Seminar On The Promotion On Energy
Efficiency & Conservation For Major
Industries In South East Asia
Sedona, Yangon, Myanmar
24th November 2006MIEEIP Background
The Malaysian Industrial Energy
Efficiency Improvement Project(MIEEIP) started in the fourth quarterof 2000 with the main aim to:
Removing Barriers to industrial
Energy Efficiency & Energy
Conservation

1

MIEEIP Objectives
To improve Energy Efficiency in Malaysian industrial
sector by:
Removing barriers to efficient industrial energy use
To create a sustainable institutional capacity toprovide EE sources and a conducive policy,planning and research framework
By Focusing on 8 energyenergy-intensive manufacturingsubsub-sectors namely Wood, Food, Glass,Glass, Cement,Rubber, Pulp & Paper, Iron & Steel, Ceramic in orderto maximize gains & attainment of targets

JG Containers

Experience And Application OF
Energy Efficiency &Conservation in
JG Containers(M) Sdn. Bhd –Glass Industry

2

Presentation Topic Company Background Auditing process Existing Energy Profile Existing Energy Consumption Figures
 Energy Management
 Energy Audits Background Energy Audit recommendations
 Energy Measures Already Implemented
 Closing remarks
 Conclusion
 General

COMPANY BACKGROUND Established in the Year 1972
 Located in Klang, Malaysia
 Present Production : 120 TPD Container

Glass Production(Before 2002- 90 TPD)
 Present Turnover : RM36 M
 Product Range: Beverage,
Pharmaceuticals and food industries 80% of production- local sales
 20% of production – export sales

3ENERGY AUDIT HISTORY•ADB Audit during 1992 – Partial Audit•Internal Audit in 1996 – Comparison with
•Internal
similarAudit
glassincompany
1996 – Comparison
belonging withwithsamesimilar
group
glassincompany
India belonging with same group in India•Pusat•PusatTenagaTenagaMalaysia
Malaysia
AuditAuditin 2001
in 2001– Total– Totalcomprehensive
comprehensive
auditaudit•PTM•PTM
AuditAudit
highlighted
highlighted
the energy
the energy
use ofuse8.0of GJ/
8.0 GJ/
Ton Tonof Glassof Glass
meltedmeltedin JGinisJG
very
is very
highhigh
as ascomparedcompared
to average
to averageof 5.0of GJ/
5.0 TonGJ/ Tonof glassof glass
meltedmeltedin Europe.
in Europe.
In some
In somecountries,countries,
the figure
the figureisevenislower
even which
lower whichis 4.8 is
GJ/Ton.
4.8 GJ/Ton.
•The•ThePTM PTM
programme
programme
formedformedthe basis
the basisfor thefor thefoundation
foundationof JG’sof JG’s
EE initiatives
EE initiatives

Energy Profile from EA in 2001
Glass manufacturing is High Energy

intensive Industrial Sector.
Energy Cost contributes over 20% ofTurnover. Consumption For -2000
UtilityUnitsConsumption
Qtty %(GJ)

Cost
RM M%
Cost

Electricity
MFO
LPG
Water

MWH
Cu.M
Cu.M
Cu.M

8358
3367
307090
36500

1.6
2.34
0.81
0.09

33.048.0
17.0
2.0

15.0
70.0
15.0
--4

Utility Consumption Analysis
Utility Consumption - January 2000 -December 2000
T o ta l c o s t: R M 4 .8 2 3 M illio n

17%

L .P .G .

2%

W a te r

E le c tri c ity
33%

48%

M .F .O

Recommendations Of PTM Audit 2001
1)

2)

3)

4)
5)
6)
7)

To Reduce Heat loss in
Annealing Lehr.
To Improve Forming Machine
Efficiency.
To Reduce Compressed Air
Loss.
To improve Lighting.
To Preheat Batch using Furnace
Exhaust.
To Recirculate Water.
To Improve Furnace Efficiency

5Measures Implemented During 2002
Rebuilding furnace with controlsystems
Old FURNACE of 90TPD lacked
control systems and suffered heatlosses since furnace built in 1992. New
furnace of 120TPD was built using
advanced crown system

Modification of one
annealing lehr Reconditioned insulation -of 1of the annealing lehrs - cost of
RM50,000, which resulted inenergy savings of 750
kWh/day

Executed
Measures
Water recycling
100 cubic m 3 /day as drinking
water & service water forcooling cleaning cullets.
~ 25 m 3 daily - washing thecullets alone the drain.
New filtration system
to recycle the water

Natural gas-powered lehr
One of the old annealing lehrs wasreplaced with a new energy efficient LPG/ NG-fired lehr at a cost of RM 400,000 in
November 2002 - production up by 50 %Energy Demand Status 2003
 Glass manufacturing is High Energy intensive

Industrial Sector.
 Consumption For -2003
UtilityUnits

Consumption Cost
Quantity
RM MilElectricity

MWH

11,340

2.089

MFO

Cu.M

207,499

2.905

LPG

Cu.M

5,061

0.577

Natural Gas

1000

303

0.150

Cu.M

6

Comparison Of Energy
Consumption For Yr.2000- 2004
987654MFO/NG(GJ/Ton)

3
2
10Electricity( GJ/Ton)

2000

2001

2002

2003

2004

Closing Remarks
 Even though the Electricity

Consumption is 13% of Total
Energy Utilised, Electricity cost
component is over 37% of Total
Energy Cost.
 Every Effort is required to reduce
Electricity consumption & Cost.
 Finally the Specific Energy
Consumption should reachbelow 4.8 GJ / Ton of Glass
Melted to reach Industry’s BestEE standard.

7

Continued….
 The investment cost is very

high in glass sector toimplement EE projects.
 Furnace rebuilt time is more
appropriate time to implement
major EE projects whichcomes generally once in 10years.
 Lack of EE measurement
tools & expertise in glass
sector hindering the progress.
 Normally during Energy crisis
period only, the EE projects
are given priority.

INTRODUCTION TO AMDB
Arab-Malaysian Development Bhd (AMDB) textile plant / Taping Fabric (Taifab).
Factory Address:Kamunting Industrial Estate
P.O. Box 98
34008 Taiping, Perak, Malaysia
Tel: 605-891 4000
Fax:605-891 2900

Number of employees

: 200



Annual turnover: RM 60 Mil

Annual production: 10.5 Mil. meters

Products range:100% cotton;Polyester Cottonblends; Polyester
Viscose blends;(of woven, dyed/finished)Market:Local and Export (Australia, N.Zealand, EU)

8

CORE RECOMMENDATIONS
Pre treatment RangeHeat Recovery from waste water
Steam Box Auto Control Maintenance
Stenter (Artos Stenter No. 3)Fixed type textometerVariable Speed Exhaust Fan
Boiler and steam distribution system
Localized boiler systemSelf Maintain steam trap

POTENTIAL COST SAVINGSRM 241, 000 / yearOr
USD 63, 142 / year9

EXECUTED MEASURES (1)Replacement of Old Boiler

BeforeOld Boiler
11 t/hEfficiency :70%

After
New Boiler
16 t/hEfficiency : >85 %15 hr/day,25 days/month 15 hr/day,25 days/month
LFO : 915 l/day
LFO : 686.25 l/day(25 % lower )RM 60 K/month (USD 15.8 K)& RM 720 K/yr (USD 189.5 K)

EXECUTED MEASURES (2)Reduce Boiler Daily Operation Time

BeforeDaily start up time :6.00 amAfter
Daily start up time :6.40 am

Old boiler requires 1 hr
start up period to supplysteamOld boiler requires 20
minutes start up period tosupply steam
RM 12 K/month (USD 3.1 K)& RM 144 K/yr (USD 38.1 K)

10

EXECUTED MEASURES (3)3) Steam Trapso Maintenance Dept. - weekly checking on steam
Traps at various machines
o Reduce the steam loss to minimumo More than 50 pcs. of inefficient or damaged steam
traps - replaced for the past two years.

EXECUTED MEASURES (4)4) Auto Temperature Control for steam supply for
Washing Basins.
• The front section of Perble Range - installed withAuto Steam Control Valves to regulate temperature• Mill will gradually replace more area to use Auto
Temperature Control devices for steam supply

11

EXEPECTED MEASURES (1)5) Convert to Natural Gas burning for our Steam Boiler• The NG line has reached the outside of thefactory. Construction work and agreement with Gas
Malaysia is finalizing.
• NG is expected to provide gas supply for Boiler earlynext year.
• With the LFO price at RM0.848/ liter (USD 0.22/l)
presently and NG at RM0.49 /Sm3 (USD 0.122/m3)• Conversion to burn on NG  Calculated cost savings•
RM132 K /month (USD 34.7 K/month)•
RM1.6 Million/yr (USD 421.1 K/yr)

SUMMARY
Recommended

Actual

RM 241 K / yr
USD 63.4 K / yr

RM 866 K / yr
USD 228 K / yr
(4 times higher thanrecommended!)12ThankYou
Pusat Tenaga Malaysia
Level 8, SAPURA@MINES
No. 7, Jalan Tasik
The Mines Resort City
43300 Seri KembanganSelangor
Website: www.ptm.org.myE-mail: info@ptm.org.my13