours each
;"< ,acilities of the rolling mill and energy conservation
%< =peration
0ecause the mill uses all imported billets ;raw material<, e6posing the production cost to the
overseas economic condition, the company is forced to make frequent ad!ustments in
procuring the raw material. &t the time of the 4hase I energy audit, the mill was in the midst of
stop-operation of % week and maintenance operation, due to a lack of raw material. &t the time
of the present visitation ;&ug. "##2<, operation appeared to be sound, as the company has
procured a large supply of Russian billets.
In the 4hilippines, the layout of rolling mills generally is in so-called cross-country typeE
however, the layout in this plant is in a simple straight line.
"< ,acilities
0illet PardG =ut of door, " gantry cranes
Reheating ,urnaceG
-ypeG 7alking beam, bunker oil burning with recuperator
4
3apacityG 92t/h ma6. %"m: billet
0urnerG -wo-row configuration
Rolling MillG %?-stand tandem, horizontal/vertical type, linear array
Incidental (quipmentG 3ontinuous quenching equipment, cooling bed, and automatic binder,
etc.
4ower Receiving (quip.G -ransformersG $ units
&ir 3ompressorsG 9 units
3ooling water supply and water treatmentG % unit
&lso emergency power source, illumination and air conditioning as devices for rolling mill
facilities were equipped.
+< (nergy consumption
Relationship between output of the rolling mill and energy consumption is presented in -able
-"-%.
-able -"-% Rolling Mill =utput and (nergy 3onsumption
Pear "##" "##+ "##$
=utput t/y %>+,>%+ ;%##< %>+,$2? ;%##< "%",%#+ ;%""<
;Ratio to year "##"<
(nergy 3onsumption
Ceavy =il ;for furnace< k:/y 2,$%".? 2,$#+.> 9,>>9.#
(lectricity ;rolling, etc< M7h/y %$,9%+ %>,>+> "#,?>>
(nergy Intensity and ratio to year "##"
Ceavy =il ;for furnace< :/t +%.%9 ;%##< +%.%2 ;%##< +%.B2 ;%#".2<
(lectrical ;for mill, etc< k7h/t ?$.%" ;%##< %#"."9 ;%"%.9< B?.$+ ;%%>.#<
In addition, the Mill uses :41 and o6ygen ;billet cutting< and diesel oil for emergency
private electric generator.
"." =utline of the Results of the 4revious (nergy &udit on 3ompany 3
Recommendations for improvement in the last energy audit were as followsG
;%< Ceat recovery in waste gas from the reheating furnace
,or heat recovery in waste gas, a metal heating tube-type recuperator is usedE in order to reduce
5
the unit consumption of fuel further, installation of regenerative burners was recommended.
'ince the regenerator in the regenerative burner system is heated by the e6haust gas of high
temperature as opposed to the recuperator uses the furnace e6haust gas, which has lost some
heat in the preheating zone and ducts as the source of heat in heat e6change with the
combustion air, the former generates preheated air of higher temperature, raising the energy
conservation effect by %# to "#L.
;"< Reduction of basic electric charge due to reduced electrical demand
-his system sounds an alarm automatically when the actual ma6imum power ;%2-minute
demand value< is to be e6ceeding the target demand value, and restricts load on electrical
equipment of lower priority ;e.g., air conditioning< in order to regulate the values within the
target demand value.
,or instance, when power contract of ?,###k7 are to be reduced by 2##k7, assuming the
mean electric cost is around 2.24C4/k7h, a cost-reduction of appro6imately 'M"9,9+#/y
based on the electric charge structure of this area will be feasible. nder this assumption, the
investment for system installation is recoverable in appro6imately % year.
;+< 4ower factor improvement through deployment of M(R&:3= Receiving 4ower ,actor
(nhancement 'ystem.
-he mean receiving power factor for "##" was B$."2L. 7hen raised to %##L, about
'M"",29#/y in power factor discount can be realized. Investment required may be recovered in
appro6imately $ and half years.
-hough demand power reduction or power factor improvement does not directly result in
energy conservation in the userJs side, such measures are beneficial for energy conservation of the
supplier of the power.
;$< &ir compressor number control in operation
3hange air compressor operation will be shifted from individually controlled system to
quantitatively controlled operation. Cowever, because actual operating condition ;on-
load/un-load condition< could not be determined, estimation was not effected.
".+ ,ollow-up energy audit
@isited the rolling mill factory of the 3ompany 3 for " days of monitoring of implementation of
the 4hase I recommendations and additional other miscellaneous activities.
(ven though the first visiting day happened to be a 'tate holiday and the mill scheduled to be
6
closed, however, the corporate management acceded to .=( request and received the survey
team. In spite of the holiday, all of the necessary personnel was present and cordially received
the surveyors.
;%< .ate of energy auditG Mon, &ug "B, "##2 3ompany 3 4lant @isit ;follow-up<
-ue &ug +#, "##2 3ompany 3 4lant @isit ;follow-up<
;"< &udit team membersG
4hilippines
.epartment of (nergy ;.=(<
Mr. Marlon R.. .omingo, 'r. 'cience Research 'pecialist, (nergy (fficiency
.ivision,ocal 4oint of the 4hilippines
Mr. Michel (strada, (nergy (fficiency .ivision
.epartment of 'cience and -echnology ;.='-<
Mr. =scarlito Malvar, 'cience Research 'pecialist, ,(.
Ms. Rochell, ,uels and (nergy .avison ,(.<
&3( ;&'(&) 3enter for (nergy<
Mr. 3hristopher Kamora, 4ro!ect Manager
Mr. Ivan Ismed, 4ro!ect =fficer
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka,
-echnical (6perts,
;+< &ttendees from the factoryG
'enior Manager, Duality &ssurance, 'afety and (nvironment ;:eader of
(nergy 3ontrol -eam<
Cead of (lectrical Maintenance and " (ngineers Cead
of Mechanical Maintenance and " (ngineers
(ngineer, (ngineering .evelopment
-hree (ngineers, 4roduction
=ne (ngineer, (nergy -eam 3oordinator ;-otal %" participants<
;$< =utline of the follow-up investigation
=n the first day of visit on &ugust "B, after confirming the purpose of the present visit and the
schedule with the receiving party, we have made rounds of the mill in order to see the present
status and to locate potential problems. In addition, we have discussed the questionnaire, which
7
has been mailed prior to the visit ;Material )o. .-%#2(<. =n the second day on &ugust +#, we
have made rounds of the mill again and quantitatively monitored electrical equipment.
'ubsequently, we have summarized our findings and presented them.
0ecause (nergy Management -eam was put in place only in May of this year, the results of
improvement effort implemented since the last visit have been somewhat ambiguous, but they were
good enough to e6pect future improvements. 7e believe that achievements such as we noted were
due to 'enior ManagerJs visit to 8apan as one of members for H,P"##2 -rainee Invitational
4rogram under International (nergy se Rationalization Measures for the 4hilippines
;(34C<I held in 8une, "##2.
-echnical details of the present summary may be found in the attached H,ollow-up of (nergy &udit
((53 &ctivities in 'teel Industry, 4hilippinesI. ;Material )o. .-%"9 ;%< 5 ;"<<
".$ Results and .iscussion of the Investigation
;%< 'tatus of production and energy intensity
,igures -"-%, -"-" and -"-+ are graphic representation of data in -able -"-%. -he
growth of output of "##$ in comparison with that of "##" was ""L. In terms of energy
intensity, the growth was close to none in fuel and electrical consumption increased by "%L
;"##+< and %>L ;"##$<.
-hese figures alone are not revealing all the reasonsE they are as followsG
a. (nergy intensity varies among products ;steel bar size< due to difference in conditions of
production operation.
;0ased on data on another rolling mill, it is reported that unit consumption of fuel
increases by %." to ".2:/t as the size of the steel bar decreases by one step.<
b. -ime lost in changing over the product size is disadvantageous in production of many
articles.
In order to make proper assessment of energy intensity, it is necessary to analyze each plant and
product on a separate basis. -his mill is accumulating the data on energy intensity of each
product, but lacked enough data to revise the above-described data.
.uring the round of &ugust "B, the indicator for fuel unit consumption in the operation room
was showing the ">:/t level for continuous rolling operation of same size product ;around "#
or "2mm<.
.uring the last visit, the management stated that only the new mill was in operation at the time,
however, M-II ;no visitationE about +##m away from the new mill< is operating during this visit.
-he data for both mills are processed in this plant so that figures alone were not useful in the
assessment.
8
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$
250%000
200%000
450%000
400%000
50%000
0
2002 2003 2002
;ear
,igure -"-% 3hange in =utput
,uel
25%000
Electricity
20%000
45%000
40%000
5%000
0
2002 2003 2002
;ear
,igure -"-" 3hange in ,uel and 4ower 3onsumption
Energy intensity
20<0
30<0
20<0
9eavy oil
40<0 Electricity
0<0
2002 2003
;ear
420<0
400<0
50<0
&0<0
20<0
20<0
0<0
2002
,igure -"-+ 3hange in (nergy Intensity
9
;"< (nergy management activities
-he 3ompany has taken a step in May "##2 toward systematic activities in internal energy
conservation by organizing the (nergy Management -eam. -he team membership consists of
representatives of departments and meets on a weekly basis. -he team leader is 'enior
Manager as mentioned above.
-he 3ompany intends to make full use of training 'enior Manager received in 8apan in 8une
"##2. &s a starting point, the 3ompany has decided to focus on Hminimization of downtime
energy consumption and in Sawareness-raisingJ of employees in general toward energy
conservation.
;+< ,urnace air ratio control and heat recovery from e6haust gas
%< Installation of regenerative burner
)o action has been taken on this matter. -he 3ompany e6plained that fuel conservation of
the e6isting recuperator is +#L and apparently is satisfied with its performance.
In actuality, the temperature of the e6haust gas at the recuperator intake port is >## and
temperature of the furnace air supply is raised from +# to +2#. 'ome times it reaches
$## ;however, under these conditions, fuel saving should be in the "#L level at the
ma6imum<.
7hile regenerative burner is effective, and installation of regenerative burner system by
8apanese manufacturers is possible in newly constructed furnace, decision is a difficult one
because conversion is costly due to the equipment price and necessity for operational
shutdown during the period of conversion.
7e do hope that 3ompany 3 considers it important to keep the pro!ect on the agenda for the
future.
"< Internal air leak of the recuperator
7hile the air ratio is maintained at %.% in the upstream part of the recuperator, the
downstream o6ygen level in the throat of the stack His measured once a weekE the o6ygen
level is 2 - >LI was the answer. 7hen the intake air-o6ygen ratio is %.%, the o6ygen level of
the e6haust gas should be appro6imately "L. -his is a separate issue, however it is quite
possible that some air meant for fuel combustion is leaking into the furnace.
7e attempted to measure the o6ygen content in the e6haust gas but due to a problem with the
sampling tube, the attempt was unsuccessful. &s an alternative, we used the o6ygen content
of the e6haust gas at the throat of the stack, the fuel oil component and the combustion air
ratio, and then estimated the amount of the air that may be leaking into the furnace. Cowever,
10
since we have not determined the o6ygen content at the air intake of the recuperator, we
disregarded air leakage at the billet charge and discharge ports, furnace body and ducts. -he
result of the calculation indicated that, of the preheated air in the recuperator, leakage rate into
the e6haust gas was %>L when the o6ygen content was 2L at the throat of the stack, "+L
when the o6ygen content was 9L and "?L when the o6ygen content was >L.
7e e6pect the (nergy Management -eam to take this matter seriously and inspect the
recuperator and repair any deficiencies it might find.
+< 3onsideration of the necessity of e6haust fan on the stack
7e have doubts as to the effectiveness of the e6isting fan on the stack. 3iting e6amples of
fan-less furnaces, we suggested review of the relationship of drafting capability with the
height of the stack and controlling of suction force on the e6haust gas by the use of a damper.
7e pointed out that it might be possible to remove the fan depending on the result.
;$< .emand control ;ma6imal power control< at the power receiving station
Recommendation was not implementedE however, it is true that reactivation of M-II altered the
condition and the issue needs to be reconsidered.
-he electric power charge is composed of the combination of basic charge and metered charge.
-he basic charge is imposed on monthly ma6imum power consumption measured in terms of
%2-minute demands. -he time period of %2 minutes is too short to render control by means of
manned watch. -hus, deployment of automatic measurement system is appropriate and
functional integration into the factory automation system ;,&'< is recommended.
7hile it is conceivable to utilize the demand meter system recommended in the "##+ 4hase I
energy audit, functional integration into the ,&' that is a control system for production
facilities may be superior, in consideration for future e6pansion of the control functions.
=n the other hand, daily power consumption control is also important. It may be implemented
on the basis of various power indications in the power distribution system.
-he simpler approach is to read off various cumulative power consumption indications at the
same time period on a daily basis, calculate the differences with the readings of the previous
day and summarize the results by .epartment. -his method would generate clues for further
approaches to energy conservation. .ata so obtained could also be used to generate the daily
load curve of power consumption.
In order to obtain more detailed equipment data for e6amining energy conservation, power
measurements would be required.
;2< Improvement of power factor
11
& condenser was already installed directly after installation of the transformer. -herefore, effect
generated by the power factor improvement on the loading side is limited to the improvement in
ohm-loss in the power distribution line.
-he 3ompany indicated that they would take care of larger motors. In this respect, we have
made some calculations based on measurements made on &ugust +#.
-ransmission loss, 7;k7< is appro6imated by formulas presented belowG
7 N @oltage drop rateOapparent power N ;T@/@< O ;4/cos U<
where,
T@ N @oltage drop rate, @ N line @oltage, 4 N load power, cosU N power factor, 4/cosU N
apparent power
-he results of the estimation are shown in -able -"-+.
.istribution loss due to pumps and compressors is below several percent of the load power.
'uch values are within the allowable range and installing a condenser on the motor for the
purpose of improvement of power factor is not a wise policy.
-able -"-+ :oad Measurements of 4umps and 3ompressors
4ump 5 ,or 4lant ,or 3ooling ,or ,or
3ompressors 7ater 'upply 7ater Duenching 3ompressors
Item ;%##hp< ;>2hp< 7ater ;"##hp<
;"##hp<
@oltage ;@< $2+ $$> $++ $+>
(lectric current ;&< BB.> 9B." %?+.9 "%B
:oad 4ower ;k7< 9?.> $?.+ %"9.# %$".%
4ower ,actor cosU #.?2$ #.B## #.B#B #.?2#
-ransmitted @oltage @ ;@< $29 $+9 $$? $$?
:oad 'ide @oltage ;@< $2+ $$> $++ $+>
@oltage .rop T@ ;@< + B %2 %%
T@/@ #.99L %.B>L +."2L ".$9L
:oad 4ower / cosU ?#.$ 2+.> %+?.9 %9>."
.istribution :oss 7 ;k7< #.2+ %.#9 $.9$ $.%#
.istribution :oss/:oad ;L< #.?L "."L +.>L ".BL
12
;9< (nergy conservation measures for air compressors
%< Reduction of number of air compressors in operation
)o air compressor consolidation system was provided.
3ompany 3 has appealed that it would like to start working on the compressor issue with
minor refitting ;changeover of control valves, etc.< for rationalization of piping and work on
such matters as revolution frequency in the future.
3ompany 3 air compressor configuration includes four "##hp and two %##hp units.
.ifference in deployment number came about as a result of reactivation of M-II. 7hen M-II was
inactive, all air compressors were moved to M-I for concentration.
&t this point, we have described an approach to determine the required capability and focal
points in controlling the number of units of air compressor in operation in the following
manner.
7hile the air compressor configuration is four "##hp and two %##hp units, however, we
assume that actual operating requirement may be met with two "##hp and one %##hp units.
3alculate the actual load rate requirement in routine operation in terms of load time -% and
unload time -" and apply them in the following formula for estimationG
:oad ratio N -%/;-%V-"<
3ompressor discharge rate N :oad ratio O rated value
=n the basis of the results of above calculations and rated output, assign main units for rated
operation and sub-units for load/unload operation. In operation control, customary approach is to
use a unit number control panel, but it is possible to accomplish the ob!ective through
ad!ustment of discharge pressure control values of each unit. 0y narrowing the range of
controllable pressure of the sub-units in comparison with the main units, they can serve as
load/unload units, respectively.
"< .etermination of leakage and control measures
-o facilitate this operational mode, it is necessary to locate leaks and repair the e6it side of
piping system. 3ompany 3 side has told us that the company has Hconducted piping
inspection based on the steps planned by the (nergy Management -eam appro6imately "
weeks ago. 'ome 2# leaks were foundI. In that case, it would be possible to lower the
pressure on the e6it side provided leaks are repaired.
In any compressed air system, invent in a newly installed system, there is generally leakage
of + to 2L, e6ceed %#L as a function of aging and even reach +2L. :eaks principally
develop in connecting parts of piping ;corrosion of the flange, deterioration and development
of gaps in the gasket, loosening of bolts, etc.<, sealed area of devices ;rubber or metal seal on
an elastic body<, slackening or break of the hose and incomplete closing of the valves.
13
Duantitative determination of leakage may be accomplished through measurement of loading
factor in operation of the compressor system when the mill is not in operation.
+< 4lacement of compressors
-he air pressurized by the compressor is delivered with pressure to the terminal equipment
through piping and is sub!ected to loss of pressure and flow ;leaks< under delivery.
-hus, needlessly distant delivery with pressure is not always warranted. -hat is, it is possible to
have an instance in which it is more effective in terms of energy conservation to set up
multiple independent compression systems according to the load.
In addition, other miscellaneous measures such as looping of branching pipes, placement of
receiver tank in locally heavy loaded area, etc. is possible against loss of pressure. -imely
response is desirable.
$< Reduction of discharge pressure
-he discharge pressure control of the compressor is set at a rather high level of %## to %%#psi
;#.> - #.>>M4a<. 3ompany 3 side e6plained that this high level of compression is needed to
maintain the terminal equipment pressure in M-II Mill, +##m far from compressor room. &
close study may reveal that it would be necessary to reinstall the compressors for M-II in the
original location.
In decreasing the discharge pressure of the compressors and determining the optimal values, it
would be desirable to first ascertain the pressure requirement of each unit before
decreasing the pressure. ,or instance, discharge pressure reduction from #.>M4a to #.9M4a
would result in power saving of appro6imately ?L.
:ow-pressure loadG 4ressure reduction by mean of reducing valve
Cigh-pressure loadG 3onsider pressure increase by means of boosters
,or e6ample, air blow pressure for the cleaner can be low ;appro6imately #.+M4a<,
etc.
&n abnormally high pressure of #.?2M4a was indicated on one of the receiver tanks. -he first
step in data management is to conduct comparative e6amination immediately to do
calibration at abnormal meter readings.
2< 'electing the inverter unit ;variable load-compatible type<
& throttle valve generally affects capacity control of the screw type compressor and such a
compressor consumes appro6imately >#L of rating under unloaded conditionE partial load
property of the screw type compressor is not good. ,or this reason, as a sub-unit requiring
volume regulation, an inverter-controllable compressor is favorable. -his topic must be on the
agenda in time of system renewal.
,igure -"-2 shows compressor characteristics and those under systematized operation.
14
P
o
+
e
r

c
o
n
s
u
m
p
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o
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)utput control of compressor
400
50
'hrottle valve control
Po+er consumption
&0
Inverter control
20
400=
80=
Po+er saving
scre+
I#>?type
7esira-le control
20
I#>@#um-er control in ope<
?type
I#>?type
0
0 20 20 &0 50 400
Air consumption
400=
.oa! factor
,igure -"-2 =perational 3haracteristics of 3ompressors
;>< Miscellaneous energy conservation measures
a. Installation of heat resistant canvas on furnace door
b. Installation of additional wattmeterG 7ill be installed within this year.
;?< 'ummary of energy conservation activities of the past " years as of the ,ollow-up visit
3oncerning status of the four measures of improvement proposed in the 4hase I visit for energy
audit and other miscellaneous items described in ".", results of the ,ollow-up visit are
presented in -able -"-+.
;B< (nergy conservation measures noted at the time of the .=( visit
(nergy conservation issues noted at the .=( offices are as followsG
%< (nglish translation of 8apanJs H2'I was on display on the office wall. It gave us the
impression that such 8apanese approach/spirit is spreading.
"< -wo bulbs of the set of + bulbs in the fluorescent light fi6ture were taken out and a large
stainless steel reflector was installed in stead.
15
-able -"-+ (nergy 3onservation &ctivities 3oncerning Improvement
Measures 'uggested at the -ime of the 4hase I @isit for (nergy &udit
Recommended -echnology &d!udication 'tatus of Implementation
;%< Ceat recovery from the Pes 0y recuperator, the combustion air is
furnace e6haust gas preheated at +2#, and fuel saving is
about "#L.
0ut no studying for regenerative burner
system.
;"< .emand control for the )o nder studying the methods
electricity receiving/
transforming equipment
;+< 4ower factor improvement Pes Installed capacitor
;$< 3ontrol of the air )o nder studying
compressors in service - Re-arranging of control valves
- se of variable frequency drive
;2< Insulation of heat ;Pes< Installed in 'eptember "##2.
resistant cloth canvass
for discharging and
charging door of furnace
;9< Installation of additional ;Pes< Installed within "##2.
A7C meters
16
+. (nergy &udit of Rolling Mill ,actory of the 4rimary 'teel 3orporation
Rolling mill of the 4rimary 'teel 3orporation is a newcomer as a sub!ect for the energy audit under our
4R=M((3 4ro!ect. )evertheless, the energy audit visit for energy conservation guidance has been
made in ,ebruary "##$ and ,ebruary "##2 under the 8(-R=-8(Q'& 4ro!ect H-he ,P"##$ 'upport
4ro!ect for (stablishment of )ational 'teel Industry (nergy 3onservation &udit 4rogram in the
4hilippinesI, and as such it was a de facto follow-up visit, and after that, improvement has been made
somewhat. 7e were given the impression that the corporate management is enthusiastic toward taking
further action in improvement effort.
Mr. 1o, @ice 4resident and 4lant Manager, has been a trainee member of the (34C 4rogram and
visited 8apan in 8une "##2. Cis awareness of the necessity of energy conservation was clear and was
very helpful toward the visiting entourage.
+.l =utline of the Rolling Mill ,actory of the 4rimary 'teel 3orporation
;%< =utline of the 3orporation
,ormer .ependable Metal 3o., through merger in %BB?, leased land and facilities from
AM(3= ;Audos Metal 3o.< and began to manufacture steel rods for concrete reinforcement, rods,
square rods and small angle irons.
-he plant is one of medium scale in the 4hilippines and its annual production capacity is "$#
thousand tons. -he company has shown aggressiveness by adding + rolling stands to the rolling
facilities in order to increase efficiency in small steel rod rolling capability in "##$ and
replaced obsolete furnace heat recuperator.
3orporate )ameG 4rimary 'teel 3orporation
4lant &ddressG )o.+ M1M Industrial 3ompound, 0agdaguin, @alenzuela 3ity, %$$",
4hilippines -elG 9+-B-+9-B>-?+
;:ocated in northwest of Metro Manila, about % hour by automobile<
4roductsG )o electric furnaceE rolling mill operation only ;=(M rolling only<,
'teel bars ;mainly of %#, %", and %9mm bars<
(mployeesG "## ;including 29 technologists<
=perationsG -hree ?-hour shifts
;"< -he Rolling Mill and (nergy 3onsumption
7e described data on energy conservation activities involving information on 8(Q'& 4rogram of
8(-R=, in ,ebruary "##$ and ,ebruary "##2.
17
%< =utline of corporate operation
-he current products consist of steel rods for concrete reinforcement and steel rods ;%#%" %9mm
in diameter<, square rods and small angle irons ;"#mm ma6imum<, and these products are
manufactured on the =(M-basis from other corporations of the steel industry. ,or this reason,
clients deliver the raw materials into the mill and receive the finished products on site. -hus,
manufacturing operation of this company is simpler than independent rolling mills to the e6tent of
the lack of row material procurement and product transportation.
In comparison with steel rods of larger size, small rods manufacturing is less efficient in rolling
efficiency and as a result higher in energy intensity. -his corporation, consequently, is
aggressive in cost-reducing efforts such as energy conservation and in its effort to e6pand its
involvement in smaller steel products other mills tend to avoid.
"< ,acilities
0illet 4oolG =utdoors, % unit gantry crane
Rolling ,urnace 4usher type bunker oil burning furnace
3apacityG $#t/h ma6. 9m: billet heating is possible
0urner configurationG -wo-side in heating zone, a6ial type of burners
in the soaking area with e6haust heat recovery recuperator
Rolling (quip. %2-stand tandem, horizontal/vertical type
:ine configuration e6cept first two roughing stages in cross-country
configuration
3ooling bed, automatic binding unit and others
4ower Receptor -ransformersG $ units ;+$.2k@<
&ir 3ompressorsG " units ;%?#k7<
3ooling water distributor and wastewater processor unitG one complete set
Miscellaneous items in the rolling mill including emergency power source, lighting and air
conditioning and others
+< (nergy consumption
Relationship between output of the rolling mill and energy consumption is presented in
-able -+-%.
18
-able -+-% Rolling Mill =utput and (nergy 3onsumption
Pear "##" "##+ "##$ "##2 ;%-><
=utput t/y %#B,9?> %++,B?% %"#,+$$ 22,9%2
;Incr. over previous year< ;%##< ;%""< ;%%#< ;&n. equiv.
?><
(nergy 3onsumption
0unker =il ;furnace< k:/y $,$?B $,??B $,#"9.# %,?22
(lectrical ;rolling, etc< M7h/y %%,9"+.2 %2,$># %+,B>2.2 9,2$%.2
(nergy Intensity
0unker =il :/t $#.B+ ;%##< +9.$B ;?B."< ++.$2 ;?%.>< ++.+2 ;?%.2<
(lectricity k7h/t %#2.B> ;%##< %%2.$9 ;%#B< %%9.%+ %%>.9" ;%%%<
;Incr. over previous yr< ;%#B.9<
(nergy 4rice 5 -ransition
0unker =il 4C4/: ?.>$ ;%##< %#.>+ ;%"+< %%.?B ;%+9< %+.?$ ;%2?<
(lectricity 4C4/k7h $.B? ;%##< 2.29 ;%%"< 2.2# ;%%#< >.#? ;%$"<
;Incr. over previous yr<
In addition, the Mill uses :41 and o6ygen ;for billet cutting< and diesel oil for emergency power
source equipment.
;%4C4 N appro6imately " yen at &ug "##2<
+." 'uggested (nergy 3onservation Measures for the Rolling Mill ,actory
Recommended improvements up to "##$ comprised of the following itemsG
;%< Increasing heat-recovery from furnace e6haust gas
,or heat recovery of e6haust gas, a recuperator of metal tube for combustible air heating is in
useE however, the temperature of pre-heated air remains below "2# ;ma6. "B><. -he
conceivable cause of inefficiency may be low temperature of e6haust gas at the intake port of
the recuperator at 9## and that the pre-heated air is leaking inside of the recuperator.
-he low temperature of the e6haust gas may be attributed to effective transfer of e6haust heat
to the billet within the preheating zone of the furnace, however heat is poring out of the billet
charging port of the furnace. Reducing this opening by half would conceivably reduce heavy
oil requirement by appro6imately %>#k:/y. In addition, the furnace appears to be taking in air
19
at the billet discharging portE it requires considerable work to keep outside air from entering.
-he furnace and ducts also require their heat-keeping capability to be raised. -he combustible
air ratio of less than %.# means either the furnace is operating under the assumption of having to
compensate for considerable penetration of outside air or malfunction of the indicator.
Recuperator was replaced in 8uly "##$, but penetration of the pre-heated air in the recuperator
was detected already in ,ebruary "##2. 4rocedure in maintenance appears to require
strengthening, now and in future.
;"< 4revention of compressed air leaks
4ersonnel of the 4rimary 'teel 3orporation has tested the air leakage in about half of the
compressed air distribution piping and measured %".%L of leakage loss. It means that the loss is
over "#L in the entire piping. ,or e6ample, if this loss were reduced by %L, the savings would
amount to appro6imately ?#,### 4C4 per year. -hus, we have recommended reducing the current
compression leak by over half with the ob!ective of lowering to 2L.
;+< Implementation of demand control
-he ma6imum electric power consumption in .ecember "##$ was $#?2k7 and those of many
of the past months approached $###k7. -he mean monthly loading rate is low in the 2#L
level.
7e have therefore proposed that the 3orporation install the demand meter. & concerted effort
of conservation by setting a ma6imum monthly level on the basis of monthly production
volume would achieve a considerable effect in reduction of the basic monthly power bill.
,or e6ample, an achievement of %,2##k7 monthly reduction would result in the savings as
followsG
%,2##k7O">#.94C4/k7O%"month/yN $,?>#,?##4C4/y
+.+ ,ollow-up energy audit
7e have made a "-day visit of the Rolling Mill of the 3orporation for the purpose of follow-up
energy audit of the status of implementation of recommendations made in the 8(Q'& visit and
monitoring of other activities.
Mr. 1o, @ice 4resident and the 4lant Manager, has participated in the M(-I-(338 reception
training program ;(34C< of 8une "##2 as a trainee and was an avid believer in energy
conservation efforts. Ce stated that cost reduction achieved in "##$ e6ceeded $ million pesos
;4C4, 4hilippines 4eso<. &lso, he is planning to achieve even greater savings this year. Ce was
very cordial toward us, the visiting investigators.
20
;%< .ate of the energy auditG
&ugust +#, "##2 ;7ed< @isitation of the rolling mill of 4rimary 'teel 3orp.
'eptember % ;-hu< Return visit of the rolling mill
;"< &udit team membersG
4hilippines
.epartment of (nergy ;.=(<
Mr. Marlon R.. .omingo, 'r. 'cience Research 'pecialist, (nergy (fficiency
.ivision,ocal 4oint in the 4hilippines
Mr. (ric )avarrete, (nergy (fficiency .ivision
.epartment of 'cience and -echnology ;.='-<
Mr. =scarlito Malvar, 'cience Research 'pecialist, ,uels and (nergy .ivision Ms.
Rochell, ,uels and (nergy .avison
&3( &'(&) 3enter for (nergy<
Mr. Ivan Ismed, 4ro!ect =fficer
8apanG International (ngineering .epartment, (338
Messrs., ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
;+< &ttendees from the factoryG
Mr. Cenry 1o, @ice 4resident - =perations ;partially involved< Mr.
Ramon R. Mangibunong, &ssistant 4lant Manager
Mr. )oel, (lectrical (ngineer
;$< 'ummary of the follow-up survey
Initially confirmed the purpose and schedule of the present visit and made the round of the site
to grasp the present conditions and possible problems. 'ubsequently we have discussed the
3orporation responses to the items in the questionnaire previously delivered by .=( ;Material
)o. .-%#9<. =n the second day, we have conducted electrical measurements of the air
compressors and measurements of o6ygen content and temperature of the e6haust gas of the
furnace. ,inally we e6plained the measurement results, and summarized the energy audit.
-he technical discussions concerning this paragraph are shown in the attached
document, I,ollow-up of (nergy &udit ((53 &ctivities in 'teel Industry, 4hilippinesI
;Material )o. .-%"9<.
21
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.
%

1
h
$
+.$ 'urvey results
;%< 'tatus of production and energy intensity
,igures -+-%, -+-" and -+-+ are graphic representation of data in -able -+-%. -he
output is variable from "##" through "##2. -his variability reflects the mode corporate
operation of production on the basis of consignment.
%< Ceavy oil
,urnace fuel is heavy oil ;)o.9 ,uel =il or 0unker =il<. ,uel tank of %##k: was used to
receive the fuel delivered by tankers. &s shown in -able -+-%, the fuel prices rose by
appro6imately +9L during "##" through "##$ and appro6imately 29L in "##2.
nit consumption of the fuel has been improving each year. -his improvement is attributable to
ob!ectified management by means of unit consumption values by productE a variety of
conservational improvement measures effected as described below.
"< (lectrical power
-he unit consumption of the electrical power has been on the decline, which, according to
corporate e6planation, is principally attributable to the increase in the consignment in product of
smaller diameter and e6pansion of operation by additional installation of + rolling finishing stands
;to total of %2 tandem stands<.
9eavy oil
4&0%000
20%000 Electricity
420%000
420%000
45%000
400%000
50%000
40%000
&0%000
20%000
5%000
20%000
0 0
2002 2003 2002
2002 2003 2002
;ear ;ear
,igure -+-% 3hanges in 4roduction ,igure -+-" 3onsumption of ,uel and
@olume (lectric 4ower
22
C
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;
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7
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/
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<
2#
$#
+#
"#
%#
#
"##" "##+
%"#
%%2
%%#
%#2
Ceavy oil
(lectricity %##
"##$ "##2;to 8uly<
Pear
,igure -+-+ 3hanges in (nergy Intensity
;"< (nergy control activity
In March "##2, H(nergy 3onservation 1roupI was organized in the following .epartments.
i< Maintenance
ii< 4roduction
iii< Materials ;warehouse, etc.< iv<
&dministration
-he activities of these 1roups are principally awareness rising of energy conservation, turning off
lights and air conditioners if not necessary and turning off equipment when the task is completed
and other such miscellaneous items.
In addition, the 3orporation is planning a program to perform energy-use audit ;principally on use
of fuels and electric power< on a semiannual basis.
;+< Recovering heat from furnace e6haust gas
-he e6isting recuperator had damaged tubing and other defects and the e6it port temperature
of air for the fuel at the time of "##+ visit was low at ""#. -he replacement with a
recuperator of same capacity in 8uly "##$ raised the e6it port air temperature to "$2
;ma6imum temperature at "B><. &ccording to 4rimary 'teel, Hthere is no more leaks after
replacementIE nevertheless, we took measurements of the e6haust gas temperature and o6ygen
content at the intake and e6it ports of the recuperator on 'eptember %. -he results are shown
on -able -+-".
-he combustion air ratio ;m< indicator located in the furnace control room was reading #.B".
-his value is doubtfulE it is displaying either a compensated value to offset the air leaks or the
23
meter is faulty. It is necessary that 4rimary 'teel pursue the matter at a later date.
-he e6haust stack was issuing a slightly smoky gas, however the o6ygen content of the
e6haust gas taken at the intake port of the recuperator ;furnace e6it port< indicated the level
indicative of good combustion condition within the furnace.
-able -+-" (6haust 1as -emperature and =6ygen 3ontent
at the ,ront-end and Rear-end of the Recuperator
Item )umber of Intake 4ort (6it 4ort .ifference
'ampling
-emperature ,irst time 9#9 +"$ "?"
;
o
3<
'econd time 2?9 +"% "92
=6ygen ,irst time ".+ 2.+ V +.#
3ontent ;L<
'econd time ".# $.$ V".$
Measurements were taken at the temperature measurement openings at the front-end and
rear-end of the recuperator. 'ince only % o6ygen meter was available, we measured
temperature first followed by o6ygenE thus, in all cases, o6ygen and temperature were not
simultaneous measured.
'ince the o6ygen content level of the e6haust gas at the e6it port was greater than that of the
intake port by ".$ - +L, it was conceivable that combustion air was leaking into the e6haust
gas inside the recuperator and, as a result, the temperature of the e6haust gas at the e6it port
was lowered. ,rom the measured o6ygen content, the air ratio could be roughly estimated to
be resulted by air leak of appro6imately %>L to flow rate of e6haust gas. -his level was
sufficient enough to be remedied from the standpoint of energy conservation. 7e have,
accordingly, advised the corporate side Hto take advantage of ne6t plant closing to inspect the
recuperator for air leaks.I In addition, we have demonstrated a method of calculating the
e6haust gas flow rate on the basis of the characteristics of the fuel and to obtain an estimate of
leaked air.
;$< Improvement of furnace doors
Improvements of the following items have been completedG
i< ,ine ad!ustment of charging billets by installation of a winch at the billet charging port ii<
Installation of width-ad!ustable door on the billet discharging port
24
iii< Improvement of sequencer on the insertion pusher side.
iv< Improvement of sequencer on the billet-discharging doorG -he door occasionally
remained open too despite the improvement. -he corporate side e6plained that the
cause was deformation of the billets and it was unavoidable.
;2< -emperature maintenance of the fuel heavy oil
7ith respect to fuel oil temperature, setting of B# was raised to %%#. In addition, we
strengthened insulation of piping and fle6ible tubing feeding the burners. 7ith these measures, the
corporate staff felt that spraying improved and combustion looked smoother ;fuel oil
temperature was slightly higher than the temperature set in usual operation<.
;9< .emand control of power reception
-his item was not implemented. -he corporate side admitted that the problem was beyond the
level of staff capability in techniques and knowledge, and the cost was prohibitive.
-he billing system for the electrical power consumption is composed of the combination of
basic and specific duty charges. -he basic charge is imposed on monthly ma6imum power
consumption measured in terms of %2-minute demands. -he time period of %2 minutes is too
short to render control by means of manned watch. -hus, deployment of automatic
measurement system is appropriate for monitoring and requires integration into the ,&'
;,actory &utomation 'ystem<.
.aily power control is also important, however, this function may be implemented on the
basis of various power indications in the power distribution system. -he simplest approach is
to read off various cumulative power consumption indications at the same time period on a
daily basis, calculate the differences with the readings of the previous day and summarize the
results by .epartment. -his method would generate clues for further approaches to energy
conservation. .ata so obtained could also be used to generate the daily load curve. In order to
obtain more detailed equipment data for energy conservation, power meters would be
required.
;>< (nergy conservation measures for air compressors
%< (nergy conservation measures of priority
- Reduction of leaks.
3urrently, half of the system accounts for %".%L of compression leaks. ,or the entire
system, the leak may e6ceed "#L. -hus, inspection and repairs are urgently required.
Institution of periodic inspection schedule is also advisable.
- (stimate the pressure requirement of compressed air and ad!ust the discharge pressure.
25
4ressure loss reduction in piping can be e6pected by looping of piping system and
eliminating leaks ;reduction in flow rate<. Installment of boosters where high pressure is
required must also be considered. In addition, consider whether there are other measures to
facilitate energy conservation.
"< 3onsideration of air compressor loading rate
-here are " units of "2#hp ;%?9k7< air compressors installed and one of them is always in
operation ;and the other in standby<. 'ince it is constantly loaded and unloaded repeatedly, it is
conceivable that the compressor is a device of overcapacity.
i< (lectrical measurements
In an effort to estimate the loading factor of the compressor, loading and unloading
time were measured and electrical measurements during periods for loading and
unloading were made. (ach measurement was carried out twice and the mean values
were adopted for calculation. -able -+-+ presents the result of measurements.
-he measurements were taken when the compressor )o. " was in line during the
production of %#mm reinforcing bars. .ischarge pressure conditions for pressure
control were set at 4ma6 N #.2>M4a and 4min N #.2$M4a.
-able -+-+ (lectrical Measurement Results
Item :oaded nloaded
-ime ;s< B.>%2 2.9B
-ime Rate ;L< 9+.% +9.B
@oltage ;@< $++.2 $"%.2
3urrent ;&< ++>.2 "+"
4ower ;k7< "%9.2 %$B.2
4ower ,actor ;L< ?>." ?9.%
ii< (stimation of loading factor
3ompressor output
4out N %?9k7O#.9+% N %%>.9k7
3ompressor input as power consumption
4in N "%9.2k7O#.9+% V %$B.2k7O#.+9B N %B%.?k7
4roportion of power consumption when in full ;%##L< operation of 4in
%B%.?k7/"%9.2k7 N #.??9 ;??.9L<
4roportion of power consumption when in unload of 4in
%$B.2k7/"%9.2k7 N #.9B% ;9B.%L<
26
iii< (stimation of optimal rate
(fficiency of the compressor may be e6pressed as a ratio of its output and input in the
following mannerG
W N %%>.9k7/%B%.?k7 N #.9%+ ;9%.+L<
7hen the ratio of the nominal output ;%?9k7< and the output of full load ;"%9.2k7< as
W%##, then it is
W%##N %?9k7/"%9.2k7 N #.?2B ;?2.BL<.
If the operational efficiency is 9%L, installment of inverter type of air compressor is
difficult to establish as economically efficient. -hus, we have made a
recommendation to consider leak detection discussed above to determine the
measures to prevent diminution of air flow rate and pressure loss at the e6it port and to
consider installation of the inverter-controlled air compressors at the time of future
occasion to replace the air compressors.
;?< Measures the 4rimary 'teel 3orporation has implemented
%< Installation of a compressor for use when the mill is shut down
In order to supply required compressed air during the period of mill shut down, the
3orporation has acquired a small, >2hp air compressor ;previously used unit< so that the larger
compressors may be turned off ;&ug "##2<.
"< -emperature control of air conditioner for offices
Issued a directive to the employees to turn off the air conditioning when not in use ;as a
matter of fact, we have noted that some of the thermostats have been set low<.
;B< Miscellaneous
%< =ne of inappropriate practices we noted was that defective finished products were stacked at
various places on the premises. 'uch a practice is serious enough to offset all the steady
efforts for energy conservation the 3orporation has been accumulating over these years. 7e
have thus attempted to convince the corporate staff that the following efforts would be
meaningful while improving the product yield significantly contributed toward conservation
of energy.
- Reducing down time
- Increasing productivity ;reducing losses< - &ccording to Mr. Ramon, the process yield
reached B2L, however, observation of the site gave us the impression it was actually less.
7e feel that raising the product yield even by %L is needed.
"< 2' of rolling operation electrical control room
7hen we looked at the electrical control room of the rolling mill, we were surprised by the
27
cleanliness of the room. Its cleanliness made us wonder that this was in a plant and gave the
impression that not a spec of dirt could be found in the room. Mr. 1o told us that the staff
decided that they should have at least one thing that they could be proud of. 7e e6pect that this
movement would affect other units of the plant, and if it does, implementation of energy
conservation would become easier in this mill.
;%#< &ssessment of corporate energy conservation activities
Implementations of the diagnostic recommendations described in +." as well as improvement
efforts conducted by the 3orporation are shown in -able -+-$.
-able -+-$ Results of 3orporate (nergy 3onservation &ctivity
Recommended -echnology &d!udication 'tatus of Implementation
;%< Ceat recovery from the furnace e6haust gas, and reheating furnace issues
a. -o raise the preheating Pes )ew recuperator was installed in "##$. &ir
air temperature temp. is "$2 from ""#.
b. -o maintain the recuperator Pes -he worn out tubes end was closed.
minimizing air leakage Recuperator house-keeping is
scheduled every month.
c. -o solves the furnace door Pes
opening issue, and to maintain
the efficient combustion
:ifting type cover was installed at charging
door. .ischarging door opening time was
reduced by + seconds. ,uel oil temperature
was raised to %%# from B# to attain the
efficient combustion.
;"< &ir compressorG Pes &ir leakage is continuously monitored by
-o minimize the air leakage mechanical maintenance.
;+< .emand control of electricity )o nder feasibility study
receiving/transformer equipment
28
$. 'eminar and 7orkshop
$.% 'ummary
-he seminar-workshop was held on 'eptember ", "##2.
Mr. Matanog M. Mapandi, &ssistant 'ecretary of .=( made the opening speech. -he seminar and
workshop attended by $" participants appeared to be meaningful to attendants and may be
considered to be a successful one.
;%< .ate and time
'eptember " ;,riday<, "##2 ?G+#G 'tart of registration, %>G##G 3losed
;"< @enue
'econd floor Pakal Room, .usit Cotel )ikko, Makati 3ity, 4hilippines
;+< Reports presented on the 'eminar and 7orkshop
-he contents discussed in the workshop are shown in the attached program ;Material )o.
.-%%#<. Representatives of the 4hilippines presented an overview of the .=(Js energy
conservation efforts and the 7holesale (lectricity 'pot Market ;7('M< as well as "
industrial-sector reports. &'(&) participants presented + reports but those of Indonesia and
@ietnam were repeated presentation of those reported in a meeting in 3ambodia.
;$< 4articipants ;:ist was not circulated<
4hilippinesG
Con. Matanog M. Mapandi, &ssistant 'ecretary, .epartment of (nergy ;.=(< Mr.
Marlon Romulo . .omingo, 'r. 'cience Research 'pecialist, .=(
Mr. (ric )aovarette, 'cience Research 'pecialist, .=(
Mr. =scarlito 3. Malvar, 'cience Research 'pecialist, .epJt of 'cience 5 -echnology
;.='-<
Ms. Rochelle Retamar, 'cience Research 'pecialist, .='-
&ppro6imately +# participants ;number of attendance certificates issued, according to Mr.
.omingo< were representing the industrial sectors ;including the steel industry< of the
4hilippines. 4resence of consultants was conspicuous among the participants ;including
('3=JsE some were former .=( staff members<.
&'(&) 3enter for (nergy ;&3(<G
Mr. Ivan Ismed, &ssistant 4ro!ect 3oordinator
29
MalaysiaG
Mr. 1hazali -alib, (nergy &udit (ngineer, (nergy Industry 5 'ustainable .evelopment
.ivision - MI((I4, 4usat -enaga Malaysia ;4-M<
IndonesiaG
Mr. 'ubagyo, 'upervisor, 4encana dan (valuasi 4roduksi, 4- Aertas :eces ;4ersero<
@ietnamG
Mr. @an :ong, =fficial on (nergy and (nvironment, Ministry of Industry, 'cience and
-echnology .epartment
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical 'pecialists
$." Results of the 'eminar and 7orkshop
;%< =pening ceremony ;speeches<
%< .=( of the 4hilippines
Mr. Mapandi, &ssistant 'ecretary of .=( made the welcoming speech. Ce pointed out that
consumers and industries ought to be conscious of energy conservation and that we all
required to faster our skills in conservation including technology and structures. Ce stressed
that, to achieve success in energy conservation efforts, cooperation within each of the
industries was mandatory and mutual support within &'(&) nations was required. Ce cited
steel, food and chemical industries of the 4hilippines as e6amples in which such cooperation
was taking roots.
"< (338
Mr. -anaka, representing the 8apan side ;M(-I and (338< discussed the intended ob!ectives
of the 4ro!ect, its development, current status as well as the intentions of the government of
8apan concerning cooperation and contribution toward the member nations of &'(&).
+< &sian 3enter for (nergy
Mr. Ismed read the message from .r. 7eerawat, (6ecutive .irector of &sian 3enter for
(nergy ;&3(<. -he message stated that, in view of the sky rocketing petroleum prices, energy
conservation was increasingly important in the current world. -he message specifically
touched upon the 4rogram of the 4romotion of (nergy (fficiency and 3onservation
;4R=M((3<.
;"< 'ession % &ctivities of ((53
%< (nergy (fficiency and 3onservation 4romotion &ctivities in 4hilippines
30
- Mr. .omingo ;Material )o. .-%"#<
Cis discussion included ob!ectives, strategies, educational campaigns, energy management
advisory services, demand-side management, the H.on (millio &bello (( &wardI and other
topics. (specially interesting was the introduction of the new .=( motto, the H(3 7ay of
:ifeI ;the .=( staff was wearing the tee shirts bearing the new motto at the time of site
visits<.
"< (nergy (fficiency and 3onservation &ctivities of Industries in 8apan
- Mr. -anaka ;Material )o. .-%"%<
Ce described structural changes in energy consumption in 8apan, historical review of
regulatory and administrative changes on energy conservation, efforts of 8apanJs industries
toward energy conservation, &ction 4lan of Aeidanren and many of the (338 activities. 7e
believe that these topics were helpful to participants as reference information.
;+< 'ession " (6amples of ((53 activities toward the industrial sectors
%< =verview of 7holesale (lectricity 'pot Market - Mr. ,ernandez ;Material )o. .-%""<
Ce described the development of the 7holesale (lectricity 'pot Market ;7('M< and what it
means to the 'outh (ast &sia and proceeded to state that 7('M is becoming the new trend in the
Region. -he talk we felt was very interesting.
"< (nergy (fficiency and 3onservation 0est 4ractices in 3hemical Industry
- Mr. @eloso ;Material )o. .-%"+<
Cis talk centered on his successful effort to develop a method of producing cold water by
applying waste heat. -hrough his work with the RI 3hemical 3orporation he was successful in
applying @apor &bsorption method to produce cold water.
+< (nergy (fficiency and 3onservation 0est 4ractices in ,ood Industry - Mr. (restain
Ce spoke on e6amples of energy conservation through efficient lighting system and motors
but he spoke without any presentation materials, rendering understanding of his talk quite
difficult.
$< (nergy (fficiency and 3onservation 0est 4ractices in Iron 5 'teel, and ,ood Industry,
Malaysia - Mr. -alib ;Material )o. .-%"$<
&s a part of 4-M ;4usat -enaga Malaysia< activity, the government of Malaysia provides free
energy conservation audit. In connection with this service, the author has visited plants of a
variety of industries for energy audit and will summarize his e6perience herein. 4-M has
acquired a variety of measuring equipment for the purpose of energy audit.
=ne of the steel industry cases, the Malayawata 3orporation has an electric furnace and a
rolling mill in its organization and worked on many of the issues of the present workshop such
31
as those involving furnaces, compressed air, electrical power and cooling water, and the case
certainly would of interest to the participants of this workshop ;many participants belonging to the
steel industry<. In another e6ample, in manufacturing addible oil ;palm oil<, the company has
shown us e6cellent results.
2< (nergy (fficiency and 3onservation 0est 4ractices in 4ulp 5 4aper, Indonesia
- Mr. 'ubagyo ;Material )o. .-%%2<
-he talk was identical to one presented in 3ambodia.
9< (nergy (fficiency and 3onservation in 3eramic Industry, @ietnam
- Mr. :ong ;Material )o. .-%"2<
-he talk was identical to one presented in 3ambodia, but a different speaker presented it.
;$< 'ession + Results of the follow-up visits and the workshop
%< ,ollow-up (nergy &udit ,indings at 1arment ,actories
- Mr. .omingo 5 Mr. &mano ;Material )o. .-%"9<
3oncerning this theme, materials were prepared by (338. =f the materials presented, Mr.
.omingo of .=( has taken initiative in the initial portion of the presentation ;covering +
slides< contributing the ob!ectives of the &'(&) 4R=M((3 and its activities. Mr. &mano
presented the remainder. Cis presentation centered on the technical aspects of electric power
and furnaces, which appeared to have amply answered the questions of many of the
participants.
"< 0arriers and Measures to implement ((53 - Mr. =gawa ;Material )o. .-%%><
sing the data of the past year, he has skillfully described the current status while
emphasizing on its ramifications on the 4hilippines and answering many of the questions
posed by the workshop participants.
+< -echnical .irectory ;-.< - Mr. -anaka 5 Mr. Ismed ;Material )o. .-%%?<
-hey have e6plained the purpose, method of compilation, format and other details of technical
directory and illustrated their talk with many actual e6amples. Mr. Ismed presented the
e6emplary cases.
$< .atabase/0enchmark/1uideline for Industry - Mr. =gawa ;Material )o. .-%%B<
0ecause of shortage of time, a short discussion of this item was presented and summarized.
;2< D5& 'ession
'ome questions were posed during presentations but this D5& session was held at the end of
the workshop. -he participants asked many questions, but perhaps because of presence of some
e6perienced consultantsE they gradually turned into criticisms against governments. Most
32
frequent voices pertained to the invalidation of the energy conservation bill submitted by .=( of
the 4hilippines due to the lack of action within the time limit after the legislation of specified
durationE they were urging the government ;.=( and .epartment of 'cience and -echnology< of
the 4hilippines requiring more efforts.
&lso numerous was the suggestion that the security protection requirements of .0/0M/1:
were impracticable and that data collection and analysis themselves ;in ma!or industries< were too
cumbersome.
;9< 3losing speech
Ms. -eresita M. 0orra, .irector, (nergy tilization Management 0ureau, .=( was scheduled
to give the closing speech but was unable to attend. Mr. .omingo, in her stead, gave the closing
talk.
33
I@. Indonesia ;4aper/4ulp and -e6tile Industries<
%. =utline of the &ctivities
-his survey includes a follow-up energy audit of 4- A(R-&' :(3(', whose initial 4hase %
energy-conservation audit was carried out from 8anuary ""-"2, "##%, and a new
energy-conservation audit recently carried out on a spinning mill. & workshop was also held in
8akarta, at which case studies of energy-conservation activities in various industries were reported.
%.% Implementation period
.ecember 2 to .ecember B, "##2
%." 'ites of Implementation
,ollow-up investigationG
)ew energy-conservation auditG
'eminar workshopG
%.+ 'chedule ;Material )o. .-%#"(<
.ecember "##2, 2 ;Monday<G
9 ;-uesday<G
> ;7ednesday<G
? ;-hursday<G
B ;,riday<G
%" ;Monday<G
%.$ Relevant 4ersons
&3(G
4- A(R-&' :(3(', 4aper Mill ;:eces @illage, 8awa
-imur .istrict, about %"#km southeast of 'urabaya 3ity<
I).'-RI '&).&)1 )'&)-&R& ;)I- 4&-&:
1R&-I< 'pinning ,actory ;8awa -imur .istrict, about
?#km southeast of 'urabaya 3ity<
8akarta 3ity
,ollow-up energy audit ;4- A(R-&' :(3('<
,ollow-up energy audit ;4- A(R-&' :(3('<
,ollow-up energy audit ;4- A(R-&' :(3('<
7alk through energy audit ;4- Industri 'andang )usantara,
4atal 1rati 'pinning Mill<
4reparation of reportE visited 4- A(R-&' :(3(' to
receive information materials.
'eminar workshop at 8akarta
.r. 7eerawat 3hantanakome, 1eneral .irector Mr.
3hristopher 1. Kamora, 4ro!ect Manager Mr. Ivan
Ismed, 4ro!ect =fficer
IndonesiaG
Ms. Meryam &yuni, .irectorate 1eneral of (lectricity and (nergy tilization, M(MR
;,ocal 4oint of Indonesia<
Mr. 4arlindungan Marpaung, Inspector of (lectricity, M(MR
IV%
8apanG
International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
-he background situation in Indonesia
;%< 1eneral information about Indonesia
- &reaG about %,?B#,###km
"
;about 2 times that of 8apan<
- 4opulationG about "%2 million ;according to the demographic survey of "##+<
- ReligionG Islam ?>L, 3hristianity %#L, Cinduism "L
- 'ystem of governmentG Republic
- (conomyG Ma!or industriesG mining industry ;petroleum, :)1, aluminum, tin<, agriculture
;rice, rubber, palm oil<, industry ;wood products, cement, fertilizer<
1.4 per capitaG MB2$ ;"##+<
(conomic growth rateG $.2L ;"##+<
3urrencyGrupiah, X% N about ?#R4 ;rupiah< ;as of .ecember "##2<
-rading ;"##+<G
(6portsG petroleum and gas ;"2L<, transportation equipment and
parts ;%>L<, te6tiles and clothing ;%"L<, etc. are e6ported to
8apan ;"%L<, .'.&. ;%+L<, 'ingapore ;?L< ;according to
Indonesian statistics<. -otal value of e6portsG M9%.#2? billion
;according to IM, statistics<.
ImportsG general machinery and transportation equipment ;"9L<,
fuel and lubricants ;"$L<, chemical raw materials and
products ;%9L<, etc. are imported from 8apan ;%9L<, 3hina
;%"L<, and 'ingapore ;%%L< ;according to Indonesian
statistics<. -otal value of importsG M+".9% billion ;according to
IM, statistics<
- (conomic situationG &fter the &sian 3urrency 3risis of 8uly %BB>, the Indonesian government
promoted structural economic reforms based on an agreement with the
IM,. -he economy is now e6periencing a recovery, supported by strong
private consumption and free from the supervision of the IM, at the end
of "##+. Cowever, domestic and foreign investments have not yet
recovered to the levels e6perienced before the currency crisis and, since
his election, 4resident Pudhoyono has given the e6pansion of foreign
investment top priority.
;"< (nergy situation
=il prices have risen %# times in the past five years, and the present gasoline price is 'M#.2/:. -he
cost of electricity is 'M#.#2/k7h.
IV"
". ,ollow-up 'urvey of the 4ulp and 4aper Mill of 4- A(R-&' :(3('
".% =utline of the 4ulp and 4aper Mill of 4- A(R-&' :(3('
;%< =utline of the company
-he company was established in %B+? during the period of .utch administration. -he pulp and
paper operation was started on ,ebruary "", %B$", with the )o. % paper machine. -he company was
originally owned by a .utch company, nationalized after independence in %B9%, and
privatized in %B?". It now has five paper machines with a total production capacity of 2>#t/d.
&ctual production is between %"# and %$# thousand tons per year.
-he first energy-conservation audit ;4hase %< was carried out in 8anuary "##%. &fter this initial
investigation, the company vigorously promoted energy-conservation activities and achieved
great success, with the results being reported at every 4R=M((3 'eminar. 7hile the company
was very cooperative in the present investigation it was, however, apparent that they were
e6periencing business problems due to changes in the e6ternal economic environment. 7hen we
visited, the plant was operating at less than half its capacity and several ma!or facilities were
inoperative.
-he situation during the first energy audit and the follow-up investigation were as followsG
3ompany nameG 4- Aertas :eces ;4ersero< 4ulp and 4aper Mill
:ocation of the plantG 8l. Raya :eces, :eces, 4robolinggo 9>"#", 8awa -imur - Indonesia
-elG 9+"-9"-++2-9?#BB+ ,a6.G 9+"-9"-++2-9?#B2$
4roductsG 4rinting paper, industrial paper, tissue paper, news print paper,
bagasse pulp
4roductionG %"#-%$# thousand t/y
)umber of employeesG &bout +,%2# ;three eight-hour shifts with three groups of workers<
;"< ,acilities and energy consumption at the paper mill
%< =utline of the operation
&lthough the production level was high during the first energy-conservation audit ;4hase %<, the
present production level is very low due to the slump in sales of the operationJs ma!or products
such as newsprint ;about $#L of total output<.
"< ,acilities
0oilers for power generationG
Recovery boilersG
'team turbinesG
B#t/h O $.$?$M4a O 2 units. ,uel was changed from heavy oil
to natural gas in "##+, and economizers have recently been
installed.
$#t/h O $.2BM4a O % unit 5 $2t/h O $.$?M4a O % unit
:iquor content N $+L
(04- ;back-pressure turbine< O % unit, output N%B,$##k7
IV+
3- ;condensing turbine< O % unit, output N%B,$##k7
(3- ;e6traction c. t.< O % unit, output N ">,###k7
4aper machines
)o. % machineG
)o. " machineG
)o. + machineG
)o. $ machineG
)o. 2 machineG
,acilities for bagasse pulp
",>##mm O %"2m/min ;for cardboard linersG +#t/d<
'team consumptionG #.9M4a

steam O +.2t/t-paper
(lectricity consumptionG ?>9k7h/t-paper
",>##mm O +"2m/min ;for industrial paper and writing
paperG 9#t/d<
'team consumptionG %."2/#.9M4a steam

O +t/t-paper
(lectricity consumptionG 9B2k7h/t-paper
9,###mm O 22#m/min ;for writing paper and printing
paperG %>2t/d<
'team consumptionG #.9M4a steamO +t/t-paper
(lectricity consumptionG ?%#k7h/t-paper
",$##mm O B##m/min ;for tissue paperG +#t/d< 'team
consumptionG +.+/%."2M4a steam O +.2t/t-paper (lectricity
consumptionG %,2"?k7h/t-paper
>,###mm O >2#m/min ;for newsprint paper, writing paper and
printing paperG ">2t/d<
'team consumptionG #.9M4a steam

O %.?t/t-paper
(lectricity consumptionG 9?$k7h/t-paper
.I4 ;.e-inking 4lantG facility for de-inking<
7astewater treatment plant
7ater supply pumpG %% units
&ir compressorG 9 units
+< &mounts of energy consumption and energy costs
-he production volume, energy consumption, and energy price are shown in -able I@-"-% and
-able I@-"-".
IV$
-able I@-"-% 4roduction volume of paper and amounts of energy consumption
Items Pear
"### "##2
4roduction 5 sed (nergy
nit
0aggase pulp
t %$,?>9 ?"+
.e-inked pulp
t $",?92 #
4aper production
t %+2,>%> %%$, ">+
(nergy source
toe/y toe/y
,uel oil k:/y %$>,?+" %$+,+B> 2,%?$ 2,#"?
:41 kg/y "9>,"B# "B> # #
)atural 1as km
+
)/y # # B2%,%$B ?%,$9$
(lectricity M7h/y "%B,9"? %$+,99B
-able I@-"-" (nergy price ;'M<
(nergy 'ource nit 4rice ;"###< 4rice ;"##2<
,uel oilY : #.#$"? #.+B+>Y
)atural 1as m
+
) - #.%""?
:41 kg #.%$>B -
(lectricityYY k7h #.#"%9 #.#2#%
Y (6cl. -ransport 3ost
YY (lectricity only, average price, e6cludes steam cost to plant
YYY :41 used at 4M ;4aper Machine< Z+ for Infrared .ryer up to )ov. "##% and then
changed to )atural 1as. )atural 1as was used at 4M Z+ and at the 4ower 4lant, but
since "##+ 4M Z+ has no longer used )atural 1as.
"." 'ummary of the Results of the 4revious (nergy &udit of 4- A(R-&' :(3(' 4ulp and 4aper
Mill
-he following issues were pointed out in the previous energy audit as being in need of
improvement. It was noted that the H2 'JsI were not being enforced sufficiently.
;%< Measures for energy conservation in the use of boilers and turbines for power generation
-he percentage in-house power generation at :(3(' Mill in "### was about BBL. 'ince the
price of heavy oil was 'M$+.2 ;X2,###</k:, which was very ine6pensive, the cost of in-house
IV2
power generation was only M#.##2" ;X#.9#</k7h for e6traction power generation and 'M#.#%B
;X".%></k7h for condensing power generation.
-he cost of condensing power generation was about half that of purchased power ;R4+%2,?$# N
X$.9"/k7h for peak hours and R4"9+,"## N X+.?2/k7h for night-time use<. -herefore, any
further investment in electricity saving was not usually worthwhile. ,urthermore, since the
condensing power generation had to be increased by about #.$2t/h in order to save %t/h of steam,
although the simply calculated steam cost was about 'M+.>? ;X$+2</t, the actual effect of any
saving was thereby reduced to little more than half this amountG 'M".#B ;X"$#</t. -his fact
indicated that any effective investment in further energy conservation was practically
impossible.
%< 3urrently, large amounts of steam are leaking from steam traps, valves, piping, and heaters all
over the plant, and heat insulation and painted surfaces are not adequately maintained.
"< Reduction of wasteful operation of water supply pumps ;0,4<
& total of four pumps ;three 0,4s for 'tage III and a 0,4 for 'tage I@< are currently in
operation. &lthough their design pressure is 9.?2M4a ;".Bm
+
/min<, 9.M4a should be adequate.
'ince the ma6imum load for pumps is "$#m
+
/h or less, one or two pumps are sufficient in
operation ;0,4G 0oiler ,eed 4ump<
-he actual loads on the pumps are "2, "2, ">, and "9 &mperes, respectivelyE making the total
load ??Bk7 while the rated load is +9.2 &mps. If only one pump was operated, then 9##k7
could be saved, and +B#k7 could be saved with two-pump operation. -he conversion cost is
estimated at 'M$,+2# ;X2##,###< for the +#m of %2#& piping and two diversion valves
required.
+< (6cessive blowdown water [ installation of drain filters
7hile the electrical conductivity of the supply water is only #.>??m'/m, the blowdown water
amounts to %2L of the average volume of supply water used for the four evaporators. -he
heat contained in the superheated blowdown water corresponds to $.9>t/h of steam and all this
heat is currently wasted. 'ince the specified ma6imum electrical conductivity of circulating
water for boilers operating at a pressure of 2.#M4a is ?#m'/m, ;according to 8I' 0
?""+-%B>>< the amount of blowdown can be reduced to about %L ;N ".2t/h< for all four
evaporators, even if the electrical conductivity of the supply water is kept at the present value of
#.>??m'/m.
:(3(' Mill has an e6cellent water purification system that provides pure water with an
electrical conductivity of #.2m'/m or less. Cowever, the electrical conductivity of the
condensate can be up to #.>??m'/m. Installation of drain filters would prevent any resultant
damage to the boiler tubes.
-otal cost for the installation of drain filters and changeover of pipingG 'M"9%,### ;about X+#
million<.
&lthough the average temperature of waste gas can be as high as "%$.", waste heat can be
recovered down to about %+# since the sulfur content of the heavy oil used at :(3(' Mill
is low as ".2L. Cowever, the price of heavy oil, about X2,###/k:, is already so low, as
described above, that it is effectively impossible to invest in further energy conservation.
IV9
0y taking the measures described above, it is e6pected that the heat efficiency of this boiler
plant could be improved up to about B+L.
$< -he temperature of the steam generated by the boilers is low.
It can be seen from the daily logs that the steam pressure is kept stable between $.$ and
$.2M4a, but the two-day average values of steam temperature for )o. % to )o. $ boilers are $"2,
$+2, $$2 and $#2, respectively, showing fluctuation among the individual boilers. -he
temperatures of )o. % boiler and )o. $ boiler are particularly low. 0y raising the temperatures of
)o. % and )o. $ boilers by %# and +#, respectively, the amount of power generated would
be increased by >k7/t and "k7/t, respectively.
'team condensate would also decrease by the following amountsG
)o. % boiler "k7/t O 2$.9t/h/"##k7/t N #.22t/h
)o. $ boiler >k7/t O +B.2t/h/"##k7/t N %.$t/h
-his would result in about "t/h in total. -herefore, a profit of about 'M9#,$##/y ;N "t/h O
?,###h/y/%%.2t/k: O 'M$+.$ ;X2,###</k:, or about X> million/y< could be e6pected.
2< (6traction pressure of the turbines is too high.
In spite of the fact that a steam pressure of #."2M4a or less is sufficient for the evaporators and
all the other facilities, e6cept for 4M" ;)o. " paper machine<, the Pankee dryer of 4M$, and the
digesters for the bagasse pulp, the pressure at the :4 steam header is set at #.2M4a. 'ince drain
attack is not a concern because the e6traction steam is sufficiently superheated, the pressure
could be decreased to #.$M4a or less ;although it would be necessary to check with the
manufacturers as to the blade strength, thrust bearings, etc. first<. -his would increase the
e6traction power generation by %#k7/t O 2#t/h N 2##k7, decreasing the condensation power
generation by about ".2t/h. & profit of 'M>2,$?#/y ;N ".2t/h O ?,###h/y/%%.2t/k: O
'M$+.$/k:, or about X?.> million/y< could be e6pected.
9< -he e6haust temperature of the condensing turbines and e6traction condensing turbines is too
high.
-he values of 2B-9" for the condensing turbines are too high and even those of +B-$9
for the condensing e6traction turbines are relatively high. -he water used is cooled in cooling
towers but the temperature of the cooling water can still be up to about ++ because the
average ambient temperature is +# and average ambient humidity can be as high as 92L.
&s a result, e6haust temperatures can rise to about $". =n the other hand, the temperature
of the fresh water is about "> throughout the year, which is comparatively low. 'ince about
>##m
+
/h of fresh water is used, it would be desirable to heat the fresh water using part of the
output from the condenser tubes.
In addition to the increase in power generation, %#L or more can decrease the amount of
condensate because the efficiency of dewatering is improved by the rise in temperature of the
showering water used for the paper machines.
'ince the fresh water has a high level of hardness and contains -.', particularly 'i=
"
, stains on
the tubes may cause a problem. It is necessary to carry out periodic flushing or to provide
automatic cleaning equipment.
IV>
;"< 4roblems and recommendations relating to evaporators and recovery boilers
%< -he wastewater from the bagasse pulp contains large amounts of calcium silicate and calcium
o6alate derived from the large amounts of calcium silicate in the fresh water and bagasse, and
this causes a serious problem with tube staining. -aking this problem into consideration,
:(3(' Mill always alternates the use of )o. % evaporator and )o. " evaporator, while the
other is being cleaned in a five-vessel quadruple-utility operation. Cowever, it is also
necessary to wash the other three evaporators. 0y raising the design value for the
concentration of rich black liquor from +>.?L to $2L, the amount of generated steam per unit
of solid content is increased and fuel costs are reduced. In addition, corrosion of the I., and
other parts are reduced due to the decrease in the use of heavy oil with high sulfur ;'< content.
-he profit from this is e6pected to be 'M"#,###/y.
"< It is recommended that the supply vessel used be changed from Z2 vessel to Z$ vessel.
'ince the temperature of the dilute black liquor supply can reach ?2-B#, the liquor should be
supplied to Z$ vessel, whose design vaporization temperature is >#->2. -his will save energy
because the steam vaporized in Z$ vessel can then be used as heating steam in Z2 vessel. -he
profit from this is estimated to be 'M>,9##/y.
+< -he 3= content can be as high as 2ppm, whereas the remaining =
"
content in the e6haust gas
can be as high as >.#L.
'ince the ma6imum allowable 3= concentration in the e6haust gas is "#ppm, this value does
not cause an environmental problem. Cowever, it is still important to control the 3= content
in the recovery boilers. (ach recovery boiler has four in!ection burners for the black liquor,
but only three are used at present. 'ince this causes non-uniform combustion, decreasing the
size of each burner should use all four burners. 0ecause a large amount of supplementary
heavy oil is used, the remaining =
"
content will then be reduced to "L or less, resulting in an
increase of generated steam by about +L. -he profit from this is estimated to be 'MB?#/y.
$< It seems that considerable amounts of )a=, )a3=
+
, and )a'=
$
are dispersed in the e6haust
gas from the cascade evaporators used for the condensation of black liquor ;making use of the
heat of the e6haust gas from the recovery boiler<. -he recovery rate of )a=C could be
increased from 2#L to B#L or more by installing a scrubber to collect )a= V )a3=
+
and by
using 3a= of better quality. -he limestone being used at present is a yellow color, indicating
that its purity is low.
If +#L of this uncollected 2#L )a=C is then successfully recovered ;assuming that ?#L of
the design value is collected<, an annual profit of 'M9%+,>##;N X>#million< could be
obtained through the increase in )a=C recovery.
'ince the cost of steam is low, it is possible to install evaporators for drying the e6haust gas
from the scrubber, but it is better to utilize the heat of the e6haust gas from the heavy oil
boilers, whose temperature is "## or higher ;&s described above< for the condensation
process, since this would not require the use of any additional energy.
'ince the necessary construction cost is estimated at only about M$+2,### ;X2#million<, this
renovation should also be made for reasons of environmental pollution control.
IV?
;+< 4roblems and recommendations relating to 4M2
%< 4romotion of the H> 'JsI ;'eiri, 'eiton, 'eiso, 'eiketsu, 'hitsuke, 'ho-shigen and
'ho-enerugi<
4ulp and scraps of paper are scattered all around the plant. -he campaign should start with the first
H+ 'JsI.
"< 'ince the surface temperature of the dryer groups is roughly equal and since there is no
difference in steam pressure between the dryer groups, the condensed steam draining from the
dryers is not always discharged satisfactorily. -his results in accumulation of the condensed
steam in the dryer cylinders causing an increase in the load on the driving motors.
3onsequently, only one doctor is used in the dryer and the others have been removed ;and
even the one remaining doctor does not actually work because it is kept raised<.
-he load on the doctors need not be large if they are well maintained. -herefore, all the
doctors should be reconditioned and put back into use. If doctors are not used, then
perforation and tearing are caused in the calender because paper scraps and powder residues
cannot be removed. In addition, adhesive materials attached to the dryer surface cause
pinholes in the paper and can adhere to the paper. -his may result in the paper tearing.
-herefore, all doctors should be reconditioned and restored.
+< In order to implement energy conservation, it is necessary to stop the process in order to in!ect
steam equally to all "# dryers in the steam drainage system, providing a pressure difference of
#.#$M4a or more between the dryer groups. If this is not done, the driving load rises making it
impossible to increase the speed. If such an improvement is carried out, the optimum speed could be
increased to >2#-%###m/min. 'peeding-up the process requires an increase in electric power
;proportional to the speed raised to the power of about "/+< and, since the steam consumption
rate is also improved, this results in significant energy conservations. Increasing the speed to
%,###m/min could increase the present ma6imum daily production of "$#t/day to 2##t/day. -his
would produce remarkable economic benefits. 'peeding-up the process can also be realized by
preventing paper break.
$< 7hen paper break occurs, the operation is often restarted without eliminating the causes of
paper break. -hus, the average resetting time can be as short as %".# min/reset, as shown
below, but another paper break may soon occur. =n 4M2, paper break sometimes occurs > to
%# times a day. .uring the +## days of operation per year, paper break accounts for %.+L of
the total operating time on 4M%, >.?L on 4M+, and $.#L on 4M2. -he effect of preventing
paper break is significant because the energy-conservation effects are doubled when the large
amounts of defective paper wasted before and after the paper break are also taken into
account.
In particular, 4M+ is out of operation for more than three weeks ;"+.$ days< each year. -he
Hzebra patternsI caused by the presence of adhesive materials are often observed on the paper
rolls at the +4 outlet of the paper press. 'uch stains must be cleaned off whenever a paper
break occurs. 'ince the removal of adhesive materials from the .I4 is not sufficient, the .I4
IVB
pulp must be cleaned thoroughly.
2< -he maintenance of dryer hoods is inadequate. &ll the hoods on the ",: are open and some of
those on the %,: are also open. -his not only wastes energy but also adversely affects the
paper drying process. Coods must be maintained properly and kept closed.
9< Repair costs in "### were only 'M%."## million, which corresponds to %.2L or less of total
sales. -he standard value for such repair costs in 8apan is between + and +.2L of total sales.
'ince the labor costs for repair work in Indonesia are even less than those in 8apan, this value
are too low. 8udging from the present status of the plant, the decent facilities will deteriorate if
spending on maintenance is not increased to about ".2L. -he low operating rates of the paper
machines shown in -able III-"-+ reflect inappropriate levels of maintenance. In 8apan, the
normal operating rate for such machines is about B2L, and some paper machines achieve B?L
or more.
-able III-"-+ =perating rates of paper machines at :(3(' Mill and the number of personnel
employed for each paper machine in "### ;four groups in three shifts<
4aper 4M% 4M" 4M+ 4M$ 4M2
machine )o.
=perating ?B.>> >2.%B >?.9" ?$.B# ?#.#B
rate ;L<
)umber of ># ?+ %#2 >B B?
personnel
'peeding-up the process, using the measures described above, would increase production by
%"2t/day O +$# days/y N about $+,###t/y.
;$< 4roblems and recommendations relating to .I4
%< &ctual production capacity is about "##t/day, whereas the design capacity is "2#t/day. -he
ma!or bottleneck is the lack of capacity for rough screening. 3hanging the shape of the slits in
the screen plate could solve this problem.
"< -he pulper has surplus capacity and the number of revolutions can be increased by 9L. -he
capacity of the present facilities would then be increased to about +##t/day. Cowever, the
following measures, described in +< and $< below, must also be taken in order to achieve this.
+< -he amount of froth in the flotator ;sponge cake-like aggregates of ink, fillers and pulp
attached to bubbles formed by the air in!ected during the de-inking operation< is abnormally
large, resulting in an e6cessive amount of good-quality pulp spilling out.
-he percentage of re!ect froth that includes a large volume of good-quality fibers can be as
high as 2.>L. -his must be reduced.
,ive flotators are being operated in parallel. Cowever, half will reduce losses if four of them
are used as primary flotators and the remaining one is used as a secondary flotator, increasing
IV%#
the pulp yield by ".BL.
4rices of used paper in Indonesia are high because used paper is currently imported. In
particular, =)4 ;waste newsprint< costs about X"$/kg, which is about twice that in 8apan. &s of
"###, $",?92t/y of .I4 was produced using 9%,%2%t/y of used paper. If this yield could be
improved from >#.%L to >+.#L, the following benefits would result. 3onsidering the fact that the
yield of =)4 in 8apan is ?2L or higher, it seems to be possible for this mill to achieve a yield of
about ?+L because the used paper at this mill is of good quality. -his means that an increase of
yield by %"L ;%?L overall< could be achieved.
9%,%2%t/y - $",?92t/y/#.>+ N ",$+"t/y
",$+"t/y O 'M"#2/t N 'M$B?,9##/y ;N X2>.+ million/y<
$< 8ohnson screens are used for the final treatment of re!ects and round holes of 2-9U are used for
all screens, e6cept for the tertiary screening.
'ince large particles of foreign material are not removed, they circulate until they are crushed and
then pass through the secondary screen.
It is strongly recommended that the screen be changed to a slit plate with #."#-#."2mm\ slits. 0y
raising the yield to ?+L, significant profits would result ;as described below< because the price of
used paper at :(3(' Mill can be as high as 'M"#2/t.
In "###, 9%,%2%t of =)4 was used to produce $",?92t of .I4. If the yield were raised to ?+L,
significant benefits would result, as described above. ,urthermore, the scale of the sludge
incineration facilities required would be reduced.
$",?92t/y/#.?+ N 2%,9$2t/y
2%,9$2t/y[ 9%,%2%t/y N AB,2#9t/y
B,2#9t/y O 'M"#2/t N 'M%,B2#,###/y N X""$ million/y
InvestmentG a rough estimation is M",###,### ;X"+# million<, including the renovation of the
incineration furnace.
;2< Pield of bagasse is low.
%< -he harvesting season for bagasse is about 9 months, during which it is stored outdoors.
:(3(' Mill says that such bagasse stored outdoors does not deteriorate since hypochlorite
solution is used to prevent bio-deterioration. &lthough CP4= solution is sprayed on to
prevent bio-deterioration, mildew is observed growing even on newly brought-in bagasse
because the CP4= solution is washed away by frequent rain. 'ilos should be installed to store
the bagasse.
"< -he yield of bagasse is only +9.?L, in spite of its high price of 'M?+ ;XB,2$2</0:-.
&lthough the yield of bleached bagasse depends on its place of origin, it is usually $"L or
higher. &ssuming that the actual production of pulp was %$,"2?t/y in "###, the benefits
obtained by reducing the deterioration of bagasse in order to increase its yield would beG
+2,2#?t/y - %$,2"?t/y O #.B/#.$" N $,+>>t/y
$,+>>t/y O M?+ N M+9+,###/y ;N X$%.? million/y<
(stimated construction cost of %2,###t of silo capacityG M%,+##,### ;N X%2# million<
IV%%
;9< 4aper machines other than 4M2
%< -here are $ single canvases of 4M" at present. It would be better to increase this number to
eight. Calf without reducing the drying capacity would then decrease the driving load.
"< 0oth the Z%4 and Z"4 presses of 4M" have a small diameter. It would be better to change
these to the Z+4 type that has a larger diameter.
+< -he doctor of the dryer for 4M+ is not being used. 'ince this is one of the reasons for paper
break, it should be reconditioned and put back into use.
$< 4M% has only primary and secondary cleaners. & tertiary cleaner should be installed, as in the
other 4Ms.
2< ,urthermore, it is recommended that a fourth and a fifth cleaners installed or that ,R be
installed for 4M+ and 4M$. -his would not be very effective in terms of energy conservations
because the energy cost is low, but it would be very effective in terms of resource savings
because the costs of used paper and pulp are high. If the amount of raw materials saved by
4M+ and 4M$ were +t/day and 2t/day, respectively, and assuming that the average price of
pulp was X2#/kg and X+#/kg, annual savings in raw materials would be about 'M$+2,### ;N
X2# million< each, totaling 'M?>#,### ;N X%## million< overall.
(stimated facility costs are 'M%>$,### ;N X"# million< and 'M"9%,### ;N X+# million<,
totaling appro6imately M$+2,### ;N X2# million< overall.
IV%"
".+ ,ollow-up (nergy &udit
7e visited the 4- A(R-&' :(3(' 4aper Mill for two and a half days to carry out a follow-up
energy audit on the implementation of previous advice given by the (338 team in 8anuary "##%
and to investigate the other operations of the mill. &lthough the Indonesian M(MR was
supposed to play a key role in the follow-up energy audit, (338 actually led the survey.
-he purpose of the visit was e6plained and the schedule was discussed. 'ince many of the
facilities were not operating, )o. + paper machine was selected as the ob!ect of investigation.
'ince a detailed energy audit had been carried out on the paper-making process in the previous
visit, this investigation focused mainly on the utility facilities and the detailed advice was given.
;%< .ate of energy auditG .ecember "##2,
;"< &udit team membersG
Indonesia
M(MRG
2 ;Mon.< %9G"# - %>G"#
9 ;-ue.< BG## - %9G##
> ;7ed.< BG## - %9G## and
B ;,ri.< %+G## - %$G##
Ms. Maryam &yuni, .epartment of (nergy (fficiency
;Indonesian coordinator, participated only in parts 2 and 9<
Mr. 4arlindungan Marpaung, Inspector, .ept. of (nergy (fficiency
4:)G
Ms. 'ut!i Rahayu, 8akarta =ffice ;participated only in parts 2 and 9<
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
;+< &ttendees from 4- A(R-&' :(3('
Mr. Ir. .!oko 7iryono, Manager :itbang ;Reporter at 4R=M((3< Mr.
Ir. M. )ugroho 0asuki, Manager 4lant %
Mr. Ir. -ri 4rasetyono, Manager 4lant +
Mr. Ir. .idik Mudiarto, 'I 4lant %0 Mr.
'upriyadi, 'I 4lant +0
Mr. Ir. 'ubagyo, 'I 44 4roduksi ;Reporter at 4R=M((3< Mr.
Ir. M. &rifin, 'I 4enelitian
Mr. 1atot 'ubroto, '@ tilitas
Mr. Ir. 0ondan &s, '@ A'4 +
Mr. 'utarmad!i, '@ 3ompressor
Mr. Imam Cadi, :istrik
Mr. K. &bldin Iw, Aonera $ ;Ir. stands for bachelor<
;$< =utline of the follow-up investigation
=n .ecember 2 ;Mon<, the purpose of the visit was e6plained and the overall schedule was
IV%+
discussed.
=n .ecember 9 ;-ue<, 4- A(R-&' :(3(' e6plained the changes in the e6ternal environment
and a walk through on-site audit was carried out for the bagasse storage yard, power generators,
boilers, )o. + paper machine, and the wastewater treatment plant. -he investigation team
toured the plant and made comments. 'ince many facilities were not in operation, )o. + paper
machine was selected as the ob!ect of investigation. 'ince a detailed energy audit had been
carried out on the paper-making process in the previous visit, this investigation focused mainly
on the utility facilities and the detailed advice was given. Issues such as the prevention of paper
break were also discussed.
=n .ecember > ;7ed<, a tour of the plant was undertaken, measurements were carried out on air
compressors and pumps ;in the water supply room<, and the rest of the time was spent writing
a report. 7e visited the mill once again on the afternoon of .ecember B ;,ri< to collect additional
information and materials.
-he information and materials we received from 4- A(R-&' :(3(' includedG
-he H0oiler 4erformance 3urveI, H0oiler 0lowdown @olumeI, H'pecification and operating rate
of &ir 3ompressorsI, H(lectrical power chart of paper machinesI, and H-able of downtime of )o. +
paper machine caused by paper break ;"##%-"##2<I.
;2< Results and discussion of the investigation
%< Recent changes in the situation
4- A(R-&' has produced significant results by following the detailed advice for
improvements given in the previous energy audit in 8anuary "##%, and by implementing its
own improvements such as fuel conversion from heavy oil to natural gas. -he results of these
improvements have been reported at every 4R=M((3 'eminar 7orkshop making 4-
A(R-&' an Hhonor studentI among the participants in this pro!ect. Cowever, our impression
was that the e6ternal economic environment was worsening, and that the company was
fighting not only to save energy but also to keep operating smoothly. 7hen we visited the
plant, it was operating at less than half capacity with many ma!or facilities lying idle.
-herefore, the original plan to convert from gas fuel to coal was in !eopardy due to financial
restrictions.
7hile production in "### was about %+2,>## tons, recent production has been reduced to a level
of %"#,### tons. Ma!or changes in the operational situation are roughly as shown in the following
sections. Measures taken by 4- A(R-&' are also described. Duestions and answers are included
in Material )o. .-%#>.
a. 'hortage of raw material ;bagasse<
7hen we visited the plant, the depithing and pulpers were lying idle. bagasse is bought in from
sugar plants in 8ava, but shipments of bagasse have now decreased because, due to the recent
increase in fuel prices, it is now used as fuel within the sugar plants. -he following two
measures may be taken to address this problem.
- -o ask 4-4) ;4lantation (nterprises< to increase the supply of bagasse by using coal as
IV%$
a fuel instead. -his measure is e6pected to secure 9?,### tons in "##9.
- -o find alternative raw materials, including long fiber wood such as Aalimantan.
b. 'luggish sales of newsprint paper
'ales of newsprint paper are decreasing because newspaper companies increasingly
produce newsprint paper by themselves. &lthough 4- A(R-&' e6ports newsprint paper,
production is decreasing. -he operation of the .I4 that treats used paper has therefore been
suspended. 3onsequently, )o. 2 paper machine ;4M2< has stopped producing newsprint
paper and is now producing printing paper instead.
c. nstable supply of natural gas
4- A(R-&' succeeded in reducing costs by converting from heavy oil to natural gas in
8une "##+. Cowever, the production volume of the natural gas field ;owned by a 4-
4ertamina-related company< is now decreasing and the pressure of the gas source supply is
also decreasing. ,or this reason, a quota system is now used for the natural gas supply,
which sometimes reduces daily production to "2#-+## tons. -o cope with this situation, the
amount of in-house power generation that uses natural gas has been reduced and electricity
is now purchased instead. -hey seem to be waiting for the discovery of new gas fields.
d. 4rice rise of heavy oil
&lthough the consumption of heavy oil is not as large, the price of natural gas goes up so
too does the price of heavy oil. &s a result, the cost of fuel, as a proportion of the total
production cost, has risen from %>L to ""-"+L. -his value is comparable to the level
before fuel conversion, which was "$L. 4ossible measures for remedying this are as
followsG
- -o improve energy efficiency.
- -o convert the fuel supply yet again.
It was originally planned to convert from natural gas to coal in "##9, but this cannot now be
realized due to the lack of investment funds.
"< 'ituation at the time of the visit
-he operating situation at the time of our visit was as follows, reflecting the changes in
environmental conditions mentioned aboveG
(quipment ;Main product< ;3apacity< =perating situation/ Reason for
suspension
4M % 3ardboard liner +#t/. In operation
4M " 4rinting paper 9#t/. In operation
/industrial paper
4M + 4rinting paper %>2t/. In operation
4M $ -issue +#t/. =peration suspended maintenance
4M 2 )ewsprint paper, ">2t/. =peration suspended production
printing paper ad!ustment
0agasse 4ulp 4lant, including the .epithing 4lant,
@acuum (vaporator, Recovery 0oiler, :ime Ailn,
IV%2
Re-causticizer 5 3hlor-&lkali 4lant, .I4 =peration suspended production
ad!ustment
&mong the other facilities inspected, only three out of five power boilers were operating, and
only one out of three turbine generators. -he wastewater treatment facilities were operating.
+< (nergy prices and activities for reducing costs and consumption
(nergy costs are as followsG
)atural gasG 'M$.+9/MM0tu
Ceavy oilG 'MB.9#/MM0tu
3oalG 'M%.B#/MM0tu ;0aseG "",%B#k8/kg, %0tu N %.#22k8<
(lectricityG
Reactive 4ower 3harge N 9#B O ]effective power ;k7< - #.9" O reactive power
;k@&r<^ R4/k7h
-his is the same in 8apan as the charge is zero when the power factor is ?2L.
&ctive 4ower 3hargeG normal time N $+BR4/k7h
_ 4eak :oad period ;%?G##-""G##< N ?>?R4/k7h
-otal power consumption at 4- A(R-&' Mill is %>,$##k7, of which ",$##k7
;%$L< is purchased from 4:) and %2,###k7 ;?9L< is supplied by in-house
generation. -he proportion of in-house generation was BBL at the time of
diagnosis in "##%.
'ince 4- A(R-&' does not have an energy manager, a comprehensive, overall perspective
seems to be lacking.
$< Results of the follow-up diagnosis ;in comparison with the previous results<
-he items advised by Miyabe ;technical e6pert of (338< in the previous energy audit ;8anuary,
"##%< are described in ".". Referring to the activity report on energy conservation submitted
by 4- A(R-&' in the 4R=M((3 'eminar 7orkshop, the e6planation presented by 4-
A(R-&' and the comments made by the investigation team are listed in -able I@-"-$
;relating only to items that have not been implemented, however<. 'ome items have not been
implemented because the level of operation is now much lower due to the environmental
changes mentioned above.
IV%9
-able I@-"-$ 3omments on the items which were identified by (338 previous audit
and have not been implemented
?
)o. ,inding 4-Js 3omment/&ction ,ollow-up result
, Recovery 0oiler
+ 3hange the ,., and I., to the Cas not been done yetG too 3ompany policy on the payback
proper size, for both the quantity e6pensive period of investment is + years
and the head or less.
1 4ower 0oiler
" 'hould be connected to each
pump by a common header so
that you can stop the two 0,4s
and thereby save about $##k7 of
electricity.
Cas not been done yetG the In the past, connecting the
characteristics of the pumps are pumps was tried and ma!or
not the same. problems resulted.
;-he issue may still be worth
studying further.<
+ 3hange the ,., and I., to the Cas not been done yetG too 'ame as ,-+ above
proper size, for both the quantity e6pensive
and the head.
$ Remaining =
"
content is too high
;$ to >L, as measured by our
team< and should be reduced to
less than "L.
=
"
monitor has been installed. 4- is now controlling the
(6cess =
"
in the stack can be remaining =
"
content at "-$L,
ad!usted to "L manually. depending on load levels.
;Recommended that =
"
be
reduced to "-+L.<
2 (6haust gas temperature is a little 7e have tried to add an -here is no space to add a heat
high at %># to %?#`3.
economizer. -he flue gas
e6changer on-site.
temperature has been decreased
to %9#`3.
C -urbine and 1enerator
+ (lectrical technician has 'ince "##% we have had to 4, has now reached about
mistakenly made some kind of repair the old capacitor and #.B2 and should be =A.
error with the 4ower ,actor ;4,< install a new capacitor. -he
power factor has now increased
from #.>% to #.>$. -he budget to
install new capacitors is
'M%##,###.
$ If the 4, is rose from >#L to over
)ew capacitors have been 3onfirmed the situation as
?2L, then the pay back from the installed in the electrical described
(lectric 3ompany will cover company ;4:)< line since
some of the cost. "##% and no payments have
been needed to the (lectric
3ompany for reactive power.
IV%>
2< Results and impressions gained from the on-site survey
-he impression gained from the on-site survey is that employees are seriously committed to
achieving a high level of operation. &s described in the previous energy audit report ;4hase %<, the
original motto of 4- A(R-&', namely the H2 RJsI ;corresponding to the 8apanese H2'JsI in 0ahasa
Indonesia<, is posted everywhere throughout the plant and offices.
a. 4aper machines
&s for the paper break problem, we obtained specific data on this problem for )o. + paper
machine. &lthough the occurrence and amount of resultant downtime fluctuates, the
frequency of occurrence is gradually decreasing compared with the data from "### ;-able I@-"-
2<. -he speed of the paper machine ;m/min< has not been changed.
-able I@-"-2 =ccurrence of paper break on )o. + paper machine
Pear )umber of .owntime due to 4roportion of downtime
paper breaks paper breaks ;min< ;L of calendar days<
"### ;4hase % data< ","B" ++,9B% 9.$
"##% ",$B# $?,2%# B."
"##" ",2>B +$,+%# 9.2
"##+ %,"2B %B,"$# +.>
"##$ ","2? $#,"$2 >.>
"##2 %,$+B "+,?$+ $.B
;p to .ecember 2<
7e e6plained our e6periences with the paper break problem in 8apan ;and how the
incidence of paper break was reduced by ensuring that the machinery was cleaned properly
whenever the operating rate dropped<. -hey commented that they had the same e6perience and
that downtime had been reduced to as little as $L.
b. 0oilers for power generation
-hree boilers are operated in order to supply the appro6imately %2#t/h of steam required
;2#t/h each<. 7e asked why they didnJt !ust operate two boilers at >2t/h each, and they
replied that they operated three boilers for safety reasons because the natural gas supply
was unstable. It was understood that this was a separate matter from that of energy
conservation.
c. 4ower generators and power receiving installationsG only one of three generators is being
operated.
d. &ir compressor plant
&lthough the plant is spread over a large area, a central air supply system is employed. -he
plant has four centrifugal compressors and two screw type compressors, of which two
centrifugal compressors ;3()-&3G 2##hp, A=0(:3=G 2##hp< were operating. -he
IV%?
A=0(:3= model was newly installed after scrapping one of the screw type compressors
;commissioning had been carried out two weeks earlier, on )ovember "+<. In fact, four
compressors ;including two screw types< were on standby, showing that the utilized
capacity was very low.
&ll the operating air compressors are of large-scaled type, and use suction vanes for
capacity control so that the partial-load vs. power consumption characteristics is poor. 4ast
data on power consumption has been obtained and will be studied ;described later<.
-he control range of the discharge pressure is between #.92 and #.>M4a, which is relatively
high. -his range has probably been set after taking possible pressure drops in the piping
into consideration. Cowever, the actual fluctuation in discharge pressure is very small and
the pressure is kept at around #.99M4a. -his may be because the compressors are of the
centrifugal type.
3ompressed air is supplied through a receiver tank and dryer ;adsorption type<.
e. 7ater supply pumps
7e investigated water supply pumps that were representative of the utility facilities,
overall.
-he eleven water supply pumps have a large capacity of "##k7, and water is supplied to
each plant from three sites located outside the mill ;two sites in Ronggo!alu and one site in
'umber Aramat<. Cowever, when we visited, the facilities at only one site were in use
because some plants were out of operation. =n the day we visited, water was being supplied
from a water reservoir in Ronggo!alu, about %km from the mill, using only two out of the
five pumps installed on the line. -his is another e6ample of low capacity utilization.
-he power factor has been improved to B2L by installing phase advance capacitors on the
pump motors. 'ince a capacitor is installed on each pump, there is no adverse leading
power factor effect. -he electricity is supplied at a high voltage ;9k@<, which is
transformed to a low voltage ;$##@<, using a transformer of %,###k@& installed at the pump site,
before the current reaches the motors.
-his case is a typical e6ample of the measures employed to reduce distribution loss. -he
installation of phase advance capacitors was reported in the 4R=M((3 workshop held last
year.
-he preceding energy audit report described how the water is taken from wells. Cowever, the
actual feed water is taken from water reservoirs, and 4- A(R-&' has an obligation to the
government to supply a certain amount of treated wastewater for agricultural use in the
neighboring region.
".$ -echnical .iscussion and Recommendations
;%< Measures for partial-load operation
It is impossible to always keep the plant operating at its full capacity and the plant is often
forced to operate with a partial load. ,igure I@-"-% shows the relationship between production
volume and operating conditions schematically.
IV%B
4
r
o
d
u
c
t
i
o
n

Capacity of ,acility
.arge Pro!uction
9igh performance
Un!er partial loa!s
o!erate
"mall Pro!uction
Average performance
Poor performance
'ime
,igure I@-"-% .ecrease in production volume and partial-load operation
7hen production corresponds to the capacity of the plant, the equipment efficiency is high and the
energy intensity is also kept at a low level. Cowever, when production decreases, waste and low
efficiency in every facility cause to raise the energy intensity. In such a case, the size of the
production facilities is usually ad!usted to the actual production volume, but it is often difficult to
ad!ust utility facilities in this manner.
-he following are countermeasures for partial operation taking 4- A(R-&'J utility facilities as an
e6ample.
%< 4artial-load operation of the boiler system
a. 0oiler systems and the present operating situation
-hree steam turbine systems are installed in the mill but only one of them is now in
operation. ,igure I@-"-" shows the layout of the operating system.
Boiler Aux. Facility
Fan and
Pumps
Boiler Aux. Facility
Fan and
Pumps
Boiler Aux. Facility
Fan and
Pumps
90t/h 90t/h 90t/h
#1 Boiler
#2 Boiler
# Boiler
Steam !0t/h !0t/h !0t/h
1!0t/h
"ur#ine
,igure I@-"-" 0oiler system of 4- A(R-&'
-hree steam boilers, capacity B#t/h per each, supply steam to a steam turbine with a rating of
%2#t/h. -he load factor of the boilers is 29L ;N 2#t/h/B#t/h<.
'ince the specified capacity is B#t/h, two boilers could supply the amount of steam required.
IV"#
If one boiler was shut down, the following benefits could be e6pectedG
Improvement in efficiency due to the increase in the load factor of the boiler.
(nergy conservation coming from the shutdown of au6iliary equipment.
b. Improving the boiler efficiency
0y reducing the number of operating boilers to two, the load factor rises to ?+L ;N
>2t/h/B#t/h<.
,igure I@-"-+ shows the partial-load characteristics of the boiler ;based on data received from
4- A(R-&'<
91
90
$9
$$
$%
$&
$!
10 20 0 '0 !0 &0 %0 $0 90 100
(oad Factor )*+
,igure I@-"-+ 4artial-load characteristics of the boiler
;0ased on data received from 4- A(R-&'<
-he partial-load characteristics are e6cellent. -his is probably because all necessary
measures for lower level combustion have already been taken and any further significant
saving of fuel cannot be e6pected. -he graph shows that the e6pected improvement is only
#.$L ;N B#.$L - B#.#L<.
c. (ffects of the shutdown of au6iliary equipment
-he amount of au6iliary equipment operated can be reduced from three units to two units.
-able I@-"-9 shows the au6iliary equipment and its rated power consumption. (6cluding
,=4 ;which currently uses a gas-fired boiler<, the total power consumption of the au6iliary
equipment is >#2k7. -aking the increase in load factors of fans and pumps into
consideration, it is assumed that the power consumption could be increased from 92L to
B#L of the rated value. -he values of estimated power consumption are shown in -able
I@-"->.
IV"%
-able I@-"-9 &u6iliary equipment for the boilers
,an/4ump ;k7<
,=4 %%
0,4 +%2
.(4 >2
,., +%2
-able I@-"-> (nergy consumption of the au6iliary equipment
Items 4resent Improved
)umber of nits in =peration + "
:oad ,actor of the 0oiler ;L< 29 ?+
4umps and ,an 4ower 3onsumption Rate ;L< 92Y B#Y
4ower 3onsumption per nit ;k7< $2?.+ 9+$.2
-otal power 3onsumption ;k7< %,+>2 %,"9B
;YG (stimated value<
,rom -able I@-"->, the energy conservation is calculated as followsG
%,+>2k7 - %,"9Bk7 N %#9k7, %#9k7/%,+>2k7N #.#>> ;N >.>L<
"< 3ontrolling the capacity of the air compressor
,our centrifugal ;turbo type< compressors, one with a 2##hp electric motor and two screw
type compressors, are installed and two or three turbo type compressors are in operation.
a. &ir compressors ;turbo type<
1enerally, dynamic compressors such as the turbo type are used as large-capacity
compressors in situations where the screw and reciprocating types cannot be used. Cowever,
capacity control is difficult due to surging and the stonewall phenomenon ;as shown in
,igure I@-"-$<.
-he turbo type is suitable for constant-power operation and is an effective way to construct a
system that addresses the fluctuation of the load by combining with positive displacement
pumps such as the screw type and reciprocating type. -hat is, a screw type or reciprocating
type pump is combined with a turbo type pump to offset the shortage of air so that the load of
the turbo type is used for the base load as much as possible. -he screw type and
reciprocating positive displacement types allow for load/unload control, and the shaft
power is significantly reduced under unload conditions.
IV""
4
r
e
s
s
u
r
e

;
4
<

'urging point
Mechanical vibration
'tonewall point
'
3
'harp decrease of pressure
&ir- flow ;D<
)arrow working region
,igure I@-"-$ 'tone-wall point and surging of a turbo type compressor
,igure I@-"-2 shows operation patterns when a turbo type compressor is combined with a
screw type compressor.
-urbo type compressorG 0ase load operation
'crew type compressorG :oad/unload operation depends on demand
:arge volume air-demand
-urbo
'crew 'crew
;0ase load< ;:oad< ;:oad/unload<
:ow volume air-demand
-urbo 'crew 'crew
;0ase load<
;:oad/unload< ;'top<
Minimum volume air-demand
-urbo 'crew 'crew
;'top< ;:oad/unload< ;'top<
,igure I@-"-2 =peration of a turbo type compressor combined with a screw type compressor
b. =perating system
-he number of turbo type compressors being operated is controlled either manually or
automatically. -wo compressors are operated continuously at the base load and one
compressor is operated intermittently according to the required load. ,igure I@-"-9 shows
the changes in power consumption over two specific months when three compressors were
operated at the base load and two compressors were operated intermittently. & peculiar
characteristic of this graph is that very few data points are found in the zone between
%2,###k7h/d and "#,###k7h/d. 'ince the load of an air compressor is normally
continuously distributed, the distribution shown in ,igure I@-"-9 is abnormal. It seems that
IV"+
this phenomenon derives from the partial-load characteristics of this turbo type compressor.
,igure I@-"-> shows partial-load characteristics of compressors that use various types of
capacity control methods.
2!,000
20,000
-acant .one//
1!,000
ay
(uly
10,000
1
' %
10 1
1& 19 22 2! 2$ 1
0ay
Po1er 2onsumption in 3ay and 4uly on 200!
,igure I@-"-9 4ower consumption of air compressor systems
%##
'uction @ane 3ontrol
?#
&round >#L
9#
:oad/nload 3ontrol
Ideal 3ontrol
$#
Inverter 3ontrol
"#
#
# "# $# 9# ?# %##
(oad Factor )*+
,igure I@-"-> 3haracteristics of air compressors using various types of capacity control method
'uction vane control is used for the capacity control of turbo type air compressors. 7hen
suction vane control is used, as shown in the figure, power consumption is about >#L of
the full load, even if the load is zero. =n the other hand, air compressors with inverter
control ;screw type< that have been put on the market recently have almost ideal control
characteristics, while those with load/unload control fall in the intermediate range. ,igure
I@-"-? shows the relationship between power consumption and capacity control in the
operation of two compressors with suction vane control when the number of operating unit
is controlled.
IV"$
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@acant
zone
%st M/3
&ir flow
"nd M/3
,igure I@-"-? =perating unit control by air compressors with suction vane control
&t ma6imum load, two air compressors are used to supply the compressed air. &s the load
decreases, the first M/3 is run at its ma6imum load and the second M/3 is partially run
according to the required load. 7hen the load decreases to about 2#L, the second M/3 is
brought to a halt, and only the first M/3 is kept running. -he y-a6is in the figure above shows
the power consumption in the operation.
&s the load decreases, power consumption decreases in accordance with the partial-load
characteristic curve of the second M/3. 'ince the partial-load performance characteristics
are inferior to those at full load, the decrease in power consumption is slow and as much as
?2L of the power consumption at the ma6imum load is still required even when the load
decreases to almost ?2L ;N 2#L V %/" O >#L<. 7hen the load drops below 2#L, the
second M/3 stops so that only the first M/3 continues to operate. In this case, as shown on
the graph, the power consumption then follows the characteristics curve of the first M/3.
In these circumstances, power consumption then drops abruptly in the neighborhood of
2#L from ?2L down to about 2#L. -his e6plains why the HvacantI region is found in the
above graph.
c. 3ountermeasures
&lthough the use of an inverter controller with superior partial-load characteristics is
desirable, in practice this is impossible because the ma6imum capacity of the e6isting
equipment ;>2k7< does not meet the required capacity of 2##hp. Cowever, using the screw
type compressor for load/unload control of the capacity control can reasonably solve the
problem.
,igureI@-"-B shows control conditions after the partial load and characteristics are
improved.
& turbo type compressor can be used for constant load operation in con!unction with a
screw type compressor whose capacity is controlled by the load and unload control. 7hen
the load is heavy, two compressors are operated. &s the total load decreases, the output of
the screw type compressor decreases and power consumption also decreases in accordance
IV"2
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with the decrease in output. 7hen the load reaches 2#L or less, the compressor of the
constant load air compressor is brought to a halt and only the air compressor whose
capacity is controlled is operated. 7ith this arrangement, the large HgapI in power
consumption, as shown in ,igure I@-"-9, does not occur.
-he improvement achieved depends on the distribution of the load factor. Cere, 2#L is taken
as the center of the distribution, and a normal distribution with "a ranging from # to 2#L and 2#
to %##L is assumed.
7hile the use of suction vane control increases power consumption by +?L relative to the ideal
control state, the calculation shows that the increase is %$L in the load/unload control, which
represents an energy conservation of about "2L. It is therefore recommended that the control
of e6isting screw compressors be investigated and the operating unit control panel be used for
capacity control.
4ower 'aving
'crew M/3
-urbo M/3
'crew M/3
&ir flow
,igure I@-"-B =perating unit control of screw type and turbo type compressors
+< 4artial-load characteristics of motors and fans
a. Motors
Measuring the power consumption and comparing it with the rated value obtain the load
factor of an induction motor. -his measurement is not always easy because both the voltage
and the current must be measured simultaneously. Cowever, it is not difficult to !udge
whether the motor is oversized or not by !ust measuring the current. ,igure I@-"-%# shows
the characteristic curves for efficiency, power factor, and current ;as a percentage of the
rated value< against the load factor of a squirrel-cage induction motor ;$##@<.
IV"9
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;
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<
%"#
%##
?#
9#
$#
"2 2#
(fficien cy
4ower factor
3urrent
>2 %## %"2 %2#
:oad factor ;L<
,igure I@-"-%# 3haracteristics of a squirrel-cage induction motor ;$##@<
It can be seen from the diagram showing the relationship between the current and the load
factor ;above< that the load factor is 2#L when the current is 9#L of the rating. -he power
factor decreases from ??L to >>L, and the efficiency decreases from B"L to B#L. In a
motor operated at a higher voltage as well, the load factor is about 2#L when the current is
9#L.
&lthough the decrease in efficiency observed is several percent, at most, in a motor driven
at a high voltage its operation must be improved because the load factor of 2#L
corresponds to about twice the actual demand.
-hat is, the criterion for !udging whether the motor used is oversized or not is 9#L of the
rated current.
b. 4umps and fans
3ompared with motors, the efficiency of pumps and fans depends more on the load factor
;,igure I@-"-%%<.
%##.#
?#.#
9#.#
Motor
$#.#
4ump
,an
"#.#
"2 2# >2 %## %"2
:oad facto r ;L <
,igure I@-"-%% Relationship between the load factor and the efficiency of pumps and fans
&t a load factor of 2#L, efficiency decreases by about %#L in both pumps and fans. In
IV">
addition, the rate of efficiency decreases drastically below 2#L.
-able I@-"-? shows the measured values of the current of Z>#%0 supplementary equipment in
the previous energy audit ;8anuary "##%<.
-able I@-"-? Measured current of the fans and pumps of Z>#%0
3apacity .esign .esign &ctual &ctual/
,an/4ump k7 @olt. &mp.
&mp. .esign
%. ,=4 %% +?# "".2 %$.2 #.9$
". 0,4 +%2 9,### +9.2 "B.2 #.?%
+. .,4 >2 +?# %+% 9>.$ #.2%
$. ,.,
+%2 9,### +9.9 %>.2 #.$?
-he measured values of current for .,4 and ,., are less than 9#L of the rated design
values. -his indicates that the load factor is less than 2#L. ,or e6ample, the damper of the
,., can be narrowed down to about 2#L. In such a case, it is possible to make significant
savings in energy by ad!usting the number of revolutions by changing either the pulley ratio
or the gear ratio.
;"< =peration of the air compressor system
%< ,low control and air leakage control
-he air compressor room is located at the center of the mill and, from there, compressed air is
delivered to each plant. 7hile such an integrated system has an advantage in that the facilities are
utilized efficiently and the operation is centrally controlled, long pipelines are required and, as a
result, air leakage, pressure loss, and imbalance between the supply and the demand are apt to
occur. -herefore, meticulous control is required.
Is it sure that little amount of air is used while the mill is closed. ,low control and periodic air
leakage checks should therefore be implemented.
(ven in newly installed pipelines, air leakage of +-2L usually occurs. &s time passes, the
leakage may e6ceed %#L and sometimes reaches +2L. &ir leakage mainly takes place at
piping !unctions and around equipment seals.
=perating the compressor when the plant is out of operation, using the method shown in
,igure I@-"-%", can check the amount of leakage.
-o check the air leakage, close all the ends of the piping completely and start the operation of
the air compressor. 7hen the pressure has reached a specified value, stop the compressor. -he
changes in discharge pressure occurring after the start and finish of compressor operation are
shown in ,igure I@-"-%". In the figure, 4% is the pressure used, which is usually set to around
4%-4" N #.#2 - #.%M4a.
&ppro6imate air leak rate, :, is calculated by the following equationG : N t%/;t% V t"< O
%##bLc
IV"?
(stimation of the &ir leakage
:G &ir leakage ;L<
t%
0.% Setting pressure
p1 = Specified pressure
0.& Working pressure range
p1 - p2 = 0.05~0.1MPa
t2 p2 = Specified pressure
0.!
t2 4ressure descent
0.'
:N O %## ;L<
4ressure ascent
t%Vt"
0.
'mall leakage
:arge leakage
-ime ;min<
4ressure 3hange in &ir 3ompressor
,igure I@-"-%" 3heck for air leakage
"< .ryer
&dsorption type dryers are installed. -he adsorption type dryer can, by purging ad!ust, be used
for electronics production plants and suchlike where a very low dew point is required. In such
a dryer, valuable compressed air may be uselessly released by purging if the dew point is set
e6cessively low. It is recommended that the dew point control be reviewed, following these
stepsG
- 3onfirmation of the required dew point.
- &d!ustment of the purging volume ;purging time<
- Investigation of the possibility of using a heating type ;or refrigeration type< dryer
;either in a changeover or in parallel use<.
;+< (6amples of successful energy conservation in the distribution system ;energy conservation in
the pump station and improvement of the power factor<
%< Reduction of distribution loss
Aey points are as followsG
.istribution loss, 7 b7c, is e6pressed by the following equationG
7 N I
"
O r
7here, IG current b&c, and rG resistance of the distribution line bdc.
-o reduce the distribution loss, it is necessary to reduce the current ;I< and the resistance of the
distribution line ;r< in the above equation.
a. -o reduce the currentG
- 'upply electricity with a high voltage to the center of the load, and
- Raise the power factor.
b. -o reduce the resistance of the distribution lineG
- Make the length of the low voltage distribution line as short as possible.
IV"B
4- A(R-&' has constructed an ideal system for the water feed pump station, which satisfies all
these conditions. &ctual measures taken are as followsG
"< 4ump station
-he water feed station is located at the water reservoir about %km from the mill, and five
pumps are installed.
,igure I@-"-%+ shows the equipment connections involved by means of a one-line diagram. -he
following are measures taken to ensure the reduction of distribution lossG
a. :ong distance feed with a high voltage ;9k@<
,or a certain amount of the electrical power supply, increasing the voltage, resulting in a
reduction in distribution loss, can decrease the current.
b. Installation of transformers as close as possible to the load
0y transmitting power with a high voltage as close as possible to the load, it is possible to
shorten the length of low voltage distribution line requiring a large current so that the loss in
the low voltage distribution line is reduced.
c. Installation of phase-advance capacitors
4hase-advance capacitors improve the power factors of motors so that the current that flows
through the distribution line is reduced. -he installation of phase-advance capacitors has
reduced the current from +"#& to "?#&, resulting in a decrease in the loss caused by the
distribution line to >>L ;N ;"?#/+"#<
"
<<.
Cigh voltage line
9k@
'tatic 3ondenser
+?#@
:ow voltage line
M
M
'.3
'.3
4 4
63kvarB5
200kWB5
,igure I@-"-%+ 3onnection diagram for the pump station
IV+#
+. 7alk-through (nergy &udit at the 4atal 1rati 'pinning Mill of Industri 'andang )usantara
7e visited a second new plant in the neighborhood, nit 4atal 1rati -e6tile ;'pinning< Mill, to
make a walk through energy audit.
'ince the visit to the 4- A(R-&' 4aper Mill was scheduled early in our trip, we asked M=( to
arrange another visit to a new plant in the neighborhood. Cowever, it was only three days before the
departure of the investigation team that the visit to the mill was confirmed. &lthough the visit was
arranged at short notice, the mill staff accepted the visit by the investigation team in a friendly and
cooperative manner.
4atal 1rati 'pinning Mill is very eager to save energy, having organized the (3 3ommittee in %BB9.
&fter hearing a description of their activities, we made a tour of the plant and then gave our
comments. -his mill is a spinning mill mainly used for polyester yarn manufacture. 3otton and
rayon yarn manufacture is carried out in other factories belonging to the same company.
+.% @isit to the 4atal 1rati 'pinning Mill
;%< =utline of the visit
)ame of the companyG 4- Industri 'andang )usantara
)ame of the millG nit 4atal 1rati
-ime and date of visitG .ecember ? ;-hu< BG##-%9G##
:ocationG 8l. Raya 1rati AM.%$ 1rati, 4asuruan 9>%?$, 8awa -imur, Indonesia
;&bout ?#km southeast of 'urabaya<
3ompany staffG Mr. )aulila, 1eneral Manager
Mr. Ir. Mulyono, Manager -eknik
'i6 staff members of (3 3ommittee ;-eam Aonservasi (nergi<Y
Y&lthough called a H3ommitteeI, it is actually a department in the company
organization.
Investigation team membersG
Indonesia, M(MRG
Mr. 4arlindungan Marpaung, Inspector, .ept. of (nergy (fficiency
8apan, International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano, and Cideyuki -anaka, -echnical (6perts
;"< =utline of the mill
Raw materialG polyester yarn. ;&lthough they have other factories that handle rayon and cotton raw
materials, the investigation team only surveyed the polyester mill.<
4roductG 4olyester thread
4roduction capacityG $##t/month ;medium size for an Indonesian spinning mill<
&ctual productionG 4roduction has increased to about +9#t/month, which is
about B#L of total capacity.
)umber of employeesG 2+9 ;including operators working three shifts in four
groups<
IV+%
&rea of the millG "9ha
-ype of operationG 3ontinuous operation, including nights, holidays and
weekends.
4eriodic maintenance and repair are carried out sequentially by suspending
operations once every three months, for four hours each time.
(nergy usedG (lectricity only ;purchased from 4:)<
;+< 4roduction process
-he production process consists of the following eight stepsG
a. 0lowingG Raw material ;yarn< is aspirated by air blowers and then transported
through a duct before being compacted on a roller-beater.
b. 3ardingG ,ilaments with a diameter of about " cm are formed ;then stored in
a drum type vessel<.
c. .rawingG &fter carding, eight strands of filament are simultaneously on one
side of the machine, which are intertwined to form threads.
d. 'peedG -he threads are further drawn and wound on longitudinal bobbins.
e. Ring 'pinningG ,inished te6tile threads are formed in this step, using several hundred
bobbins connected to a single machine.
f. 3one 7indingG -he final twist is given to the threads and the threads are wound
around cone type bobbins.
g. 4acking ;not investigated.<
h. 'torage ;not investigated.<
;$< (nergy being consumed and energy-conservation activities
&s described above, energy-conservation activities started in %BB9 and successful results have
been achieved. Cowever, power costs still account for $>L of the total production costs.
Installed 3apacity of power receiving systemG ",>>#k@&
.iesel 1enerator 3apacityG %,"2#k7O"units, +##k7O%unit
Mr. Mulyono ;-echnical Manager< is the energy manager ;director of the (3 3ommittee<.
&lthough some managers and staff members from other departments are included as members,
the committee mainly consists of about $# dedicated personnel with knowledge of technology
and electricity and who have been recruited from within the mill and trained especially for their
role on the committee. -he committee members are divided in half into the following two
groupsG
1%G In charge of process mattersG patrolling the plant periodically to check processing
equipment and to promote efficiency.
1"G In charge of utility mattersG In addition to the same responsibilities relating to utility
equipment, maintenance is within the scope of !ob.
IV+"
-he following improvements in unit cost have been achieved as a resultG
%BB9G B2#k7h/0ale-4roduct ;% 0ale N %?%kg<
"##"G ?2#k7h/0ale
"##2G >2#k7h/0ale ;4eak :oadG 92#k7h/0ale<
;2< =n-site survey and impressions
,irst, the flow of the process from raw materials to products was surveyed, and then the utility
facilities ;air conditioning, chillers, air compressors, power receiving system, generators, etc.<
were checked.
It was e6plained that the members of the (3 3ommittee patrol every hour to check the
temperature and humidity and correct the environment if it is outside the specified range.
Cowever, it was hot and humid when we visited.
1eneral HhousekeepingI of the plant seemed to be insufficient, and the 8apanese H2 'JsI is
needed to implement more thoroughly.
%< Illumination
&ttempts to save energy could be seen, such as the diligent reduction in the number of or
e6tinction of fluorescent ceiling lamps in use. 'ome of the regular bulbs are also being
replaced with fluorescent lamps.
"< &ir conditioning
-he control targets for temperature and humidity are from +#`3 to ++`3 and 92L respectively, and
wet and dry bulb thermometers are provided to monitor the workplace environment. Cowever,
there are no actual facilities to control the humidity.
'ince the workplace environment for spinning and winding must be carefully controlled, cold
water is provided by chillers, and two large-scale &C units are installed.
'ince it was the rainy season, the temperature was not too high and the two water-cooled
turbo chillers ;?##R-< were not operating. -hey are operated during the dry season. sing the
&C, cold water for showering is prepared by e6changing heat with the cold water of the
chiller, and the cold water is then used to directly e6change heat with the air to provide cool
air for the building.
&lthough the system is basically a circulating system, it is possible to take in outdoor air or
e6haust indoor air according to the enthalpy relative to outdoor air. -he temperature of the
incoming air on the day of our visit was "B.+`3.
+< &ir compressor
-he main compressors used are four screw type compressors driven by +#k7 motors. -hree
compressors were running on the day of the visit and the discharge pressure was #.>"M4a at
the receiver tank. -here was very little pressure fluctuation between the screw type
compressors.
&lthough the person in charge e6plained that the compressors were controlled by load-unload
control within the range of #.92 to #.?M4a, no load-unload action was observed while we
were on the site ;about "# minutes<. -he air is supplied to the load equipment through a dryer.
Cot air is directly released into the environment and the condition of the indoor atmosphere
IV++
was fairly good when we visited. -here is both a compressor line and a blower line, and it
seems that the discharge pressure of the compressors can be reduced.
$< 4ower receiving system and the emergency generator
-he electricity is received at "#k@ and the system consists of two linesG one line that reduces the
voltage to +.+k@ using two main transformers ;%,9##k@&< and another line that directly reduces
the voltage to the low voltage used in the plant using a one-stage transformer.
'even low-voltage transformers decrease the +.+k@ to +?#@. -his two-stage step down
appears to be redundant and may be a historical result. -he main transformers are of an old oil-
immersion type equipped with a conservator and should be replaced shortly. It is also
necessary to reconsider the distribution system when doing this.
Cowever, since the output voltage of the emergency generator is +.+k@, some consideration
must be given to the type of linkage used.
&lthough all the feeders are equipped with ammeters, watt-hour meters are only provided for the
three systems used for receiving power. (nergy meters are installed in all the workshops. Mr.
Mulyono e6plained that measurements were being made, but no measuring system was seen for
any of the utilities, including the power receiving system.
4atal 1rati Mill submitted the following materialsG
H4ower 'ingle-:ine .iagramI, H4lant :ayoutI and H'pecifications for ma!or facilitiesI
+." &dvice and Recommendations for ((53 &ctivities
&t the end of the meeting, the investigation team gave the following advice and commentsG
;%< Measures suggested ;in order of priority< based on the analysis of the power consumption data.
&lthough it is appreciated that the members of the (3 3ommittee are dedicated to the
patrolling and collection of data on equipment use, how the data are analyzed is also important.
,or e6ample, the data may be classified according to the processes and areas concerned, but
they should be further classified according to use ;such as illumination, air conditioning,
compressed air, and pumps<. -he data should then be analyzed in order to set priorities based on
their importance and effectiveness for energy conservation.
;"< Aey points for selecting appropriate operating conditions and facility capacities
In the on-site survey, it was found that some facilities are oversized for the capacity actually
required. It is necessary to ad!ust their size according to actual operating conditions. It is also
necessary to maintain high efficiency in accordance with the fluctuating load. =ne e6ample of
an inappropriate specification is the air compressor outlet pressure of #.?M4a. -his value is too
high.
Mr. Mulyo said that #.?M4a was required to prevent thread breakage in cone winding, but the
pressure gauges for compressor operation and the receiver tank actually indicated #.>M4a.
;+< Aeeping efficiency high by carrying out regular maintenance
Maintenance plays an important role in keeping (3 efficiency high. ,or e6ample, periodically
IV+$
checking the leakage of compressed air pipelines and repairing when necessary is an effective
means of ensuring efficiency. 1rati 4lant e6plained that they check for leakages once a week.
;$< Investment in energy conservation is necessary in the future
It seems that 1rati Mill has either not invested in energy conservation at all or has carried out
only a small investment in energy conservation which has now finished. ,urther investment is
required to promote (3 in the future.
;2< &dvice and comments from Mr. 4arlin ;M=(< are as followsG
%< =penings on the vacuum suction part of the roller-beater used in the blowing process should
be closed.
"< 'uction air for the ventilation fan in the air compressor room should be taken directly from
outdoors ;where the temperature is lower than that of indoor air<.
+< @entilation in the main transformer room should be improved in order to lower the ambient
temperature.
+.+ Recommendations for Improvements and (6pected (ffects
-he following are recommendations for improvements proposed by (338 ;in addition to the
advice and recommendations described above<.
;%< 3ontrolling the cold water temperature of the turbo chiller
-wo ?##R- turbo chillers are installed. &lthough detailed operating conditions are not known, the
general principles of energy conservation using cold water and cooling water are as followsG -he
following conditions are required to increase the 3=4 of refrigerator operationG
- :oad factor ;N capacity ratio< should be higher.
- 3ooling water temperature should be lower.
- 3old water temperature should be as high as possible.
4ower consumption is e6pressed by Htotal power N power of cooling water pump V power of
cooling tower V power of refrigeratorI. &ll these components must be considered
comprehensively.
1enerally speaking, in any turbo refrigerator controlled by speed, the total power consumption drops
when the cooling tower is not controlled. Cowever, it is said that when controlled only by the
suction vane, the total power consumption still drops even when the cooling tower is
controlled. =ptimum operation patterns therefore need to be set, in relation to the season, and both
alternatives compared.
%< (nergy conservation by raising the temperature of the cold water
,igure I@-+-% shows the relationship between the cooling water temperature, cold water
temperature, and power required for the motor ;corresponding to power consumption<.
-he graph shows the required motor power when the cold water temperature and cooling
water temperature are changed ;taking the base cold water temperature as +" and base
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cooling water temperature as 2<. 7hen the outlet temperature of the chiller is raised from 2
to > and then to B, the power consumption ;motor power< decreases to B9L and then to
B"L if the cooling water temperature is maintained at +".
-his means that raising the cooling water temperature when the load is light can reduce the
power consumption.
%%#
%## %##
B#
?#
>#
B9 B"
?2
Inlet -emp.
of 3ooling 7ater ; <
+"
+#
"?
"9
2 > B %%
=utlet -emp. of 3hiller ; <
,igure I@-+-% Relationship between cold water temperature cooling water temperature,
and motor power ;turbo refrigerator<
"< (nergy conservation by changing the cooling water temperature
-he performance of a cooling tower depends on the wet bulb temperature. -able I@-+-% shows
meteorological data from the 'urabaya region.
-able I@-+-% -emperature and humidity in the 'urabaya region
Items Ma6. Min. &ve.
&mbient -emperature ;e3< +" "B +#
Relative Cumidity ;L< ?# 22 92
7et 0ulb -emperature ;e3< "B "% "2
-he wet bulb temperature was calculated from ambient temperature and relative humidity. -he
wet bulb temperature varies between "%e3 and "Be3. ,igure I@-+-" shows the relationship between
the wet bulb temperature and cooling water temperature at the outlet. 'ince the cooling tower
is usually operated with Tt N 2e3, the minimum temperature of the cooling water is "?e3 and the
ma6imum temperature is ++e3.
0y lowering the cooling water temperature from +"e3 to "?e3 while the cold-water
temperature is kept at Be3, the refrigerating capacity increases by about ?L ;N %-?2L/B" N
#.#?< so that the motor power required decreases.
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It depends on the method used to control the capacity of the refrigerator whether it is better to
save the energy of the cooling tower by fi6ing the cooling water temperature at +"e3 or to
save the energy of the refrigerator by lowering the cooling water temperature according to the
decrease in the wet bulb temperature. -he cooling tower and refrigerator should both be taken
into consideration when choosing the optimum operation pattern to use in order to save power.
+2
+#
"2
"#
%2
? %#

%" %$ %9 %? "# "" "$ "9 "? +#

Wet Bulb Temperature (e3)
,igure I@-+-" Relationship between the wet bulb temperature and
cooling water temperature of the cooling tower
;"< &ir compressor
,our screw type compressors with +#k7 motor each are operated with the control of the
number in operation. &lthough there are some problems in the treatment of waste heat, no
significant problems have been identified in the arrangement of the facilities and the installation
environment. -he following items should, however, be taken into consideration in order to
promote energy conservationG
%< .ischarge pressure and power consumption
-he control range of #.92 - #.?M4a for the discharge pressure is relatively high.
& decrease in the discharge pressure would be desirable, based on the required pressures for
equipment loading.
4ossible measures areG
:ow-pressure loadG Reduction of pressure using a pressure reducing valve.
Cigh-pressure loadG Investigation of the possibility of increasing the pressure
using booster.
&ir pressure for the cleaner can be reduced to about #.+M4a.
"< &ir pressure and air leakage
3ompressed air from the compressors is supplied to all equipment through pipelines, resulting
IV+>
in pressure loss caused by friction in the pipelines and flow loss due to leakage. -he pressure
loss is ad!usted considering the piping costs and the flow loss can be controlled, aiming at
zero leakage. 4lease refer to Item " for details of the leakage measurements and
countermeasures.
;+< &utomation of collection and control of data
:et us now discuss energy conservation in the production line. (nergy consumed can be divided
into effective energy that is utilized for the production process, and ineffective energy that is
wasted. Ineffective energy derives from defective products, waiting time loss, loss caused by
machine faults, and material loss. ,igure I@-+-+ shows effective energy and energy loss in the
production line.
Machine
Material loss
problems
(ne rgy
los s
(ffective
(nergy
(nergy
loss
.efect
7aiting time
,igure I@-+-+ (ffective energy and energy loss
'ince there is little material loss in 4atal 1rati Mill because materials are not processed there, other
losses are discussed below.
%< :oss due to defective products
-he energy that has been used to produce defective products represents the ineffective
consumption of energy. 3onsequently, activities for improving yield are also
energy-conservation activities. &mong the factors that affect yield and quality, the following are
those related to environmental control of the workplace.
In 4atal 1rati Mill, the temperature and humidity in the plant are periodically checked and
controlled. Cowever, there are concerns about the control system used and the speed of
response because the number of sampling points is limited and the data is collected manually.
'ince temperature and humidity are important factors that affect quality and yield, a system is
required that can constantly monitor and maintain the environment. 4articularly in workplaces
where products are produced on a continuous basis, it is necessary to assess the situation and
take immediate measures in an emergency. 7ith this in mind, the ne6t step that 4atal 1rati
4lant should take is to automate the data collection and control procedures.
-emperature and humidity sensors are easily obtained and there is plenty of watt-hour meters
IV+?
available equipped with a data transmission function. It is recommended that a system be
constructed utilizing such functions.
"< :oss due to machine breakdowns and waiting time
-he energy lost due to machine breakdowns and waiting time is ineffective energy that does not
contribute to production. 7aiting time is a matter of production scheduling and the
occurrence of machine breakdowns is a matter of maintenance.
4atal 1rati e6plained its system of preventive maintenance in which maintenance is
implemented periodically so that breakdowns are avoided. -his system is recognized as being
very effective. It is suggested that this maintenance system could be improved further by
adding an automated system for the trend control of deterioration and abrasion of equipment.
IV+B
$. 'eminar and 7orkshop
$.% 'ummary
& seminar 7orkshop was held on .ecember %", "##2 ;Mon<.
&t the 'eminar 7orkshop, the Conorable Mr. 'oekanar of the Ministry of (nergy and Mineral
Resources made the opening speech and .r. 7eerawat, .irector 1eneral of the &'(&) 3enter for
(nergy ;&3(< gave the closing speech. -here were about 9# active participants and the
7orkshop was very successful and productive.
;%< .ate and time
.ecember %", "##2 ;Mon< ?G+#G registration %>G+#G closed
;"< @enue
1ran Mahakam Cotel, ", ;0all Room<, 8akarta, Indonesia
;+< Reports presented on the 'eminar and 7orkshop
-he program of the 'eminar 7orkshop is described in Material )o. .-%%%.
&3( reported on the ((53 activities of &'(&), and (338 e6plained the guidance on energy
conservation matters in the industry. It seemed that private participants were disappointed that the
Indonesian government did not report anything at the seminar.
-he Indonesian pulp and paper mill for which we made the follow-up energy audit submitted a
report and other &'(&) countries such as :ao 4.R, Malaysia, 4hilippine and -hailand also
made presentations.
;$< 4articipants
Ma!or participants were as followsG
IndonesiaG
Mr. 'oekanar, 'ecretary for .irector 1eneral, M(MR, .irectorate 1eneral of (lectricity
and (nergy tilization ;.8:4( or .1((<
Ms. Maryam &yuni, .8:4(, M(MR
Mr. Ir. 4arlindungan Marpaung, Inspektur Aetenagallistrikan, .8:4(, M(MR
Ms. 'ut!i Rahayu, -ariff (6pert, Marketing .ivision, 4):
Mr. .!oko, Manager of R 5 ., 4- Aertas :eces ;4ersero<
&bout 9# Indonesian delegates from government offices and various industries attended the
seminar. &lthough we asked to see the list of participants later, in an electronic form, we have
not received it yet.
&3(G
.r. 7eerawat 3hantanakome, .irector 1eneral Mr.
3hristopher Kamora, 4ro!ect Manager
Mr. Ivan Ismed, 4ro!ect =fficer
Mr. 8unipard
Ms. Maureen
IV$#
Ms. -ewi
:aosG
Mr. @anthong Ahamloonvylayvong, .eputy Manager of )am )gum Cydropower 4lant,
(lectricite du :aos ;(.:<
MalaysiaG
Mr. 4ubalan, (nergy &uditor, 4-M
4hilippinesG
Mr. Marlon .omingo, .=(
-hailandG
Mr. &rthit @echaki!, Managing .irector, (6cellent (nergy International 3o., :td.
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical e6perts
$." Results of the 'eminar and 7orkshop
;%< =pening ceremony ;congratulatory address and opening speech<
%< 'peech by &3(
.r. 7eerawat, (6ecutive .irector of &3(, stated in his speech that, in recognition of the
recent high price of crude oil, energy conservation was now more important than ever. Ce also
e6plained that the basic plan for the period from "##$ to "##B was decided at the &'(&)
Ministers Meeting held in Manila last 8uly and he then introduced the activities of 4R=M((3 and
the outline of the program for the day.
"< (338
Mr. -anaka, representing 8apan ;M(-I and (338<, made a speech. Ce e6plained the
significance, history and recent developments of this pro!ect, and described 8apanJs
cooperation with and contribution to &'(&).
+< .8:4(
-he Conorable Mr. 'oekanar made a speech e6plaining the energy-conservation policies of the
Indonesian government and announced the opening of the meeting.
;"< 'ession %G 4olicies and initiatives on ((53
%< =verview of &'(&) 4lans and 4rograms on ((53 ;.r. 7eerawat, &3(< ;Material )o.
.-%"><
-he establishment of &'(&) in %B9> and its subsequent development was e6plained from the
viewpoint of geopolitics, and the history and the present role of &3( were outlined. Mention
was also made of H&'(&)V+I that had been held in Auala :umpur !ust before the seminar.
Ce then introduced the outlook for primary energy every 2 years until "#%#, in &'(&) region
and predicted that the consumption of oil would decrease and that of natural gas would
increase. ,urthermore, he remarked that the estimated amount of investment necessary for the
development of energy resources in each &'(&) countries adding that the amount of
IV$%
Indonesia is enormously large. Ce also reported that basic principles are being negotiated with the
( on the (nergy 3harter 'ecretariat. 'i6 basic strategies for Multinational 3ooperation in the
period between "##$ and "##B were also e6plained.
"< Initiatives and 4rograms of (338 on ((53 in Industry in 8apan ;Mr. -anaka, (338<
;Material )o. .-%"?<
Mr. -anaka outlined the status of energy consumption in 8apan, the history of energy
conservation, methods of energy conservation, designated factories, qualified persons for
energy management, (338 activities such as energy audit, education and training courses, and
presented successful cases of energy conservation and the award system.
;+< 'ession "G 4resentation of successful cases of ((53 in industry
%< 4aper and pulp industry, Indonesia - Mr. .!oko
-he attendees seemed to be interested in the e6planation given about the conversion from
heavy oil to natural gas and then to coal. ,uel prices largely depend on governmental policies
;such as subsidies and ta6es< so it is necessary to note the difference between countries. -he
report was made based on Material )o. .-%%2 together with Material )o. .-%"B HRecent
difficult situationsI, as e6plained when the investigation team visited the mill.
"< Cydroelectric power generation, :aos - Mr. @anthong ;Material )o. .-%+#<
-his report was the same as that presented at the 3ambodian 4R=M((3 'eminar 7orkshop.
)eatly arranged data since %B>" were reported in a series of graphs.
+< 1lass and te6tile industries, Malaysia - Mr. 4hubalan ;Material )o. .-%+%<
-his report was about the glass industry ;81 3ontainers< and the te6tile industry ;&M.0<. 7hat
impressed us was that 4-M is functioning as an (nergy &uditor and that high quality portable
measuring instruments are being used.
$< 'teel industry/cement industry, 4hilippines - Mr. .omingo ;Material )o. .-%+"<
-he present situation of the 4hilippine steel industry and the activities of two companies ;a
rolling mill company and a steel sheet coating company< who received .on (milio &bello ((
&wards in "##2 were reported. -his &ward honors distinguished companies involved in ((
activities in the 4hilippine industry. In addition, some comments were made on the cement
industry, based on information Mr. .omingo had received from one of his friends.
2< 0iomass, biomass cogeneration, and ('3=, -hailand - Mr. &rthit ;Material )o. .-%++<
Mr. &rthit, the president of ('3=, talked about cogeneration, which is his favorite sub!ect,
and about ('3= ;rather than the scheduled topic concerning a caustic soda plant<. Ce was
asked to fill in for Mr. 4rasert ;,4 of -hailand< !ust before the 'eminar. &lthough his
presentation was not related to successful cases, his story was highly instructive, including %#
A,' ;Aey ,actors for 'uccess<. -he attendees showed much interest and there were many
questions.
;$< 'ession +G -he 7ay ,orward
%< 0arriers and Measures for the implementation of ((53 - Mr. =gawa ;Material )o. .-%%><
IV$"
-his presentation was based on past data, with the Indonesian paper industry in mind and
referring to the reports submitted earlier that day.
"< -echnical .irectory - Mr. &mano and Mr. Ivan, &3( ;Material )o. .-%+?<
-he purpose, method of preparation and format of -. were e6plained, and e6amples were
presented to help develop a better understanding. Mr. Ivan presented several actual e6amples
of -. sheets.
+< .atabase/0enchmark/1uidelines for Industry - Mr. =gawa ;Material )o. .-%%B<
& plan to construct an &'(&) database by linking the databases of participating countries
was outlined.
;2< D5& 'ession
Duestions and answers were e6changed at the end of each session. -here were as many as "#
brisk questions in total. -he following are some of those questions and answersG
DG Cow can Indonesian private companies ask (338 for an energy auditR ;-here were
several similar questions.<
&G (338 acts within the framework agreed upon between governments. ,or general issues,
it is recommended that you consult the government of your own country or &3(.
DG 7ho funds the H:ow Interest :oanI which is one of the incentives for (3 in -hailandR
&G & gasoline ta6 of #.#$ baht/: is collected and this is used as an energy-conservation
fund. -he government lends the money to private banks with interest set at #.2L. -he
banks then loan this money to those who implement (3, with interest set at $L.
Many other questions, in addition to those described above, were also asked relating to bio-
diesel, risk management of ('3=, time of completion of -., etc.
;9< 3losing speech
&fter the comments made by the three @I4s ;including Ms. Maryam, speaking on behalf of Mr.
'oekanar of Indonesia<, .r. 7eerawat closed the meeting with a final speech.
IV$+
@. 0runei ;3ement Industry and ,ood 4rocessing Industry<
%. =utline of the &ctivities
-his survey includes a follow-up energy audit of a cement company whose initial ;4hase %< energy
conservation audit was carried out in ,ebruary "##%, and a new walk through energy audit
implemented for energy conservation at a beverage factory. & seminar workshop was also held in
0andar 'eri 0egawan ;0'0<, 0runei, at which case study of energy conservation activities in
various industries were reported.
-he follow-up energy audit and survey of the cement factory was only a walk through energy audit and
no measurements were carried out using instruments. Many people participated in the diagnosis
including ,4 representatives from the government. (338 played a key role in the energy audit and the
company presented the results of its energy conservation activities over the past five years. -here
were many participants in the energy audit of the beverage factory as well and several people, including
the factory manager, also participated in the seminar workshop.
%.% Implementation 4eriod
%$ to %> .ecember "##2
%." 'ites of implementation
,ollow-up investigationG
)ew walk through energy auditG
'eminar workshopG
%.+ 'chedule ;Material )o. .-%#"<
3ement factoryG 0utra Ceidelberg 3ement '.) 0C.
0everage factoryG Aingston 0everage 5 3reamery 'dn.
0hd
3enter 4oint Cotel, 9, ;4urple 8ade Room<, 0'0, 0runei
.arussalam
.ecember %$ ;7ed<G ,ollow-up energy audit of the cement factory of 0utra Ceidelberg
%2 ;-hu<G walk through energy audit of Aingston 0everage 5 3reamery
%9 ;,ri<G =bservation tour of oil fields in 'eria ;7estern 0runei<. ;=bserved the oil
fields from the car<
%> ;'at<G 'eminar workshop
%.$ Relevant 4ersons
&3(G
.r. 7eerawat 3hantanakome, (6ecutive .irector Mr.
Ivan IsmedG 4ro!ect =fficer
0runeiG 4rime MinisterJs =ffice, .('
Mr. C! mar bin C! Mohd -ahir, Cead of (nergy 4olicy 5 4lanning
@%
Mr. Ca!i &bd 'hawal bin Paman, (nergy .ivision
Mr. 4g. Kamra ;4g. stands for Royal ,amily.<
Mr. Ismail bin C!. Mohd. .aud, Cead of 'afety and (nforcement nit
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
1eneral situation in 0runei .arussalam
;%< 1eneral information on 0runei
- &reaG 2,>92km
"
- 4opulationG +2#,### ;"##+< ;including foreign residents<
- ReligionG Islam ;national religion<, 3hristianity, 0uddhism, -aoism, etc.
- 'ystem of governmentG limited monarchy
- (conomyG Ma!or industryG petroleum and natural gas
)ominal 1.4 per capitaG 'M%+,$%? ;provisional for "##+<
3urrencyG 0runei dollar ;equal to the 'ingapore dollar, % 0runei dollar
is about X92, as of 8anuary "##2<
-rading ;"##+<G
(6portsG 4etroleum and natural gas ;about B#L of total e6ports< are
e6ported to 8apan ;$%L<, Aorea ;%%L<, and -hailand ;BL<.
-otal e6port value is 'M$.$ billion.
ImportsG Machinery, transportation, industrial products, and
foodstuffs are imported from 'ingapore ;"#L<, Malaysia
;"#L<, .'.&. ;%"L<, and 8apan ;%#L<.
-otal value of imports is 'M%.+ billion.
- (conomic situationG &bundant petroleum and natural gas resources maintain a stable economy
and a high income level. Cowever, 0runei aims to diversify its economy by
developing downstream industries related to petroleum and to reduce its
e6cessive dependency on energy resources.
In the past, 8apan provided =.& mainly in the form of technical development, but
this assistance was terminated in 8anuary %BB? after 0runei became an =.&
graduate country in 8anuary %BB9.
;"< (nergy situation
0runei is a producer of petroleum and natural gas, e6porting significant amounts to 8apan,
Aorea and other countries. -here is a monument in the oilfields of 7estern 0runei that
commemorates the production of one billion barrels of petroleum in "###. -he price of
gasoline at .ecember "##2, was 0M#.2/: ;N 'M#.+"/:< and electricity price was
0M#.#>/k7h ;N 'M#.#$2/k7h<.
@"
". ,ollow-up 'urvey of the 3ement ,actory of 0utra Ceidelberg 3ement ;0C3<
".% =utline of the 3ement ,actory of 0utra Ceidelberg 3ement ;0C3<
;%< =utline of the company
)ame of the companyG 0utra Ceidelberg 3ement '.) 0C. ;a 2#-2# !oint venture with a
1erman cement company<
)ame of factoryG 0utra Ceidelberg 3ement ;0C3< ,actory
:ocationG :ot +, 'erasa Industrial &rea, Muara 0-%>"?
4roductG =rdinary 4ortland cement ;shipped by tank trucks and packed in
paper bags<
&mount of productionG ""#,###-"2#,### t/y
)umber of employeesG %%# ;,ebruary "##%<
7orking systemG -hree shifts, eight-hours per shift
;"< -he cement production process and energy consumption
-he following is a summary of what we learned from our two visitsG
%< =utline of the operation
0utra Ceidelberg 3ement ,actory ;0C3< was established in %BB+. It is about a +#-minute
drive from 0andar 'eri 0egawan, the capital of 0runei, and is the only cement factory in
0runei that specializes in crushing cement. -he company is a !oint venture with a 1erman
company and was originally called 0utra Ceidelberger Kement before it changed its name.
-he production capacity is 2##,### tons per year but the present annual production is only
"2#,### tons due to the stagnant economy. &ll the raw materials, cement clinker and gypsum,
are imported from (ast &sian countries such as 8apan and -aiwan. -he harbor has a water
depth of B meters and permits the berthing of "2,###-ton vessels. 7hile two vessels usually
enter the harbor monthly, only about one vessel enters each month at present due to the low
level of production. -he factory has a production line with a closed-circuit tube mill whose
capacity is >" tons per hour and a high performance =-'(4& ;=noda type< separator.
'torage facilities include a clinker silo, storage of gypsum, and two cement silos, and
shipping facilities include packers and tanks for loading the materials onto trucks.
-he factory has obtained I'=B##" certification in %BB>, which proves its high level of
quality. Measures are taken for dust prevention, and dust collectors ;of the %-bag
filter/hopper type<, dust prevention nets, and water sprinklers are provided.
"< ,acilities
3linker storage siloG 2#,###t O %unit
1ypsum storageG 9,###t O %unit
,inishing millG
-ype of finishing millG 3losed-circuit type tube mill O %unit
@+
3rushing capacityG
Mill sizeG
Mill motor capacityG
'eparatorG
Mill bag filterG
Mill bag filter fanG
>"t/h
$,"##mm diameter O %#,2##mm length
",?##k7
=-'(4& )-%2## type O +,###mm diameter
.ust collecting capacity %#,###m
+
/h O %unit
%%#,###m
+
/h O >##mm&q O +22k7 O %unit
3ement transport equipmentG ,A screw pump ?#t/h O 22k7 O "units
3ement storage siloG 3apacity >,###t O "units
4ower receiving facilityG Receiving voltageG %%k@, transformerG >,2##k@&
+< &mount of energy consumption
(lectricity is the only energy source. -able @-"-% summarizes the production, power
consumption, and unit consumption of electricity from "### to )ovember "##2, based on the
data provided by 0C3.
-able @-"-% (nergy consumption ;"### to "##2<
Improvement
Items "### "##" "##$ "##2 ;"##$/"###<
;%*%%< b"##2/"###c
4roduction 3ement "+",%>$ "+%,9B> "$>,>++ "%+,"$# ;%.#><
;t/y< b%.#c
(nergy (lectricity ;%.%+<
consumption ;M7h/y< %$,>"+.$ %$,"B9.$ %9,9>$.9$ %$,%2#.? b%.#2c
;(ntire 4lant<
(nergy (lectricity 9+.$" 9%.># 9>.+% 99.+9 ;%.#9<
Intensity ;k7h/t< b%.#2c
(nergy 4rice (lectricity #.#$2 #.#$2 #.#$2 #.#$2 ;%.#<
;'M/k7h< b%.#c
"." =utline of the Results of the 4revious (nergy &udit of 0C3 3ement ,actory
-he aim of the previous energy audit was to survey the cement crushing line. -he results of
temperature and pressure measurements were close to specified values, which suggested fairly
good operating conditions. 7e recommended implementing the following items to further
improve energy efficiency under these operating conditions.
;%< pgrading and maintenance of sensors and meters ;for pressure, temperature, and electric
power<
-he piping of pressure gauges had been left in a clogged condition, electrical meters were not
working, and all the sensors and meters were uncontrolled. 'ince it is very important that
meters and sensors function correctly and without error in order to ensure the normal and
@$
efficient operation of facilities, as well as to prevent accidents, daily checks of measured values and
periodic calibration of all instruments are required.
;"< tilization of the e6haust from the dust collector as secondary air for the =-'(4&
&lthough ambient air is used as secondary air for the =-'(4&, the specification of the =-'(4&
permits the use of air containing dust. .edicated dust collector ;bag filter< is installed in front
of the mill to collect dust from the clinker hopper and the gypsum hopper. 'ince this dust
collector is located close to the =-'(4&, connecting the dust collector and the secondary air
duct of the =-'(4& with pipelines can use the e6haust from the dust collector. -his reduces the
operation of the dust collector and saves power. ,urthermore, maintenance of the dust collector
is no longer needed so that maintenance costs are also reduced. -he annual saving in power
consumption ;$+.?M7h/y< and maintenance costs could total 'M2,+##.
;+< 3hanging the method of cement transport
& screw pump, which is a type of pneumatic conveying system, is used for the transport of
cement to the storage silo. 1enerally speaking, pneumatic conveying systems ;such as airlifts
and screw pumps< consume about three times more energy to transport the same amount of
cement than mechanical conveying systems ;such as a combination of air slides and bucket
elevators<. -herefore, changing the screw pump to a mechanical conveying system should be
considered. 'avings in power consumption ;%??M7h/y< would reduce the power cost by
'M?,9##/y.
;$< 4reparation of manuals and check sheets for periodic maintenance
-o prevent the malfunction of facilities, periodic maintenance should be carried out. -o do this,
manuals and check sheets that stipulate standards for the repair and replacement of facilities
must be prepared in order to facilitate preventive maintenance.
;2< Measures for preventing any recurrence of breakage in the clinker shoot and gas duct
-he amount of wear on the gas ducts and clinker shoot is remarkable. (ven though this damage is
repaired immediately, the repair work is always done in the same way so that the cycle of wear-
damage-repair is simply repeated. -he actual causes of the damage should be identified in order to
prevent any recurrence of the problem.
;9< .ividing the air layer of the air slide
'ince the long air layer of the air slide is not divided, any breakage of the canvas ;even at a
single point< causes clogging of the raw material all over the air layer so that the operation is
stopped. ,urthermore, once such an accident has occurred, considerable labor and time are
required to restore operations. -he air layers should be divided so that any damage is limited,
thereby enabling the operation to continue.
@2
".+ ,ollow-up (nergy &udit
7e visited 0C3 3ement ,actory to carry out a follow-up energy audit on the progress made in
addressing the issues raised in the previous visit and to review new activities.
;%< .ate of (nergy &uditG .ecember %$ ;7ed<, "##2, BG## - %9G+#
;"< &udit team membersG
0runeiG 4rime MinisterJs =ffice, .epartment of (lectrical 'ervices ;.('<
Mr. C!. &bd 'hawal bin Paman, (nergy .ivision ;,ocal 4oint<
Mr. Ismail 0in C!. Mohd .aud, Cead of nit, 'afety and (nvironment Mr.
8unidi bin C!. 8afar
Mr. C!. )or &min bin Mohd Passin
Mr. C!. 'hamshul Kamicse bin C!. 'abtu
Mr. &hmad bin C!. Mohammad
Mr. Mohad. -azim bin &kub
Mr. C!. &ziz bin C!. &li
Ms. .yg. )oor .ina Khrina binti C!. Pahya
0runeiG 4rofessors of niversity of 0runei .arussalam ;0.<
.r. &. D. Malik ;from 4akistan, specialist in materials<
.r. M. 0lundell ;from 0ritain, specialist in electrical engineering<
8apanG International (ngineering .epartment, (338
Messrs. Cideyuki -anaka, ,umio =gawa and Cisashi &mano, -echnical (6perts
;+< &ttendees from 0C3G
Mr. &rdi 7id!a!a, 1eneral Manager
Mr. &chmad Cidayat, Maintenance Manager ;attended the previous audit<
'everal other people
;$< =utline of the follow-up investigation
-he (338 team carried out an energy audit at this factory in ,ebruary "##%, and the present visit
was for a follow-up energy audit. -his was their second e6perience of energy audit for 0C3 since
the start of operations.
&s shown in the list of participants, above, many people from .(' participated in the
investigation, including a lady from 4erth who was studying Hrenewable energyI in &ustralia,
and two professors from foreign countries who had been teaching at the niversity of 0runei
.arussalam for a long time. &ccording to Mr. Paman of 0runei ,4, the reason for the high level
of .(' participation was to train staff members of .(' by =8- in the energy audit.
-he investigation included 0C3Js e6planation of activities relating to energy conservation over
the past five years, confirmation of questions from 0C3, walk through audit, and the
e6planation and discussion of further improvements. 7hen we visited the factory, operation
@9
was under a halt due to a failure at the mill and only the shipping facilities were operating.
'ince we received the written replies to the questions that had been submitted to .(' through
&3( ;included in Material )o. .-%#?< on the way to visit 0C3, the investigation proceeded
smoothly. Cowever, the report on 4hase % had not been sent to 0C3 so it was necessary to
e6plain some of it to them.
7e found that their business prospects were worsening because of low-cost cement imported
from 3hina since 8uly "##2. &s a result, the company is facing a serious crisis with a low
operating ratio of only about 2#L, making it difficult to invest in energy conservation.
-he president of the 1erman stock-holding company only visits the factory once every three
months, for several days at a time, and no technical assistance is provided. -he factory manager,
Mr. 7d!a!a, has had e6perience working at the Indonesian 3ement 3ompany, located about
+#km south of 8akarta. Ce was doing his best to cope with the low operating ratio.
-he government of 0runei announced that .ecember marked the start of an energy
conservation campaign and the activities of 4R=M((3 appeared in newspapers in both
(nglish and the 0runeian language.
7e obtained the following materials from 0C3G
H0rochure about 0C3I, H4ower consumption in "##2I, H-able showing the operating ratio of the
millI and HMaterial for presentation at the seminarI
".$ Results and .iscussion of the Investigation
;%< Recent changes in the situation and operating conditions of the facilities
&s described in Material )o. .-%+2, demand from the 0runei domestic market recorded a
ma6imum value of about >>#,### tons in %BB9 and has decreased since then due to the
economic stagnation in the region. .emand over the past five years has varied from "+#,### to
"2#,###t/y, which corresponds to about 2#L of the ma6imum production capacity of
2##,###t/y.
-he quality of the cement produced by 0C3 is a little higher than that of regular cement due to
the higher content of clinker, but 0C3 is not competitive because their factory is not an
integrated operation provided with its own kiln, and neighboring countries charge import duties
of about 2L. -herefore, it is difficult for them to e6port their products. In addition, ine6pensive
3hinese products ;of uncertain quality<, which are imported ta6-free into 0runei, began to
invade their market in 8uly "##2. &bout "#,### tons of cement has been imported from 3hina.
;"< 'tatus of production and unit consumption of energy
(lectricity is the only energy source used, and this is purchased from the government ;.('<.
-he unit consumption of electricity in the mill is 2#-29k7h/t-product. In "##2, the electricity
consumption was 22.$k7h/t in 8anuary and 2>.Bk7h/t in )ovember, which was a little higher
than usual. -hese values are about ?$L ;on average< of the unit consumption of electrical
power for the whole factory. It was e6plained that consumption would only be $2k7h/t if the
plant had been operating at %##L of production capacity and that the inferior power
@>
consumption was due to the higher quality of the products produced and the increased loss
caused by the starting and stopping brought about by the low operating ratio.
;+< 7alk through energy audit of the cement factory
.uring the plant tour, we inspected the mill and the drive unit in the crushing plant, the raw
material feeders for clinker and gypsum, the dust collectors, electric room, cement transport
devices, receiving equipment for clinker and gypsum, and the storage silo, cement silo, air
compressors and cement-bagging devices. -he facilities were almost the same as those
described in the previous report. -he finishing mill, which is a ma!or user of electricity, was not
operating due to a problem that had occurred two days before. In the previous report, it was
pointed out that the mill motor ;made in 3hina< could not achieve the rated crushing capacity
due to the restriction placed on its use by the bearing overheating. -he motor had therefore
been replaced with one made in the .'.&. &lthough the new motor has only the same capacity
of ",?##k7, it can be used without problems because of its higher design temperature.
-he only facilities operating at the time of the investigation were the cement-bagging machine and
the loading machine for tank trucks. 4roducts were being shipped in bulk using tank trucks and
packed in bags. -hese are 2#kg bags made of paper and printed with a mark indicating that the
product conforms to 0' certification. -he overall impression gained was that the
workplaces were disorganized.
-he factory had received I'=B##% and I'=%$##% certification since the previous energy audit.
-he following comments are based on those issues discussed during and after the walk through
energy audit.
;$< 4ower receiving and distribution system.
(lectricity is received at %%k@ and reduced to a high voltage of 9.9k@ by a >,2##k@&
transformer. Motors ;",?##k7< for the mill and fans ;+22k7< for conveyors are operated with this
voltage. & phase advance capacitor of %,"##kvar is provided for the high voltage line.
Cowever, since costs are not charged to the power factor in this country, the only advantage
gained is loss reduction at the main transformer.
It seems to be insecure that only one receiving transformer is installed. 'ince the factory only
operates at 2#L of full capacity, and from the viewpoint of energy conservation, it would be better
to use two transformers of about +,###k@& each.
(lectricity at a low voltage of +?#@ is obtained from the 9.9k@ supply using a %###k@&
transformer. & phase advance capacitor is also provided for the low voltage line to reduce the loss
in the distribution system.
7e commented on these matters as followsG
%< 4roblems relating to the present power receiving and distributing system
-he data for "##2 show that ?$L ;N %%,B29M7h/%$,%2%M7h< of the total power
consumption is high voltage power for the mill. -he operating ratio of the mill is only about
2#L ;$>L by calculation< due to the reduced production level. ,igure @-"-% shows a
schematic diagram of the e6isting power receiving and distribution system.
@?
%%k@
M=,
>,2##k@&
9.9k@
Mill 5 related
facilities
%,###k@&
+?#@
=ther
facilities
,igure @-"-% 1eneral connection diagram for the power receiving and distributing system
-he demand factor ;N ma6imum power demand/facility capacity< of the receiving transformer
is $>L ;N +,2##k@&/>,2##k@&< when the mill is operating but only $L ;N
+##k@&/>,2##k@&< when the mill is idle. -herefore, the amount of electric power required for
the mill is assumed to be +,"##k7, and the amount of power and the power factor of the other
facilities are assumed to be +##k7 and %##L, respectively.
"< Remedial plan
-he following procedure is recommended to reduce the loss from the >,2##k@& transformer in the
low-demand period.
se the >,2##k@& transformer only for the mill and parallel off when it is not operated. -his
eliminates the loss from the >,2##k@& transformer during the low-demand period. Install a
>2#k@& transformer for the other facilities. -he transformer can be connected to the %%k@
power source separately. ,igure @-"-" shows the connection diagram for the remedial plan.
%%k@
M=,
30
>2#k@&
>,2##k@&
9.9k@
Mill 5 related
facilities
+?#@
=ther
facilities
,igure @-"-" 4ower receiving and distributing connection diagram for the remedial plan
+< (stimation of benefits
&ssuming that the demand for mill-related power is +,"##k7, and it is operating 2#L of the
time, while the other facilities use +##k7 constantly throughout the day with a power factor
of %##L, then the benefits can be estimated as shown below. ;-he values shown in -able
@B
@-"-" are used for the no-load loss and load loss of the transformers<.
-able @-"-" :oss characteristics of transformers used for receiving and transforming power
-ransformer 3apacity )o-load :oss ;k7< :oad :oss ;k7<
>,2##k@& %$.2 9#.9
%,###k@& %.?? %%.?B
>2#k@& %.$$ B.2"
-he transformer loss per day is found by calculating the load loss and no-load loss, as
followsG
- -ransformer loss in the present arrangement
>,2##k@& transformerG %$.2k7 O "$h/d V 9#.9 k7 O ;+,2##/>,2##<
"
O %"h/d
V 9#.9 k7 O ;+##/>,2##<
"
O %"h/d N 2#>.2k7h/d
%,###k@& transformerG %.??k7 O "$h/d V %%.?Bk7 O ;+##/%,###<
"
O "$h/d N
>#.>k7h/d
- -ransformer loss in the improved arrangement
>,2##k@& transformerG %$.2k7 O %"h/d V 9#.9 k7 O ;+,"##/>,2##<
"
O %"h/d N
+#9.$k7h/d
>2#k@& transformerG %.$$k7 O "$h/d V B.2"k7 O ;+##/>2#<
"
O "$h N >%.%k7h/d
-hus, the following energy conservation benefits are obtainedG
;2#>.2V>#.><k7h/d - ;+#9.$V>%.%<k7h/d N "##.?k7h/d ;N >+M7h/y<.
&ssuming that the power consumption in "##2 is %2,$+>M7h ;N%$,%2%M7h O %"/%%<, then the
improvement ratio isG
>+M7h/%2,$+>M7h N #.##$> ;N #.$>L<.
In this plan, while the >,2##k@& transformer requires only a change of connection, the
>2#k@& transformer must be newly installed. 'ince the improvement ratio is not very high, this
plan should be implemented in the future on a suitable occasion unless low voltage power
receiving is possible.
;2< &ir compressors
-wo screw type compressors of "##hp ;N %$Bk7< are currently installed. 7hen we visited the
factory, one of them was still operating even though the factory was almost at a halt. It was
e6plained that discharge pressure was controlled between %#2 and B#psi by capacity control
and that the pressure was about %#+psi. :oad/unload action was not observed. Cowever, the
pressure was reduced to about B#psi when the regenerative cooler was operated in the
regenerative mode. ;)oteG %##psi N #.9?BM4a<
& receiver tank is provided for each air compressor, ne6t to the cooler, from which the air is
supplied throughout the plant. &lthough a pressure gauge was provided at each receiver tank, it
was hard to read the gauge because cement powder covered the surface of the gauge. =ne of
the facilities making use of the air was the packing equipment, and the pressure for this
@%#
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equipment was kept stable at #.9M4a. Cowever, it seemed that pressure control was insufficient
because a rubber tube of about %#mm diameter, probably used for cleaning, was attached
directly to the piping system.
7e asked whether the regenerative cooler was really necessary for the cement factory. -heir
reply was that it was necessary because problems had resulted when they had carried out
e6periments at high dew points. -hey also said that the pressure could not be reduced. -here must
be problems involving the capacity of the air compressors.
%< .ischarge pressure and power consumption of the compressors
3ompressed air supplied to the plant is dried first in adsorbent type dryers. =n the day we
visited, one dryer was operating and another was on standby. -he discharge pressure of
#.>M4a seems to be too high.
-able @-"-+ shows the effect on energy conservation resulting from a reduction in discharge
pressure from the present #.>M4a standard.
0ase pressureG #.>M4a1
%.%
%
#.B %?L
#.?
#.>
#.9
#.2
#.$
#.+ #.$ #.2 #.9 #.> #.?
.ischarge pressure ;M4a<
,igure @-"-+ Relationship between discharge pressure and power consumption
Reducing the discharge pressure from #.>M4a to #.9M4a

saves about %#L of power and about
%?L by reducing it to #.2M4a. &fter studying the pressure needed for each load facility, it is
therefore recommended that the discharge pressure be reduced.
4ossible measures for reducing the pressure areG
:ow-pressure loadG Reducing the pressure using pressure-reducing valves
Cigh-pressure loadG Increasing the pressure using a booster
-he air blow pressure for cleaning can be reduced to about #.+M4a.
"< 4ressure and air leakage
-he compressed air generated by the air compressors is supplied to all facilities through
pipelines, during which some pressure and flow volume are lost, as shown in ,igure @-"-$.
@%%
3ompressor
4i
Di
4i
4o
4ipe line
:oss C4
CD
C4 4ressure loss
-erminal system
4o
Do
&ir power
:eakage loss
at terminal system
CD
# Do Di
,igure @-"-$ 4ressure loss and air leakage
In the figure, T4 is the loss generated by friction, the curvature of the pipe, and e6pansion and
reduction of the pipe, while TD is the leakage from the pipeline. -he former problem is set
based on the balance with the piping cost and the latter can be controlled, aiming at zero
leakage.
+< ,low control and air leakage control
-he factory air compressor system is centralized. 7hile such a system has advantages in
ensuring the effective utilization of facilities and centralized control, air leakage and pressure loss
due to the long pipelines and an imbalance between supply and demand are apt to occur. -herefore,
careful control is required for effective operation.
'ince little air is consumed when the plant is not in operation, this is an opportunity to install
flow meters to control the airflow and implement periodic air leakage checks.
1enerally speaking, leakage of + to 2L occurs even in newly installed pipelines and increases
over time, up to %#L or even +2L. &ir leakage occurs mainly at the following pointsG
4iping !ointsG due to the corrosion of flanges, creation of gaps between flanges, and
the loosening of bolts,
'ealsG elastic seals ;rubber<, and metal seals.
-he amount of leakage can be checked by operating the compressors when the plant is not in
operation, as shown in ,igure @-"-2.
&fter completely closing the ends of all pipelines, operate the compressor until the pressure
reaches the specified value. -hen stop the compressor. -he discharge pressure will change as
shown in ,igure @-"-2, where 4% is the working pressure. sually, 4%-4" is set at #.#2 to
#.%M4a.
@%"
(stimation of the &ir leakage
:G &ir leakage ;L<
t%
0.% Setting pressure
p1 = Specified pressure
0.& Working pressure range
p1 - p2 = 0.05~0.1MPa
t2 p2 = Specified pressure
0.!
t2 4ressure descent
0.'
:N O %## ;L<
4ressure ascent
t%Vt"
0.
'mall leakage
:arge leakage
-ime ;min<
4ressure 3hange in &ir 3ompressor
,igure -"-2 &ir leakage check
$< .ryer
&dsorbent type dryers ;heatless dryers< have been installed. &dsorbent type dryers can, by
ad!usting the amount of purge, be used in electronics plants producing electronic parts and the like,
where very low dew points are required.
-able @-"-+ shows the relationship between purge and dew point. & dew point of -%Be3 can be
obtained with %2L purge.
-able @-"-+ 4urge ratio and dew point in heatless dryers
.ryer 4urge &.4 4.4 sage
Ratio ;L< ;e3< ;e3<
3hiller -ype #L -%> %#
Ceatless -ype %2L -$# -%B Measuring 5 3ontrol
"2L -># -22 (lectronic parts
&.4G &tmospheric .ew 4oint, 4.4G 4ressure .ew 4oint
-he dew point of the 0C3 factory is -?e3, with saturated water content of ".2+%g/m+.
,igure @-"-9 shows the relationship between dew point and saturated water content.
@%+
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/
m
+
<
%##
%#
%
-2# -+# -%# %# +# 2#
#.%
#.#%
.ew point ; <
,igure @-"-9 'aturated water content and dew point
In this cement factory, there is no process in which the temperature of the compressed air
pipelines drops below #e3. (6cessive dew point setting results in the wasteful release of
precious compressed air by purging. -herefore, it is recommended that a review of dew point
control be undertaken, comprising the following stepsG
3onfirmation of required dew points,
&d!ustment of purging volume ;purging time<
'tudying the possibility of using heat type dryers ;chiller type<, ;either in changeover
or in parallel use<
2< Reduction of purging volume
,igure @-"-> is a schematic diagram showing a drying system in which the dew point is
reduced using a chiller type dryer for the first stage, followed by an adsorbent type dryer.
-o M/3
"##hp
3ompressor .ryer
;3hiller type<
R'
Ceatless dryer
R'
,actory
3ompressor yard
,igure @-"-> 'ystem in which a chiller type dryer is used in the first stage
In this system, since regeneration is carried out using dry compressed air, less time is
required and the purging volume of the absorber is reduced. &ssuming that the present
purge is %2L, the reduction in purge volume is estimated as follows.
&ccording to the manufacturerJs catalog, the discharge volume of an air compressor of
@%$
"##hp ;N %$Bk7< is "?.2m
+
/min. -hus, the amount of air used for purging isG
"?.2m
+
/min O 9#min/h O #.%2 N "29.2m
+
/h
3onverting to electricity, this value corresponds to %2L of the supplied power. &ssuming that
the motor efficiency is B#L, the following value is obtainedG
%$Bk7/#.B O #.%2 N "$.?k7
&ssuming that the temperature of the output air from the compressor is $" and the air is
%##L saturated with water, the amount of water contained in it is 29.2g/m
+
. 7hen the dew
point of the outlet air ;4.4< of the chiller type dryer is %#, the amount of water
contained in it is B.+Bg/m
+
.
'ince the water content of the purging air has dropped from 29.2g/m
+
to B.+Bg/m
+
, the
efficiency of purging has been improved. -he amount of reduction in the purging of the
adsorbent dryer due to the installation of a preliminary dryer is proportional to the water
content at the inlet. -herefore, the ratio of the reduction in purging volume isG
% - B.+Bg/m
+
/29.2g/m
+
N #.?+.
-hus, the amount of reduction in power saving isG
"$.?$k7 O #.?+$ N "#.>k7.
'ubtracting the power consumption of the preliminary dryer ;about 9.2k7< from "#.>k7
results in energy saving of %$."k7. -he ratio of this amount to the total power
consumption is %$."k7/;%$Bk7/#.B< N #.#?2?.
-his indicates that the total efficiency is improved by adding a preliminary dryer to the
adsorbent type dryer.
;9< 3entral control room and data control
-he ,&' data control system has been installed, which monitors all ma!or data collected in the
factory using two 3R-s. -his system is made in 3hina. &lthough many data printouts are
produced, the data do not seem to be utilized systematically.
-he data are manually recorded on daily log sheets on an hour-to-hour basis instead of being
automatically recorded directly from the 3R- display. -hese data are then manually entered into
a computer in order to prepare charts for analysis. 'ince there are %# personnel in the utility
section for maintenance, etc., there seems to be enough labor to carry out all this manually.
-hey therefore have no plan to computerize the data collection/calculation process. 'ome old-
fashioned operating systems are incompatible with other versions and this system may be one of
them, making it difficult to add a data logging function. 'ince data collection is the basis of energy
conservation activities, however, it is recommended that a computerized central data monitoring
system be introduced as soon as possible.
;>< 4artial load characteristics of motors and fans
%< Motors
7hile the load factor of an induction motor can be obtained by measuring its power
consumption and comparing this with the rated value, the measurement of electric power is
not always easy because the voltage and current must both be measured simultaneously.
Cowever, it can be easily !udged whether the motor is oversized or not !ust by measuring the
@%2
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current. ,igure @-"-? shows the performance characteristics of a squirrel-cage induction
motor ;driven at $##@<. -hese characteristics include the efficiency, power factor, and current ;as
a percentage of the rated value< plotted against the load factor.
-he relationship between the current and the load factor indicates that the load factor is 2#L
when the current is 9#L of the rated value. It can also be seen that the power factor decreases
from ??L to >>L and that efficiency decreases from B"L to B#L. In motors that are driven at a
high voltage, the load factor also decreases to about 2#L when the current is 9#L.
&lthough the decrease in efficiency is only several percent at most, even in high voltage
motors, the load factor of 2#L means that each motor has double the capacity needed and so the
overall system is in need of improvement.
-herefore, a rough guide to !udge whether the motor is oversized or not can be obtained from
9#L of the rated value.
%"#
%##
?#
9#
$#
"2 2#
(fficien cy
4ower factor
3urrent
>2 %## %"2 %2#
:oad factor ;L<
,igure @-"-? 3haracteristics of squirrel-cage induction motor ;driven at $##@<
"< 4umps and fans
,igure @-"-B shows the relationship between the load factor and the efficiency of a pump and a
fan. It can be seen from the figure that the efficiencies of pumps and fans are both more
dependent on load factor than those of motors.
(fficiencies decrease by %#L at a load factor of 2#L in both pumps and fans. -he efficiency then
decreases drastically at even lower load factors.
-able @-"-+ uses the current of a motor measured in the 4hase % energy audit ;,ebruary "##%< as
an e6ample. -he current ratio of the separator is e6tremely low. &lthough it is necessary to
confirm these measurements, if these values are correct then the capacities of the motors and fans
in use need to be checked.
-he use of bag filter fans must also be reviewed. 7hen the opening of the damper is
narrowed to 92L, air flow is reduced. (nergy conservation may be implemented by ad!usting the
number of revolutions by changing the pulley ratio.
@%9
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%##.#
?#.#
9#.#
Motor
$#.#
4ump
,an
"#.#
"2 2# >2 %## %"2
:oad facto r ;L <
,igure @-"-B Relationship between load factor and efficiency of a pump and a fan
-able @-"-+ 3urrent measurements of motors
3apacity .esign .esign &ctual &ctual/
Motor k7 @olt &mp &mp .esign
Mill motor "?## 9,### +## "9+ #.??
'eparator B# +?# %2" +2 #."+
0ag filter fan $## 9,### $+ "B #.9?
,igure @-"-%# shows the ratio of shaft power of the motor for the damper control and
rotational speed control.
%"#
.amper
%##
?#
9#
$#
"#
#
#
'uction damper
'peed control
"# $#
&ir ,low ;L<
Ideal curve
9# ?# %##
,igure @-"-%# .amper control and rotational speed control
@%>
7hen the airflow is reduced to ?#L, energy conservation of $#L is realized by ad!usting the
rotational speed. 'ince the amount of energy conservation is appro6imately in proportion to the
capacity of the motor, the energy conservation is $##k7 O #.$# N %9#k7. &ssuming the
operating ratio is 2#L, annual savings will beG
%9#k7 O "$h/d O +92d/year O #.2 N >##,?##k7h/y.
-his value corresponds to $.2L of the estimated total power consumption of %2,$+>M7h/y of the
factory.
".2 'tatus of Implementation by 0C3
;%< 'tatus of Implementation of previous advice
&s described in the attached written reply to the questions submitted, there are many items that
have not yet been implemented. -his is probably because the factory is too busy with
day-to-day activities to address the other critical conditions affecting the company, as described
earlier, and because the (3 investments cannot be easily recouped at the present low operating
ratio.
%< pdating, maintenance and control of sensors and metersimplemented.
-he company has obtained 0', I'=B##%, and I'=%$##% certification, and it was e6plained that
these items have been implemented as a matter of course.
"< tilization of the dust collecting gas as secondary air for =-'(4&not yet implemented.
-his item has not been implemented in case this results in deterioration in product quality.
+< 3hanging the method of cement transportnot yet implemented.
-he company agrees with the basic idea, but the investment cannot be recouped at the present low
operating ratio.
$< 4reparation of manuals and check sheets for periodic maintenanceimplemented.
-he '=4 ;'tandard =perating 4rocedures<, mentioned below, includes all the items relating to
factory operations, including the preparation of manuals and check sheets.
2< 4revention of any further breakage of the clinker shoot and gas ductnot implemented.
0C3 did not understand the previous advice given on this topic ;the previous report written in
(nglish had not been delivered to 0C3< so (338 e6plained it again. Mr. 7id!a!a replied
positively saying, H-he idea is interesting, but there are some other possible methods such as
changing the materials used to castable refractory or stainless steel, so further studies will be
carried out firstI.
9< .ivision of the air layer of the air slidenot yet implemented.
-he situation here was as described above for the preceding item, and (338 e6plained the
process again.
-he basic idea here is to continue the operation for the time being, even if about 2#L of the
canvas is broken, and not stop the operation for repairs under the present low operating ratio of
only about 2#L.
@%?
;"< 0C3Js original improvements
&s described in the e6planatory material ;attached 44- Material< and the written reply to the
questions, the following items have either been implemented or plannedG
%< Improvement of the power factor by introducing a Reactivated 3apacitor 0ank
implemented.
"< se of a 1rinding &id ;an aqueous solution of chemicals that functions as an antiadhesive
agent. -his solution prevents the pulverized powder from adhering to the milling balls<
at the planning stage.
+< Introduction and establishment of '=4implemented.
$< Reducing the clinker receiving time from > days to $ daysimplemented.
-his contributes not only to a reduction in the power consumption of the receiving operation but
also to the prevention of demurrage payments.
2< -imers added to the lighting equipment to save the outdoor illumination during daytime
implemented.
9< 'ince two of the three pier hoppers were not provided with bag filters, these were added to
both hoppers.implemented.
;-his item is not for energy conservation but for environmental improvement.<
In addition, changing the present mill to a more energy-efficient type is under consideration.
Cowever, profitability is doubtful under the present operating conditions.
@%B
+. 7alk-through (nergy &udit of the 0everage ,actory of Aingston 0everage 5 3reamery 'dn.
0hd.
.(' selected a factory that produces beverages and ice cream, owned by Aingston 0everage 5
3reamery 'dn. 0hd., as the second factory for energy audit. -his factory is located in an
industrial comple6 close to the center of the capital. -his was the first e6perience by the factory
of an energy audit and the management responded in a very friendly and cooperative manner.
In 0runei, there are not many factories that consume large amounts of energy, and more energy is
consumed by other facilities such as night golf courses owned by hotels and resort facilities.
+.% =utline of the 0everage ,actory of Aingston 0everage 5 3reamery 'dn. 0hd.
;%< =utline of the visit
3ompany nameG Aingston 0everage 5 3reamery 'dn. 0hd.
-ime and date of visitG .ecember %2, "##2, ;-hu< %#G"# - %>G##
:ocationG 4lot >+ 5 :ot +,$,2 5 9, 0eribi Industrial 3omple6, 8alan 1adong,
1adong 0(%%%?
4articipants from the companyG Mr. @alentine Con, general Manager
Mr. &lbert A. 1. :im, 4lant Manager
'urveyorsG
0runeiG .('
Mr. C!. &bd 'hawal bin Paman, (nergy .ivision ;,ocal 4oint<
Mr. Ismail 0in C!. Mohd .aud, Cead of nit, 'afety and (nvironment Mr.
C!. 'hamshul Kamicse bin C!. 'abtu
Mr. Mohad. -azim bin &kub
Mr. C!. &ziz bin C!. &li
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
;"< =utline of the factory
-he company was established in %B>9, and the factory we visited was built in the industrial
comple6 in %BB$. 0everages ;mainly H4epsi 3olaI< and ice-cream are produced by %2#
employees.
0everages are canned or bottled, and %,### cartons of each are produced and delivered monthly. In
the busy season, after the month of Ramadan, the factory is operated "$ hours a day with a three-
shift system, but for the rest of the year the factory is only operated for half a day. ;& carton
contains 2# to 9# cans of about "2#cc or %" plastic bottles of %.2:.<
;+< 4roduction process and facilities
-here are four production lines. -wo lines are for blending and bottling H4epsi 3olaI, one line
@"#
is for ice-cream production, and one line is for molding plastic bottles. Most parts of these lines are
automated by electrically operated devices. 4art of the cartoning operation is the only process
carried out manually.
(nergy consuming facilities ;e6cept in the beverage bottling process< are as followsG
0oilerG
&ir compressorsG
&mmonium compressorsG
RefrigeratorsG
7ater supply pumps
.iesel oil-fired smoke tube boilerG %2#4'I ;N %.#2M4a< O 2t/h
O %unit
- 1eneral purpose centrifugal compressorsG ""hp O $units
- Reciprocating type compressors for ice-cream production
%.+M4aG "#hpO %unit and +#hpO %unit
%##hp O %unit
2hp and >.2hp, one each
Many pumps
(mergency diesel generatorG +?#k@& O % ;8ust enough capacity for the operation of the
ice-cream process when there is a power outage. It is kept
outdoors on a wheeled rack.<
4ower receiving facilitiesG -he receiving voltage of %%k@& is transformed to $##@ by
a %,###k@& transformer.
& watt-hour meter ;owned by the government< is provided.
;$< 3onsumption
(lectricity and diesel oil are used as energy sources. .iesel oil is used for the boilers and
transport equipment such as trucks and forklifts. & receiver tank of $# to 2#m+ is installed in
the factory.
+." =n-site 7alk-through (nergy &udit
;%< &fter listening to the outline of the factory, we surveyed the production lines for beverages and
ice-cream, related utility facilities, and the plastic bottle molding machines.
&s might be e6pected of a food manufacturer, special care is taken for hygiene in the
production lines, and quality inspection is carried out frequently. ,acilities related to utilities
are separated in a different building from those used for food, and include city water receiving
and storage facilities, boilers, diesel fuel receiving and storage facilities, refrigerator
compressors, and air compressors.
&mong the machines present, the %##hp ammonium compressor for the ice-cream production
process uses the most energy, followed by the plastic bottle molding machine, consisting of a 2#hp
motor and a "-stage molding machine. 'ince the voltage drop caused by reactive power was our
main concern, we asked about the phase advance capacitor. Cowever, they replied that they did not
have a phase advance capacitor. -hey are not interested in reactive power because they donJt have a
rate system for reactive power.
-here seems to be a considerable amount of reactive current loss, including the outdoor
@"%
electricity distribution lines. 'ince capacitors are relatively ine6pensive, it may be an effective
strategy for the government to promote improvement of the power factor at a national level.
&mong the various power loads, compressors are the most numerous, comprising a wide range
of types and discharge pressures. 'ince all the compressors are of a reciprocating type, partial
loads do not cause a serious problem, but energy conservation may be possible by reducing the
discharge pressure.
;"< (nergy conservation activities
&fter the plant tour, several energy conservation issues were discussed at a meeting in the
conference room. .uring the course of the discussion, it was found that the factory did not
possess fundamental data on energy consumption. -he amounts and costs of electrical power
are known only from the monthly bills sent by .('. In the same way, the amounts of diesel oil
received are managed as a lump sum, but it is not known how much is used for boilers and
transportation equipment. -his shows that energy conservation activities are not really
performed at all. =ne reason for this may be that energy costs are low in 0runei. Cowever, we
urged them to start energy conservation immediately, and e6plained how to promote energy
conservation activities.
-he first step in saving energy is to collect data on energy consumption. 'ince the main energy
source is electricity, we e6plained how to collect data on electricity consumption using a
watt-hour meter, which can be carried out rather easily. 7e also e6plained how to collect
appro6imate data on power consumption in production lines and utilities using the clamp-type
ammeters that they already possess. ,urthermore, we e6plained the concept of unit
consumption of energy and advised them to calculate the energy consumption per sales volume for
the time being, if it is difficult to collect data on the energy consumption per production
volume, and to then look at the trends.
Materials we obtained from Aingston includeG H0rochure about AingstonI, H,low 3hart for the
0everage 4roduction 4rocessI, H,low 3hart for Ice-3ream 4rocessingI, and H:ist of
4articipants in the 'eminar 7orkshop ;hard copy<I.
+.+ &dvice and Recommendations for ((53 &ctivities
;%< nderstanding the energy consumption status
-he first step in any energy conservation activities is to understand the status of energy
consumption.
.ata on the amounts of electrical power, fuel, and water resources used must be made available on a
daily and monthly basis. -he types of data required depend on the purpose of the energy
conservation activities. -hey may include detailed measurements collected using instruments or
specific data on individual facilities.
%< &scertaining data on electric power consumption
@""
a. Monthly use
Monthly use can be determined from the electrical bills, but this involves a time delay.
.aily consumption data are required in order to assess day-to-day activities. .aily
consumption is easily measured using a watt-hour meter, but it is also possible to calculate the
power consumption by reading the supply meter of the electric power company if a
dedicated watt-hour meter is not available.
& simple method is to read the watt-hour meter at a specific time every day then compare
this with the values obtained on previous days. -able @-+-% shows an e6ample of a
record-keeping form.
-able @-+-% .aily report for receiving power
Receiving po+er !aily report
Apr< 2005
'ransformer D4 'ransformer D
>oltage Current P< ,actor Acc< po+er Po+er >oltage Current P< ,actor Acc< po+er Po+er
!ay > A = 01h 01h > A = 01h 01h
4(,ri$ ! !
2("at$ ! !
3("un$ ! !
2(on$ ! !
b. .aily load chart
& daily load chart is prepared to help determine hourly electric power consumption on a
daily basis.
-his chart can be obtained using the same principle described above. Read the watt-hour
meter every hour, calculate the difference from the previous hour, and then draw a daily load
chart by plotting the differences. 7hen the receiving board is provided with a
voltmeter, ammeter, and power-factor meter, electrical power can be calculated using the
measurements from these instruments.
-he following method is another way to determine electrical power consumption based on the
rotational speed of the circular plate in the watt-hour meter. -his method does not require
any other measuring instruments. ,igure @-+-% shows a photograph of a supply meter and a
drawing of the rotating circular plate.
=btaining the value of 7h/r
-he circular, rotating plate with a black mark is actually a dial plate that indicates
integral power consumption, and the specifications of the meter are displayed nearby.
-he specification H"%.97h/rI shown ;surrounded with a red circle in the above
photograph<, means that "%.97h of electricity are required for one rotation of the
circular plate.
-he supply meter at Aingston reads H%.2r/k7hI. In this case, use the inverse of this value
;i.e. %/%.2r/k7h N 99>7h/r<.
@"+
Measuring the rotational speed of the circular plate
-o measure the rotational speed of the circular plate, utilize the black mark on the edge of
the plate. -he speed can be measured in many ways, but one simple method is to
measure the time required for %# rotations.
-he rotational speed of the circular plate thus obtained is then designated as '
brevolutions/minc.
3ircular 4late
Direction of the rotation
Mark
,igure @-+-% 'upply meter and circular plate
3alculation of the electric power
Rotational speed brevolutions/minc is then converted into revolutions per hour by 9# O '
brevolutions/hc. -he electric power is obtained by multiplying this value by the 7h/r value
using the following equationG
9# O ' brevolution/hc O electric power for a revolution ;7h/r value<
&n e6ample of measurement
In the case of the Aingston site, the value of 7h/r is known to be 99>7h/r ;calculated from
the reading displayed of H%.2r/k7hI<.
7hen the rotational speed is ' N "# brevolutions/minc, the electric power 4 is obtained as
followsG
4 N 9# O "# brevolutions/minc O 99>7h/r N ?##k7
-he purpose of the above e6planation is to introduce a method for measuring the power used
when other instruments are not available. -he use of a watt-hour meter provided with a
recording function enables an even more complete daily load chart to be compiled.
0y drawing a graph noting the power consumption every hour, a daily load chart can be
obtained, as shown in ,igure @-+-".
@"$
P
o
+
e
r

c. (lectric power consumption by use

-o get a better understanding of detailed power consumption by classifying the loads, it is
convenient to divide the received power by the number of trunk lines at the electricity
receiving board. Measure the current of each trunk line using a clamp ammeter and assume
that the power factor is about #.?. -hen divide up the total received power in proportion to
the calculated currents. -his calculation includes some error due to the estimation of the
power factor, but this will only deviate by %#L at most, which does not matter for the
purpose of this calculation.
Cowever, this measurement gives only those values for a given moment in time, and a
watt-hour meter must be used to compare the proportion of power consumption used over
periods of days or months. It is therefore recommended that a watt-hour meter be installed to
implement comprehensive electric power control.
250
Pea0
200
350
300
250
200
Average
450
400
50
#ight po+er
0
0 2 2 & 5 40 42 42 4& 45 20 22 22
Time (hour)
,igure @-+-" .aily load chart
"< 1etting a better understanding of fuel consumption
It is recommended that a flow meter be installed in the fuel pipeline for boiler fuel. 'ince the
diesel fuel for the boilers is transported through a pipeline, a flow meter should be installed
in this pipeline. It is also necessary to install a flow meter to monitor the steam supply.
;"< &nalysis of data and e6ploitation of themes for energy conservation
-ry to comprehend the pattern of energy consumption by analyzing the fluctuations in use and the
correlations between the data, in order to identify both potential problems and
countermeasures.
%< &nalysis of the daily load chart
-he daily load chart is analyzed in order to decide how best to reduce power consumption.
Reducing power consumption during the night and reducing peak power can be especially
@"2
(
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e
r
g
y

3
o
n
s
u
m
p
t
i
o
n
(
n
e
r
g
y

3
o
n
s
u
m
p
t
i
o
n
effective.
3ompare the chart with the operation pattern of the factory to check whether there is waste
power consumption during recess time or at night, when factory operations halt. 'ince power
consumption during the night and on holidays is fi6ed, any reduction in power consumption is
very effective because the loss is constantly integrated over time.
3hanging the operation schedule can sometimes disperse peak power. 4eak power is directly
related to the electricity tariff. -he same measures described for reducing power
consumption during off-peak operation should be taken when the electricity rate is high.
"< nit consumption
nit consumption is defined as the inde6 e6pressed Hby dividing the energy used for
production by the production volumeI. nit consumption can therefore be calculated as
followsG
nit consumption N amount of energy used/production volume
nit consumption is a useful inde6 for evaluating the achievements of energy conservation
activities, and can be used for many different purposes such as comparison with other
companies and setting targets for energy conservation ;for e6ample, a %L R(.3-I=) I)
)I- 3=)'M4-I=)<.
'ince the unit consumption e6presses the degree of energy conservation on a macroscopic level,
the ratio of energy consumption to the production volume for each process can also be used to
assess the degree of energy conservation at each stage of the process.
+< 3onverting fi6ed energy to variable energy
0y plotting energy consumption against production volume on a graph, as shown in ,igure @-+-
+, energy consumption can be divided into fi6ed elements and variable elements.
fi6ed
changing
fi6ed
4roduction
4roduction
,igure @-+-+ ,i6ed elements and variable elements of energy consumption
In a production system where the fi6ed elements dominate, unit consumption drastically
increases as the production decreases. =ne of the targets of energy conservation is therefore
to convert fi6ed elements into variable elements. ,acilities that operate regardless of
production must be converted so that they operate in con!unction with production. 1enerally
@"9
speaking, facilities for utilities are apt to contribute more to fi6ed elements.
;+< Implementation of improvements
=nce targets for energy conservation are set, specific measures to achieve these targets can be
implemented.
-he procedure for this should follow the 4.3& ;4lan-.o-3heck-&ction< cycle, as illustrated in
,igure @-+-$.
7hat is important here is to numerically assess each achievement in the H3heckI stage.
)umerical e6pression enables the sharing of the achievements resulting in vitalization of the
activities. -his is the reason why numerical measurements are important in all energy
conservation activities.
7hen the set target is achieved, the results are standardized as a work standard to ensure
further improvement.
4lanG -o find the loss and waste of energy consumption
and find countermeasures to minimize them.
.oG 3arry out the countermeasures
3heckG (valuate the result
&ctionG Reform the process
Making improvements using the PDCA cycle
,igure @-+-$ -he 4.3& cycle
;$< Ma!or ob!ect facilities
%< Motors, fans, and pumps
(nergy audit
-he capacities of fans and pumps are apt to be in e6cess of what is actually required. In the case
of a pump, for e6ample, various allowances can be made, such as %#L for the deviation from
actual conditions, 2#L for leakage in the pipeline, and %# - %2L for pump capacity. &fter
adding up all these allowances, the load factor in the actual operation may only be >#L or
thereabouts, in many cases.
,igure @-+-2 shows the relationship between the load factor and efficiency for a motor, fan,
@">
(
f
f
i
c
i
e
n
c
y

;
L
<
and pump.
%##.#
?#.#
9#.#
Motor
$#.#
,an
4ump
"#.#
"2 2# >2 %## %"2
:oad facto r ;L <
,igure @-+-2 Relationship between load factor and efficiency for a motor, fan, and pump
7hen the load factor is only 2#L, efficiency decreases by %#L both in the pump and the fan.
7hen the load factor decreases even further, efficiency decreases drastically. 'ince a load
factor, 2#L means that a motor capacity is more than twice as necessary used. -his situation
must be improved.
-he easiest way to identify a facility with e6cessive capacity is to measure the current of the
driving motor. If the current is less than 9#L of the rated value, it is possible that the load
factor of the pump or fan is 2#L or less.
& simple method to improve the load factor is to ad!ust the capacity by reducing the
rotational speed by changing either the pulley ratio or the gear ratio.
"< &ir compressors
a. Reduction of discharge pressure
'ince the number of operating compressors is controlled using a main compressor and an
au6iliary, reciprocating compressor, partial load must be dealt with appropriately. -o
confirm this, it is recommended that the current be measured both when loaded and
unloaded to check whether the capacity is ad!usted properly. -he control is appropriate if the
current decreases to about +#L when unloaded.
In displacement compressors such as a reciprocating or screw type, decreasing the
discharge pressure can reduce the shaft output of the motor.
,igure @-+-9 shows the energy conservation effect when the discharge pressure is reduced,
taking the reference pressure as #.>M4a. ;'ame ,igure @-"-+<
7hen the discharge pressure is reduced from #.>M4a to #.9M4a, the results in power
saving is %#L and about %?L when the pressure is reduced to #.2M4a. -herefore, reducing
the discharge pressure to the value actually required by the load facility should save the
energy.
@"?
4
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r

c
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n
s
u
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p
t
i
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r
a
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o

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o

b
a
s
e

0ase pressureG #.>M4a1
%.%
%
#.B
%?L
#.?
#.>
#.9
#.2
#.$
#.+ #.$ #.2 #.9 #.> #.?
.ischarge pressure ;M4a<
,igure @-+-9 Relationship between discharge pressure and power consumption
b. .ew point control and leakage control
'ince there are many low-temperature workshops in the Aingston factory, compressed air
must be dried properly before use. 7ater condenses at temperatures lower than the dew
point, causing the lowering of partial pressure of the compressed air and leakages due to the
corrosion of the pipelines.
It is said that even in newly installed pipelines + to 2L of the air leaks out, and that leaks
will e6ceed %#L with age, eventually reaching +2L or more. Ma!or sites of leakage areG
8oints of pipingG corrosion of flanges, creation of gaps between flanges, loosening of
bolts,
'ealsG elastic seals ;rubber<, and metal seals.
In the case of reciprocating compressors, since the pressure is not constant, air leakage
must be checked by operating the compressors when the operations of the factory have
been suspended. &ir leakage is e6pressed by the load/unload ratio ;,igure @-+-><.
&ir leakage is estimated as followsG
: N t%/;t%Vt"< O %##bLc.
:oad
Pa
.oa! factorE
'4
nload
'4@t2
Pa
'4 '2
@"B
,igure @-+-> &ir leakage check
c. 0oiler and steam system
,or liquid fuels, the air ratio m ;N amount of combustion air/amount of theoretical
combustion air< should be controlled at about %.".
-o effectively utilize the heat contained in e6haust gas, the combustion air should be
preheated by the e6haust gas. -he supply pressure of the steam should also be reduced in
accordance with the pressure actually required.
Cigh-temperature boiler drums, pipelines and valves should be insulatedE steam leakage
from the pipelines should be preventedE and the drain should be recovered for recycling and
heat e6change.
In tropical regions, insulation is apt to be neglected because the ambient temperature is
high, but it should be noted that even a high ambient temperature is still more than %##
lower than that of the steam.
;$< Installation of a watt-hour meter provided with a recording function
&lthough Aingston has a clam-type ammeter, to implement energy conservation on specific
items of equipment, a better measuring instrument is required as a tool for the energy manager.
,or this reason, it is recommended that watt-hour meters provided with a recording function
should be installed.
7att-hour meters are available that enable data analysis by inputting data directly to a personal
computer. -hese instruments are provided with various functions such as harmonic
measurement and distortion factor measurement. ,or e6ample, the watt-hour meter shown in
,igure @-+-? is available in 8apan at a price of about X$##,###.
,igure @-+-? 7att-hour meter provided with a recording function
@+#
$. 'eminar and 7orkshop
$.% 'ummary
& seminar workshop was held on .ecember %> ;'at<, "##2.
-he seminar workshop started with the opening address of Mr. 4g. Kamra ;.('< of 0runei who took
the chair. -he seminar was well attended with more than %## people, including participants from
0runei .(' and three presenters from &'(&) countries. -here were many relevant questions
and answers and the seminar workshop was very successful.
;%< -ime and date
.ecember %> ;'at<, "##2, ?G+#G 'tart of registration, %>G+#G 3losed
;"< @enue
-he 3entrepoint Cotel, 9, ;4urple 8ade Room<, 0'0, 0runei .arussalam
;+< Reports presented on the 'eminar and 7orkshop
-he program of the presentation is shown in Material )o. .-%%".
In 'ession %, a general overview of energy in &'(&), an energy overview in 0runei, and an
overview of ((53 activities in 8apanese industry were presented. In 'ession ", successful cases
of energy conservation activities in &'(&) countries f 0runei, Indonesia, @ietnam, and Malaysia
f were reported. (338 presented reports on behalf of the 4hilippines and :aos, whose
representatives could not attend the seminar due to the inconvenient schedule. In 'ession +,
-. and .0/0M/1: were discussed.
'ince Mr. 3hristopher Kamora of &3( was absent from the seminar, Mr. 4g. Kamra of .('
took the chair. In the 2-minute question and answer session held after each presentation, the
participants asked many relevant questions and productive discussions took place. Media
representatives were also present at the seminar, including Media 4ermata ;the local paper< and
0orneo 0ulletin ;an (nglish paper<. -he seminar proceedings were also televised in the
evening.
;$< 4articipants
0runeiG .('
Mr. C! mar bin C! Mohd -ahir, Cead of (nergy 4olicy 5 4lanning Mr.
Ca!i &bd 'hawal bin Paman, (nergy .ivision
Mr. 4g. Kamra ;4g. stands for Royal ,amily<
Mr. Ismail bin C!. Mohd. .aud, Cead of nit, safety and (nforcement
Many other people
&3(G
.r. 7eerawat 3hantanakome, (6ecutive .irector Mr.
Ivan Ismed, 4ro!ect =fficer
@+%
IndonesiaG
Mr. 'ubagyo, 4- Aertas :eces
@ietnamG
Mr. -ran Minh Ahoa, Institute of -echnology
MalaysiaG
Mr. Ibrahim Cishamdin, 4usat -enega Malaysia ;4-M<
8apanG International (ngineering .epartment, (338
Messrs. ,umio =gawa, Cisashi &mano and Cideyuki -anaka, -echnical (6perts
More than %## participants from 0runei attended the seminar, including .(' members. Many
of them represented governmental organizations, but people from the state-controlled
petroleum company, 0runei 'hell, and the two factories we visited were also among the
attendees. 7e asked to see an electronic file listing the participants, but we have not received
this yet.
$." Results of the 'eminar and 7orkshop
;%< =pening ceremony
%< &3(
-he speech given by .r. 7eerawat, (6ecutive .irector of &3(, was almost the same as that
delivered in Indonesia. Cowever, he added that he was impressed by the lush beauty of
0runei, which he was now visiting for the first time, and that energy was one of the most
important topics of the recent (ast &sian summit meeting held in Auala :umpur. Ce further stated
that his successor in &3( would be selected from @ietnam and that it would be 0runeiJs turn
to fill the position if @ietnam was to decline.
"< (338
Mr. -anaka represented 8apan ;M(-I and (338<. Ce stated the significance, history, and
recent background of this pro!ect and outlined the 8apanese cooperation and contribution to
&'(&).
+< .('
-he Conorable C!. mar bin C!. Mohd -ahir greeted all those present. Ce outlined the
energy conservation policies of the government of 0runei, introduced recent activities such as
the 4R=M((3 ;industry< audit, and then declared the seminar open. Ce attended the
workshop for the whole day, listening carefully to the discussions and, at the end of the
seminar, handed a diploma to the participants and shook their hands. Ce also participated in the
question and answer session.
;"< 'ession %G 4olicies and initiatives on ((53
@+"
%< =verview of &'(&) 4lans and 4rograms on ((53 ;.r. 7eerawat, &3(<
-he same material used in Indonesia was presented again, although emphasis was placed on
the portion most relevant to 0runei. ;Material )o. .-%">, the same as that used in
Indonesia<.
"< (nergy =verview in 0runei .arussalam ;Mr. Paman, .('< ;Material )o. .-%+$<
4roduction of petroleum and natural gas, power generation facilities, the use of energy by
industry, changes in the demand and supply of energy in the past, policies on energy use
;petroleum and electric power<, and policies on energy conservation in 0runei were all
e6plained.
+< Initiatives and 4rograms of (338 on ((53 in Industry in 8apan ;Mr. -anaka, (338<
;Material )o. .-%"?<
Immediately before the presentation, the chairman, Mr. Kamra, stated that although he had
understood the significance and aims of energy conservation, how should energy
conservation actually be implementedR -echnical (6pert -anaka replied that it would be
helpful to refer to 8apanese cases, and he then started his presentation. &s a result, the
attendees listened to Mr. -anakaJs e6planation very carefully. Ce described such topics as
harmonization of the H+ (JsI, methods of energy conservation, designated factories,
qualified energy managers, and the national convention of energy conservation.
;+< 'ession "G Reports on successful cases of ((53 in industry
%< 3ement industry, 0runei - Mr. 7id!a!a ;Material )o. .-%+2<
-he factory manager, Mr. 7id!a!a of 0utra Ceidelberg 3ement ;which the energy
conservation follow-up investigation team had visited<, reported on energy conservation
activities. Ce e6plained key points clearly. -aking the opportunity, he also requested that the
government restrict the import of cement for the time being.
"< 4ulp and paper industry, Indonesia - Mr. 'ubagyo ;Material )o. .-%"B<
4- Aertas :eces ;which the investigation team visited in Indonesia< presented the same
report made in Indonesia.
+< 3eramics and chinaware industry, @ietnam - Mr. Ahoa ;Material )o. .-%+9<
Mr. Ahoa acted as a last-minute replacement for Mr. 4hon. Cis report was on the energy
conservation activities of C&4=3=, which the investigation team visited in "##$, and
another company ;Mailam 3eramic<.
$< 1lass industry and te6tile industry, Malaysia - Mr. Cishamdin ;Material )o. .-%+%<
4-M presented the same report made in Indonesia.
2< 'teel industry ;4hilippines< and hydroelectric power generation ;:aos< ;part of Material )o.
.-%+# and )o. .-%+><
Mr. -anaka and Mr. =gawa of (338 reported in place of the scheduled presenter. 0ecause
the presenter from the 4hilippines could not attend due to a flight cancellation, two
-echnical (6perts from (338 reported in place of the scheduled presenter. 'ince neither of
@++
these industries actually e6ists in 0runei, only the general principles were reported, and
-anaka gave a lecture relating to methods for promoting energy conservation in general.
;$< 'ession +G -he 7ay ,orward
%< 0arriers and Measures to implement ((53 -Mr. =gawa
Ce used Material )o. .-%%> and referred to the presentations from 'ession ".
"< -echnical .irectory - Mr. &mano ;Material )o. .-%+?<
&s in the 7orkshop held in Indonesia, &mano e6plained the purpose of -. sheets, how to
prepare them, and the format to be used, showing actual e6amples. In addition, Mr. Ivan
e6plained actual e6amples of -. sheet use. ,urthermore, .r. 7eerawat urged people from
0runei to prepare -. sheets for themselves.
+< .atabase/0enchmark/1uideline for Industry - Mr. =gawa
Ce based his presentation on Material )o. .-%%B, as used in Indonesia.
In the middle of the presentation, an engineer from 0runei 'hell asked many questions.
H7hat is the advantage of developing this databaseR &re there any political motivesR IsnJt it better
to collect data on the whole energy chain from the start of supply through to final
consumptionR IsnJt it difficult to compare different countries because subsidy conditions are
differentRI 7hile =gawa was replying, Mr. Paman said, H&s I recall, an &4(3 database is being
developed separately, and it is difficult to coordinate different countries with different conditions.
,or e6ample, it is sometimes difficult even to standardize the energy units being usedI. -hese, and
other such matters, were then discussed.
-here was also a supplemental question concerning the development of the database being
undertaken and the agreement among the governments of &'(&) countries. (ventually time
ran out, however, and Mr. 7eerawat wound up the discussion with the comment, H-his matter
cannot be brought forward if even a single country is against it. 7e must have e6haustive
discussions to gain a consensus among all members.I
;2< Duestions and answers
&s described above, a D5& session was held and there were many relevant questions. -he
following are some e6amplesG
DG Is there any incentive for a factory to have an energy audit carried outR &G
Pou pay less energy bills. -hatJs it. ;Mr. Paman<
DG 7hat are the penalties for violation of the energy conservation laws in 8apanR
&G ,ines are charged. Cowever, 8apanese companies abide by the laws because they value
their reputation.
;9< 3losing address
-he seminar was closed by the closing address of .r. 7eerawat and Mr. -anaka.
@+$
@I. &ctivities and (fforts as &'(&)
%. =utline of 'ummary 7orkshop and 4ost-7orkshop .iscussions
'ummary workshop and post-workshop discussions on three pro!ect areas shared by all
participating &'(&) countries -- promotion of energy conservation in ma!or industries and
buildings, and the development of a common basis for energy management -- were held in
0andung, Indonesia. -hese workshops were attended by the representatives of the seven &'(&)
countries and the representatives of the &'(&) 3enter for (nergy ;&3(< and the (nergy
3onservation 3enter, 8apan ;(338<, in order to assess the results and achievements of each
pro!ect carried out this year and to confirm the activities to be carried out in coming years. In the
summary workshop, the yearJs activities for each of the three pro!ect areas -- promotion of energy
conservation in ma!or industries and buildings, and the development of a common basis for
energy management -- were reported by 8apanese representatives. &ll participants then discussed the
assessment of the achievements and problems to be resolved.
%.% 4eriod of 'ummary 7orkshop and 4ost-7orkshop .iscussions
"9 ;-hu< - "> ;,ri.< 8anuary "##9
%." :ocation of 'ummary 7orkshop and 4ost-7orkshop .iscussions
1rand 4reanger Cotel ;0andung<, 8: &sia &frica ?% 4.=. 0o6 %""#, 0andung, 7est 8ava,
Indonesia
%.+ 4articipants in the 'ummary 7orkshop and 4ost-7orkshop .iscussions
,ocal 4oints ;,4s< from %# &'(&) countries were supposed to attend the seminar. Cowever,
thirteen people from seven &'(&) countries, five from &3(, and four from (338, totaling ""
people, actually attended. -he names of the participants are listed below. .elegates from
Myanmar, 'ingapore, and @ietnam were absent because the holidays of the :unar )ew Pear had
already started.
Indonesia ;> persons<
Ms. Maryam &yuniG Cead of (nergy 3onservation .iv., M(MR
Ms. (ndang :estaliG 3oordinator, (nergy 3onservation and (nvironmental Research
4rogram, 3enter for R 5 . on (nergy and (lectricity -echnology,
M(MR
Ms. .evi :aksmiG 'taff of (nergy 3onservation .iv., M(MR
.r. )ugroho 'ulamiG .epartment of (ngineering 4hysics, Institute -echnology
0andung
Ms. 'ut!i RahayuG -ariff (6pert, Marketing .iv., Indonesia (lectricity 3orporation
;4- 4:) ;4ersero<<, =bserver
.r. Ir. 7idodo 7. 4urwantoG Cead of 3lean (nergy 5 4roducts Research 1roup, niversitas
Indonesia, as an observer
@I - %
Mr. 4ramdi 0. 4rad!a 4- A=)(0&, =bserver
0runei .arussalam ;% person<
Mr. Ca!i &bd 'hawal bin PamanG Cead of (nergy .iv., .('
3ambodia ;% person<
Mr. :ieng @uthyG .eputy .irector, .ept. of (nergy -echnique, MIM(
:ao 4.R ;% person<
Mr. Ahamso AouphskhamG .eputy 3hief of (M., Ministry of Industry and Candcrafts, .ept.
of (lectricity, (lect. Manage. .iv. ;(M.<
Malaysia ;% person<
Mr. &hmad Kairin IsmailG .eputy .irector, (nergy Industry 5 'ustainable .evelopment
.iv., 4-M
4hilippines ;% person<
Mr. Marlon R. .omingoG 'enior 'cience Research 'pecialist, (nergy (fficiency .iv.,
(nergy tilization Management 0ureau, .=(
-hailand ;% person<
.r. 4rasert 'insukprasartG .epartment of &lternative (nergy .evelopment and (fficiency
;.(.(<
&3( ;2 persons<
.r. 7eerawat 3hantanakomeG
Mr. 3hristopher KamoraG
Ms. Maureen 3. 0alamientoG
Mr. Ivan IsmedG
Mr. 8unianto M.G
(338 ;$ persons<
Mr. -suzuru )uibeG
Mr. Aazuhiko PoshidaG
Mr. Poshitaka shioG
Mr. Cideyuki -anakaG
(6ecutive .irector
&dministration and ,inance Manger
.atabase and I- 'pecialist
4ro!ect =fficer
I- 'taff
'enior 1eneral Manager
1eneral Manager
1eneral Manager
-echnical (6pert
@I - "
2
+

5
5
6
2

A
c
t
i
7
i
t
i
e
s
". 'ummary 7orkshop related Ma!or Industries
,or the outline of the achievements of the pro!ect, related to ma!or industries, .r. 4rasert took the
chair of the meeting, which proceeded according to the workshop agenda ;Material )o. .-"#%<.
".% &ctivities for Ma!or Industries in ,our 3ountries in ,P"##2.
In the 4hase % activities, energy conservation audit were carried out for %# &'(&) countries by
&3(-(338. In the second year ;4hase "< activities, follow-up energy conservation audit were
carried out on ma!or industries in the four countries described below. ,urthermore, in the course of
4hase " activities, some factories were newly surveyed in order to check on the dissemination of the
energy audit and guidance provided in 4hase %. In addition, a seminar workshop was held in each
country. In the summary workshop, an outline of the activities in all these four countries was
presented. ;Material )o. .-"#"(<
3ountries visited in the second year ;4hase "< activities and periods of activities.
3ambodia "" to "9 &ugust, "##2
4hilippines "B &ugust to " 'eptember "##2
Indonesia 2 to %" .ecember, "##2
0runei .arussalam %$ to %> .ecember, "##2
-able @I-"-% shows an overview of the activities in each country.
-able @I-"-% =verview of 4hase " &ctivities in "##2
2ountry
8tems "ime
1. Follo19up / 5ner:y Audit
2. Seminar9;or<shop
1+ 5562 Policy
Brunei 2am#odia
0ec. 1"1% Au:. 22"2&
2ement 6 Food =arment
Processin: Factories Factories
Brunei 9 3>5 2am#odia93835
A25 5224
8ndonesia Philippines
052. !"12 Au:. 29"Sep.2
Pulp/Paper and 2 ?ollin: 3ill
"extile Factories Factories
A25 Philippines 9 0>5
5224 5224
2ement )Brunei+ Brunei 9 B@2
2eramics )-ietnam+ -ietnam 9 3>8
-ietnam 9 3>8 -ietnam 9 3>8
2hemical )2austic Soda+ Philippines 9
)"hailand+
?.8. 2hemicals 2o.
=arment )2am#odia+ F9upA 3835/5224
Food )Sin:apore+
8ron/Steel )Philippines+ )5224+
Philippines 9 0>5
3alaysia 9 P"3
Philippines9 B?2
F9upA 0>5/5224
3alaysia 9 P"3
>il ?efinery )3yanmar+
Po1er )(ao P0?+
Pulp/Paper )8ndonesia+
)5224+ (ao P0?938@
8ndonesia 9 8ndonesia 9
P" Certas (eces P" Certas (eces
(ao P0?938@ Po1er 9 0>5
8ndonesia 9 8ndonesia 9
P" Certas (eces P" Certas (eces
"extile )3alaysia+ 3alaysia 9P"3 3alaysia 9P"3
=lass93alaysia =lass93alaysia
>ther 8ndustries
=lass 9 3alaysia
2o9=ene 6 5S2>
9 "hailand
+ ;ay For1ard
1) What are the Barriers & Measures for the Implementation of EE & C [ECCJ]
2) Development of Technical Directory, DB/BM/GL for Industry [ECCJ & ACE]
@I - +
In the seminar workshop, the host country reported policies on energy conservation and the
energy conservation activities carried out by the industry. 4resenters from three or four &'(&)
countries, listed above, attended the meeting in order to report on the status of activities for
energy conservation in the ma!or industries of their own country. 7hen the presenters from other
countries/industries could not attend the seminar in person, (338 representatives took their
place.
-here were many reports presented by various countries other than the host country, describing
ceramics in @ietnamE hydroelectric power generation in :aosE the pulp and paper industry in
IndonesiaE glass, te6tiles, food, iron and steel in MalaysiaE iron and steel in the 4hilippinesE and
cogeneration and ('3= in -hailand.
-he following overview concerns the activities carried out in these four countries. ;Refer to
items II to I@ for details of the activities of each country.<
;%< &ctivities in 0runei
.uring the four days of activities, a follow-up energy audit of a cement factory and a walk
through energy audit of a food-processing factory were conducted. =n the last day, a seminar
workshop was held. More than %## people participated in the seminar workshop, which was a
proof of the profound interest in energy conservation in 0runei. &mong the &'(&) countries
present, @ietnam reported on activities in the ceramics industry, Indonesia reported on those in the
pulp and paper industry, and Malaysia reported on those in the glass and te6tile industries. -he
question and answer session held after each report was very lively. -he cement factory prepared
a written reply to the questionnaire submitted by (338 and presented an activity report on energy
conservation, demonstrating a high level of factory management. -he factory manager attended the
seminar workshop and reported on all these activities.
;"< &ctivities in 3ambodia
.uring a weeklong visit, follow-up energy audits were carried out on two garment factories. In
addition, a sister company of one of these factories, which had !ust started operation, also
requested a walk through energy audit and 3ambodian ,4 and (338 personnel visited this
factory. & seminar workshop was held on the last day.
-he two factories for which follow-up energy audit were carried out were very serious about the
promotion of energy conservation. (338 had to report the results of each follow-up energy audit,
and it seemed that these energy audits were well received by the industry staff.
&mong the &'(&) countries participating, successful cases of energy conservation presented
included the ceramics industry in @ietnam, hydroelectric power generation in :aos, the pulp and
paper industry in Indonesia, and the glass industry in Malaysia. -he selection of these industries
was made by the 3ambodian MIM(, which provided suitable information for the preparation of
the reports.
;+< &ctivities in Indonesia
& follow-up energy audit was carried out on a pulp and paper factory located in (ast 8ava.
-aking travel to and from 8akarta into consideration, a si6-day visit was scheduled. &nother walk
@I - $
through energy audit was also carried out in the same region and a seminar workshop was held on
the si6th day.
-he staffs of the pulp and paper factory were very serious about energy conservation, and all the
items for improvement recommended in 4hase % had been implemented, wherever possible.
-hey have reported on energy conservation activities at every 4R=M((3 seminar workshop,
having a significant influence on the industrial world of the &'(&) countries.
&mong the &'(&) countries, successful cases of energy conservation were reported by :aos,
regarding hydroelectric power generationE by Malaysia, regarding the glass and te6tile industriesE
by the 4hilippines, regarding the iron and steel industryE and by -hailand, regarding
cogeneration and the ('3= industry.
;$< &ctivities in the 4hilippines
In the 4hilippines, a follow-up energy audit was carried out on a steel rolling mill and a walk
through energy audit was carried out on another rolling mill. & seminar workshop was held on
the fifth day.
-he rolling mill for the follow-up energy audit was very serious about energy conservation and
keeping costs down and had organized an energy conservation team. 'uch activities began rather
recently after one of their managers participated in a training seminar on energy conservation in
8apan. (338 had to report the results of the follow-up energy audit.
'uccessful cases of energy conservation activities in &'(&) countries were reported by
Malaysia on the food and steel industriesE by @ietnam on the ceramics industryE and by
Indonesia on the pulp and paper industry.
"." 'tatus of (nergy 3onservation &ctivities in &'(&) 3ountries
;%< ,ollow-up energy audit of factories
-able @I-"-" shows a summary of the results of activities at the factories for which an energy
conservation audit was carried out in 4hase %. -he results are for the factories and ma!or
industries in each of the four countries we visited this time and those we carried out follow-up
energy audits on in "##$. ;&dditional information obtained afterwards is included in the latter<. -he
results achieved ;relating to the recommendations and advice given< are classified as either Hfinished,I
Hunder study,I or Hnot implementedI.
7ith regard to the follow-up energy audits of "##2, the sum of HfinishedI and HstudiedI, ;which means
that at least some measures have been taken< is about B#L of the total. -he remaining %#L is
Hunder studyI or Hnot implementedI and it is e6pected that some kind of measures will be taken in the
near future.
3ombining the results for "##$, it can be seen that ?+.+L of all activities have been implemented,
which surpasses the 9$.2L figure for "##$. -his indicates that all activities are being
energetically carried out. -his table also shows that energy conservation activities are especially
common in the Indonesian pulp and paper factory studied. -he results at the @ietnamese
ceramics factory were achieved after the follow-up energy audit in "##$, which shows that the
@I - 2
2
0
0
!
2
0
0
'

D

P
r
e
s
e
n
t
a
t
i
o
n
achievements there are due to the concerted efforts of the whole factory.
-able @I-"-" 'ummary of ((53 &ctivities ;,ollow-up (nergy &udit<
8tem Eum#ers and ?atio )*+
2ountry
2ompany Eame
)8ndustry+
?ecommended Finished
#y 5224 or Studied
Bnder Eot 8mp9
lmented
Study
Brunei Butra @eidel#er: 2ement ! 0
1
)2ement 8ndustry+
&
$* 0*
1%*
2am#odia
36- 8nternational 3f:
)=arment 8ndustry+
2ompany A
)=arment 8ndustry+
2
&%*
2
&%*
0 1
0* *
0 1
0* *
8ndonesia P" C5?"AS (525S '
2$ ' 0 & 0
)Pulp/Paper 8ndustry+ 100* 0* 0*
Philippines
2ompany 2
)8ron/Steel 8ndustry+
2
'
!0*
1 1
2!* 2!*
-ietnam @ai 0uon: Porcelain 2o.
11
2 10
0
9 1
)2eramics 8ndustry+ 91* 0* 9*
(ao P0?
Eum E:um @ydropo1er
'
' 0
0
Plant )Po1er 8ndustry+ 100* 0*
0*
3alaysia
3yanmar
Ara#93alaysia 0. B.
)"extile 8ndustry+
3ann "han#aya<an
)>il ?efinery+
'
9
''*
2
'
!0*
! 0
!&* 0*
2 0
!0* 0*
"otal %$ &! )$.*+ $ )10.*+ ! )&.'*+
200' only
&2
'0 )&'.!*+ % )11.*+1! )2'.2*+
;"< (nergy conservation activities at the newly visited factories
,our new factories were visited in "##2, one in each of the four countries. .etails are as
described above in the introductory paragraph supplied for each country. -hree of the four
factories had !ust started energy management. -he other factory had previous e6perience of
energy audit and the factory manager had taken a training course on energy management in
8apan. -herefore, the level of energy conservation activities at this factory was comparable to that
of the factories that had participated in 4hase % of the 4R=M((3 program.
.ue to the recent steep rise in energy prices, all the factories were eager to take some measures for
energy conservation, and this probably contributed to the welcome e6tended to the
investigation team. It is hoped that the information obtained from the on-site energy audit and
guidance will be utilized for the promotion of further energy conservation.
;+< 4articipants in the energy audit of factories and the seminar workshop
In the 4R=M((3 activities of "##2, government officials from member countries and managers
and engineers of private companies were supposed to play a proactive role in the follow-up
investigation and energy audit of new factories, with the assistance of (338 e6perts, on an =8-
basis. &s a matter of fact, nothing happened unless (338 e6perts took the initiative themselves.
=8- training had the intended result of increasing the number of participants in the energy audit
of factories in "##2 from an average of %.9 to an average of $.", as shown in -able @I-"-+.
=n the other hand, the number of attendees at the seminar workshop decreased from >%.2 to 29.2,
@I - 9
which may have been caused by budget restrictions.
-able @I-"-+ )umber of participants in the diagnoses and seminars in various countries
Item Pear
"##$ "##2
(nergy audit )umber of factories > B
-otal number of %% +?
participants
&verage number of %.9 $."
participants/factory
'eminar workshop )umber of seminars $ $
-otal number of "?9 ""9
participants
&verage number of >%.2 29.2
participants/seminar
;$< =utline of successful cases of energy conservation reported in the seminars
Representatives from si6 countries reported on %$ successful cases of energy conservation. 'ome
e6amples are shown in -able @I-"-$. &ctivities in hydroelectric power generation reported by :aos
and those in the glass industry and te6tile industry reported by Malaysia are omitted here because
they are not significantly different from those reported last year. Indonesia reported on energy
conservation activities in the pulp and paper industry, but these are also omitted because they appear
elsewhere in the description of activities in Indonesia.
;2< 'ummary of energy conservation activities in &'(&) countries in "##2
-he activities carried out in "##2 gave a strong impression that energy conservation is being
actively promoted in &'(&) countries. In particular, it seems that the recent steep rise in
energy prices has caused energy-poor countries to increase their efforts to promote energy
conservation in order to keep costs down.
-o promote energy conservation activities, recognition of their importance and clear leadership
by top management is required to trigger activity in each individual factory. =nce it is
understood that energy conservation leads to profits for the company and that it will eventually
benefit the society as a whole, energy conservation activities will be stimulated even more. It
cannot be denied that barriers e6ist to the promotion of energy conservation in &'(&)
countries, but we believe that such barriers will be overcome through the 4R=M((3 programs
and through various kinds of training seminars for further energy conservation.
@I - >
-able @I-"-$ 'uccessful cases of energy conservation reported by &'(&) countries
2ountry
8ndustry 5562 Acti7ities
Food 8ndustry
)5di#le >il ?efinery+
3alaysia
8ron/Steel 8ndustry
2apacityA
5AFA %00<t/y,
3illA !!0<t/y
2hemical 8ndustry
?8 2hemical 2orp.
Philippines
8ron/Steel 8ndustry
)By 0>5+
1. 8nstallation of economi.ers on (P #oilers
2. ;aste heat reco7ery from hot 1ater #oilers
. Process oil coolin: #y cold feed 1ater
'. 2ondensate collection system
"otal fuel sa7in: F 11&,%0=4/y )FApprox. 2,920<(/y+
1. 29sta:e recuperator )?eco7ery of flue :as temp.+
2. Air compressor chan:e, from piston type to
scre1 typeA Po1er sa7in: F '!*
. -S0 for rollin: mill coolin: 1ater pump process
Po1er sa7in: F 2!* compared to throttle 7al7e
Po1er sa7in: F 1.%*, Fuel sa7in: F 1.%*
"otal cost reduction F *
2han:e the 200?" refri:eration system from a 7apor
compression type to a 7apor a#sorption type, 1here7er there is
1aste heat and a need for chilled 1ater.
5ffect on producti7ityA D.&*
8ntroduction of outline of PhilippinesG steel industry and
H200! 0on 5milio A#ello 55 A1ardsI
J?ollin: 3ill 2o. sa7ed !$0<(/y of fuel oil #y heat reco7ery from
the furnace, etc. and Steel sheet coatin: 2o. sa7ed 10%<(/y of
oilK
Porcelain 8ndustry
Si:nificant percenta:e impro7ement after 200' follo1 up
)By 3>8+
Similar presentation at last Summary9;or<shop
-ietnam
Bric< 8ndustry
)By 3>8+
5ner:y audit at #ric< factoryA Fuel sa7in: F *.
Po1er sa7in: F 1* #y insulation stren:thenin:, etc.
5ner:y Audits at 12
3ain measures identified #y auditA
industrial factories
-S0, #oiler impro7ements, condensate collection
)By 8nstitute of
system, maintenance method, compressed air
5ner:y+
systems, etc. Sa7in:A Fuel F 0L$*. Po1er F !L'0*
;9< 0arriers to (nergy 3onservation in Industry and 4ossible 3ountermeasures
7e felt that this yearJs on-site survey highlighted the same barriers that e6isted last year. ,or
e6ample, lack of policies, shortage of personnel resources, low technical levels, a shortage of
finance, and a lack of information were frequent topics of discussion. -he attitude of top
management is yet another barrier to the promotion of energy conservation. It may be true that
companies with favorable business prospects make profits without promoting energy conservation, but
the situation will change as energy prices continue to rise.
".+ =utline of the Reports 4resented by the ,our Cost 3ountries at 'ummary 4ost 7orkshop
-his yearJs four host countries submitted reports on ((53 activities.
;%< Report of 0runei ;Material )o. .-"#+<
'ince 0runei is a producer of petroleum and natural gas, energy prices are low in this country,
whereas facilities for energy conservation are costly. -herefore, people are not always
interested in energy conservation and it is difficult to promote energy conservation without
reasonable incentives. It is therefore necessary to promote ((53 education of the general
public, to prepare policies and action plans, and to discuss how best to implement them.
@I - ?
;"< Report of 3ambodia ;Material )o. .-"#$<
-o overcome the low electricity diffusion rate of %>L and high electricity prices, it is planned to
triple the power supply over the ne6t decade. -he report presented was mainly concerned with
4R=M((3 activities in the garment industry. ,urther dissemination of energy
conservation in this country still seems to be necessary.
&ctivities planned in the future areG cooperation with -hailand regarding renewable energy and
energy conservationE participation in further 4R=M((3 activitiesE and the promotion of 3((4
;3ambodian (nergy (fficiency 4ro!ect< as a local initiative.
;+< Report of Indonesia ;Material )o. .-"#2<
It was reported that si6 walk through energy audits and %2 detailed energy audits had been
carried out for more than si6 types of industry. ;-his number includes the energy audits carried out
in the present 4R=M((3 program.<
It was also reported that M(MR was developing an energy conservation database ;.0< and an
energy efficiency model ;((M<, whose menu includes company profiles, facilities and power
consumption, fuel consumption, energy consuming facilities, and energy conservation
activities.
;$< Report of the 4hilippines ;Material )o. .-"#9<
-he energy conservation audit for the iron and steel industry carried out as part of 4R=M((3
and the results of the seminar held in the 4hilippines were presented. -he 4R=M((3 activities
are helpful for establishing information networks among private companies, and -. and .0
are useful for the ((53 of private companies. Cowever, there are many barriers still to be
overcome.
-he 4hilippines has an award system for the Industry and 0uilding sector and, in the Industry
category, "+ companies received these awards in "##$ and %2 companies received awards in
"##2.
&lthough energy conservation has not yet been legislated, the relevant regulations and rules
were e6plained.
".$ 4R=M((3 &ctivity 4lan for ,P"##9 ;Material )o. .-"#><
M(-I-&'(&) 4R=M((3 will be continued in "##9 with the &3(, (338 and ,4s ;,ocal
4oints< of each country carrying out the same key roles as they did in "##2. &s shown in ,igure
@I-"-%, on-site surveys in "##9 are scheduled for &ugust and )ovember, visiting two countries
each month. -his will include 'ingapore and -hailand, two countries that have not yet been
involved in any energy audit. -wo more countries that are actively promoting energy conservation
activities and can host the survey are invited to apply. -he selection will be decided at the
inception workshop in "##9.
7hen implementing the on-site survey, those &'(&) countries involved in energy audits are
obliged to select the factories to be audited, establish an energy audit team consisting of five or
more members sharing the necessary roles, implement preliminary education, and prepare a
@I - B
written reply to the questionnaire. & weekJs visit is scheduled for each country and a ma6imum of
two factories are selected for the follow-up energy audit and new energy audit. & seminar
workshop is then held where the energy audit team presents the results. &lso at the seminar, the
host country reports on its energy conservation activities and member countries designated by the
host country report on their activities. In the workshop, the preparation of -echnical .irectories
;-.<, and the formulation and status of .atabases ;.0<, 0enchmarks ;0M<, and 1uidelines ;1:<
are also discussed.
& final workshop is then held after summarizing all activities carried out in "##9.
Mear 200& 200%
Acti7ities 3onth
' ! & % $ 9 10 11 12 1 2
Preparation of 0etailed
)1+
8mplementation Plan 6
Preparation for 1st Site Acti7ity
"1o
1st Site Acti7ity )Follo19up
2ountries
)2+ Sur7ey 6 ;or<shop )2
2ountries++
Analyses of 1st Site Acti7ity
)+
?esults / Preparation for 2nd
Site Acti7ity
"1o
2nd Site Acti7ity )Follo19up
2ountries
)'+ Sur7ey 6 ;or<shop )2
2ountries++
Analyses of 2nd Site Acti7ity
)!+
?esults / Preparation for rd
Site Acti7ity
rd Site Acti7ity )S 6 P9
)&+ ;or<shop, "0 disemmination 6
0B/B3/=( formulation+
)%+ ?eport ;ritin:
,igure @I-"-% Implementation 'chedule, 4R=M((3 ;Industry< for "##9 - "##>
".2 .iscussion
;%< (nergy conservation energy audit, aiming at =8-
%< -here were no ob!ections to the request from (338 that an energy audit team consisting of
about five members should be established and that sufficient preparation must be undertaken.
-here was an opinion e6pressed that the required capabilities of the members must be clearly
defined. It is doubtful whether competent personnel can always be found.
'everal &'(&) countries, including 0runei, 3ambodia, Indonesia, :aos, and the 4hilippines
requested that the (338 e6pert team give a detailed lecture for about several hours on the
methods and techniques used by the energy audit team. It was pointed out that independent
energy audit is possible for some industries but not always possible for others. (338 and &3(
commented that those countries that are conducting an independent energy audit can make use
of the energy audit team. -he request for a field e6ercise to be held for all team members prior
to any actual energy audit will be considered as required.
"< -here was also recognition ;from -hailand and Indonesia< that the (338 e6perts are e6pected
@I - %#
to give supervision and guidance in energy audit to local engineers.
(338 and &3( concluded that energy audit is a key component of energy conservation and
that actual e6perience is important in developing energy audit techniquesE that it is important
to continue the energy audit activities, aiming at =8-, and differences in the level of training
must be taken into considerationE and that (338 staff should propose the methods to be used.
;"< Importance of successful cases of energy conservation
%< It is important to highlight successful cases of energy conservation in the seminar in order to
help motivate the participants. -his is also an effective way to promote energy conservation
and to introduce the follow-up activities planned for those factories where energy audit has
already been conducted. Aey points and methods of energy conservation are instrumental in
bringing about improvements for all the industry. ;Malaysia, :aos and 0runei<
"< 'uccessful cases serve as useful reference points for others. 1overnments should therefore
assist in the preparation of reports so that more cases are collected. -hey are also helpful for
legislation. ;Indonesia<
In Indonesia, it is a requirement that a report be submitted within si6 months of the energy
audit, and some successful cases have been reported. Cowever, it is often very difficult to have the
business world understand the meaning and ob!ectives of the energy audit and so the number
of successful e6amples reported is still very small. ,rom this year on, the Indonesian government
will attempt to have the business world understand the ob!ectives of the reporting process by
communicating the intentions of the government through the association. &t present, pilot
factories have been designated in four to si6 industrial fields in (ast 8ava to promote energy
conservation pro!ects.
+< 4roblems related to the location of the factory to be diagnosed ;:aos<
=ne energy audit was carried out in a town that took one whole day !ust to get to. &n effective
audit can be conducted even in a far away location. It depends on the situation ;&3(, (338<.
@I - %%
+. 4ost-7orkshop .iscussions
+.% -. ;-echnical .irectory<
&3( introduced a technical directory ;for the Industry and 0uilding sector< which has been
compiled from data provided by 8apan but and does not include successful cases, along with a
database ;for the 0uilding sector<. &lthough the system is being formed, the contents must be
enriched from now through the cooperation with the personnel of &3(.
+." .0/0M/1: ;.atabases/0enchmarks/1uidelines<
;%< 3larification of the ob!ectives and scope of the pro!ect
& common recognition is that there is a difficult problem about establishing
.atabases/0enchmarks/1uidelines due to the problem of confidentiality. -he purpose of this
pro!ect is to systematically construct an HIn-house .atabase/0enchmark/1uideline 'ystemI
utilizing the results from the energy audit activities so that energy management can be smoothly
implemented by each factory and building. -herefore, it must be emphasized that the ob!ective
is to design a standard database that can be used by all factories and buildings, and not to
construct a statistical system merely as a tool for formulating policies ;such as the &'(&)
labeling of buildings<. &3( added that although it takes time to establish, they e6pect to
complete a system ;including the industrial sector< to be completed ne6t year, and that they will
then discuss the matter further.
;"< .iscussion on the establishment of a .atabase/0enchmark/1uideline system
%< It is important to recognize what databases ;such as energy consumption, process, or facility<
are to be constructed and what their ob!ectives are. -he data currently available on the internet
are often meaningless. .etailed data are required. ;-hailand<
"< ,easible in-house .ata Management and in-house 0enchmarking systems are important.
&n in-house database is a collection of all the data required on site. 'uch databases are
actually used to implement energy conservation ;(338<. 'tatistical databases are quite
different.
&n in-house database is also a useful tool for policy making if it is used as a kind of model.
;0runei<
+< & Malaysian glass factory has succeeded in energy conservation by setting a benchmark at the
request of the government. (nergy conservation cannot be promoted based only on in-house
data. It is important to obtain information on successful e6ternal cases. ;(338<
$< -here are in-house benchmarking and e6ternal benchmarking systems, but it is inevitable that
private companies will refuse to provide some information in order to maintain confidentiality.
-herefore, it is recommended that each industrial association arrange some kind of agreed
system among its member companies by which information can be e6changed. Malaysia has
adopted such systems in four different industrial sectors. It is also possible to use the results of
the energy conservation audit as the database. Information from three to four factories would
@I - %"
be adequate. ;Malaysia<
2< .ata from the energy audit are not sufficient to establish an entire database. It is impossible to
establish a system that can be used at the factory level for all industrial sectors. (ven the
amount of data provided by "# or so companies is insufficient. ;-hailand<
It is definitely better to have more data but, as shown in 8apan, even a small amount data can
be effective. ;(338<
9< -he discussion has been very instructive for &3(, and &3( will make use of it in their future
work. &3( intends to collect further information with the cooperation of the 33I ;3hamber of
3ommerce 5 Industry< of member countries. ;&3(<
&'(&) countries agreed to accept the proposal of &3(.
Indonesia will cooperate in establishing databases in three industrial sectors.
-he compilation of the database is certainly an important activity but it will be difficult to
decide who can access it. -he problem of confidentiality arises if the database is made open to the
public. ;:aos<
It is difficult to construct a common system for all the &'(&) members. It must be
constructed on a country-by-country basis. ;-hailand<
In conclusion, it was agreed that the ob!ective of the basic policy should be to utilize the results
since "### for the establishment of specific databases so that all members can use the data. It was
also decided that the original approach we have adopted, to date, should be maintained in the
future.
-he yearJs achievements and the results presented in the above discussions were much
appreciated by all who participated. In the post-workshop session, the philosophy, basic approach
and plans for the ne6t year were unanimously agreed upon, and the basic plan proposed by 8apan
was adopted unanimously with the consent of all the ,ocal 4oint representatives from the member
countries and &3(.
@I - %+
. ?eference 3aterial
-he materials used at site activities in $ countries and summary 5 post workshop regarding to the
ma!or industries are listed here.
-hese materials are as followsE
- 'ite activity schedules
- &nswers to questionnaires at energy audit
- 'eminar/7orkshop programs
- 4resentation materials at site visits from &'(&) countries, &3( and 8apan
- 4resentation materials at '-4 workshop from &'(&) countries and 8apan
-he 4articipant :ists are omitted because (338 could receive this from only one country. -he
material numbers are shown as H.ocument )o. .-%##I, etc.
4< aterials for the energy au!its an! "eminar?1or0shop in each country
%.% &ctivity 'chedules of (338 -echnical (6perts
.-%#%( 'chedule of %st 'ite &ctivity
.-%#"( 'chedule of "nd 'ite &ctivity
%." &nswers to questionnaires at follow up and walk through energy audit
.-%#+( &nswers from 3ompany &, 3ambodia
.-%#$ &nswers from M5@ International Manufacturing :td., 3ambodia
.-%#2( &nswers from 3ompany 3, 4hilippines
.-%#9 &nswers from 4rimary 'teel 3orporation, 4hilippines
.-%#> &nswers from 4-. Aertas :eces ;4ersero<, Indonesia
.-%#? &nswers from 0utra Ceidelberg 3ement 0.) 0C., 0runei .arussalam
%.+ 'eminar-7orkshop 4rograms in $ countries
.-%#B 'eminar-7orkshop 4rogram in 3ambodia
.-%%# 'eminar-7orkshop 4rogram in 4hilippines
.-%%% 'eminar-7orkshop 4rogram in Indonesia
.-%%" 'eminar-7orkshop 4rogram in 0runei .arussalam
%.$ 4resentation materials at 3ambodia
.-%%+ =verview of ((53 &ctivities in 3ambodia
.-%%$ 3ase 'tudy, 1lass Industry in Malaysia
.-%%2 3ase 'tudy, 4ulp and 4aper Industry in Indonesia
.-%%9 ,ollow p of (nergy &udit ,indings at 1arment ,actories, 3ambodia
-
%
.-%%> 7hat are the 0arriers and Measures on the Implementation in IndustryR
.-%%? -he .evelopment of -echnical .irectory ;%< and 'ample ;"<
.-%%B -he .evelopment of .atabase/0enchmark/1uideline for Industry
%.2 4resentation materials at 4hilippines
.-%"# ((53 4romotion &ctivities in the 4hilippines
.-%"% ((53 &ctivities in Industries in 8apan
.-%"" =verview of 7holesale (lectricity 'pot Market, 4hilippines
.-%"+ ((53 0est 4ractices in 3hemical Industry, 4hilippines
.-%"$ ((53 0est 4ractices in Iron 5 'teel, and ,ood Industry, Malaysia
.-%"2 ((53 0est 4ractices in 3eramic Industry, @ietnam
.-%"9 ,indings of ,ollow p (nergy &udit at Iron and 'teel Industry in the 4hilippines,
Introduction ;%< and ,ollow p ;"<
%.9 4resentation materials at Indonesia
.-%"> =verview of ((53 4rograms of &'(&), &3(
.-%"? Initiatives and 4rograms of (338 on ((53 in Industry in 8apan
.-%"B 3ase 'tudy of 4ulp and 4aper, Indonesia
.-%+# 3ase 'tudy of Cydropower, :ao 4.R
.-%+% 3ase 'tudy of 1lass/-e6tile Industry, Malaysia
.-%+" 3ase 'tudy of 'teel and 3ement, 4hilippines
.-%++ 3ase 'tudy of 3o-generation and ('3=, -hailand
%.> 4resentation materials at 0runei .arussalam
.-%+$ (nergy =verview in 0runei .arussalam
.-%+2 3ase 'tudy of 3ement Industry, 0runei .arussalam
.-%+9 3ase 'tudy of 3eramics/4orcelain and 0rick Industry, @ietnam
.-%+> 3ase 'tudy of 'teel and (nergy &udit, (338 for 4hilippines
.-%+? -he .evelopment of -echnical .irectory, (338
2< aterials for the "ummary:Post 1or0shop (ajor In!ustries$
.-"#% 'ummary 7orkshop &genda ;Industry =nly<
.-"#"( 'ummary of :ocal &ctivities, (338
.-"#+ (valuation and ,uture Improvement of :ocal &ctivities, 0runei .arussalam
.-"#$ (valuation and ,uture Improvement of :ocal &ctivities, 3ambodia
.-"#2 (valuation and ,uture Improvement of :ocal &ctivities, Indonesia
.-"#9 (valuation and ,uture Improvement of :ocal &ctivities, 4hilippines
.-"#> 4roposed 4lan for "##9-"##>, (338
-
"
Any in!ivi!ual or organiFation +ho ma0es part or all of this report
pu-lic must o-tain prior permission from International Engineering
7epartment of Energy Conservation Center (apan<
Phone 54?3?5523?3045
,a* 54?3?5523?3022