2008 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 Conservationin Major Industries in ASEAN Countries)

Activity Report 2008-2009

March, 2009

The Energy Conservation Center, Japan

Preface
In recent years, prevention of global warming has become a common issue for mankind
on one hand, while sustainable economic development is actively demanded on theother. Thus, we are trapped in a situation in which we must overcome two challenges
that completely contradict each other. Necessary for overcoming this situation aretechnical innovations, such as development of technologies for the efficient use ofenergy, technologies for utilizing energy with minimum burden on the environment, andenergies having little impact on the environment.
To contribute to the balanced development of economy and the environment indeveloping countries, we need to provide an assistance that is acceptable andappropriate to each country, by assessing the reality of energy usage and environmental
conservation measures, and thoroughly examining the state of infrastructuredevelopment, life styles, and other national conditions in respective countries.
Under this situation, we entered a new phase of activities in 2004, with an aim to
implementing energy audits and improvement measures, and strengthening themechanism for greater dissemination, based on the results of energy audits and related
technology transfers implemented between 2000 and 2003, which targeted one industry
each in ten ASEAN countries.
This year, we have continued to implement and disseminate achievements obtained in
the past 8 years. Specifically, we focused our attention on the food industry in Thailand,
the ceramics industry in Indonesia, and the textile industries in Myanmar.
In addition, we held a seminar-workshop in each country with the participation not onlyof people from the host country, but also of governmental authorities and factory
personnel of different industries in other countries as well. They were invited to present
successful cases of energy conservation measures, to enhance information sharing in the
ASEAN region and create a foundation for dissemination activities. The
seminar-workshops also provided a forum for discussing the concept and formulation
policies regarding the technical directory and in-house database, and some specificexamples were presented.
Meanwhile, in the effort to strengthen the mechanism for implementing anddisseminating our activities, we have conducted follow-up surveys in factories that wereaudited in the past, to assess the implementation status of recommended improvement
measures, as well conducted walk-through energy audits in other factorie s to ensure thetransfer of energy audit technologies.
Moreover, as an effective means of achieving our objectives, we have continued

on-going effort to develop a technical directory and in-house database system foreach industry.
On concluding this year, we made an evaluation of the PROMEEC project in thesteering committee, and confirmed a foundation steadily established for energy
conservation promotion in the ASEAN countries. From now on, self- help efforts are
required in order to utilize the transferred technologies and to disseminate all over thecountry and region.
We hope this project will contribute to energy and environmental conservation inindustrial sectors in the ASEAN countries, and thereby allow each country to achieveenvironmentally friendly and sustainable economic growth. We also hope this projectwill serve as a bridge of technical exchange and friendship between Japan and theASEAN countries.
March 2009
The Energy Conservation Center, Japan

Contents
Abbreviations
Overview
I. Purpose and background of project
II. Thailand (food industry)
1. Overview of local activities
2. OJT energy audit (May Ao Foods)
3. Overview of seminar/workshop
4. Attached documents
III. Indonesia (ceramic industry)
1. Overview of local activities
2. OJT energy audit (LIK)
3. Follow- up survey (textile industry)
4. Overview of Seminar/workshop
5. Attached documents
IV.
Myanmar (textile industry)
1. Overview of activities
2. OJT energy audit (Mayangone Textile (1))
3. Advisory visit (FAME Pharmaceuticals)
4. Overview of Seminar/workshop
5. Attached documentation
V. Summary/post workshop
1. Overview of workshop
2. Activity report for 2008 and action policies for 2009
3. Basic policies towards Phase 3

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I-1
II-1
II-1
II-1
II-8
II-16

III-1
III-1
III-1
III-17
III-21
III-31

IV-1
IV-1
IV-1
IV-5
IV-7
IV-16

V-1
V-1
V-2
V-4

Abbreviations
ASEAN
Association of Southeast Asian Nations
APAEC
ASEAN Plan of Action for Energy Cooperation
PROMEEC Promotion on Energy Efficiency and Conservation
ISO
International Organization for Standardization
GMP
Good Manufacturing Practice
HACCP
Hazard Analysis and Critical Control Point
EE&C
Energy Efficiency and Conservation
TD
Technical Directory
DB/BM
Database / Benchmark
IHDB
In-House Database
OJT
On the job training
EMS
Energy Management System
SEC
Specific Energy Consumption
CSR
Corporate Social Responsibility
SCADA
Supervisory Control and Data Acquisition
COP
Coefficient of Performance
VSD
Variable SpeedSH
Sensible heat
DHCR
Direct Hot Charge Rolling
EM H/B
Energy Management Handbook
TPM
Total Production Management
ESCO
Energy Service Company
ACE
ASEAN Center for Energy
METI
Ministry of Economy, Trade and Industry
ECCJ
The Energy Conservation Center, Japan
SOME-METI ASEAN Senior Officials Meeting on Energy - METI
EAS-ECTF
East Asia Summit - Energy Cooperation Task Force
ADB
Asia Development Bank
UNEP
United Nations Environmental Programme
UNIDO
United Nations Industrial Development Orga nization
UNESCAP
United Nations Economic and Social Commission for Asia and thePacific
GDP
Gross Domestic Product
FP
Focal Point
Vietnam
DOE
Department of Energy
ECC-HCMC Energy Conservation Center in Ho Chi Minh City
iii

MOIT
EECO
HUT

Ministry of Industry and Technology
Energy Efficiency and Conservation OfficeHanoi University of Technology

Philippines
DOE
PNOC
PCIEROMERALCO

Department of Energy
Philippines National Oil Corporation
Philippines Council for. Industry & Energy and Development
Manila Electric Railroad and Light Co.

Indonesia
BPPT
EMI
DGEEU

Energy Technology Center, MOST
former KONEBA
Directorate General for Electricity and Energy Utilization

Malaysia
PTM

Pusat Tenaga Malaysia

Thailand
DOE
DEDE
BSI
FTI/IIE
ENCON
MOE
MOF

Departme nt of Energy
Department of Alternative Energy Development and Efficiency
Bangkok Steel Industry Public Co., Ltd.
Federation of Thai Industries/Institute of Industrial Energy
Energy Conservation
Ministry of Energy
Ministry of Finance

Myanmar
MTI

Myanmar Textile Industriesiv

Overview
The member countries of ASEAN continue to post rapid economic growth and are
expected to report dramatic increases in the volume of energy consumption in the
coming years. It will likely become necessary to focus on using energy more
efficiently and on preventing global warming. As this project enters its ninth year, theactivities of project counterparts, ACE and ASEAN countries, become even moredeveloped, and changes in their attitude with respect to reducing energy consumption
have become widespread against the backdrop of rising energy costs in line with recent
price hike of crude oil and of the ratification of the Kyoto Protocol on February 16,
2005.
As the last year of Phase 2, this year has been positioned as the year in which we will
sum up the results of activities undertaken in Phase 2 over the last four years and verify
the implementation and dissemination of results achieved to date through continuingself-help efforts. That is to say, it has been determined that we will aspire to establish afoundation for implementing and disseminating the results of energy audits conducted
at industry factories in all ten ASEAN member countries over the last eight years,
inclusive of Phase 1. Specifically, the following activities were conducted in each of
three countries: Thailand (food industry), Indonesia (ceramic industry), and Myanmar(textile industry).
♦ Follow- up surveys and energy audits
At factories an energy audit has been conducted in the past, a follow- up survey shallbe undertaken. At factories no energy audits have been made before, an energy audit
shall be undertaken.
♦ Holding seminars/workshops
Factory officials, including those from other industry sub-sectors, and concerned
persons from other ASEAN countries will participate and present successful cases inorder to disseminate achievements in this project to ASEAN member countries,
including successful cases and know-how.
♦ Development of technical directories (TDs)
Technologies and successful cases will be registered and disseminated through TDs,
expecting to be effective in the iron&steel industry and ceramic industries of
ASEAN.
♦ Development of in-house databases (IHDBs)
As conducted last year, a promotion and dissemination of IHDBs for cement, textile
and food industries will be continued. In addition, development of IHDBs foriron&steel and ceramic industries shall be started for aiming at evaluating theeffectiveness thereof through a trial use at the actual factories.

vThrough follow-up surveys conducted in each country, considering how effectively
knowledge and skills concerning energy audit technologies are transferred to ASEAN
engineers, firsthand guidance was provided to local concerned persons, and activities
to further accelerate technology transfer were carried out. At factories where theimplementation of recommended measures was slowly progressing, an examination
was conducted to identify the problems against implementation of measures as well as
the solutions thereof.
Seminars/workshops held in each country have attracted numerous factory andgovernmental participants. These seminars/workshops have fulfilled their significant
role in terms of sharing and dissemination of information.
Local activities for this year were commenced through an inception workshop held in
July 2008 in Port Dickson (Malaysia), which was attended by representatives (i.e.,
focal points) from ASEAN countries. At the workshop, implementation plans for thisyear, countries in which local activities were to be implemented, and preparations
required for local activities were confirmed. Local activities, which included
workshops in the three countries, were thereafter steadily carried out until December
2008.
As the final activity of this year, a summary/post workshop was held in Manila(Philippines) in February 2009. Focal points from ASEAN countries attended thisworkshop. Reports were presented to share the results of activities in the three
countries among ASEAN countries and deliberations pertaining to the development of
TDs and IHDBs were conducted. This workshop was concluded with a discussion of
the policy governing future project initiatives, including with respect to efforts to beundertaken next year.
The main activities for this year corresponding to major industry sub-project are as
follows:
I. Local activities in Thailand :September 28 to October 4, 2008
1. An energy audit was conducted at a food factory in the province of Samutprakarn.
The local audit team consisted of engineers from the Ministry of Energy, energy
consultants, and engineers of the food factory. A focal point served as leader andaudits were carried out on an OJT basis.
2. A seminar/workshop was attended by approximately fifty persons and a proactive
exchange of information was undertaken through the following presentations anddiscussions:vi

(1) Thai and Japanese presentations pertaining to energy conservation policy andmeasures;(2) Presentations of successful cases concerning energy conservation by officials fromThailand and other ASEAN countries;(3) Presentation of energy audit results by the local audit team;(4) Presentations by ACE and ECCJ pertaining to development of TDs and IHDBs.
II. Local activities in Indonesia:
November 17 to November 25, 2008
1. In Indonesia, an energy audit was made at a ceramic factory on the outskirts of
Jakarta. Engineers from the Ministry of Energy and Mineral Resources, the Ministryof Science and Technology, a state-owned company dealing with energy
conservation services, and the ceramic factory participated as members of the local
audit team; unfortunately no representatives of the ceramic industry did not takepart in the audit. A technological conference was held with a participation ofengineers from textile factories in East Java, where audits had been conducted in thepast. After briefing on the situation of implementation of proposed measures as wellas the following discussion, practical advice and guidance were given by ECCJ
engineers
2. Approximately 50 persons participated in a seminar/workshop. In addition toparticipants from industrial circles, including the ceramic industry, representatives ofenergy service companies were also in attendance and lively discussions were
facilitated. Presentations on best practice were made by officials from ASEAN
countries and a report on the results of the audit conducted at the ceramic factorywere delivered, such that we believe that this seminar/workshop was meaningful for
attendees.
III. Local activities in Myanmar:
November 27 to December 2, 2008
1. An energy audit was implemented at a textile factory in Yangon city. The local audit
team consisted of engineers belonging to the Ministry of Industry (1), the Ministryof Industry (2), the Ministry of Energy, and the textile factory to be audited. The
audit was conducted on a simplified OJT basis over 1.5 days and basic audit
technologies were transferred to Myanmar engineers.
An advisory visit was paid to a pharmaceutical factory producing herbal medicines
in the same city for half a day. After interviewing about the actual state of energy
conservation activities, factory walk-through was followed by guidance and advice.

vii

2. A seminar/workshop was attended by approximately 40 persons, consisting
primarily of engineers belonging to state-run enterprises, and was concluded on a
successful note. Presentations concerning best practices from ASEAN countries
were informative for participants from the state-run enterprises of Myanmar.
IV. Summary/post workshop
February 26 to 27, 2009:
A summary/post workshop was held in Manila, Philippines, and was attended by atotal of twenty-two participants: ten participants from ten ASEAN countries, five
participants from ACE, three participants from ECCJ, and the remainder from hostcountry, Philippines. As this year constitutes the last year of Phase 2, an evaluation of
Phase 2 was first conducted to identify and account for the specific activities that wereattained and not attained. Based on this evaluation, we verified and agreed on basic
policies toward Phase 3, including project policies for the coming year.
Finally, in implementing this project, we were able to obtain the full cooperation of
persons in charge at ACE and at relevant organizations and companies from eachcountry. We hereby take this opportunity to express our sincere appreciation for theirefforts.

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Activity Report 2008-2009
Programs for Promotion of Energy Conservation in Major Industries in ASEANCountries
I.

Purpose and background of project

In order to promote the dissemination of energy saving technologies in major industriesof ASEAN countries, this project contributes to the promotion of energy conservationand the protection of environment by supporting the activities implemented in eachcountryThis project was commenced in 2000 with the aim of reducing energy consumption in
ever- growing industrial sectors in the ASEAN region. ASEAN refers to this project as
PROMEEC (Major Industries). PROMEEC project was certified at a meeting ofministers in charge of an energy portfolio in ten me mber countries of ASEAN. The
project has been carried out in collaboration with the Ministry of Economy, Trade andIndustry of Japan.
* PROMEEC stands for Promotion of Energy Efficiency and Conservation
The objectives of this project are as follows:
1. To establish close collaborative links between ASEAN countries and Japan in theenergy sector;
2. To promote energy efficiency and conservation in major industries based in ASEAN
countries;
3. To transfer the Japanese technologies and disseminate excellent energy conservation
measures in these fields into ASEAN countries;
4. To build a capacity of engineers of ASEAN countries through energy audit and its
related OJT;
5. To develop technical directories (TDs) and in- house databases (IHDBs) andformulate benchmarks (BMs) for utilizing on energy audit in ASEAN countries.
Based on the recognition that this cooperative project is to be continued to Phase 3, thisyear is positioned as the fourth year of Phase 2 according to consultations held to datewith ACE and ASEAN countries. Based on the achievements attained in ASEAN
countries in Phase 1 & 2, a foundation for deploying energy conservation activities wasestablished within all ASEAN countries on an equal footing with one another.

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Phase 1: Technologies and experiences were transferred from Japan to ASEAN
countries (completed in 2003).
Phase 2: Japan and ASEAN countries implemented improvement measures jointly anddisseminated the said measures within each country as well as within othercountries (completed in 2008).
Phase 3: Energy conservation is promoted through the self- help efforts of ASEAN
countries (started in 2009)
With Phase 2 initiated in 2004, activities for establishing a foundation to
implementation and dissemination was started. A follow- up survey has started in orderto monitor the implementation of EE&C measures proposed in previously-audited
factories. Midst the Phase 2, activities for development of energy management tools has
started, for example, technical directories (TDs), in- house database (IHDBs) for eachindustry by each country. This year, development and dissemination of the IHDBs were
implemented for the food industry in Thailand, the ceramic and textile industries inIndonesia, and the textile industry in Myanmar. Needless to say, activities concerningenergy audits and seminars/workshops have been conducted since a start of Phase 1 .

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II. Thailand (food industry)
1. Overview of local activities
ECCJ experts visited Thailand on official business between September 28 and October
4, and conducted an energy audit at a food factory and held a seminar/workshop withthe aim of exchanging information with ASEAN countries. The energy audit was
conducted with the participation of twenty-two engineers from the Ministry of Energy,
an audit services company, the food factory to be audited, ECCJ, and ACE. At thefactory, guidance on OJT audit was provided with respect to technologies for auditing
high energy-consumption equipment consisting of refrigeration systems, cookers andfryers, rotary machineries, and systems for recovering waste heat from discharged water.
A seminar/workshop was successfully held and attended by approximately 50
participants. Presentations of successful cases concerning energy conservation were
given at the seminar by representatives of Malaysia, Philippines, Vietnam, and Thailand.
The caliber of presentations of audit results by energy audit team was high. Based onreasonable inferences, these local activities are believed to have contributed
significantly to the promotion and dissemination of energy conservation in the Thai
industry
Dispatched officials: Hiroshi Kuroda, Kokichi Takeda, and Taichiro Kawase of the
ECCJ International Engineering Department
Schedule of activities:
Sept. 29 – Oct. 2: OJT energy audit (May Ao Foods)
Oct. 3: Seminar/workshop
2. OJT energy audit (May Ao Foods)(1) Participants
DEDE: 5 participants (Mr. Sarat and 4 engineers)
Arun Chaiseri Consulting Engineers Co.: 4 participants (Vice-President Mr. Panjaand 3 engineers)
May Ao Foods: 8 participants (Vice-President Mr. Prasit and 7 engineers)
ACE: 2 participants (Mr. Zamora and Mr. Ninh Hai)
ECCJ: 3 participants (Mr. Kuroda, Mr. Takeda, and Mr. Kawase)II-1

Total: 22 participants(2) Overview of the factory
Operations started in August 1996
Situated in the Bangpoo Industrial Estate near the seacoast along the Gulf of Thailand
30 kilometers southeast of Bangkok
Product: seafood (frozen shrimp)
Production output: 4,299 tons per year (2007)
Production equipment: thawing, washing/cleaning, boiling, quick freezing,
frying, packing, refrigerated storage, shipping
Energy consumption: fuel 444 kL/yr., electricity 8.71 million kWh/yr. (2006)
Employees: 850 workers, 2 shifts
Website: www.mayaogroup.com(3) Overview of energy audit
1) Local audit team
The audit team consisted of fourteen engineers belonging to the Ministry of Energy(DEDE), the audit services company (Arun), ACE, and ECCJ and was led by focal point
Mr. Sarat. Mr. Sarat and Mr. Panja (Arun) acted effectively as interpreters between Thaiand English. Arun provided the measuring instruments as requested, and conductedmeasurement work. May Ao Foods proactively disclosed utility equipment as well as
production equipment.
2) Interview
Before commencing an inspection of equipment, an oral interview was conducted withrespect to the production process, recent production output and energy consumption
figures, responses to a preliminary questionnaire, and problems concerning energy
conservation as perceived by the factory. With the company having been granted ISO,
GMP, HACCP, and various types of certification, the interview proceeded efficiently.
3) Expectations of the factory toward the audit
The factory indicated that energy conservation in its refrigeration system and water
conservation were the most important issues. Reduction of refrigeration energy andwater conservation are common issues in all seafood factorie s and not unique to thisfactory.

II-24) Equipment inspection
The audit team spent a whole day inspecting equipment. The main issues revealed
through this inspection were as follows. Various types of measurement wereconducted in order to further analyze these issues in detail.
・Reduced efficiency of refrigeration equipment
・Unnecessary refrigeration load
・Dissipation of heat from hot surfaces in the processing room
・Excessive lighting energy in the processing room
・Unnecessary heat sources within refrigerated stores
・Improper placement of items within refrigerated stores・Low boiler efficiency
・Cold heat recovery from low-temperature wastewater
・Energy conservation with respect to pumps and fans
(4) Audit results
On the final day of the on-site audit, an overview of audit results was presented to thefactory executives and engineers as a preliminary report. The collected data wereanalyzed in detail upon return to Japan of ECCJ experts, and the following conclusions
were obtained. Refer to Attach II-1 (Analysis of Energy Audit Data for Heat Energy)
and Attach II-2 (Analysis of Energy Audit Data for Electric Energy) for investigation
details, including technical calculations.
1) State of energy management
Establishment of an energy conservation promotion committee, appointment of persons
in charge of energy management, implementation of employee education programs, andother activities were indicated as being completed on the responses to questionnaire.
With respect to production equipment, it was found that knowledge acquired throughthe process of obtaining various types of certification was taken advantage of forcarrying out the methodical operations, including in terms of maintaining proper logs.
With respect to utility equipment, however, it was felt that, while some measures had
been undertaken, there was still room for further improvements. For example, while
specific energy consumption (SEC) was monitored and managed with the prescribedtargets for the factory as a whole, management by equipment had not been carried out

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for utility equipment, in particular for the refrigeration system. As it is believed thatmonitoring through use of in- house databases (IHDBs) is effective for management by
equipment, IHDB input forms were provided (Attach II-3 (In-House Database for Food
Industry)).
2) Identified problems in equipment inspectiona) Reduced efficiency of refrigeration equipment
Having been installed over ten years ago, the refrigeration system of the factory showedsigns of aging. Specifically, it was suspected that the condensers had suffered a drop in
efficiency. Various measurements were then made for evaluating the efficiency ofcondensers on ice- making machines (M2 factory) and the efficiency of cooling towers.
These measurements verified a decline in the efficiency of condensers. Fouling ofcondenser tubes (water side) and air-intrusion into ammonia refrigerants were thoughtto account for this decline. These issues should be immediately addressed, such that full
rehabilitation can be expected to reduce power consumption for refrigeration equipment
by between five and ten percent. The operation of cooling tower unit was properly
managed, and performance was demonstrated according to design. While otherrefrigeration equipment could not be audited owing to time restrictio ns, condenser
performance is expected to have declined, which means that performance measurements
should be promptly undertaken.
b) Unnecessary refrigeration loads
Several unnecessary refrigeration loads were detected where refrigeration is used. If
appropriate measures were taken to address, for example, heat dissipation from hot
surfaces in the processing room, excessive lighting energy in the processing room, andheat sources within refrigerated sections, these issues could be removed from therefrigeration loads. Each of these issues is described in detail below.
c) Dissipation of heat from hot surfaces in the processing room
The surfaces of cookers and fryers have not been treated for thermal insulation. As theseunits have been installed in the air-conditioned processing room, heat dissipation fromthe surfaces of equipment contributes not only to an increase in the refrigeration load
but also to an increase in the air-conditioning load. In order to quantitatively evaluate
the said dissipation, surface temperature measurements and other assessments were
undertaken at non-thermally insulated points. As a general rule, high-temperatureII-4

equipment should be kept separate from air-conditioned spaces. Partitioning by way of
the use of simple plastic curtains or other such measures would be desired.
d) Excessive lighting energy in the processing room
A high ceiling in the processing room and numerous fluorescent lighting fixturesinstalled contribute to an increase in the air-conditioning load. In order to reduce thenumber of fluorescent lighting tubes, a shift from general lighting to task-ambient
lighting is expected to be effective. To ascertain current energy use for lighting, theintensity of illumination in the processing room was measured. While detailed
calculations have not yet been completed, the number of fluorescent lighting tubes canlikely be reduced by half.
e) Unnecessary heat sources within refrigeration stores
Within refrigerated stores, there are several heat sources, for example, fan coil motors,
interior lighting, heat penetration through walls, forklift power motors, outdoor air
penetration through door openings, and heat release due to worker’s metabolism. In
order to examine these sources, the state of fan coil operations, state of interior lighting,temperature of outside walls, and the air-tightness of doors were investigated.
Where the interior temperature of refrigerated stores has been sufficiently low, fan coilmotors should be either shut off or switched to low-speed mode. While it could not be
confirmed whether the fans were of a type that allows for switching between low-speed
and high-speed modes, these fans should be replaced by two-speed-type fans if no such
option is available on existing fans. Where work is not being undertaken, lighting within
refrigerated stores should in principle be turned off. For this purpose, existing lighting
should be replaced with lighting linked to motion sensors. The temperature of theoutside walls of refrigerated stores was measured. With the temperature of the outside
walls being one to two degrees Celsius lower than the ambient air temperature, the heatinsulation performance of the outside walls was determined to be normal. As for the
air-tightness of the doors, no particular issue of note was observed.
f) Improper placement of items within refrigerated stores
It is important that the flow of cold air inside refrigerated stores come into contact
evenly with all items. Items placed in dead zones not exposed to a flow of cold air willtake time to cool down, which in turn extends the duration of operations of refrigerationequipment. Accordingly, items should be spaced apart. In addition, it is important that aII-5

passageway of air be secured in front of fan coil air outlets. While the factory has awarehouse for finished products and a warehouse for intermediate products, items were
found to be piled up excessively in front of fan coil air outlets in the finished products
warehouse.
g) Low boiler efficiency
Two natural gas- fired boilers are operated in the factories. The outside service company
is entrusted to conducting measurement work of boiler gas emissions six times a year.
This data was obtained and analyzed by the audit team. The concentration of oxygen
found in gas emissions was between two and eight percent. Typically, oxygen
concentration should be maintained at between 2 and 3.5 percent. There was some data
exceeding this standard. it is likely that measurement work was done either at the timeof low boiler load operations or immediately after combustion chamber purging
operations The concentration of oxygen rises during low- load operations, whichsuggests that the volume of combustion air is not being adjusted. When low- load
operations are ongoing, the volume of combustion air needs to be adjusted. On the other
hand, the temperature of gas emissions was found to be between 150 and 200 degree
Celsius. At these temperatures, it seems difficult to realize an economic payout withmeasures to recover heat from gas emissions, such as by way of the installation of
economizers.
h) Cold heat recovery from low-temperature wastewater
In the frozen fish processing room, low-temperature wastewater with approximately 18
degree Celsius is generated from the thawing and cold-water cleaning/washingprocesses. At the same time, a water chiller has been installed in order to produce cold
water for cleaning/washing purposes. If cold heat from low-temperature wastewater
were used to pre-cool raw soft water chilling energy in the water chiller could be
reduced. In this connection, estimation of the volume of low-temperature wastewater
was made, and the temperature of low-temperature wastewater was measured. While theresults thereof are based on many assumptions, it is expected to recover at least 30,000
kWh per year in case of the M1 plant.
i) Energy conservation with respect to pumps and fans
The factory has numerous pumps and fans operated with significant load fluctuations.
As countermeasures have not been adopted to mitigate load fluctuation since thecommencement of operations, the potential for energy saving through mitigation of load

II-6

fluctuation was examined. To illustrate, daily fluctuation of motor power consumptionof some pumps and other variables was measured. As a result, it is expected that power
consumption can be cut at least by fifty percent. Supposed that other pumps and fans are
similarly positioned, huge saving potential can be expected in the factory as a whole. It
is recommended that measures should be taken immediately to pumps audited in thisaudit in collaboration with audit services company (Arun), and likewise, investigations
into applicability to other pumps and fans should be undertaken.
(5) Comments
1) In contrast to OJT audits conducted until last year, this year very few participants justobserved the progress in audit activities, which was carried out mainly by Japaneseexperts; instead most of participants behaved positively and took charge of somefunction or duty in the audit, for example, measurement work. The audit teamconstituted a well-rounded lineup, consisting of fourteen engineers from the Ministry ofEnergy (DEDE), the audit services company (Arun), ACE, and ECCJ. The organizationof the audit team could be a model case on which to base PROMEEC activities in the
future. In the OJT audit, ECCJ experts understood the excellent capacity of engineers in
the energy service company (Arun) of Thailand as well as a high level of technicalknowledge and skills. .
2) While the responses to preliminary questionnaire were received upon arrival of theauditing team on the audit site, required questions were properly answered, and the
responses were of considerable assistance in carrying out the audit activities. Measuring
instrument s were prepared as requested, which helped to generate quantitative results.
3) It is admirable that focal point Mr. Sarat contributed to a success of OJT audit formaking thorough preparations, including organization of the audit team, provision of
responses to the preliminary questionnaire, and arrangement of measuring instruments.
4) The factory also arranged requested matters perfectly for the audit. In addition,
production equipment was also satisfactorily disclosed for the audit team Thanks tothese efforts, various energy saving measures were proposed, taking into account actual
operations of the factory as a whole. We both perceive a strong desire of top
management of the factory toward energy saving measures and would like to express
our appreciation for the cooperation that was extended for the audit team.

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3. Overview of seminar/workshop(1) Time and place
October 3, 2008 (08:30 to 16:40)
Ramada D’ma Bangkok Hotel(2) Participants: approx. 50 persons
Thai government officials: 7 persons
Mr. Danai Egkamol (Director, Bereau of Energy Regulation
and Conservation, DEDE)
Mrs. Amaraporn Achavangkool (DEDE)
Dr. Prasert (DEDE)
Mr. Sarat Prakobchart (Senior Engineer, DEDE)
Mr. Napha Wongpardit (Senior Engineer, DEDE)
Mr. Pinyo Tanthumart (Senior Engineer, DEDE)
Mr. Pittaya Kruakuanpet (Senior Engineer, DEDE)
Thai private-sector participants: approx. 35 persons
Audit services company:
Mr. Panja Thanghirun (Arun Chaiseri Consulting Engineers Co.)
Mr. Chartdanai (Able Consultant Co.)
Food industry:
Mr. Serresak Kodchompoo (May Ao Foods)
Mr. Thongchai Meechaiyo (May Ao Foods)
ASEAN: 3 persons
Philippines: Mr. Maximino Marquez (DOE)
Malaysia: Mr. Phubalan (PTM, Malaysia)
Vietnam: Mr. Phan Nguyen Vinh (ECC-HCMC)
Others: 5 persons
ACE
Mr. Christopher Zamora, Mr. Nguyen Ninh Hai
ECCJ
Mr. Kuroda, Mr. Takeda, Mr. Kawase(3) Presentation overview
With Dr. Prasert presiding, presentations were given in accordance with the program
outlined in Attach II-4 (Agenda of Intensive Seminar – PROMEEC Major Industry
Thailand Oct. 3, 2008).

II-8

Session 1
Policy and Initiatives on EE&C in Industry Sector
1) Update of EE&C Activities in ASEAN
Mr. Christopher Zamora presented an overview of the activities of ACE according to thefollowing breakdown of headings:
・2004-2009 APAEC Program
・ASEAN-Japan cooperation (SOME-METI, PROMEEC, and multilateral training)
・ASEAN Best Practice Competition (Energy Conservation Division)
・ASEAN + 3 Energy Conservation and Renewable Energy Forum・Other programs implemented in collaboration with EAS-ECTF, UNEP, the ASEAN
Foundation, ADB, and CDC.
A detailed explanation was provided in regards to the 2004-2009 APAEC Program. This
program consists of six program areas. Energy conservation is addressed in the fourth
program area. As a key element of the fourth program area, the process and results withrespect to PROMEEC activities through Phase 1 and Phase 2 were reported. An outlineof how these activities unfold in Phase 3 was also presented.
(Note: These six program areas consist of the following: information sharing andnetworking, ASEAN energy standards and labeling, private-sector
participation, capacity building, cultivation of ESCO enterprises, andtransportation sector.)

2) Update of EE&C Activities in Thailand (Attach II-5)
Mrs. Amaraporn Achavangkool of DEDE presented an overview of the latest energy
conservation measures in Thailand according to the following breakdown of threeheadings:
・Current state of energy use in Thailand
・Revisions to the Energy Conservation Promotion Act
・DEDE’s energy conservation promotion measures
The growth rate in the consumption of energy in Thailand in 2007 was 3.8% on a
year-on-year basis (2006). The transportation sector was the largest consumer of energy

II-9

in the country. Imported energy accounted for 63% of all energy consumed and 10% of
GDP. 88% of imported energy consisted of petroleum. Energy consumption per unit of
GDP amounted to 15.2 kgoe/1,000 baht.
Thailand’s Energy Conservation Promotion Act was revised last year, such that the prioremphasis on technological measures was shifted to an emphasis on energy management.
It was also explained that there had been a paradigm shift from controls to support. The
key revisions affecting industry were as follows:・Authority with regards to energy matters was transferred to the Energy Minister.
・Measures for energy management was reinforced.
・Jurisdiction over the ENCON fund was transferred from the MOF (Ministry of
Finance) to the MOE (Ministry of Energy).
・Authority of energy management auditors and auditing institutions was reinforced.
Detailed explanations were provided of energy conservation promotion measuresinstituted by DEDE, the competent agency in charge of promoting energy conservation.
These measures consist of the following: 1) standards and regulations, 2) technicalsupport, 3) financial support measures, 4) network cooperation among groups andorganizations, and 5) raising awareness of energy conservation.
3) Japan’s Energy Conservation Policy and Measures for Industrial Sector
ECCJ’s Mr. Taichiro Kawase presented an overview of energy conservation policies inJapan and measures applicable to industrial sectors according to the following
breakdown of five headings:
・Changes in energy consumption by industrial sector in Japan・Legal measures and energy conservation policies applicable to industrial sectors inJapan・Voluntary activities on the private-sector companies and organizations in industrial
sectors
・Roles and main activities of ECCJ・Successful cases at food factories as accumulated through collaborative initiatives
carried out by ASEAN and ECCJ
Session 2
EE&C Best Practices in Food Industry

II-104) Successful Cases from Malaysia
Mr. Phubalan of Malaysia Energy Center (PTM) presented two cases of energy
conservation in Malaysia (palm oil factory and pouch-packed food factory). In the caseconcerning a palm oil factory, the following numerous measures were reported: stearicacid tank temperature management, steam leakage management, steam trap
management, condensate recovery, recovery of waste heat from deodorized oil as a
pre-heat source for oil bleaching, measures to prevent compressed air leaks, thermal
insulation applied to high- temperature surfaces of processing equipment, and changing
boiler fuel.
In the case concerning a pouch-packed food factory, various measures, including thefollowing, were proposed: improving boiler efficiency, improving the COP ofrefrigeration equipment, reinforcing the thermal insulation of outside walls of therefrigerated warehouse, applying thermal insulation to the high- temperature surfaces ofboilers and sterilizers, and lowering the discharge pressure of air compressors.
5) Successful Cases from the Philippines
Mr. Marlon Domingo of the Philippine’s Department of Energy (DOE) reported onenergy audit activities being conducted by DOE, and on energy saving measures forfood factories implemented in the Philippines utility by utility (lighting, refrigerationequipment, exhaust gas fans, heat recovery, pumps, boilers, and air compressors).
Cases concerning pineapple-processing were also reported, with particular focus placedon technologically advanced energy saving measures relating to refrigeration equipment
and steam co- generation. These cases could be highly informative for factories seeking
to promote energy conservation as it applies to refrigeration equipment. It seems
worthwhile registering in technical directories (TDs), which constitute an ASEAN
energy management tools.
6) Successful Cases from Vietnam
Mr. Phan Nguyen Vinh of Energy Conservation Center of Ho Chi Minh City
(ECC-HCMC) in Vietnam reported an overview of the activities of ECC-HCMC in
addition to an overview of energy saving measures applicable to industrial sectors in
Vietnam. According to Mr. Vinh’s report, the energy saving potential in food processing
factories in Vietnam is estimated to be 20%. In addition, ECC-HCMC has actively

II-11engaged in audit activities, having audited 288 factories between 2001 and 2008. This
figure includes 34 food processing factories, 22 textile factories, 16 pulp and paper
factories, and 8 ceramic factories.
Next, a case concerning energy conservation at a beer factory was reported. The factoryis small in that it produces 4,700 kiloliters of beer per year (in 2006). As a result ofconducting an energy audit, the following six measures were implemented, production
capacity rose by 25%, and consumption of coal and electricity declined by 30% and43%, respectively:
・Establish an energy management system.
・Replace fluorescent lamps (T10 with T8) and adopt high-efficiency ballasts.
・Cool hot wort with soft water (pre-heated soft water is used as hot water for
cleaning/washing and boiler feed water).
・ Replace piston-type refrigeration compressors with screw-type refrigeration
compressors (improve COP).
・Introduce a water heat-storage system.
・Lower the discharge pressure on air compressors and adopt VSD drives.
7) Successful Cases from Thailand (Attach II-6)
Mr. Panja Thanghirun of Arun Chaiseri Consulting Engineers Co., an energy audit
services company, reported on a case concerning an audit conducted at the food factoryin Thailand. This case was highly informative and presented technologies that we
believe should be disseminated to ASEAN member countries:
・Recover cold heat from low-temperature wastewater.
・Recover waste heat from refrigeration condensers.
・Clean boiler tubes (combustion gas side).
・Heat heavy fuel oil (viscosity control).
・Apply automatic control to sterilization tank.
・Clean refrigeration equipment condenser tubes (coolant water side).
・Treat coolant water with ozone or low- frequency waves.
・Replace cooling tower fans with light weight fans (use FRP blades).
・Enable use of inverters with cooling tower fans and pumps.
・Employ evaporative cooling.
・Dry cans and bottles using an air knife.
・Replace fluorescent lighting (T10 with T8).
・Replace discharge lamps (mercury lamps with metal halide lamps).

II-128) Tentative Result of Audit of May Ao Foods (Attach II-7)
Mr. Hiroshi Kuroda of ECCJ reported on the following suggestions concerning theresults of energy audit conducted at May Ao Foods:
・Insulate the high- temperature surfaces of cookers and surrounding pipes with 50
degree Celsius or higher.
・Utilize cold waste heat from low-temperature wastewater as a pre-cooling heatsource.
・Install an inverter-controlled motor in the municipal water pump and eliminate
inefficiencies during low- load period.
・ Apply load- fluctuation countermeasures to all air-conditioning equipment;
specifically, use an inverter-controlled motors with cold water and coolant water
pumps and eliminate inefficiencies during low- load period.
・Change the lighting system used in the processing room from general lighting totask-ambient lighting.
・Clean the coolant side of condenser tubes in refrigeration equipment and also purge
air contaminated in refrigerant fluid.
・ Investigate into replacement of the current shell-and-tube condensers with
evaporative condensers.
・Minimize heat sources in cold stores and batch freezer units.
・Convert the fan coil motors used in cold stores and batch freezer units to
two-speed-type motors and prevent unnecessary chilling.
9) Successful Cases from Japan
Mr. Kokichi Takeda of the ECCJ presented successful cases (electrical energy
conservation) achieved in Japanese food processing factories:
・Case concerning a beer factory (inverters were incorporated into refrigerationequipment pumps)
・ Case concerning a starch factory (water hammer prevention, remote on/off
operations)・Case concerning a food oil factory (VSD feature was incorporated into boiler fans,and several dust-collection fans were integrated)
・Case concerning a food oil factory (air compressors were reduced in size)
・Case concerning a tobacco factory (inverters were installed in air-conditioning units

II-13

to accommodate low loads during off-season)
・Case concerning a beer factory (high-efficiency refrigeration equipment replaced
older equipment and refrigerant superheat settings were relaxed)

Session 3
Energy Management Tools and the Way Forward
10) Updating on Development of Technical Directory & Updating of In-House Data
Base, Energy Management System Cyber Search
Mr. Nguyen Ninh Hai of the ASEAN Center for Energy (ACE) gave, with respect to
ASEAN energy management tools, a briefing on the purpose of technical directories(TDs), the method of developing TDs, the input format applicable to TDs, and otherrelevant topics, as well as presented the example of actual TD sheet. Furthermore, he
explained the purpose and content of in- house databases (IHDBs) using the input format
for textile industry as an illustrative example.
11) Introduction to Trial Use of In- house Database in Food Industry
Mr. Taichiro Kawase of ECCJ gave a briefing on in-house databases (IHDBs) designed
specifically for food industry. IHDBs are notable for monitoring important operating
parameters and energy efficiency benchmarks, as well as production data, energy
consumption data, and equipment data. The databases provide reference information forengaging in energy efficient operations at every level within a factory. In order todisseminate the databases to all ASEAN countries, their proactive adoption was urged
for food processing factorie s in Thailand.
(4) Remarks
1) It was beneficial to have an active communication with all the audit participants andexchange various information and skills throughout the seminar. The technical expertisepresented by one engineer from Thai energy service company was marvelous at asignificantly advanced level. Japanese experts including ECCJ experts must continue topolish their expertise in order to satisfy developed ASEAN engineers.

II-14

2) The latest energy conservation measures adopted in Thailand was highly instructive
as briefed by Mrs. Amaraporn Achavangkool of DEDE. Last year’s amendment of theEnergy Conservation Promotion Act indicates that Thailand shifted a gravity of EE&C
policy & measures from technology to energy management. Also it shows a steady
growth and development of Thai industry since an enforcement of the first generation of
ENCON promotion Act in 1992.
3) It is unfortunate that number of participants was less than expected, and Q&A session
was very calm.
Seminar/workshop

Mr. Danai (DEDE), fifth from the rightMrs. Amaraporn (DEDE), third from the right

II-15

May Ao Foods

Mr. Prasit (Vice-President), sixth from the right
Mr. Sarat (DEDE), eighth from the right4. Attached documents
II-１．Analysis of Energy Audit Data for Heat Energy
II-２．Analysis of Energy Audit Data for Electric Energy
II-３．In-House Data Base for Food Industry
II-４．Agenda of Intensive Seminar – PROMEEC Major Industry Thailand Oct. 3,
2008
II-５．Update of EE&C Activities in Thailand
II-６．Successful Cases from Thailand
II-７．Tentative result on Audit of May Ao Feeds

II-16

III. Indonesia (ceramic industry)
1. Overview of local activities
ECCJ experts visited Indonesia on official business between November 17 and 25, 2008
and conducted an energy audit at a ceramic factory, carried out a follow-up survey at a
textile factory, and held a seminar/workshop with the aim of exchanging information
with ASEAN countries.
The energy audit was conducted with the participation of twenty-six engineers from the
Ministry of Energy and Mineral Resources, the Ministry of Science and Technology, astate-owned company dealing with energy conservation services, the ceramic factory to
be audited, ECCJ, and ACE. As a result of energy audit, it was found that as much as
20 to 30% of energy saving is expected by taking several measures such as
improvement of thermal efficiency of ceramic kilns. Approximately fifty persons took
part in the seminar/workshop, where several best practices concerning energy
conservation were reported by representatives of ASEAN countries and results of OJT
audit was reported. .
Dispatched officials: Kenjiro Hata, Kokichi Takeda, and Taichiro Kawase of ECCJInternational Engineering Department
Schedule of activities:
Nov. 17 – 21: OJT energy audit (LIK)
Nov. 24: Follow- up survey ISN:(Industri Sandang Nusantara)
Nov. 25: Seminar/workshop
2. OJT energy audit (LIK)(1) Participants
DGEEU: 4 participants (Ms. Feby, Ms. Devi, and 2 engineers)
BPPT: 5 participants (Mr. Kito, Mr. Diding, Mr. Fahruddin, and 2 engineers)
EMI (formerly KONEBA): 1 participant (Mr. Kelik)
LIK: 10 participants (factory manager, principal contact, and 8 engineers)
ACE: 3 participants (Mr. Ivan, Mr. Junianto, and Mr. Bernard)
ECCJ: 3 participants (Mr. Hata, Mr. Takeda, and Mr. Kawase)
Total: 26 participants

III-1

Notes: BPPT: Energy Technology Center, MOST
EMI: former KONEBA(2) Outline of the factory
Location: Kota Tangerang, 35 kilometers west of Jakarta
Product: tableware
Production output: 21,008 tons per year (2007)
Customers: 80% domestic, 20% overseas (exported)
Production equipment: 11 kilns (3 biscuit kilns, 4 glost kilns, 2 decorator kilns, and2 micro-kilns; both biscuit kilns and glost kilns are tunnel kiln). All kilns
were made by Takasago Industry (based in Gifu Prefecture, Japan).
Energy consumption: natural gas 15,362 cubic meters/yr.,electricity 7,639 MWh/yr (2007)
Employees: 1,800 , 3 shifts(3) Overview of energy audit
1) Local audit team
The audit team consisted of twenty-six persons from Ministry of Energy and Mineral
Resources, Ministry of Science and Technology, the state-owned company dealing withenergy conservation services, the ceramic factory to be audited, ECCJ, and ACE.
DGEEU’s Ms. Feby and ACE’s Mr. Ivan served as facilitators of OJT audit since aleader was not appointed. In actual, ECCJ experts conducted a substantial part of audit
work except for measurement work.
2) Interview
Before commencing an inspection of equipment, an interview was made with respect tothe production process, recent production output and energy consumption data, andproblems concerning energy conservation as perceived by the factory. Next, responses
to the preliminary questionnaire were checked.
3) Expectations of the factory toward the audit
The factory expected (1) to learn methods of energy conservation, (2) to know feasible
measures of energy conservation, and (3) in particular, to have an audit conducted withrespect to kilns and dryers. The factory stated that it had never before been audited byan outside consultant.

III-24) On-site inspection and measurements
One biscuit kiln and one dryer attached to glost kilns were intensively inspected. A
general inspection was conducted on the first day, and a detailed inspection was
conducted on the following two days, using measuring instruments. The factoryarranged several engineers on full time basis during the audit. It also extended
significant cooperation in other ways, such as by providing a manometer andhigh-temperature thermometer, and by preparing temporary measuring holes in kiln
exhaust duct. EMI and BPPT engineers made a measuring work in scorchingly- hotenvironment. In addition to the kiln and dryer, ball mills, filter presses, water systemand dust collectors were inspected in a short-cut manner.
5) data analysis and reporting
On the final day, gathered data were analyzed, missing data were collected, and theresults were reported to top management of the factory. The factory manager, wholearned material science in the United Kingdom, asked many questions from managerial,
operational and technical standpoints.
(4) Energy saving measures and energy saving effects
Energy saving measures
Energy saving effects
Reduction of kiln exhaust
gas loss:
Kiln fuel saving:(1)maintain sand seal gutter
22.2% (not including(2)prevent outside air from effect of adjusting
entering the kiln
dampers)(3) manage combustion air(4)adjust exhaust-gas dampers
Kiln
on fans
Effective use of cooling zone
Kiln fuel saving:cooling gas:
(1)use as secondary air for kiln 1.8% (accounted forburners
effect of secondary(2)use as heat source for air)dryer
Uniform temperature profile
Improvement in yield
inside kiln for preventing
and sho rtening of
uneven burning:burning time (energy
Dryer(1)install an internal gas
saving effects not
circulation fan
calculated)(2)make dryer entrance andexit airtightIII-3

Investment scale

Medium scale(repair of sand seal
gutter)Small scale(addition of ducts)

Medium scale(addition of
circulation fan)Recover heat by recirculating
Dryer fuel saving :exhaust gas :50%(3. Suspend dryer operations)

Dryer fuel saving :100%

Incorporate variable speed
Pumps & control:
Elec power saving :fansfeature into over-capacity Usually 50%
pumps & fans

Small scale(additionofrecirculation fan)Medium scale(additionofcirculation fan)
Small scale(additionofsimple inverter)(5) Results of OJT audit
1) Identifying energy saving opportunities through on-site inspectiona) Analyzing energy consumption data
Regression analysis was undertaken based on production output data and energy
consumption data for the period from 2006 to 2008 as provided by LIK. It was thereby
revealed that specific fuel consumption range s between 19.0 and 23.0 GJ/t, and thatspecific electric power consumption ranges between 280 and 380 kWh/t.
According to the report issued by the American-based Lawrence Barkley National
Laboratory (Report No. LBNL46990), specific fuel consumption in the latest-designed
tunnel kilns is 2.43 to 4.44 GJ/t as best case ,and 10.8 GJ/t in average case. Thismeans that specific fuel consumption for LIK is such that approximately double theamount of energy is consumed as consumed in the latest equipment. See Attach III-1(Regression Analysis of Energy Consumption) for more details on the regression
analysis.
b) On-site inspection
Investigation on energy saving potentials was conducted in the firing process (kiln) anddrying process (dryer). 60% of all energy use is accounted for the kiln, while 20% is thedryer. In addition, the material milling process and rotary machines, including pumps
and fans, were examined. 40% of all electrical energy use is accounted for the material
milling process.
For the firing process, it was found that exhaust gas can be decreased by suppressing theinfiltration of outside air, and energy consumption can be reduced by recovering waste
heat from exhaust gases.

III-4

For the drying process, this investigation revealed that vertical temperature profile in thedryer can be rendered uniform by way of the installation of internal circulation fans,which reduc es uneven drying and shortens drying time. Accordingly, uniform verticaltemperature profile inside the dryer leads to fuel saving in the dryer. In addition, an
opportunity of dryer fuel saving was pointed out when exhaust gas from the coolingzone of firing kiln can be used as heat source of drying process.
For rotary machines, it was found that there is a possibility of electric power saving inpumps and fans if variable speed drives (VSD) are incorporated into exhaus t gas fans,combustion air fans and grinder dust-collection fans.
c) Data collection and measurements
In order to estimate energy saving effects, several measurements were made.
For the firing process, residual oxygen content and temperature of gases passing
through the pre-heat zone of the kiln were measured so that thermal efficiency wascalculated. In addition, the pressure and temperature at several points inside the kiln
were measured in order to analyze the flow of combustion gas inside the kiln.
For the drying process, vertical temperature profile at the entrance and exit of the dryer
were measured so as to confirm the uniformity of vertical temperature profile inside thedryer. In order to estimate the moisture content of exhaust gas, dry-bulb temperature andwet-bulb temperature inside the kiln near the exit were measured.
In order to ascertain whether there are any opportunities for energy saving in rotary
machines, electric current of motors in several fans and the opening/closing status ofdampers were measured.
d) Identification of problems affecting EE&C
Firing process (kiln)
・Poor maintenance of sand seal gutter, which causes an infiltration of outside air
through breaches in the sand seal gutter (a cause of reduced kiln efficiency).
・Cool outside air is used as combustion air in the firing zone burner, where hot
exhaust gas leaving the cooling zone in the firing should be effectively used (a causeof reduced kiln efficiency).
・No management in flow rate and pressure of natural gas in the firing zone burner(manometer is broken).
・No management in pressure profile throughout the kiln. For example, current exhaustgas fans installed in the pre- heat zone are too powerful and draw excessive gases than

III-5

necessary (damper adjustments are required; a cause of reduced kiln efficiency).
・Although there are two suction ports drawing kiln inside gas in the pre- heat zone,
only the upper port is used in actual operation (a cause of non-uniform verticaltemperature profile).
・Gap between kiln carts and kiln wall is large and uneven (uneven firing due tonon-uniform velocity profile of gas flow inside the kiln, which in turn is a cause ofirrational extension of firing time).
・No internal circulation fan has been installed inside the kiln (a cause of non- uniform
vertical temperature profile).
Drying process (dryer)
・Uneven drying is caused by non-uniform vertical temperature profile (a primarycause of occurrence of defective goods).
・Drying temperature are not adjusted (a cause of occurrence of defective goods).
・Exhaust gas heat is not recovered (a cause of reduced dryer efficiency).
Raw material preparation process
・No operation manual for ball mill section (Ball mill charge volume, Ball make-up
volume, ball size management, and idling stop management).
・No operation manual for filter press section (no measurement of moisture content).
Rotary machines (fans and pumps)
・Numerous fans, including kiln combustion air fans and grinder dust-collection fans,are oversized.
・Suction dampers are being throttled (leading to a loss of power).
2) Data analysis and energy saving measures in the firing processa) Heat balance of No. 4 glost kiln
A heat balance was calculated with an aim of quantification concerning how muchenergy is inputted and consumed in where in the firing process, especially to clarify
how much energy is used effectively for firing purpose and how much energy is wasted
in where. The following conclusions were drawn with detailed calculations shown in
Attach III-2 (Heat Balance of No. 4 Glost Kiln).

III-6

Based on results of heat balance calculation, it was determined that loss of exha ust gas
leaving the preheat zone of the kiln (34.8%), the loss of exhaust gas leaving thecooling zone of the kiln (32.7%), and the loss of heat radiation from the kiln surface andother points (28.1%) were significant. In addition, while quantitatively insignificant, theheat carried over with kiln carts accounts for to 3.8% of all energy consumed in the kiln.
To reduce these losses, the following measures can be considered.
Heat Balance of No. 4 Glost Kiln
heat input
103kcal/theat of combustion
5183.9SH of wet fired goods
0.0
SH of saggar
0.0
SH of kiln car refractory
0.0

%
100.0
0.0
0.0
0.0

SH of kiln car iron part

0.0

input total

0.0

5183.9100.0

Production (ton/mo) :228.5
heat output
103kcal/t
SH of fired goods
32.0
SH of saggar
101.3
SH of kiln car refractory
65.9
SH of kiln car iron part
25.4
SH of waste gas fromcooling zone
1697.2SH of combustion
exhaust gas
1803.5other losses (radiation,
etc)
1458
output total
5183.9

%
0.6
2.0
1.3
0.5
32.7
34.8
28.1
100.0

b) Reduc tion of kiln exhaust gas loss and energy saving effectResidual oxygen content in the kiln exhaust gas is measured to 17% at the inlet of
exhaust gas fans. High oxygen content is a result of several causes, including theinfiltration of outside air through the broken sand seal gutter, the infiltration of outside
air through the entrance of the kiln, the excessive gas aspiration due to oversizedexhaust gas fans, and the excessive infusion of combustion air due to improper damper
management of combustion air fans. By eliminating these causes, oxygen content canbe reduced to about 9 to 12%, which is a current level measured in Japan. Heat balance
was calculated as the following, assuming that oxygen content of kiln exhaust gas is
reduced to 12% :Heat Balance of No. 4 Glost Kiln
heat input
103kcal/theat of combustion
4035.0SH of wet fired goods
0.0
SH of saggar
0.0
SH of kiln car refractory
0.0

%
100.0
0.0
0.0
0.0

SH of kiln car iron part

0.0

input total

0.0

4035.0100.0

Production (ton/mo) :228.5
heat output
103kcal/t
SH of fired goods
32.0
SH of saggar
101.3
SH of kiln car refractory
65.9
SH of kiln car iron part
25.4
SH of waste gas fromcooling zone
1697.2SH of combustion
exhaust gas
655.1
other losses (radiation,
etc)
1458
output total
4035.0

III-7

%
0.8
2.5
1.6
0.6
42.1
16.2
36.1
100.0

Accordingly, amount of natural gas saving was calculated to be 438 x 103 m3 -gas/yr,
which corresponds to an energy saving of 22.2%.
228.5 tons/mo x 12 x 5183.8 x 103 kcal/ton = 14213980 x 103 kcal/yr
228.5 tons/mo x 12 x (1803.5-655.1) = 3148913 x 103 kcal/yr= 438 x 103 m3 -gas/yr (natural gas)3148913 x 103 /14213980 x 103 x 100 = 22.2%
In the above calculation, some of variables and parameters are an estimated number,based on design specification and operation data in the similar type of kilns in thecertain ASEAN country. When actual data can be obtained, the above result has to berecalculated according to the calculation procedure outlined in Attach III-2.
c) Effective use of exhaust cooling gas leaving the cooling zone and energy saving
effectEnergy loss of exhaust cooling gas leaving the cooling zone in the kiln was estimated toaccount for 32.7% of all energy used in the kiln. As the cooling gas fan is installed in
the kiln, some of exhaust cooling gas can be supplied to the firing zone and the rest is tothe adjacent dryer.
However, this fan is presently out of service for unknown reason, such that it is believedthat most of exhaust heat of the cooling gas is either discarded into the atmosphere or
released into the atmosphere from the preheat zone of the kiln via the firing zone.
Probably the volume of the cooling gas supplied to the firing zone or the adjacent dryer
is small.
With recent models of kiln, heat of exhaust cooling gas is typically used as secondary
air to the firing burners or as hot air fed to the preheat zone, or as dryer heat source. In
this audit, measurement data concerning how much the cooling gas went to the dryer
were not obtained due to unavailability of gas flow instrument. It is recommended tomeasure the volume of the cooling gas going to the dryer under an assistance of BPPTor energy service companies in order to know how much energy is recoverable.
Energy saving effect expected in case that the cooling gas is made used of as secondary
air is estimated to be approximately 1.8% in terms of kiln fuel consumed. This iscorrespond ing to natural gas of 34.9 x 103 m3 -gas/yr. For more details on thecalculation process, see Attach III-3 (Heat Recovery of Kiln Cooling Gas Waste Heat).

III-8d) Reduc tion of heat radiation loss from hot surfaces of the kiln and energy saving effectHeat balance revealed that loss of heat radiation from hot surface of the kiln is as
significant as 28.1%. However, authors of the report did not feel it is overly hot whentouched by hand, although surface temperature was not measured due to time restriction.
Reason of the difference is not clear.
Japan’s Energy Conservation Law illustrates a guideline regarding as thermal insulation
measures to industrial furnaces as shown below. Where surface temperature is 110-160
degree Celsius or higher in the firing zone, and/or 70-90 degree Celsius or above in thepreheat zone or cooling zone, addition of insulation should be considered.
Guideline for furnace insulation (Japanese Encon Law)surface temp, deg C
inside temp, deg C
ceilingside wallbottom1300 or higher
120
110
160
1100 - 1300
110
100
135
900 - 1100
100
90
110
900 or lower
80
70
90

3) Data analysis and energy saving measures in the drying processa) Heat recovery through exhaust gas recirculation in the drying process
Exhaust gas temperature is normally 200 degC or higher in the dryers of ceramics
factory. It is as high as worthwhile recovering waste heat of dryer exhaust gas.
Generally in case that drying temperature is 140 degC or higher, exhaust gas
recirculation is very effective measure for energy saving. The technical ground is that
relative humidity drops very low under such high temperature and accelerate a drying
speed. In fact, there are many cases reported in which the exhaust gas is recirculated,combined with high temperature drying. Attach III-4 (Exhaust Gas Recirculation in
Dryer of No. 3 Biscuit Kiln) outlines the estimation procedure for energy saving effectwith exhaust gas recirculation. According to the result, drying speed remains nearly
unchanged even when 50% of exhaust gas is recirculated. Therefore, 50% reduction in
the fuel consumption can be expected.
b) Causes for uneven drying/firing and installation of internal gas circulation fans

III-9

In the dryer linked to No. 3 biscuit kiln, there is a problem of uneven drying, whichbrings about both low yield of dried goods and irrational extension of drying time.
Non-uniform vertical temperature profile could be one conceivable cause of this unevendrying. In this connection, vertical cross-sectional temperature profile was measured at
the entrance of the dryer. As a result, the upper temperatures was 70 degC or more,while the lower temperatures equaled to 55 degC or less. This can likely suggest ashortcoming in vertical circulation of dryer internal gas. While vertical temperature
profile was not measured near the center of dryer, it is expected that there is the same
situation in the center as at the entrance. It would be effective to install a internal gas
circulation fan at three longitudinal locations inside the dryer.
In the firing kiln, there is a problem of uneven firing. This could be also caused byineffectiveness of vertical gas circulation. If uneven firing is eliminated, improved
product yield and shorter firing time are attained. Additional data and measurement arenecessary to estimate energy saving effect by even firing.
c) Improper horizontal temperature profile in the dryer
Ordinary dryers are designed to have internal temperatures gradually rise as ceramic
items move from the entrance of the dryer to the exit (horizontal temperature profile) inorder to minimize thermal shocks to ceramic items.
However, in this dryer, the drying air temperature is high at the entrance while thedrying air temperature is low at the exit. As thin ceramic items are produced in thefactory, few cracks develop at the entrance even at the high temperature environment.
However, there is a risk of cracking where bricks or other thick items are being dried.
To resolve this issue, drying air temperature should be adjusted through damper opening
adjustment, such that the temperature at the entrance is lowered and the temperature at
the exit is raised.
In addition, as temperature variation is large between top and bottom of kiln carts(vertical temperature profile), products placed at the bottom of kiln carts are not being
sufficiently dried. To resolve this issue, internal circulation fans should be installed asindicated above in order to secure the vertical, internal circulation of hot air.
See Attach III-5 (Effect of Temperature Profile in Dryer against Product Quality) for
details regarding b) and c) above.
4) Feasibility of shutting down the dryer

III-10(by converting a part of the pre-heat zone into a drying zone )In Japan, there are cases where dryers have been shut down by using a part of the kiln
pre-heat zone as a drying zone. This is possible where the kiln has room to spare along
its length. In the factory, the re is a feasibility of shutting down the dryer, because thefiring kiln, at nearly 100 meters in length, is sufficiently long for producing thintableware. In addition, the actual temperature profile in the kiln pre-heat zone is similar
to the temperature profile of the dryer. In this case, the length of required drying zone is
expected to be about 20 meters. In order to shorten the duration of pre-heating process
and make up the room for drying process, it is necessary to eliminate theabove- mentioned inefficiencies, such as by minimizing infiltration of outside air into thekiln, improving the circulation of gas inside the kiln, and rendering uniform thetemperature profile at the top and bottom of the kiln. All energy consumed in the dryer
could be crossed out. Although a quantitative study is yet to be conducted, it isanticipated that fuel saving of at least 20 to 30 percent can be achieved.

Pre-heat Z.

Drying Z.

Pre-heatFiring Z.

Cooling Z.

Firing Z.

Cooling Z.

As explained in the dryer section, it is recommended that sand seal gutter be repaired inorder to minimize the infiltration of outside air into the dryer, and that a circulation fan
be installed in order to improve the circulation of internal gas.

III-11

5) Energy saving measures concerning operational management and equipment
maintenance
As indicated above, on-site inspection revealed that energy consumption was rising due
to insufficient operational management and insufficient maintenance. the following
individual measures had better be implemented promptly. See Attach III-6(Management of Operation and Maintenance in Kiln & Dryer) for details.
a) Maintenance of Sand Seal Gutter – Restore Sand-seal Function
Sand seal gutter is an important component for preventing the infiltration of outside air
into the kiln. However, on-site inspection revealed that grains of sand in use were toolarge to enable sand seal gutter to be effectively used as a air seal, and that sand itself
had not been properly placed in the gutter. This situation thus allowed large amounts of
air to seep into the kiln. In addition, heated air flowing from the firing zone should be
prevented from infiltrating the underside of kiln carts. In this connection, it isrecommended that sand seal gutter be fully replenished with sand of which grain size
should be between 1 and 5 millimeters in diameter.
b)Maintenance of Sand Seal Gutter – Relocate Shooter and Optimize Sand Management
Sand had not been supplied to a section of the preheat zone with approximately 30
meters in length. The sand shooter should be relocated near the inlet part of preheatzone. As a shortage of sand will prevent sand seal gutter from functioning properly, theseal height of sand seal gutter should be properly set.
c) Prevention of Air Leakage through Gaps between Carts
Air leaks tend to occur through two types of gap at the connection between carts : one isin a labyrinth at the connection, and the other is at the bottom part of carts. The
labyrinth gap should be padded with ceramic fibers, while the bottom gap should becovered with aluminum foil made of solidified water glass.
d) Sealing of Entrance Door for Air-tightening purpose
While a door is installed at the entrance to the kiln, there are many gaps between the

III-12

door and the kiln wall, such that hot inside air blows out. In order to ensure an airtightdoor, seals should be secured on both ends of the door and that a pusher for pushing thedoor into the kiln wall should be installed. Push and release actions can be enabled byrotating the pusher cam.
e) Installation of Air-curtain at Kiln Exit
A significant volume of hot inside air was escaping through the kiln exit. In order toprevent gas escaping, installation of forced draft fan and air curtain are recommended..
f) Optimization of Internal Gas Flow for Achieving Uniform Vertical Temperature
ProfileThere are two air supply ports—an upper one and a lower one—for gas that circulates
inside the kiln. The preferable use of a lower air supply port is recommended for the
purpose of optimizing the internal gas flow. This would enable hot gas to circulate up to
the upside of kiln cars inside the kiln and achieve a uniform vertical temperature profile.
Besides, sand that accumulated on port inlet should be removed when in maintenancetime.
g) Optimization of Stacking Items for Preventing Uneven Gas Flow – Flattop
In order to prevent uneven gas flow inside the kiln, it is important to stack ceramic
items on the carts in such a manner that stacked pile forms a flattop. At the LIK factory,
ceramic items are stacked on a flattop basis and the management thereof looks sound.
h) Installation of Circulation Fan for Enhancing Heat Transfer to Materials
No circulation fan had been installed in either the kiln or the dryer. For this reason, thevertical temperature profile in the kiln is rendered non- uniform, which leads to unevenfiring or drying. This also accounts for longer firing time beyond what should be
required. In order to resolve this issue, a circulation fan is recommended to install.
Circulation fan can be installed either inside the kiln or outside the kiln, depending onsite-specific restrictions like site geometry or available capital.
i) Reduction of Thermal Mass of Cart Furniture
It is important to make heat-resistant supports of each kiln cart as light-weighted as
possible. Replacing solid refractory bricks conventionally employed with hollow-core

III-13

refractory bricks would help to achieve energy conservation. On-site production methodof hollow-core refractory bricks implemented in Japan was provided for reference
purposes. While hollow-core bricks and light-weighted insulation bricks have alreadybeen adopted at the LIK factory, there is still room to make each kiln cart more
light-weighted. For that purpose, donut-shaped Scabbards or thin- walled metal
Scabbards could be introduced.
j) Burner Management (Monitoring of Fuel Gas Pressure)
It is important that firing rate of each burner is uniform. To this end, the pressure of fuelgas and combustion air needs to be maintained at a required level. However, on-sitepressure gauges were broken and not in working condition. Proper maintenance andburner management are to be needed.
6) Energy conservation for fans and pumps
There are many rotary machines with significant load fluctuations at the LIK factory
which forces the factory to pay unnecessary expenses. However, in actual few
countermeasures are undertaken except for adjusting suction and discharge dampers. In
this connection, study on identifying energy saving opportunities was implemented forrotary machines, including application of variable speed adjustment to electric motors
of fans.
Investigation on motor power input and extent of load fluctuation was made for thefollowing machines: exhaust gas fans in No. 4 glost kiln, combustion air fans in thesame kiln, and grinder dust-collection fans. Measurement work was conducted byengineers from EMI and other Indonesian organizations. After gathered data wereanalyzed, it was found that current fans have excess capacity than required. In order tocut excess fan capacity, replacement of belt drive pulley to smaller one wasrecommended mainly for economical reasons.
Energy saving effects of this measures are estimated approximately as follows: 23,000
kWh/yr., 37,400 kWh/yr., and 22,400 kWh/yr., respectively. Prompt implementation incollaboration with technological services company EMI should be explored. No pumps
and other machines which the same measures are applicable to were found in this study.

III-14

a) Kiln exhaust gas fan
Energy audit on exhaust gas fan in No. 4 glost kiln
Data collection and Input power: average 9.53 kW (as shaft power:8.23 kW),measurement
Load fluctuation: 9.1 to 10.1 kW
Suction damper opening: 50%
Air velocity at entrance door when entrance door left open:
1 to 6 m/sec
Energysaving Reduction of power wasted in suction damper
opportunities
Energysaving Decreasing fan rotation speed by replacement of belt drive
measures (example)
pulley to smaller size
Assumptions Performance curve is estimated based on similar type of fansEsti(actual curve is not available)mation Calculation
Revolution after measure: 82.2% of rated revolution
results
Shaft power after measures: 5.83 kW(as input power: 6.90 kW)
Power saving 2.63 kW (28% reduction),
23,000 kWh/y (operation: 8,760 h/y)
Other options for Reinforce air-tight sealing around entrance door
energy saving
Kiln pressure control feature (manual or automatic)b) Kiln combustion air fans
Energy audit on combustion air fans in No. 4 glost kiln
No. 1 combustion air fan No. 2 combustion air fan
Data collection Input powerandDampermeasurement
opening
Energy saving opportunities
Energysavingmeasures(example)
Assumptions
Estimation

7.86 kW (as shaft power: 9.07 kW (as shaft power:
6.64 kW)7.66 kW)
Disc.damper: 50% open
Disc.dampers: 53% open
Reduction of power wasted in suction damper
Decreasing fan rotation speed by replacement of belt
drive pulley to smaller size
Combust air pressure: 4,903 Pa (500 mmAq),
Kiln pressure: 49 Pa (5 mmAq)
Piping resistance: 490 Pa (50 mmAq)
Performance curve is estimated based on similar typeof fans (actual curve is not available)

Calculation results
Revolutions
Shaft power

Othersaving

86.9% of rated revol’n
85.9% of rated revol’n
4.82 kW5.45 kW(as input: 5.94 kW)(as input: 6.72 kW)Power saving
4.27 kW (No. 1: 1.92, No. 2: 2.35);(25% reduction after measures).
37,400 kWh/y (operation: 8,760 h/y)
options for energy Minimization of damper loss by application of VSD

III-15c) Grinder dust-collection fans
Energy audit on grinder dust-collection fans
Data collection and Input power: 17.8 kW (as shaft power: 15.2 kW),measurement
Load fluctuation: 15.2 to 18.4 kW
No suction damper
Air handling rate: 91.2 m3 /min (air velocity was measured at 8
inlets)Energysaving Reduction of power wasted in suction damper
opportunities
Energysaving Decreasing fan rotation speed by replacement of belt drive
measures (example)
pulley to smaller size
Assumptions Performance curve is estimated based on similar type of fansEsti(actual curve is not available).
mationSystem resistance curve shall remain unchanged.
Calculation
Revolution after measure: 90% of rated revolutions
results
Shaft power after measure: 13.3 kW
Power saving 4.5 kW (25% reduction),
22,400 kWh/y (operation: 4,970 h/y)
Other options for In case of one grinder operation, fully close suction damper ofenergy saving
air fan of the other grinder.
(6) Comments
1) Preparatory work was excellently conducted before local activity through excellent
collaborative ties with DGEEU and ACE. Local audit team was appropriately
constituted by participant engineers from Ministry of Energy and Mineral Resources,
Ministry of Science and Technology, a state-owned energy service company and the
LIK factory. Concerning measuring instrument s, BPPT and EMI provided a gas
analyzer, thermometers, anemometer and electric power monitor. The factory also
provided a manometer, and high- temperature thermometer as well as instrument
engineers. Although some area of the factory was prohibited to enter or takephotographs, maximum cooperation was given by the factory with regards to equipment
inspection and measurement work. In addition, coordinators from DGEEU and ACE
served as competent facilitator, including a briefing of PROMEEC project.
2) Responses to preliminary questionnaire arrived in Japan just prior to our departurefor Indonesia. Responses concerning production output, fuel and electrical power
consumption were satisfactory. However, responses regarding production equipment
and implementation of energy saving measures were incomplete and imprecise. On theother hand, currently- used questionnaire is a bit complex and difficult to answer. Early

III-16

revision of input format is requested to make respondent easy to understand and answer.
3) There are still remaining plenty of energy saving measures that have yet to beundertaken in the LIK factory. For examp le, no energy conservation team has beenorganized, no operational management standards has been prepared, important
operating variables have not been monitored.
4) The author of the report would like to express our great appreciation to the DGEEU
officia ls, who, as a focal point, made all necessary preparatory arrangements, such as byorganizing the audit team, providing answers to the preliminary questionnaire, andsetting up measuring instruments.
3. Follow- up survey (textile industry)(1) Background
Follow- up survey was conducted for the Surabaja factory of ISN where an audit wasmade in 2005. Generally follow-up survey is held in a manner of visiting the factory.
However, according to request from ISN, this survey was conducted as an informationexchange meeting with participation of the concerned parties. The meeting was held in
the conference room of ACE office in Jakarta. Five engineers from ISN participated in
the meeting together with officials from DGEEU, ACE staffs and ECCJ experts. The
meeting was chaired by Ms. Indarti, director of DGEEU..
(2) Participants
DGEEU: 2 participants (Ms. Indarti, Ms. Feby)
ISN: 5 participants (3 from the Bekasi factory, 1 from the Surabaja factory, and 1
from head office)
ACE: 2 participants (Mr. Ivan, Mr. Bernard)
ECCJ: 3 participants (Mr. Hata, Mr. Takeda, Mr. Kawase)
Total: 12 participants(3) Overview of 2005 audit
The following recommendations were made in 2005 audit.
Ventilation system
・Energy saving by raising the temperature of chilled water (in air washer unit)

III-17

・Energy saving by adjusting the temperature of cooling water (in chilled water unit)
Compressed air system
・Lowering air compressor discharge pressure
・Preventing air leakage from compressed air piping system
Management of specific energy consumption
・Measuring electric power and analyzing data
(4) Follow-up results
First, responses to preliminary questionnaire were checked. Responses consisted only of
specifications key equipment at the Surabaja factory (polyester yarn manufacturing), but
included no operational information required for the purpose of follow-up survey.
Therefore, follow-up survey was carried out by way of asking questions and answering
them. Key energy-using equipment at the Surabaja factory consists of the ventilation
system, air compressors, fiber-spinning machine s, water supply and treatment system,and power-receiving equipment.
a) Ventilation system
Ventilation system maintains air conditions (temperature and humidity) within aprescribed range in order to prevent thread breakage and constitutes a key energy- using
system in the spinning process. The system includes chilled water production equipment
as well as peripheral equipment consisting of a cooling tower, air-supply fans, andcirculating air fans.
The chilled water production equipment supplies chilled water for use in air showers
only during dry season when atmospheric temperatures are particularly high. Most of
the time (including rainy season), the chilled water production equipment is shut down,
and cooling water is directly supplied to the air washers. Target temperature of air in thespinning room ranges between 25 and 35 degC and target relative humidity ranges
between 55 and 65%.
Air-supply fans and circulating air fans are operated at a constant velocity and airflow iscontrolled by adjusting damper openings. Operators monitors air conditions in thespinning room daily with a hygro-thermograph, and adjusts manually the openings of
air-supply dampers and circulating air dampers according to prepared tables. Therefore,
the ventilation system is operated in a energy-efficient manner. Also, proposals made in2005, to raise the temperature of chilled water and to adjust the cooling water

III-18

temperature , was not implemented due to the short duration during which the chilledwater production equipment is operated.
Additional comments for the ventilation system were made by ECCJ experts as thefollowing;i) application of variable speed drives, optimally inverters, to circulating air fans inorder to reduce energy wasted in dampers, and (ii) investigation of cooling tower
performance in case there is 5 degC or lower of temperature difference in circulationwater between at cooling tower inlet and at outle t (for example, check mineral
concentration of water, check water channeling, and inspect plugging of spray nozzles).
b) Compressed air system
In the spinning process, large volume of compressed air is used for auto-coner drive andfor air-jet room drive. No special measures were implemented to prevent air leakages
from compressed air piping system. At the same time, measures to lower the dischargepressure on air compressor have being taken. That is to say, the discharge pressure was
reduced from the previous 8 bar to 6.8 bar. The required pressure is 6 bar for the
auto-coner equipment. Considering that the difference in pressure between air
compressor and the far process end is, generally speaking, 0.5 bar or less, it isunderstood that certain measures has been taken. In order to further reduce the dischargepressure, employment of a loop-type air supply system and elimination of fluid
resistance such as undersized pipes and something else are required to study.
c) Management of specific energy consumption
Concerning electric power management, power consumption in the factory as a whole ismeasured and recorded, but process-wise consumption is not known. Processing andanalysis of collected data are not conducted. Visualization of monthly power
consumption and production output on the graph is helpful to monitor trend of powerusage in the factory.
Visualization by graph makes data analysis easy. Graph shows there are a fixed part anda variable part in energy usage. The fixed part is independent of production output. It isenergy to be consumed even during off-production period. For example, energy forlighting and air conditioning is classified in the category of fixed energy. Reduction of
the fixed energy is the most effective measures towards energy conservation.
The variable part is proportional to production output. In other words, as production
increases, energy consumption goes up. Supposing linear relationship between
production output and power consumption, the slope of line means incremental energy

III-19per unit of production, so called specific energy consumption. In order to reduce thevariable energy, the slope has to be gentle. Installation of heat recovery equipment is
one example.
Historical trend of energy consumption can be easily understood on the graph. The
movement of energy consumption data on the graph is helpful for prediction of a future
direction. It can be a tool for setting a target of energy conservation activities. It iseffective to share energy data and to raise awareness of all employees in the factory.
d) Spinning machinery
Spinning machinery is generally operated with a fixed-speed motor. Production output
is adjusted by changing a number of machines in service. At the same time, the fluff
generated through the spinning process is removed by dust-collecting machines.
Dust-collecting machines are also generally operated with a fixed-speed motor. Whenthe volume of fluff to be removed is low, efficiency of dust removal is going down andsome energy use is wasted. The adoption of an inverter control is recommended forenabling to adjust dust-collection capacity according to the fluctuating volume of fluff.
Manually-adjustable inverter is preferable because it is cheap and precise adjustment is
not required. Other options of energy saving measures applicable in the spinning
process are outlined in Attach III-7 (Energy Saving Measures in Spinning and Weaving
Processes).
e) Water pumps
Water consumption tends to fluctuate according to production plans. For this reason,water pumps are generally designed to allow for flexibility to accommodate fluctuationsof water requirement. In reality, production output falls frequently below production
plan and inefficiency in pumping machineries is brought about according to low- load
operation. In order to prevent a decrease in energy efficiency in such a case, pumps
should be operated on a variable speed basis. Manually-adjustable inverter is preferable.
Opening of discharge valves can be an indicator of whether required pump load is low
or not.
f) Power receiving station
Under the Indonesian electric tariff system, a penalty is levied where power factor is 0.9
or under. Where power factor is 0.9 or above, improvement of power factor does notearn a bonus. Power factor at the receiving end is normally 0.92. Accordingly, there are
no problems in power factor management. As no information are available concerning

III-20the load factor of transformers, no assessment is presented in this report.
(5) Comments
1) Engineers from ISN’s two factories and head office gathered and were able to engage
in a meaningful exchange of information. Although the visit to the Surabaja factory wascancelled, the follow-up meeting was meaningful with many useful information shared
among participants.
2) While the participating engineers are in charge of production and energy
management, their understanding of the factory facilities had better be improved interms of energy use. For example, there was an engineer who did not know why
humidity control was required, despite the fact that the ventilation system constitutes thebiggest consumer of energy at the spinning process. Knowledge about the processes had
better be brushed up to a further extent. In addition, inverters are an item with which
participants should be familiar. While they are familiar with the word “inverter”, they
do not know where and how inverters are applied. Knowledge is not properly linked topractice.
4. Overview of Seminar/workshop(1) Time and place
November 25, 2008 (08:30 to 17:00)
Maharadja Hotel, Jakarta(2) Participants: approx. 60 persons
Indonesian government officials
Ms. Indarti (DGEEU, Ministry of Energy & Mineral Resources)
Ms. Feby (DGEEU, Ministry of Energy & Mineral Resources)
Ms. Devi (DGEEU, Ministry of Energy & Mineral Resources)
Mr. Edi H (BPPT, Energy Technology Center)
Mr. Immanuel Kelik (PT.EMI)
Mr. Iwan Rustandi (PT.EMI)
OthersIndonesian private-sector participants
Mr. Pandithakorale (P.T. LIK, General Manager)

III-21

Mr. T.A. Kularatne (P.T. LIK, Product Advisor)
Mr. Badwi (P.T. LIK, Coordinator)
Numerous others
Case presenters (ASEAN member countries)
Philippines Mr. Marlon Domingo (read by Mr. Nguyen Ninh Hai(ACE))
VietnamMr. Phuong Hoang Kim (EECO, Ministry of Energy)
Indonesia Mr. Subagyo (Leces Pulp & Paper Mill, Indonesia)
ACE (ASEAN Center for Energy)
Mr. Christopher Zamora
Mr. Nguyen Ninh Hai
OthersECCJ (The Energy Conservation Center, Japan)
Mr. Kenjiro Hata (Technical Expert)
Mr. Kokichi Takeda (Technical Expert)
Mr. Taichiro Kawase (General Manager)(3) Presentation overview
With a chairmanship of Ms. Maureen Balamiento, presentations were given inaccordance with the program outlined in Attach III-8 (Agenda of Intensive Seminar –PROMEEC Major Industry Indonesia Nov. 25, 2008). An overview of presentations
given is indicated as follows:
Session 1: Policy and Initiatives on EE&C in Major Industries
1) Overview of ASEAN Energy Efficiency Promotion Activities
Mr. Christopher Zamora presented an overview of activities of ACE according to thefollowing headings:
・2004-2009 APAEC Program
・ASEAN-Japan cooperation (SOME-METI, PROMEEC, and multilateral training)
・ASEAN Best Practice Competition (Energy Efficiency Division)
・ASEAN + 3 Energy Efficiency and Re newable Energy Forum・Other programs implemented in collaboration with EAS-ECTF, UNEP, the ASEAN
Foundation, ADB, and CDC.

III-22

A detailed explanation was provided in regards to the 2004-2009 APAEC Program. This
program consists of six program areas. Energy conservation is addressed in the fourth
program area. As a key element of the fourth program area, the process and results withrespect to PROMEEC activities through Phase 1 and Phase 2 were reported An outlineof how these activities unfold in Phase 3 was also presented.
(Note: These six program areas consist of the following: information sharing andnetworking, ASEAN energy standards and labeling, private-sector
participation, capacity building, cultivation of ESCO enterprises, andtransportation sector.)
2) Overview of Plans & Programme on EE&C in Indonesia (Attach III-9)
Ms. Indarti Suharto of DGEEU presented an overview of the latest energy conservation
policies and measures in Indonesia according to the following items:
・Indonesian energy consumption trends
・Recent energy conservation policies
・Measures to promote energy conservation in industrial sectors
With respect to energy consumption trends in Indonesia, energy consumption increased
rapidly in line with economic growth, such that it grew by 7.8% between 1970 and 2006.
Energy consumption per unit of product is quite high in industrial sectors whencompared to one in developed and neighboring countries. In particular, improvement inenergy efficiency is lagging in the iron- making, cement, ceramics, glass, textile, and tiresectors. For example, the energy consumption in the ceramics sector in Indonesia hasreached 16.6 GJ/ton compared to 12.9 GJ/ton in Vietnam. Accordingly, the potential forenergy saving is high, which is estimated to be between 15 and 30% for industrial
sectors.
With respect to recent energy conservation policies in Indonesia, Presidential
Regulation No. 5, which stipulates a target for energy elasticity of 1 or less by 2025,
was issued in 2006. Article 25 of Energy Law No. 30, which was promulgated in 2007,
sets forth incentives and disincentives for the promotion of energy conservation.
Presidential Regulation No. 2, which was proclaimed this year, calls on the central andregional governments to implement specific measures concerning air conditioning,lighting, and other matters in order to promote the conservation of energy and water. In
the same Regulation, it was provided that a national team was organized to pursue theseIII-23

goals.
In terms of the promotion of energy conservation in industrial sectors, it is notable thatthe shifting of weekday power loads to Saturdays has been made obligatory through thecollaborative efforts of five concerned ministries. Details, such as the identity of these
five ministries and the specific means by which this shifting is to be undertaken, areunclear. In addition, projects tied to ASEAN, JICA, UNDP, UNIDO, Denmark, andHolland were briefly introduced as projects connected to foreign donors (detailed
information unavailable).
3) Japan’s Energy Conservation Policy & Measures for Industrial Sector
ECCJ’s Mr. Taichiro Kawase presented an overview of energy conservation policies inJapan and measures applicable to industrial sectors according to the following headings:
・Changes in specific energy consumption by industrial sector in Japan・Policies and energy conservation measures in industrial sector in Japan・Voluntary activities of the private companies and organization in industrial sector
・Roles of ECCJ and overvie w of its activities
・Energy conservation measures and best practices at the Japanese ceramic factories
Session 2: EE&C Best Practices in Industries
4) EE&C Practices in Philippines Food Companies
Energy audit activities conducted by Energy Ministry and energy saving measures infood factories implemented in the Philippines were reported utility by utility (lighting,refrigeration equipment, exhaust gas fans, heat recovery, pumps, boilers, and air
compressors).
Cases concerning pineapple-processing factory were also reported, with particular focus
placed on technologically advanced energy saving measures relating to refrigerationequipment and steam co- generation. These cases could be highly informative forfactories seeking to promote energy conservation as it applies to refrigeration equipment.
It is believed that there is worthwhile including these cases in technical directories(TDs), one of the ASEAN energy management tools.
As Mr. Marlon Domingo of the Philippine’s Department of Energy (DOE) was unable
to visit Indonesia, Mr. Nguyen Ninh Hai of ACE read on his behalf.

III-24

5) Best Practices for EE&C: Case Study of Ceramic industry in Viet Nam
Mr. Phuong Hoang Kim of Energy Efficiency and Conservation Office (EECO), an
office belonging to Vietnam’s Department of Energy (DOE), presented an energy savingcase concerning a ceramic factory. This case involves a factory that was subject to anenergy audit in 2000 and a follow-up investigation in 2004.
Overview of the Hai Duong Porcelain factory:・Public-priva te joint enterprise; produces ceramics; annual output of 14 million units;
workforce of 955 employees
・Production process: raw materials grind ing, mixing, preparation, forming, drying,inspetion, and shipping
・5 kilns: 1 tunnel kiln, 2 decoration kilns, and 2 shuttle kilns
The current state of implementation of improvement measures proposed as part of the
PROMEEC project is as follows:a) Tunnel kiln
・Reduce the heat loss by adding ceramic fiber insulation: This measure was investigatedbut has yet to be implemented (no reason given for non- implementation).
・Reduce the exhaust gas loss by repairing sand seal gutters and adjusting the internalkiln pressure: These measures have been implemented.
・Reduce the infiltration of air into the kiln from the bottom of kiln carts by optimizing
the volume of sand in sand seal gutters: This measure has been implemented.
・Improve the internal temperature profile by securing clearance between the saggar andkiln carts and the height of saggar: These measures have been implemented.
･Prevent the infiltration of outside air by installing a kiln entrance door: As analternative, an air-curtain with FD fans has been installed.
・Shift two or three burners to operate in an oxidizing atmosphere: This measure was not
implemented because such a shift would not be possible as it requires a temperatureadjustment in order to maintain product quality.
b) Roller hearth kilns
・Maintain the kiln pressure at a slightly positive and prevent the infiltration of outside
air: These measures have been implemented.
・Shorten firing time by introducing a biscuit firing approach: This measure has been
implemented.

III-25c) Shuttle kilns
・Shorten firing time by introducing high-speed burners: This measure has been
implemented.
6) Experience & Application of EE&C in LECES Pulp & Paper MillMr. Subagyo of LECES gave a report on energy conservation activities in thepapermaking mill in Indonesia. This mill is situated in East Java and an integrated
papermaking mill of which processes encompass everything from tree and pulp to paper.
Main products consist of liner paper, printing paper, newsprint, and sanitary paper. Main
equipment consist of bagasse pulp equipment, de- inking equipment, five papermaking
machines, wastewater treatment equipment, and a power plant. Energy cost accounts for
24% of production cost.
Rehabilitation project of inefficient aged steam-power plant was reported In the boilers,
the surface of fireside tubes was severely corroded., In the steam turbine, cracks on theturbine shaft occurred. Power factor was as low as 0.74 in the power receiving station.
To overcome these problems, boiler fuel was converted from crude oil to natural gas.
Steam turbine was repaired and capacitors were installed in transformer station. In
addition, various other measures were undertaken, including the installation of
economizers, incorporation of steam extraction control in the steam turbine, steam trap
management, and steam leakage management. These measures helped reduce energy
cost from 22.05 millionUSD to 11.45 millionUSD and improve the power factor from0.74 to 0.90.
7) Results of OJT Audit in one Indonesian Ceramic Factory
Mr. Kenjiro Hata presented a report on the results of energy audit conducted at LIK. See
Attach III-10 (Results of OJT Audit in one Indonesian Ceramic Factory) for details.
8) Best Practices in Japanese Ceramic industry (Electrical Energy)
Mr. Kokichi Takeda of ECCJ presented successful cases achieved in Japanese ceramic
factories (electrical energy saving):・Shut down existing electrical heaters by reinforcing the recovery of kiln waste heat・Install inverters into tunnel kiln fan motors;
・Install inverters into motors of water pumps and exhaust gas fan in the boilers

III-26

・Install inverters into fan motors in the dust-collecting machines
・Install inverters into ventilation fan motors in the air-conditioning equipment
・Integration of transformers and air compressors
・Energy conservation in lighting (high-efficiency ballasts, task-ambient lighting, andlighting management)
See Attach III-11 (Best practices in Japanese Ceramic Factory (Electrical Energy)) for
details.
Session 3: Energy Management Tools
9) Updates on Technical Directory
Mr. Junianto M of ASEAN Energy Center (ACE) gave a briefing on the purpose oftechnical directories (TDs), which constitute an ASEAN energy management tool, andon the method of developing TDs and the format applicable to TDs, as well as presented
an example of the actual TD sheet.
10) Updates on the In-House Database and Cyber Search system
Mr. Junianto M of ACE gave a briefing on the purpose of in-house databases (IHDBs)
and the Cyber Search system, which constitute ASEAN energy management tools, andon the method of producing these tools, the input format applicable to these tools, andother relevant topic s, as well as presented an example of an inputted sheet.
11) In-House Database system for Ceramics Factory
Mr. Taichiro Kawase of ECCJ gave a briefing on the development of in-house databases(IHDBs) for use in ceramic factories. An IHDB consists of production data, energy data,
equipment data, important operational parameters, energy efficiency indicators, andmore. Accumulated data are provided to the production section, technology section,
maintenance section, and others within the factory. PROMEEC project aims at
disseminating the developed IHDB to all ASEAN countries. A proactive adoption of thissystem by ceramic factories in Indonesia is strongly recommended. See Attach III-12(In-House Database System for Ceramic Factory) for more information.

III-27

(4) Comments
1) Sixty participants gathered at the seminar/workshop. It was more than expected andextra chairs had to be brought into the seminar room. Considerable interests were drawn
to presentations by officials from other countries and reporting of energy audit
conducted at the LIK factory. Unfortunately, less questions were asked than expected.
2) Presentation regarding recent policies on energy conservation in Indonesia given by
Ms. Indarti Suharto of DGEEU was highly significant. In particular, it was impressive
to know efforts to shift weekday power loads to Saturdays through the collaborative
efforts of five concerned ministries. It signaled that the promotion of energy
conservation in Indonesia stepped up to more developed stage where various measures
produces a real crop, however small i is.

Reference photographs

Energy audit at LIK

LIK factory manager: fourth from left
Mr. Feby (DGEEU): second from rightIII-28

Dryer audit

Textiles follow -up investigation

Ms. Feby & Ms. Indarti (DGEEU): fifth and sixth from the right side

III-29

Seminar: presentation by field expert

Seminar: group photoIII-305. Attached documents
III-1. Regression analysis of energy consumption
III-2. Heat balance of No. 4 glost kiln
III-3. Heat Recovery of kiln cooling gas waste heatIII-4. Exhaust gas recirculation in dryer of No. 3 biscuit kiln
III-5. Effect of Temperature Profile in Dryer against Product Quality
III-6. Management of Operation and Maintenance in Kiln & Dryer
III-7. Energy saving measures in spinning and weaving processes
III-8. Agenda of Seminar/Seminar –PROMEEC Major Industry Indonesia Nov. 25,
2008
III-9. Overview of Plans & Programme on EE&C in Indonesia
III-10. Results of OJT Audit in one Indonesian Ceramic Factory
III-11. Best Practices in Japanese Ceramic industry (Electrical Energy)
III-12. In-House Database System for Ceramics FactoryIII-31

IV. Myanmar (textile industry)
1. Overview of activities
Local activity of 2008 in Myanmar was implemented in Yangon between November 27
and December 2, in which two ECCJ experts took part as an advisor. Local activity
included three events as followings; OJT audit, advisory visit and seminar/workshop.
Energy audit was made at the state-run textile factory in collaboration with the local
audit team which was organized for the OJT audit. Advisory visit was paid to a
private-sector pharmaceutical factory for making brief factory tour, discussing thefindings and problems, and giving an advice and guidance. Seventeen engineers
participated in the OJT audit, who are coming from Ministry of Industry 1, Ministry ofIndustry 2, Ministry of Energy, ECCJ, and ACE. In the textile factory, various problems
were identified mainly resulting from aged factory equipment and poor energy
management, and poor maintenance practices. On the final day of local activity,
seminar/workshop was held with the aim of exchanging information among participants
and disseminating best practices and useful energy management tools into ASEAN
countries. Approximately forty persons were present at the seminar/workshop, most ofparticipants were engineers coming from state-run companies.
Dispatched officials: Kokichi Takeda, Taichiro Kawase of the ECCJ International
Engineering Department
Schedule of activities:
Nov. 27 – Nov.28 (morning): energy audit (conducted at Mayangone Textile (1))
Nov. 28 (afternoon): advisory visit (paid to FAME Pharmaceuticals)
Dec. 1: Seminar/workshop
2. OJT energy audit (Mayangone Textile (1))(1) Participants (17 persons )Ministry of Industry (2): 7 participants (Mr. San Lynn (focal point) and 6 engineers)
Ministry of Industry (1): 5 participants (Ms. Ni Ni (factory manager) and 4 engineers)
Ministry of Energy:
2 participants (Mr. Soe Naing (Than Lyin oil refinery)
And 1 engineer)ACE:
1 participant (Ms. Maureen Balamiento)

IV-1

ECCJ:

2 participants (Mr. Takeda and Mr. Kawase)(2) Overview of the factory
Ms. Ni Ni, the factory manager provided an overview of the factory based on Attach
IV-1 (Summary of Mayangone Textile (1) Factory).
Factory: one of twenty-four factories operated by MTI (Myanmar Textile Industries,
state-run textile company). The factory is located in Maya ngone district of
Yangone city. MTI is under the jurisdiction of Ministry of Industry 1. A
Toyota weaving machine was introduced in 1979; no major replacement inequipment has been made since then.
Products: fabric for suits, fabric for shirts, and fabric for lonji
Production output: 356,400 m2 of fabric for suits, 631,629 m2 of fabric for shirts,
and 24,685 m2 of fabric for lonji (2006)
Customers: 100% domestic
Production process: yarn twisting ? cone winding ? weaving ? warping ? sizing? calendering
Energy consumption: crude oil 98,064 L/yr. (unit price: 2,643 kyat),electricity 243,700 kWh/yr. (unit price: 25 kyat)(reference: 0.09 JPY = 1 kyat, as of December 2008)
Employees: 207(3) Overview of energy audit
1) Local audit teamLocal audit team consisted of twelve engineers from Ministry of Industry 1, Ministryof Industry 2, and Ministry of Energy. Participants were an engineer and belonging tovarious state-run enterprises which produces respectively textiles, food products, beer,
sugar, pulp and paper, tools and electricity, trucks and diesel fuel, and tires and rubber.
Ms. Ni Ni was appointed as a leader and a presenter in the seminar.
2) On-site inspection and measurements
Led by ECCJ experts, this audit was conducted on a walk-through basis. In order toinvestigate the performance of ventilation system in the spinning process, measurementof the following points were performed; temperature and humidity of outside air aroundthe refrigeration equipment, temperature of chilled water and cooling water, andIV-2

electrical power supplied to pumps and fans. Measuring instruments were provided by
ECCJ and Myanmar government; portable thermometer (ECCJ) and power monitor(Myanmar government). The observations gleaned from the walk-through were reported
to factory executives the following day.
3) Data Analysis and reporting
Collected data were analyzed substantially by ECCJ experts. As shown below, various
measures for energy saving were found and summarized as recommendations. These
recommendations were reported on a preliminary basis to factory executives on thesecond day of energy audit. Further, the preliminary report was presented by factory
manager Ms. Ni Ni at the seminar/workshop.
a) Findings and recommendations regarding energy saving measures
・Power-receiving equipment
Current load factor is extremely as low as 14%. Transformer rating should be reduced,
for example, to 50% of current capacity.
・Boilers
Viscosity of fuel oil is not managed. Target temperature of fuel oil should be set
Correlation data regarding temperature vs fuel oil viscosity is provided by ECCJ
experts. Floor around boiler was found to be wet with black fuel oil. Maintenance offuel oil piping should be performed to prevent oil leakage. Exhaust gas ducts areseverely corroded and punctuated by a large hole. Therefore flue gas stack does not
generate drafting power. Urgent maintenance is expected.
・Underground water pump
Water is leaking from the head tank, and falling down like rain. Urgent maintenanceis expected.
・Steam pip ing
Insulation is torn down and some part of piping is with nearly bare surface which is
wasting huge steam energy and in turn increasing boiler fuel consumption. Urgent
maintenance is expected.
・Cooling tower
Channeling of falling water was observed beneath the plastic fills zone in the cooling
tower. Measurement data of water temperature, etc around cooling tower suggested
very poor cooling tower efficiency. Cleaning of spray nozzles and replacing of plastic
fills are urgently expected.

IV-3

Motor power input was measured and compared with rated power input, as a result,chilled water pump and IDF fan have considerably large capacity compared withactual power requirement. Replacement of current pump to smaller pump and/or
impeller trimming are effective to reduction of current machine capacity.
・Ventilation system
Many defects and problems were observed, including complete blockage of cool air
fan filter, malfunctioning of humidity sensors, and a large hole in the ceiling of theweaving room. As a result, the ventilation system is not functioning at all. In otherwords, shutdown of the ventilation system does not impede weaving operation. The
ventilation system can be shut down at least during the dry season and at night time.
It is worthwhile trying a shutdown.
・Sizing equipment
Degraded insulation, fallen-off insulation, and steam leakage were observed in thesteam pipes. (Maintenance work should be undertaken.)Temperature of sizing tank seems too high which causes energy loss from the surfaceof sizing tank. Set a target of sizing tank and perform temperature management.
Moreover, steam condensate is not recovered, which should be reused as make-up
water to the sizing tank.
・Calendering machine
Degraded insulation, fallen-off insulation, and steam leakage were observed in thesteam pipes. (Maintenance work should be undertaken.)・LightingTask-ambient lighting is thoroughly utilized in the spinning/weaving room.
Fluorescent lamp reflectors are dirty and maintenance work should be undertaken.
b) Comments regarding energy management
・Establishment of energy management system
The first to do is to organize an energy conservation promotion committee and to
declare a strong support of top management towards EE&C to all employees. A
person in charge of energy should be appointed for each process of the factory.
Education of employees, particularly workers, is very important and strongly
recommended. The support of concerned governme nt officials should be sought.
・Equipment maintenance
Equipment and parts are not being effectively maintained at all, especially withrespect to boilers, thermal insulation, steam leaks, cooling tower, the ventilation
system, and lighting fixtures. Early repair is expected.

IV-4

・Measurements and records
Important energy-consumption variables should be monitored and recorded; for thispurpose, an in- house database could be helpful.
(4) Comments
1) Preparations made by focal point, Mr. San Lynn, and officials from Ministry ofIndustry 2 were excellent. It was notable that the local audit team consisted of manyengineers from concerned ministries and government offices with jurisdictional ties toindustrial sectors. A measuring instrument (a power monitor) contributed greatly to thesuccessful audit. The factory welcome visitors and extended kindly all possible
cooperation. For example, the factory manager presented an overview of its EE&C
activities excellently with well-designed PowerPoint documents. Consequently, the time
for interview session was shortened, and spared time was effectively used for aninspection of equipment.
2) Unfortunately, efforts to promote energy conservation in the factory have, for themost part, not always been successful to date. In particular, the concept of energy
management has yet to penetrate, and maintenance activities have been nearly neglected.
Various no-cost or low-cost energy saving measures were pointed out in the course of
the walk-through investigation. These measures should be implemented promptly.
3) Many engineers from other industrial sectors participated in the OJT audit. The
authors of this report believes that they learned about significance of energy
management, importance of maintenance, and no-cost and low-cost energy saving
measures.

3. Advisory visit (FAME Pharmaceuticals)(1) BackgroundThough not initially planned, a visit to FAME Pharmaceuticals was paid in response
to a request from Myanmar officials. An outline of the factory is described below:
Product: herbal medicines (30% exported)
Production process: raw materials drying (solar), extraction (with alcohol),IV-5

concentration (solar or electric heater)
Energy consumption: electricity 218,400 kWh/yr.
Employees: 250(2) Date and participants
November 28 (afternoon)
17 participants (Mayangone Textile Factory (1), all of OJT audit participants)(3) Energy conservation activities
The factory is one of winners in ASEAN Energy Conservation Award 2008. The
factory is making positive effort to promote energy conservation as the following;・Solar drying of raw herbs
・Evaporation of solvent alcohol by solar heat・Reuse of clean discharged water (for lawn watering)
・Day-lighting (reducing lighting energy)
・Lighting management by lux meters
・Power factor compensators
・Management of air conditioning units (adjusting temperature and humidity)(4) Walk-through results・Two biggest energy-consuming equipment are alcohol-based solvent evaporators andair-conditioning units.
・Evaporation of solvent is carried out through two-stage process, i.e., solar heating andan electric heating. Electric heater was sufficiently insulated.
・68 packaged air conditioning units have been installed mainly in the production roomand the warehouse. Internal room conditions are manually controlled by adjusting a
number of units in service.
・Heat infiltration through walls and/or windows into air-conditioned spaces was
examined. Outside surface has nearly the same temperature as outdoor air
temperature. It was found that wall is insulated with enough thickness.
・Ordinary glass was used for window glass. Window is one of the places where heat
intrudes into air conditioned space. Double-glazed glass or thermal insulated glass arerecommended.
・ Motors and lighting increases a required load of air conditioning units as an internal
heat source. Heat load due to motor operation seems not so large because not so many
motors are used. Also, Lighting load is not a large load because it was managed

IV-6

excellently with light sensors.
・The room temperature in the office was maintained at twenty-seven degC, anappropriate level.
(5) Comments
・Energy management has been made excellently with less room of energy conservation
measures remaining. It was understood that the factory was nominated for an ASEAN
energy conservation award.
・While energy saving effect was small owing to the small size of this factory, themeasures employed are very helpful. It is expected that the experiences are spreadovern Myanmar as a model of energy conservation for buildings, in particular air
conditioning unit.

4. Overview of Seminar/workshop(1) Time and place
December 1, 2008 (08:30 to 17:00)
Chatrium Hotel, Yangon, Myanmar(2) Participants: approx. 40 persons
Ministry of Industry (2): 10 persons
Mr. Kyaw Swa Khine, Deputy Minister
Mr. San Lynn, Director, Myanmar Industrial Construction Services (current focal
point)Engineers form state-run factories (tools and electricity, trucks and diesel fuel,and tires and rubber)
Ministry of Industry (1): 13 persons
Ms. Ni Ni, Factory Manager, Mayangone Textile Factory (1)Ms. San San, Factory Manager, Than Lyin Textile Factory
Engineers from state-run factories (textiles, food products, beer, sugar, pulp andpaper)
Ministry of Energy: 6 persons
Mr. Maung Maung Ohn Thaw, Assistant Director, Energy Planning Department
Mr. Soe Naing, Maintenance Engineer, Thanlyin Oil Refinery

IV-7

Other technical staffs
Ministry of Electric Power (2): 1 person
Ms. San San Win, Deputy Director
Ministry of Forestry: 1 person
Mr. Ne Win, Office of National Environment Commission
Ministry of Science & Technology: 2 persons
Dr. Thet Htoo Han, Deputy Professor, University of Technology (Kyauk-se)
Dr. Min Zaw Aung, Acting Principal, University of Technology (Pakok ku)
Myanmar Engineering Society: 1 person
Mr. Ohn Myint, Director, Central Executive Committee (former focal point)
Myanmar Economic Corporation: 1 person
Mr. Yin Maung Nyunt, Deputy General Manager
Myanmar Engineering Society: 3 persons
Mr. Aung Myint, Joint General Secretary
ASEAN (speakers): 3 persons
Mr. Zul Azri Bin Hamidon, Expert, PTM, Malaysia
Mr. Marlon Romulo Domingo, Senior Specialist, DOE, The Philippines
Mr. Le Duc Huy, Executive Director, ECC-HCMC, Vietnam
ASEAN Center for Energy (ACE): 1 person
Ms. Maureen Cruz Balamiento, IT specialist
The Energy Conservation Center, Japan (ECCJ): 2 persons
Mr. Taichiro Kawase, General Manager, International Engineering department
Mr. Kokichi Takeda, Technical Expert, International Engineering department(3) Presentation overview
One official of Ministry of Industry (2) chaired in accordance with the program outlinedin Attach IV-2 (Agenda of Intensive Seminar - ROMEEC Major Industry Myanmar Dec.
1, 2008).
Session 1: Policy and Initiatives on EE&C in Major Ind ustries
1) Overview of ASEAN Energy Efficiency (EE&C) Activities (Attach IV-3)
Ms. Maureen Balamiento presented an overview of activities of ACE according to theIV-8following headings:
・2004-2009 APAEC Program
・ASEAN-Japan cooperation (SOME-METI, PROMEEC, and multilateral training)
・ASEAN Best Practice Competition (Energy Conservation Division)
・ASEAN + 3 Energy Conservation and Re newable Energy Forum・Other programs implemented in collaboration with EAS-ECTF, UNEP, the ASEAN
Foundation, ADB, and CDC.
A detailed explanation was provided in regards to the 2004-2009 APAEC Program. This
program consists of six program areas. Energy conservation is addressed in the fourth
program area. As a key element of the fourth program area, the process and results withrespect to PROMEEC activities through Phase 1 and Phase 2 were reported An outlineof how these activities unfold in Phase 3 was also presented.
(Note: These six program areas consist of the following: information sharing andnetworking, ASEAN energy standards and labeling, private-sector
participation, capacity building, cultivation of ESCO enterprises, andtransportation sector.)

2) Overview of Plans & Programme on EE&C in Myanmar (Attach IV-4)
Ms. Soe Soe Nyein of Ministry of Energy presented an overvie w of the latest energy
conservation measures in Myanmar according to the following headings:
・Focus of energy policies
・Organizations in charge of energy sectors
・Energy conservation measures
The energy policies in Myanmar is focused on energy self-sufficiency, use of renewableenergy, promotion of energy conservation, and promotion of alternative fuels forhousehold use.
Organizations in charge of each energy sector are as follows:
・Petroleum and gas: Ministry of Energy (focal point of PROMEEC project)・Electricity (hydro power): Ministry of Electric Power (1)・Electricity (thermal power, power transmission): Ministry of Electric Power (2)・Coal: Ministry of Mines
・Biomass: Ministry of Forestry, Ministry of Agriculture and Irrigation

IV-9

・Renewable energy: Ministry of Science & Technology
・Nuclear power: Ministry of Science & Technology
Past energy conservation activities
・UNDP/ADB project (1991, energy audit and seminar)
・UNESCAP seminars (3 times, energy conservation)
・PROMEEC project (training, audit, seminar), currently on-going3) Japan’s Energy Conservation Policy & Measures for Industrial Sector(Attach IV-5)
ECCJ’s Mr. Taichiro Kawase presented an overview of energy conservation policies inJapan and measures applicable to industrial sectors according to the following headings:
・Changes in specific energy consumption by industrial sector in Japan・Policies and energy conservation measures in industrial sector in Japan・Voluntary activities of the private companies and organization in industrial sector
・Roles of ECCJ and overview of its activities
・Energy saving measures and best practices at the Japanese ceramic factories
Session 2: EE&C Best Practices in Industries(4) EE&C in Textile and Glass Industries in Malaysia
JG Containers, which first began operations in 1972, produces 150 tons per day of glass
containers for food, medical, and other uses. Fuel used to melt glass accounts for 85%
of energy consumption. The fuel consumption of the factory (8.0 GJ/ton), wasconsiderably high, compared to 5.0 GJ/ton, typically in Europe and the United States.
Three audits have been conducted in the past; the following measures have been
implemented based on the results of these audits, such that the fuel consumption rate
has declined to 5.7 GJ/ton.
･Revamp of the melting furnace (added a furnace control system)･Revamp of the annealing oven･Fuel conversion in the annealing oven･Reuse of cullet cleaning water (installed a filter)

IV-10

(5) EE&C in Pulp & Paper and Cement Industries in Philippines
Mr. Marlon Domingo reported energy saving measures which was identified in theenergy audits for cement and pulp and paper factories carried by DOE of the Philippines.
There are seventeen cement factorie s, ranging from small factorie s with an annual
output of 100,000 tons to 2,000,000 tons. Most of factories employ dry process, thoughsemi-dry processes are still used in part. Identified energy saving measures are as
follows;
・Modification of semi-dry kiln into a dry kiln
・Capacity increase by adding pre-calciners
・Modification of clinker coolers
・Installation of high-efficiency fans into clinker coolers
・Installation of 5-stage NSP・Introduc tion of vertical roller mill・Introduction of VSD in place of damper control
・Fuel conversion (use of rice-husks)
Exhaust heat recovery-based power generation system are being studied as a possibleenergy saving measure in the future. An exhaust gas from clinker coolers or suspension
pre-heaters are utilized as a source of heat recovery
With respect to pulp and paper factorie s, an introduction of circulating fluidized bed
boilers has been facilitated in order to enable the use of inexpensive coal and /orbiomasses.
(6) Best Practices in Textile and Food Industries in Viet Nam
The presenter of this topic was unable to enter Myanmar due to cancellation of the flight.
An overview of the presentation materials is outlined below;
・ The activities of Energy Conservation Center in Ho Chi Minh City werebriefed ,including energy audits, training, and public relations.
・The 288 factories were audited between 2002 and 2007 (pulp and paper, machinery,textile, food products, etc).
・The textile industry in Vietnam accounts for 28% of aggregate production output and
15% of aggregate added value. The potential for energy saving in this industry is
estimated at 30%. The result of OJT audit made as the last year’s PROMEEC activity

IV-11

was reported.
・The food industry in Vietnam accounts for 15% of aggregate production output and
17% of aggregate added value. The potential for energy saving in this industry is
estimated at 20%. The successful case involving a beer factory were reported as an audit
case.
(7) Results of OJT Audit in Mayangone Textile Factory (1) (Attach IV-6)
Ms. Ni Ni, a local team leader and factory manager, presented a report on results ofenergy audit conducted at Mayangone Textile Factory (1). Proposed measures focus
primarily on the maintenance of aged equipment and on the energy management system.
The presentation is believed to have been highly informative for the engineers of otherstate-run factorys in attendance at this seminar.
(8) Best Practices in Japanese Ceramic industry (Electrical Energy) (Attach IV-7)
Mr. Kokichi Takeda of ECCJ presented successful cases, in particular, electrical energy
saving in Japanese textile factories:
・Reducing the capacity of solvent gas blowers and introducing high-efficiency blowers
at the acetate manufacturing factory・Reducing unloading losses from air compressors by introducing inverter machines
・Energy saving applied to ventilation systems (using outside air, incorporating an
inverter control system into fans, and utilizing a humidification system)
Session 3: Energy Management Tools(9) Updates on Technical Directory, In- house Database, Cyber Search System
Mr. Junianto M of ASEAN Energy Center (ACE) gave a briefing on the purpose of
three ASEAN energy management tools—namely, technical directories, in- house
databases, and the Cyber Search system—and on the method of developing these tools,
as well as presented an example of how data is tinputted with respect to these tools.

IV-12(10) Trial Use of In-House Database for Textile Factory, and TPM for Equipment
Maintenance (Attach IV-8)
Mr. Taichiro Kawase of ECCJ gave a briefing on in- house databases (IHDBs) used in
the textile industry. IHDBs are used as energy monitoring tool inside a factory. They
accumulate various kinds of information, for example, production data, energy usage
data, equipment data important operation data and energy performance indicators.
Beneficiaries are factory management, technical staffs, accounting staffs as well as
operational personnel. The presenter asked audiences to adopt the tools not only in the
Myanmar industrial sector but also ASEAN region.
In addition,(4) Comments
1) The seminar/workshop was attended by many attendants from the public sector,
while no participant from the private sector.
2) Many questions were asked, covering a broad range of topics, although most are
fundamental. For example, what is the advantage of pre-grinding in the cement factory?,
which process is the cheapest, chemical or mechanical in the paper factory?, what are
the energy saving measures available in the truck assembly factory?, and Can Japan
comply with the commitment in the Kyoto Protocol?
3) The author exchanged information with engineers from state-run factorie s during the
break of presentations. Three of them learned in the Japanese universities, and apro-Japanese. Their knowledge reached a necessary level enough for promoting energy
conservation. The next is to put their knowledge into actual practice in the factory or
missions and to accumulate as practical skills and experiences.

IV-13

OJT audit at Mayangone Textile Factory (2)Ms. Ni Ni (factory head), sixth from the left side
Mr. San Lynn (focal point), fifth from the left side

Audit of cooling tower

IV-14

Visiting investigation of FAME Pharmaceuticals

Mr. San Lynn (focal point), middle row, second from the left side

Myanmar government officials

Mr. San Lynn (new FP)

Mr. Ohn Myint (former FP)

Mr. Kyaw Swa Khine (Deputy Minister, Ministry of

IV-15

Seminar: group photo

Mr. Kyaw Swa Khine (Deputy Minister, Ministry of Industry

5. Attached documentation
IV-1. Summary of Mayangone Textile Factory (1)IV-2. Agenda of Intensive Seminar – PROMEEC Major Industry Myanmar Dec 1, 2008
IV-3. Overview of ASEAN Energy Efficiency (EE&C) Activities
IV-4. Overview of Plans & Programme on EE&C in Myanmar
IV-5. Japan’s Energy Conservation Policy & Measures for Industrial Sector
IV-6. Results of OJT Audit in Mayangone Textile Factory (1)IV-7. Best Practices in Japanese Textile Industry (Electrical Energy)IV-8. Trial Use of In-House Database for Textile Factory, and TPM for Equipment
Maintenance

IV-16

V. Summary/post workshop
1. Overview of workshop
This workshop was attended by twenty-two participants consisting of focal points fromthe ten ASEAN countries, ACE officials, ECCJ officials, and officials from host country
the Philippines.
The year 2008 was a transient year when project phase stepped up from Phase 2 toPhase 3. In other words, this year project activities moves from technology transferfrom Japan to self- help energy conservation by the ASEAN countries
From this standpoint, this year’s project activities were evaluated, its achievements wereshared with ASEAN countries. Further, basic policies towards Phase 3 were formulated,discussed and agreed.
In conclusion, local activities to be implemented in 2009 are proposed by each country,
and forwarded to ACE till a deadline of the May the first week. Considering the
proposed local activities, ECCJ and ACE make a draft implementation plan which are
finalized in the inception/workshop slated to be held at the beginning of July later thisyear.
(1) Time and Place
Schedule: February 26 (Thu.) to 27 (Fri.), 2009
Richmonde Hotel: Ortigas Center, Pasig City, Philippines(2) Participants:
ASEAN officials: 14 participants
Ms. Loreta G. Ayson, Undersecretary, Department of Energy, Philippines
Mr. Prasert Sinsukuprasert, Director, DEDE, MOE Thailand (Chairman)
Mr.Ahmad bin Haji Mohamad, Special Duty Officer, Energy Division, Prime
Minister’s Office, Brunei Darussalam
Mr. Lien Vuthy, Head of Energy Efficiency and Standard Office, MINE, Cambodia
Ms. Devi Laksmi, EC Division, Ministry of Energy and Mineral Resources(MEMR), Indonesia
Mr. Bouathep Malaykham, Director of Electric Power Management Division,
Ministry of Energy and Mines
Ms. Norhasliza Mohd Mokhtar, Program Manager, PTM, Malaysia
Mr. Thaung Nyunt, General Manager, No. 1 Machine & Machine Tool Factory,

V-1

MOI (2), Myanmar
Mr. Jesus C. Anunciacion, Chief Science Research Specialist, EE&C Division, DOE,
Philippines
Mr. Malon Domingo, EE&C Division, Department of Energy, Philippines
Mr. Abdul Rashid B. Ibrahim, Deputy Director, Energy Market Authority, Singapore
Mr. Nguyen Van Long, Officer, Science and Technology dept., MOIT, Vietnam
2 officials, Department of Energy, Philippines Government
ACE: 5 participants
Mr. Manh Hung, Executive Director, ACE
Mr. Christopher Zamora, Manager, ACE
Mr. Ivan Ismed, Project Officer, ACE
Ms. Maureen C. Balamiento, Database and IT Specialist, ACE
Mr. Junianto M., IT Staff, ACE
ECCJ: 3 participants
Mr. Tsuzuru Nuibe, Director General
Mr. Kazuhiko Yoshida, General Manager
Mr. Yoshitaka Ushio, General Manager)
2. Activity report for 2008 and action policies for 2009
The local activity implemented in 2008 was reported by the focal point of each country.
Next, ECCJ gave a briefing on action policies in 2009, which was agreed to by allparticipants;(1) Countries implemented local activity
Thailand (food industry)
Indonesia (ceramics industry)
Myanmar (textile industry)(2) Results of local activities and evaluation thereof
1) Local audit teams were well organized as planned, and great improvements were
undertaken especially in energy audit and follow-up survey. Most participants made an
positive effort to understand a basic process principle.
2) Seminars/workshops gathered many participants and induced active discussions,and as a result, attained the aim for dissemination of the project achievements.

V-2

Successful cases from countries other than the host country were also helpful toparticipants.
3) Great progress was made in the development of energy management tools.
thirty-five technical items were added in the TD ,and 145 technologies were disclosed in
the website of ACE. In-house databases (IHDBs) pertaining to iron/steel and ceramics
sectors are currently being developed by ACE. These tools, including IHDBs previously
completed for the cement, food, and textile sectors, are presently being applied on a trial
basis through OJT in each country.
4) Points to be improved- In some countries, ECCJ experts made an audit substantially. More self- help effort
is required by the local team.
- Some have suggested that one-day training sessions is provided on the first day of
OJT energy aud it in each country.
- More participants should be invited to seminar/workshop from the same or relatedindustries as the industry to which the audit venue belongs.
- Efficient preparation by ACE are required for more use of IHDBs and feedback on
problems on its usage are important.
- In order to raise reliability, TD should receive a technical review by ASEAN
experts.
- For successful cases registered in TD, consideration should be given to allow award
examples to be cited.
- Accessibility should be improved to TD and IHDBs.
(3) Action policies for 2009
1) Request a proposal of local activity from each country, satisfying the following
terms. Activities shall be undertaken in countries that can commit themselves tofulfilling these terms :- Reflection of the aforementioned points to be improved.
- A Call for enhanced OJT energy audit, thorough follow-up survey, and/or
well-organized seminar/workshop.
- Local audit team with reliable and workable organization- Selection of industrial sector from the standpoint of securing sustainability andeffective dissemination.
- Reliable pre- investigation preparations shall be undertaken.
- Fundamental understanding of industrial processes principles.
- Submission of basic idea of audit training program

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2) Preparation of training tools for OJT and improvement activities;- Process handbooks for major industries- Revision of In-house databases by industry- Improvement of technical directories
3) Skeletal framework of activities in each country:- Countries where local activity is implemented: maximum three countries- Duration of local activity: maximum 7 days,- Duration of each activity;
OJT energy audit: maximum 4 working days
Follow- up survey: maximum 2 working days
Seminar/workshop: 1day
3. Basic policies towards Phase 3
Presently, a draft concerning the ASEAN Plan of Action for Energy Cooperation for the
next term (APAEC 2010-2015) is currently under investigation. The PROMEEC project
constitutes an important set of activities in the APAEC 2010-2015 for cultivating humanresources concerning energy conservation. Accordingly, assistance is increasingly
important in the PROMEEC project in order to make sure implementation anddissemination of the transferred technologies. At the same time, policy measures aretaken in each country to support the assistance.
Under these circumstances, Phase 3 of this project will call on concerned parties to aim
at reaching a higher level of engagement in independent, constructive activities
according to results achieved to date. To this end, the following basic policies have beenverified and shared among participants:
1) Development of human resources
2) Provision of system and tools contributing to human resources development
3) Undertaking of measures in each ASEAN country to support the above two policies
In accordance with the above basic policies, the following four points are to beestablished as specific activities for sustaining and disseminating the transferredtechnologies:
1) Organizing a trainer group in each country2) Elaborating a basic plan for energy audit training program in each country3) Self- help implementation of the transferred technologies and follow-up of theresults

V-44) Improving necessary basic tools
A basic plan was discussed and agreed to, according to the outcome of theaforementioned discussion. Generally speaking, it was acknowledged that the firstpriority for Phase 3 is to enhance current activities, and in order to do that, important are
to identify the activities to be concentrated, to strengthen the synergy of three
sub-projects ,and to set a target and apply a verification method.

The permission of the International Cooperation
Department of the International Cooperation Divisionof the Energy Conservation Center, Japan, must be
obtained in advance when publicly disclosing thecontents of this report.
Tel.: 03（5543）3018
Fax: 03（5543）3022

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