2003 Survey Report
ＮＥＤＯ−ＩＣ−０２−ＥＤ−０３

Infrastructure Improvement Project for
Rationalization of International Energy Use(Energy Audits Implemented in
Major Industries in ASEAN Countries)

Report on the results of the audits

March, 2004

New Energy and Industrial Technology
Development Organization (NEDO)
Entrusted to The Energy Conservation Center, Japan

Energy Audits Implemented in Major Industries in ASEAN Countries
The Energy Conservation Center, Japan
March, 2004
Purposes:
We have conducted energy audits of typical factories and businessestablishments in the major industries of ASEAN countries jointly with specialists
participating from the ASEAN countries concerned with an aim to establish
standardized procedures of energy audit for ASEAN counties based on the
results of these surveys and also intending to understand the actual condition ofenergy consumption in the factories concerned and provide appropriate advice intheir energy conservation measures.

Preface
Recently, efforts to prevent global warming have been recognized as a challenge to be sharedby all humankind, while sustainable development of economy has been sought for. Mankind
is facing with the challenge of overcoming the two different conditions entirely conflicting
each other.
In order to get over these severe conditions, what are required are technical innovations suchas technologies to use energy efficiently with as little burden on the environment as possible
and the development of energy having little impact on the environment, etc.
In order to contribute to the balanced development of economy and environment indeveloping countries, it is necessary to render support that is adaptable and appropriate to therespective countries concerned based on the understanding of the actual condition of theirenergy use and environmental measures and on the results of in-depth surveys on the
progress in development of infrastructure, living habits, etc.
Having these circumstances as a background, we had conducted energy audits and energy
audit technology transfer programs in 8 ASEAN counties regarding one selected industry
sector each during the past 3 years. Then, we conducted the mentioned activities in theremaining 2 countries this year, the last year of the project. While problems and methods ofimprovement clarified in the surveys conducted on the major industries by last year werebeing shared by ASEAN countries, we continued surveys in the hope that these activities
would provide the foundation for creating database/benchmark/guideline to further promoteenergy conservation. In 2003, we conducted surveys in Thailand and Singapore whose
economies have been developing at an increasing speed with new equipment and advanced
technologies among ASEAN countries. We conducted energy audits in the factories of thechemical industry (caustic soda industry) in Thailand and the food processing industry in
Singapore.
In the job site, we carried out energy audits employing OJT (On the Job Training) system tofurther ensure technology transfer. In the workshops, we developed specific discussions
based on the analysis results of the collected data.
We completed energy audits and workshops on an OJT basis in all 10 ASEAN countries forthe past 4 years. We believe that it is very promising and meaningful that we could create acommon ground for promoting energy conservation in the major industries and determined
its direction in the respective countries.
We hope that this project will contribute to energy conservation and environmental
protection in the respective ASEAN countries so that they can eventually achieveenvironment-friendly and sustainable development in economy and also that this project willserve as a bridge of technical exchange and friendship between Japan and the countries
concerned.
March 16, 2004
The Energy Conservation Center, Japan

Summary
The economy in ASEAN countries has been rapidly growing, as a result, it will be more
required to efficiently use energy and to consider about the prevention of the global warming
because of the quick increase in energy consumption.
The activities of ASEAN Center for Energy (hereinafter referred to as "ACE") have been
established, which results in enhancing and disseminating the awareness of reducing energy
consumption in the ASEAN countries.
This fiscal year, the target countries were Thailand and Singapore, where energy audits formain industries were not implemented yet.
Energy audits and workshops were carried out at each 2 factories at the two countries. These
achievements would be basis of implementation and dissemination based on technology
transfer regarding energy conservation improvement policies of major industries of eachcountry.
We had had the opportunity to share experience on energy conservation activities withJapanese experts at all of the ASEAN countries. Every country member experiences andunderstands basic issues, which means foundation is established to deal, on even ground,with energy conservation activities in ASEAN countries.
This fiscal year is a year to consolidate the past activity accomplishment, and a year to go on
to the second phase toward implementation and dissemination of the past achievement.
On-site activities of the project this FY, started at the Inception Workshop in late October of2003 (same with the Building Project), and ended at the Post Workshop at the end of Januaryof 2004 (same with the Building Project).
To start the project smoothly, action plan was explained and finalized, as well as Japanesetechnology was introduced for the understanding of auditing points at the Inception
Workshop.
At the Post Workshop, there was a report of activity results and achievements of the 2
countries so that they could be shared among other countries, and activity accomplishmentsof ASEAN taskforce toward establishment of database/ benchmark/ guideline in the futurewere discussed.
At the end, there was a discussion on implementation and dissemination of improvement
measures and approach strategy of creation of database/ benchmark/ guideline.
Specific details of activities through this project for this year are as follows:
Oct. 23-24, 2003;
Participate in "Inception Workshop of The SOME-METI Project on PROMEEC - Buildings
and PROMEEC - Industries" (location: Singapore, same as Building project)

(1)

(2)
(3)
(4)

Latest policies and legal issues on energy conservation promotion of building andindustry sectors in Japan, introduction of energy management of this project andtypical energy conservation technology
Implementation and dissemination of improvement measures of each country up tonow, and report on the activity
Explanation and discussion of action plan regarding FY2003 projects (building andindustry)
Meeting on schedule and arrangement of site surveys of building and industry projects

Oct. & Nov., 2003;
Audit Survey of Main Industries in Thailand & Singapore (primary)
Activity in Thailand (Nov. 24-28)(1) Introduction of energy conservation activities and technology of the caustic soda
industry in Japan(2) Introduction of EE&C technology and application of the caustic soda industry, audit of
2 caustic soda plants, and summarization
Activity in Singapore (Dec. 1-5)
(3) Introduction of energy conservation activities and technology of food processing
industry in Japan(4) Introduction of EE&C technology and application of the food processing industry,
audit of 2 food processing factories, and summarization
Jan., 2004;
Audit Survey of Main Industries of Thailand & Singapore (secondary)
Activity in Singapore (Jan. 6-9)(1) Introduction of audit points for food processing industry and result report of the
primary survey(2) Explanation and discussion of the audit results at 2 food processing factories andperforming additional survey (secondary survey)(3) Result report of the secondary survey and introduction of database, benchmark andguideline, and introduction of EE&C Management
Activity in Thailand (Jan. 12-15)(4) Result report of the primary survey at caustic soda factories(5) Explanation and discussion of the audit results at 2 caustic soda factories, andperforming additional survey (secondary survey)(6) Result report of the secondary survey and introduction of database, benchmark, andguideline and introduction of EE&C Management
Jan. 28-31, 2004;
Participate in "Post Workshop on Promotion of Energy Efficiency and Conservation

(PROMEEC) (Major Industry and Building), SOME - METI Work Program 2003 - 2004
(Location: Singapore, same as Building project)(1) Special lecture: Introduction of energy management and energy manager system inJapan(2) Energy audit of factories by industry in FY2003 (caustic soda industry in Thailand andfood industry in Singapore) result report, and comments and discussion by target
countries(3) Report and discussion on activity outcomes of taskforce of database, benchmark andguideline establishment for ASEAN(4) Proposals of activity strategy for the future year and discussion on issues to beconsidered regarding ASEAN Plan of Action for Energy Cooperation (APAEC) 20042009, etc.
2 sites were selected as target factories for auditing in 2 countries. Audits were implemented
at caustic soda plants of Rayong district for Thailand, and factories in the city and northernarea for Singapore.
We were provided effective cooperation like last year in Thailand and Singapore, this fiscal
year's target countries.
We would like to thank, sincerely, the efforts of persons from ACE and governments of eachcountry for selecting factories for survey, and related preparation and cooperation.
Energy conservation of factories in Japan was introduced at the primary survey, and at thesecond survey, points of audit were introduced in concrete, as well as explanation ofmanagement and facility maintenance.
Economically, Thailand and Singapore are pursuing active industrial activities at the level ofadvanced countries. However, enthusiasm to energy conservation of the participants of thisproject could be sensed due to its large import share of energy.
Every involved person worked earnestly with us, and businesses were carried out smoothly.
On implementation, OJT for participants of site surveys was emphasized and surveys werecarried out.
Accordingly, improvement proposals by Japanese experts were put in practice, or going to be
in practice shortly, which could be evaluated as a large achievement.
By the energy audit of major industries in the 2 countries, all 10 countries of ASEAN
experienced energy conservation audit activities under the training of Japan experts.
Each country has established basis to develop energy conservation promotion activities inhome country and ASEAN countries in the future.
We would very much like to see these proposals put into practice at the earliest opportunityand effective use made of the manuals, thereby enabling us to contribute to the conservationof energy and protection of the environment in the ASEAN countries.
Finally, we would like to thank all those at ACE (ASEAN Center for Energy) along with theorganizations and factories involved in each country for their cooperation

Contents

Preface
Summary .................................................................................................................................. 1
I. Chemical Industry (Caustic Soda Industry) .................................................................... I-1
1. Summary of Project ........................................................................................................ I-1
1.1 Subjects of Energy Audit and Organizations involved ........................................... I-1
1.2 Political and Economic Conditions in Thailand...................................................... I-2
1.3 Energy Situation in Thailand .................................................................................. I-7
1.4 Caustic Soda Industry in Thailand ........................................................................ I-12
2. Overview of Factories subject to Audit ........................................................................ I-14
2.1 Outline of Co. A (caustic soda factory) ................................................................ I-14
2.2 Outline of Co. B (caustic soda factory)................................................................. I-15
3. Plan of Energy Audit .................................................................................................... I-17
3.1 Audit Procedure .................................................................................................... I-17
3.2 Selection of Equipment subject to Audit .............................................................. I-18
3.3 Audit schedule ...................................................................................................... I-18
4. Equipment Subject to Audit.......................................................................................... I-20
4.1 Brine Electrolysis Cell .......................................................................................... I-20
4.2 Caustic Evaporator................................................................................................ I-23
5. Energy Conservation Survey and Measurement Results .............................................. I-24
5.1 Measurement Results ............................................................................................ I-24
5.2 Other Survey Contents .......................................................................................... I-26
6. Energy Conservation Proposals and Expected Effects.................................................. I-27
6.1 Point of View of Energy Conservation Measures................................................. I-27
6.2 Reduction of Electric Power Unit Consumption for Electrolysis ......................... I-29
7. Guideline for Promotion of Energy Conservation and Audit Manual .......................... I-33
7.1 Outline of Caustic Soda Production Process......................................................... I-33
7.2 Energy Conservation Measures............................................................................. I-38
7.3 Special Notes for Promotion of Energy Conservation .......................................... I-38

Attachment
Attachment I-I

Attachment I-2

Attachment I-3

Energy Consumption Status of Co. A
Annual utility consumption, Monthly utility consumption,
Daily utility consumption and unit energy consumption
Energy Consumption Status of Co. B
Recent trend of production
Utility consumption: Annual
consumption,
Monthly
consumption, and Daily consumption
Energy Use Status of Caustic Soda Industry in Japan(Excerpts from presentation slide pictures used in the field)

II. Food Industry ................................................................................................................. II-1
1. Summary of Project ....................................................................................................... II-1
1.1 Subjects of Energy Audit and Organizations involved .......................................... II-1
1.2 Political and Economic Conditions in Singapore................................................... II-2
1.3 Energy Situation in Singapore ............................................................................... II-7
2. Overview of the Food Industry (Food Processing Factories) Subject to Audit ............. II-8
2.1 Outline of Co. C (dairy food processing industry)................................................. II-8
2.2 Outline of SCM...................................................................................................... II-9
3. Plan of Energy Audit.................................................................................................... II-10
3.1 Audit Procedure ................................................................................................... II-10
3.2 Selection of Equipment subject to Audit and Reviewing of Responses to
Questionnaire ............................................................................................................... II-11
3.3 Audit Schedule..................................................................................................... II-15
4. Equipment subject to Energy Audit ............................................................................. II-17
4.1 Energy Audit of Co. C ......................................................................................... II-17
4.2 Energy Audit of SCM .......................................................................................... II-23
5. Energy Measurement and Survey Results.................................................................... II-27
5.1 Audit and Measurement Results of Co. C............................................................ II-27
5.2 Audit and Measurement Results of SCM............................................................. II-31
6. Energy Conservation Proposals and Expected Effects................................................. II-33
6.1 Proposals to Co. C and Expected Effects............................................................. II-33
6.2 Proposals to SCM and Expected Effects.............................................................. II-38
6.3 Summary of Energy Conservation Effects........................................................... II-41
7. Guideline for Promotion of Energy Conservation and Audit Manual ......................... II-43
7.1 Outline of Production Process.............................................................................. II-43
7.2 Guideline for Promotion of Energy Conservation and Audit Manual ................. II-45
Attachment
Attachment II-1
Attachment II-2

Check Items at Factory Energy Audit (Excerption frompresentation slides used in the visited company)
Guideline for Promotion of Energy Conservation(Excerption from presentation slides used in the visitedcompany)

I. Chemical Industry(Caustic Soda Industry)

Participants in the Workshop of ASEAN Major Industry Energy Audit(Persons concerned from DEDE and the caustic soda factories audited and members of
ACE and ECCJ) at the workshop venue in Bangkok, Thailand (January 12, 2004)

I.

Chemical Industry (Caustic Soda Industry)

1.

Summary of ProjectThis project was implemented as part of the Infrastructure Improvement Project for
Rationalization of International Energy Use, with an aim to contribute to energy
conservation, environmental preservation and sustainable development of economy in
ASEAN countries that have achieved remarkable economic growths recently.
This project is designed to promote energy conservation in the major industries of
ASEAN countries with ACE as the core organization and with cooperation of ASEAN
countries. As one of the countries and industries subject to energy audit for the current
year, the chemical industry (caustic soda industry) of Thailand was chosen. Then,energy audit plans were developed based on discussions with persons in charge fromThailand. Energy audits were implemented at the sites of two companies of chemicalindustry (caustic soda industry) over 6 days for the periods from November 24 through28, 2003 and January 12 through 15, 2004 with persons in charge from DEDE, Thailand(Department of Alternative Energy Development and Efficiency).
We hereby report on the results of the energy audits along with an overview of thepolitical and economic situations of the country as follows;

1.1

Subjects of Energy audit and Organizations involved(1) Country and companies subject to energy audit
Country:
ThailandCompany: Co. A (caustic soda factory)
Co. B (caustic soda factory)(2) Organizations involved and participants
1) Thailanda. DEDE (Department of alternative Energy Development andEfficiency):
Mr. Pravit Teetakaew (the 1st site survey only) Mr. Thamayos Srichuai
Mr. Chalermchai Phadunghus
Mr. Sarat Prakobchat
Mr. Ittipol Intamat
Mr. Chawalit Boonsang
Mr. Chatchawan Sripetchdee
Ms. Amaraporn Utchawangkul (the 2nd site survey only)
Mr. Sarawutt Preecha (the 2nd site survey only)
Dr. Prasert Sinsookprasert (the 2nd site survey only)b. Co. A: 3 personsc. Co. B: 6 persons

I-1

d.

AC (Accredited Consultants)
Mr. Chaisak Chatriejansakul
Mr. Suwit Maungaram
Mr. Nutdhaoun Ngernbumroong
Mr. Viroj Tethuthapak
Mr. Sanit Athasart2) ACE (ASEAN Center for Energy):
Mr. Christopher ZAMORA
3) Japan: The Energy Conservation Center, Japan
Participants from the International Engineering Department of the Energy
Conservation Center, Japan (ECCJ)
Hiroshi Shibuya
General Manager (the 1st site survey only)
Shigeru Kumanashi
Technical Expert
Hideyuki Tanaka
Technical Expert (the 2nd site survey only)
1.2

Political and Economic Conditions in Thailand(1) National indicatorCountry name:Area:
Population:
Capital:Language:
Religion:
Brief history:

Kingdom of Thailand
514,000 km2
61,810,000 (2001)
BangkokThai
Buddhism 95%, Muslims 4%, others 1%
The foundation of Kingdom of Thailand was establishedby Sukhothai Dynasty in the 13th century and thenfollowed by Ayutthaya Dynasty (14–18 century),
Thomburi Dynasty (1767–1782) and the present Chakri
Dynasty (1782–). In 1932, the king agreed to theabolition of absolute monarchy and the transfer of
power to the constitution-based system of government.

(2) Political system and domestic policy
Form of government:
Head of state:

Parliament:

Constitutional monarchy
His Majesty King Bhumibol Adulyadej (Rama IX)(enthroned in June 1946 and has been on throne for 57
years)
Bicameral National Assembly consisting of the Senate(200 seats) and the House of Representative (500 seats)(Members of both the Houses are elected by popular
vote)

I-2

Government:
Prime Minister Taksin Shinawat
Foreign Minister Surakiart Sathirathai
Domestic policy:
Since the power transfer to the constitution-based
government in 1932, the military-lead government had
ruled the country until 1992, when the military forces
and pro-democracy movement crashed (May incident).
After 1992, the military has refrained from its
interference in the politics and the democratic
procedures for change of administrations have been
established.
(3) Political situation in Thailand
In accordance with the new Constitution established in 1997, the election of theHouse of Representative members was held in January 2001. Thai Rak Thai
Party (TRT) made a landslide victory and the Taksin Administration was
installed.
1) Characteristic points of the Taksin Administration
The Taksin Administration has promoted a number of economic reform
policies under the strong initiative of Prime Minister and with the support ofthe majority (366 seats of 500 seats) forming the coalition party in theLower House [Thai Rak Thai Party, (TRT), Chat Thai Party (TNP Thai
National Party) Chat Phattana Party (NDP, National Development Party)]
•

•

•

•

In January 2001, in the election of members of the House ofRepresentatives, Thai Rak Thai Party (TRT) lead by the Taksin
Shinawat almost solely won the majority of the seats and became theleading party.
TRT formed the 4-party power-sharing coalition government and on
February 18th , 2001, the Taksin Administration was officially installedwith a stable majority (325 seats out of 500 seats at that time).
The Taksin cabinet, in its policy speech, introduced an emergency
priority policy package underlining economic reforms that Taksin hadpromised in the election campaigns as the best priority policy and has
implemented each policy in specific ways.
Prime Minister Taksin has demonstrated his strong leadership andpromoted various economic reform measures based on the rulingparty’s comfortable majority in the Lower House and his firm powerbase in the administration. The current administration is characterizedwith its top-to-down and the policy-driven government management
unlike the conventional administrations that focused on coordination ofI-3

different interests among the coalition member parties. The foundationof the Taksin Administration is firm and it is a common view that theadministration will sustain itself until February 2005 when its term
expires.
2) Recent political situation• On October 3rd, 2002, the law concerning the reorganization ofministries and agencies was enacted. And the government was
restructured from the Prime Minister’s Office, 13 ministries and one
agency to the Prime Minister’s Office and 19 ministries. In thisrestructuring, the Agency of University was abolished (integrated into
the Ministry of Education), while 6 ministries were newly set up. Theyare Ministries of Tourism and Sports, Social Development and Human
Services, Natural Resources and Environment, Information andCommunications Technology, Energy and Culture.
(4) Basic foreign policy
Thailand makes it a basic foreign policy to pursue partnership with ASEAN
countries and cooperation with major countries, such as Japan, the United States
and China while it is maintaining its traditional policy of flexible and omnidirectional diplomacy.
The Taksin Administration demonstrates its proactive and strong initiative in theregion by strengthening relationships with neighboring countries, developing
active economic diplomacy aiming at the conclusion of Free Trade Agreement(FTA) with the respective counties, proposing Asia Cooperation Dialogue(ACD), etc.
(5) Economy
Major industries: Out of the 2000 GNP, the nonagricultural sector makes up
about 90% and the industrial sector alone accounts for 33.4%.
Although the portion of agriculture in GNP is shrinking, it isstill an important industry having 40% of the employed
population.

I-4

Table I-1-1
Item
GDP
Per capita GNP
Economic growth rate
Commodity price increase
rate
Unemployment rate
Total trade value
ExportImport(Exchange rate

Basic Economic Data

Year
100 Mln US$
US$
%
%

1999

2000

4.4

4.6

2001
1114
1818
1.8
1.6

2002

5.2

%
3.3
100 Mln US
653
100 Mln US618$ 1.0= about 41 baht (as of September 2002))

Major trade items:
Exports: Computer, Computer parts, IC, Automobiles, Clothes, Frozen
shrimps, Jewelry, Rice
Imports: Machines and machine parts, Electronics and components, Crude oil,
Chemical products, IC board, Iron and steel
Major trade partners (2001):
Exports: 1. US, 2. Japan, 3. Singapore, 4. Hong Kong, 5. China, 6. Malaysia
Imports: 1. Japan, 2. US, 3. China, 4. Malaysia, 5. Singapore, 6. Taiwan
Table I-1-2 Trades with Japan
ExportImport
Major
trade
item

100 mln yen
100 mln yen
Export

1999
10082
12848

2000
11423
14694

Import(Foreign Trade Statistics of Finance Ministry)

I-5

2001
12605
14425
Exports: Sea foods,
Office equipment, AV
equipment, Meats,
Electronics components
including semiconductors
Electronics components
including semiconductors, Iron andsteel, Car parts,
Plastics, Motors

2002
13146
16486

1) Economic overview:
Thailand’s economy had rapidly increased having foreign investments
including that from Japan as a spur since late 1980’s, while current-accountdeficits expanded, causing the advent of a bubble economy mainly in thereal estate sector. Then, following the collapse of the bubble, bad debts
increased and the pressure for the devaluation of baht was heightened withthis deterioration in economy as a background. In July 1997, after thefloating-rate system was introduced, the value of baht drastically dropped
and created an economic crisis.
The government of Thailand endeavored to reconstruct its economy
implementing structural reforms including disposal of bad loans, etc. withthe support from the international society including IMF and Japan. Owning
to the government’s stimulative measures backed up by its financial policy,
growing exports, etc., Thai economy that has long been sluggish started topick up.
The Taksin Administration inaugurated in February 2001 introduced
measures to stimulate agricultural communities and medium- and small-size
companies underlining the role of domestic demand as a driving force for
economy in addition to promoting the conventional export-oriented
economy. Due to the consumer spending invigorated as a result of The
Taksin Administration’s domestic demand expansion measures and otherfavorable factors, the economy of Thailand appears to be on a recovery
track and the economic growth in 2002 was 5.2%, the highest rate after the
recent economic crisis.
2) Economic situation in Thailand (Economic crisis and Thai government’s
measures)• The Chavalit Administration implemented a belt-tightening policy
based on the IMF program in order to get over the economic crisis withwhich it was confronted in July 1997. While his policy produced
certain results such as stabilized exchange rates, a turnaround to surplus
in the current-account balance, etc., the actual economy of Thailand
continued to be depressed, causing bankruptcy of a number of financial
institutes and other corporations, increases in the unemployed
population, a deep social impact on the poor people, etc.
• The Chuan Administration inaugurated in November 1997 made a
policy shift from the belt-tightening policy to a policy to promote
domestic demand, obtaining agreement from IMF and introduced
comprehensive economic packages including tax cuts, job creation,
public investments, support for medium- and small-size companies, etc.
along with extra budget in three times in order to achieve economic
recovery. Particularly, intending to make progress in disposal of bad

I-6

•

debts, the administration proposed that an assets management company
be established for each bank and revised and executed economy-related
laws such as the law concerning restructuring of private sector’s
liabilities, bankruptcy laws, etc.
The Taksin Administration established in February 2001 criticized theChuan Administration for adopting a policy favoring large-scalecompanies and started his administration upholding an economic
recovery from the grass-root level as a priority political agenda and has
promoted domestic demand as well as export conventionally promoted
as a driving force of economy. Specifically, it introduced bottom-up
income growth-based domestic demand expansion measures such as
temporary moratorium on farmers’ loan payments, the foundation ofdevelopment funds in villages, one-product-for-one-village movement,
the establishment of people’s bank for micro credits, etc., while it aims
to improve the nation’s international competitiveness by strengthening
domestic industries through development of medium- and small-size
companies, etc. and proactively inviting foreign capitals. In addition, inorder to solve problems of bad debts as early as possible, it set up agovernment-led organization for non-performing loan purchase.

3) The current status and future prospects• Supported by growing exports and the government’s financial policies,
Thai economy came back on an upward trend in 1999. In June 2000,
Thai government discontinued IMF proposed Structural Adjustment
Programs (SAP). In 2001, Thailand’s economic growth slowed down
due to slowdown in the US economy, delay in the restructuring of thefinancial sector including disposal of bad loans, etc. and the economic
growth in 2001 resulted in 1.8% on a year-on-year basis.
• Recently the economy of Thailand has been on a recovery track owning
to vitalized personal spending, etc. which appear to be the effects of theTaksin Administration’s bottom-up policy. The National Economic andSocial Development Board (NESDB) announced an economic growthrate of 5.2% for 2002, the highest figure after the recently experienced
economic crisis.
1.3

Energy Situation in Thailand(1) Energy index (2001)
c Primary energy consumption :75.53 million TOE (about 14.5% of thatof Japan)d Primary energy self-sufficiency rate: about 47.4% (Japan: about 20%)

I-7

e Final energy consumption:

54.3 million TOE (about 15% of that ofJapan)
f Production of electricity:
102Twh (about 10% of that of Japan)
g Final energy consumption by sector (%):
Industry 39%, Transport 34%, Residence and Business /Agriculture 27%
h Primary energy consumption by fuel (%):
Petroleum 43%, Natural gas 27%, Coal 11%, Renewable energy 17%,
Hydropower and other sources 1%
Table I-1-3 Primary Energy Consumption Intensity per Unit GDP(Unit: toe/1,000US$ in the price of 1995)
1990
1995
2000
Thailand
0.39
0.38
0.43
Japan (reference)
0.089
0.094
0.092
Source: IEA Energy Balances of OECD Countries (2000-2001)
IEA Energy Balances of Non-OECD Countries (2000-2001)

2001
0.43
0.09

(2) Energy situation
The energy demand structure in Thailand dramatically changed along with therapid growth in economy resulting from the nation’s policy shift from anagriculture-centered economy to an export-oriented economy that had been
advanced since the mid 1980’s. Although Thailand had depended on rapidly
increasing oil import for more than 90% of its commercial energy except for
conventional energies (such as wood, straw, bagasse etc.) in around 1980, its
energy self-sufficiency improved and exceeded 40% in the 1990’s owing to thedevelopment and commercialization etc. of natural gas in Gulf of Thailand andbrown coal in the inland.
1) Energy resources in Thailand:
While Thailand is not rich in energy resources such as oil, coal, natural gas,
it has comparatively large quantities of proven deposits of natural gas. The
ratios of R/P for oil and natural gas are 9.5 years and 19.9 years respectively.
Thailand is not a so-called resourceful country.
2) Production and consumption of primary energy
The annual average growth of production of primary energy in Thailand forthe period from 1995 through 2001 was 0.33% and showed no significant
change. However, as an energy source, the use of natural gas dramaticallyincreased and so did the use of oil. On the other hand, biomass decreased.
Although the self-sufficiency rate of natural gas was 100% in 1995,
domestic production became insufficient to meet the recent increasing

I-8

demand and Thailand imported natural gas from neighboring countries(Malaysia, Indonesia). As a result, the self-sufficiency rate dropped to75.1% in 2001. The government of Thailand had promoted a policy ofimporting supply from ASEAN pipeline and started importing from
Myanmar from 1999 and the import volume increased. Currently, Thailand
is planning and studying pipeline supply from Malaysia, Vietnam andIndonesia.
The self-sufficiency rate for oil (2001) was only 17% and Thailand
imported oil from Middle East, Asia and other countries (74%, 20% and 6%
respectively). As Thailand s dependency on crude oil of Middle East is high,
the government is aware of risks that may arise in supply and the necessityof both long-term and short-term approaches in order to improve security ofoil supply. Long-tem approaches currently being considered include
diversification of oil supply sources, improvement of energy efficiency,
development of alternative energies, and improvement of market efficiency
through privatization and deregulation. Short-term approaches generally
include information sharing, demand control, ensuring technologies for fuelconversion, expansion of oil production and oil storage.
3) Final energy consumption by use:
The average annual growth rate of final energy consumption in Thailand
during the period from 1995 through 2000 was about 1.5%. In terms of use,
it increased by 0.3% in the transport sector and by comparatively high 3 to
6% in the industrial/agricultural/commercial sectors while it decreased in
the residential sector by 2.9%. In the industrial sector, particularly in thechemical field, the energy consumption dramatically grew while it dropped
in the fields of nonmetallic minerals (cement, glass, etc.), mining industry,
and construction.

I-9

Table I-1-4 Changes in Actual Consumption of Final Energy in the Industrial
Sector (by line of business)
1995

2000

Average2001

Volume Composition Volume Composition Volume Composition annual
growth rate
ratio
ratio
ratio
(1995–2001)
(%)
(%)
(%)
Iron and Steel

522

3.2

645

3.2

617

3.0

2.8

Chemical

977

6.1

4040

19.9

4805

23.6

30.4

Non-ferrous

-

-

-

-

-

-

-

4018

24.9

3130

15.4

3509

17.3

-2.2

-

-

-

-

-

-

-

Machinery

627

3.9

751

3.7

819

4.0

4.6

Mining

28

0.2

11

0.1

17

0.1

-8.0

Food

4954

30.7

5428

26.7

4756

23.4

-0.7

269

1.7

381

1.9

388

1.9

6.3

101

0.6

123

0.6

156

0.8

7.5

Construction

278

1.7

150

0.7

130

0.6

-11.9

Textile/leather

1249

7.7

1071

5.3

1061

5.2

-2.7

Others

3119

19.3

3777

18.6

4079

20.1

4.6

Total

16142

100.0

19507

95.9

20337

100.0

3.9

metal
Non-metallic
mineralTransport
equipment

products/
Cigarette
Pulp andPaper
Wood
working

In units of 1,000 ton converted into heavy fuel oil (ktoe)
Source : IEA Energy Balances of Non-OECD Countries (1995-1996, 1999-2000)
4) Electric power
The average annual growth rate in electric power generation in Thailand
during the period from 1995 through 2001 was 4.2%. In terms of source, thegeneration by oil-fired power and hydraulic power decreased while natural
gas-fired and biomass fuel power generations increased significantly. In
2001, thermal power generation by oil, coal and natural gas accounted for
92.6% and hydraulic/geothermal power generation and biomass power
generation made up 6.3% and 1.3% respectively.

I-10

Table I-1-5

Changes in Actual Power Generation Volumes (by energy source)
1995

Power
generation

2000

2001

Composition Power Composition Power
ratio
genera- ratio
genera(%)
tion
(%)
tion

Average
Composition annual
growth rate
ratio
(1995–2001)
(%)

Oil

24403

30.5

10021

9.8

2926

2.9

-29.8

Coal

14780

18.5

17604

17.2

19622

19.2

4.8

Natural gas

33900

42.3

60808

59.4

72205

70.5

13.4

Hydraulic
power

6712

8.4

6026

5.9

6303

6.2

-1.0

Geothermal
power

1

0.0

2

0.0

2

0.0

12.2

Biomass

265

0.3

1516

1.5

1362

1.3

31.4

Total

80061

100.0

95977

93.7

102420100.0

4.2

Unit: GWh
Source : IEA Energy Balances of Non-OECD Countries (1995-1996, 1999-2000)
5) Energy price:
Market-driven energy prices are introduced in Thailand in principle.
Electric power is supplied via 3 organizations: EGAT (Electricity
Generating Authority of Thailand) in charge of generation and transmissionof electricity, MEA (Metropolitan Electricity Authority) in charge ofdistribution of electricity in the metropolitan area and PEA (Provincial
Electricity Authority) in charge of distribution in other areas. These are allstate-owned companies. Electric rate structure in Thailand consists of basic
charge and Ft (Fuel Adjustment Clause) charge. Basic charge and Ft charge
very depending on demand type and contract. The average prices(Baht/kWh) in 1999 are as follows;
Urban area (MEA)
Other areas (PEA)
Household use
2.39 Baht/kWh1.98 Baht/kWh
Business use
2.23
1.94
Industrial use
2.07
2.00
Agricultural use 1.59
Total
2.21
1.99
Fuel prices (based on the data from PPT (Petroleum Authority of Thailand)
are as follows.
Gasoline (Leaded)
15.19 Baht/L
Gasoline (Unleaded)
16.19
Diesel13.19
Grade A Heavy fuel oil
7.80
Grade C Heavy fuel oil
7.20
Energy prices as of November 2001 in Thailand (Bangkok) are as follows;

I-11

Electricity rate for business use
Electricity rate for general use
Gas rate for business use
Gas rate for general use
Regular gasoline

US$ = ¥120
0.037–0.039 US$/kWh
0.03–0.07 US$/kWh
0.10 US$/m3N
0.18 US$/m3N
0.30US$/L

4–5 ¥/kWh
4–8 ¥/kWh
12 ¥/m3N
22 ¥/m3N
36 ¥/L

Source: Comparison of Investment-related costs in major cities and areas in
Asia (Issued by JETRO Overseas Research Department, March
2002)
1.4

Caustic soda industry in Thailand
ASEAN key countries have caustic soda factories in their basic material industry. In
recently built plants, the ion-exchange membrane process is adopted, while thediaphragm process and the mercury process are still used in some factories.
Thailand has the second highest production capacity of caustic soda following
Indonesia. In Thailand, there are 10 plants, out of which 8 were constructed during
the past 20 years. Before we started the current survey, we obtained information that
only 3 out of these factories were currently in operation. We had an impression that
this industry was really a roller-coaster industry. We strongly felt that it was necessary
for companies to further advance cost cuts as well as saving energy in order to survive
the competition.

I-12

Table I-1-6

ASEAN Counties’ Production Capacities of Caustic Soda

Country name
Brunei Darussalam
Cambodia
Indonesia

Capacity t/y-100%NaOH

Type of process

634700Ion exchange membrane
method in new plants

Lao PDR
Malaysia

85300

Ion exchange membrane
methodMyanmarPhilippines

Potential capacity
33000

Singapore

65000

Thailand

471800Vietnam

92500

Japan

Iron exchange membrane
method in new plants
Ion exchange membrane
methodIon exchange membrane
methodIon exchange membrane
method in new plants

Actual production:
Ion exchange membrane
4,350 kt/y (2002)
method(Blank box means no capacity or data unavailable)

I-13

2.

Overview of Factories Subject to Energy Audit
In preparing for the implementation of the planned energy audits of the chemicalindustry (caustic soda factories) in Thailand, ECCJ requested to ACE for selection of
two factories in or near the city of Bangkok. DEDE of Thai, in response to the requestfrom ACE, determined the two caustic soda factories in the Rayong area (about 180km
southeast of Bangkok), not the Bangkok area. As it was requested from the 2 factories
that we would conclude a nondisclosure agreement with them on the site at the time of
the first site survey, we note here that the report described hereunder is only on thematters concerning energy conversation.
Brief outlines of the respective 2 caustic soda factories are given below.

2.1

Outline of Co. A (caustic soda factory)(1) General information
Location:
Products:
Employees:

Rayong area (about 180km southeast of Bangkok)
Caustic soda, chlorine gas, etc.
About 170 persons (including 16 engineers and 150 workers
engaged in operation)Work system: 3-shift operation
Organization: The organization chart of Co. A is shown in Figure. I-2-1

Factory Manager
ISO/Safety Dept.

Administration

Warehous

Utility

Production 2

Production 1

Caustic Soda
Plant No. 1

Caustic Soda
Plant No. 2

Figure. I-2-1

By product plant(99.99% NaOH)

Organization of Co. A

I-14

MaintenanceElectrical/
Instrument
Dept.

Mechanical
Dept.

Operation:

This factory was constructed in 1995 and the operation wasstarted in 1996. The main purpose of the plant is
production of caustic soda. In 1998, additional bipolar
equipment was installed. Salt used as raw material is rocksalt domestically produced and refined on the place of
production.
3 shifts are engaged in production and caustic soda
(NaOH) is produced for 24 hours (345 days/year). Eachline receives regular maintenance for a total of 20days per
year.
In-house activities: Obtained ISO14001 certification and plans to obtain
ISO9001 certification in 2004.
Small group activities are in practice and there are about 20
groups.
(2) Installation and capacities of Co. A
There are no boilers and steam is supplied from the nearby company. Since thetargets of our survey were caustic soda producing electrolytic devices andcaustic soda enrichment devices, no utilities-related data such as those on thepumps, air compressors, etc. were provided.
(3) Factory layout
Although the drawing was provided, it was too small to clearly show. In addition,
the process of a chemical factory is very complicated and it is protected under
the nondisclosure agreement, the attachment of the drawing has been omitted
here.
2.2

Outline of Co. B (caustic soda factory)(1) General information
Location:
Products:
Employees:

Rayong area (180 km southeast of Bangkok)
Caustic soda and chlorine gas
Caustic soda factory: 21 persons including Manager (2 areengineers)
Work system: 4 teams on 3 shifts, 325 operation days/year
Organization: The organization chart of Co. B is shown in Figure. I-2-2

I-15

ManagerEngineers (2)Day Operator (2)Shift Supervisor

Shift Supervisor

Operator (3)Figure. I-2-2

Shift Supervisor

Operator (3)Shift Supervisor

Operator (3)Operator (3)Organization of the Caustic Soda Factory of Co. B

Operation:

This factory was constructed in 1990 for production of chlorine gas.
Salt as raw material is rock salt produced in the country and refined in
the place of production.
In-house activities: Obtained ISO9001 in 1998, ISO14001 in 1999 and TIS18001 in 2001
Introduced the TPM system and set up an energy conservation council
in the factory to promote energy conservation(2) Installation and capacities of Co. B
There are no boilers and steam is supplied from the nearby company. Since thetargets of our survey were caustic soda producing electrolytic devices andcaustic soda enrichment devices, no utilities-related data such as those on thepumps, air compressors, etc. were provided.
(3) Factory layout
We could not obtain the drawing due to the nondisclosure agreement.

I-16

3.

Plan of energy audit
The planned energy audits in Thailand were intended to grasp the actual situations of
the production process, energy consumption and the use of exhaust heat in the selected
2 caustic soda factories and to propose improvement plans to advance their energy
conservation efforts. The plans of energy audit also included conducting workshops on
the sites and introducing energy conservation technologies, activities, etc. in Japan toraise, promote and disseminate the awareness of the energy conservation among thoseconcerned in Thailand. Furthermore, these energy audits were planned with the view togiving support to energy conservation leaders on the side of ASEAN in establishing thestandardized energy audit method after the implementation, based on the understandingof the actual situations of the same industry in ASEAN countries, the levels of theirenergy audit skills, etc.
The survey was conducted twice for the respective facilities.
In the first site survey, the first workshop was conducted. The points for energy auditsof caustic soda factories and energy conservation technologies practiced in caustic soda
plants in Japan were introduced to help and boost their understanding.
In the actual auditing, a local energy audit group arranged by ACE took specificmeasurements at the respective sites under the instructions of the experts dispatchedfrom Japan while the points to be checked in energy auditing that we had asked in apreliminary questionnaire to these factories were confirmed. The energy audit group
visited each factory twice in two days.
In the second site survey, energy conservation improvement plans determined based on
the results of the first survey were explained to DEDE (Department of Alternative
Energy Development and Efficiency), the department of the government of Thailand in
charge, and the managing persons of the respective companies. Then, we visited thesites again and conducted a one-day energy audit for the respective facilities to confirm
the results of the first energy audits and our subsequent proposals.

3.1

Energy Audit Procedure
The main process of caustic soda production consists of dissolution of industrial salt,
high-degree refining of salt water, electrolysis of salt water, concentration of diluted
caustic soda solution and refining of chlorine gas and hydrogen gas generated.
In preparing for the energy audits, we had obtained a flow sheet of the production
from the 2 companies and confirmed that it was almost the same as the standard oneused in factories in Japan.
Accordingly, we decided to focus our auditing on brine electrolysis vessels(electrolyzers) and caustic soda evaporators that consume large quantities of energy inthe process of caustic soda production.

I-17

We confirmed the operation data of these two devices by reading the values indicatedon the DCS (Distributed Control System) and the measuring instrument panel in themeter room. On the sites, we observed and then confirmed sometimes using a digital
thermometer the condition of heat insulation of the devices with the staff members incharge from the receiving companies.
Photo shooting was strictly prohibited by the both factories and no photopictures
could be obtained.
3.2

Selection of Equipment Subject to Energy Audit
Since the number of energy audit days was limited, we focused our energy audit, as
we mentioned above, on the salt water electrolysis baths and caustic soda evaporators
both of which were energy intensive equipment in the caustic soda production process
after discussions with the respective companies. We decided to examine electrolytic
cells by series (by type) and caustic soda evaporators individually.

3.3

Energy Audit Schedule
Both of the energy audit sites for the two companies were located in the East
Industrial Complex about 30 minutes by car from our accommodation in Rayong
where roads were maintained well and we had an impression that the development of
infrastructure was completed.
Responses of the two companies undergoing our energy audit were kind andcooperative and they were ready to answer the questionnaire that we had sent inadvance. We could conduct our auditing efficiently.
We conducted auditing according to the schedule shown below.
(1) 1st site survey schedule: Implemented in November 2003
November 24 (Mon.)

November 25 (Tue.)
November 26 (Wed.)
November 27 (Thu.)
November 28 (Fri.)

1st workshop:
Introduction of 2 caustic soda manufacturing companies(Co. A and B)
Introduction of profile of ECCJ, energy audit procedureand method for these companies
Factory energy audit of Co. A
Factory energy audit of Co. A, summarization of data
and reporting on the energy audit results
Factory energy audit of Co. B
Factory energy audit of Co. B, summarization of data
and reporting on the energy audit results

I-18

(2) 2nd site survey schedule: Implemented in January 2004
January 12 (Mon.)
January 13 (Tue.)
January 14 (Wed.)
January 15 (Thu.)

2nd workshop: Reporting on the results of the 1st
auditing
Factory energy audit of Co. A and proposal of
improvement plans
Factory energy audit of Co. B and proposal of
improvement plans
Final workshop: Reporting on and summary of the 2nd
auditing and proposal of improvement plans.

I-19

4.

Equipment Subject to Energy Audit
In caustic soda factories, most of the energy consumption is electricity for brineelectrolyzers and steam for concentration of caustic soda. Thus, as mentioned in theprevious chapter, we conducted energy audits focusing on brine electrolytic vessels andcaustic soda evaporators.

4.1

Brine Electrolysis Cell
(1) Brine electrolyzers of Co. A
Caustic soda production capacity:•

250,000 t/y (as 50% caustic soda)

Series 1 (RCA-1)
Manufacturer of brine electrolysis vessel:
Asahi Glass Co., Ltd. - Japan
Name of brine electrolysis vessel: Ion-exchange membrane method
AZEC-F2 (Figure. 1-4-1)
Type:
Unipolar system (Mono-polar)
Electrolytic current (Max):154 kA
No. of electrolyzers possessed:
49

Figure. I-4-1

Structure of AZEC-F2 Electrolyzer
I-20

•

Series 2 (RCA-2)
Manufacturer of brine electrolysis vessel:
Asahi Glass Co., Ltd. - Japan
Name of brine electrolysis vessel: Ion-exchange membrane method
AZEC-B1 (Figure. 1-4-2)
Type:
Bipolar system
Electrolytic current (Max):
14.4 kA
No. of electrolyzers possessed:
300 units (4 vessels × 75 units/vessel)

Figure. I-4-2 Structure of AZEC-B1 Electrolyzer

I-21

(2) Brine electrolyzers of Co. B
Caustic soda production capacity: 55,000 t/y (in 50% caustic soda)
Manufacturer of brine electrolysis vessel:
Asahi Glass Co., Ltd. - Japan
Name of brine electrolysis vessel: Ion-exchange membrane method AZEC-M3(Figure. 1-4-3)
Type:
Mono-polar
Electrolytic current (Max):
80 kA
No. of electrolyzers possessed:
30

Anode chamber frame

Ion-exchange
membrane
AnodeElectric
current
Cathode chamber Support pin
frame

Figure. 1-4-3

High-performance
low overvoltage
cathodeStructure of AZEC-M3 Electrolyzer

I-22

4.2

Caustic Soda Evaporator
The simple outline of flow of evaporator is shown in Figure. I-4-4.

50% caustic soda

32.5% or 35%
caustic soda

Hot water
Steamcondensor

Hot well

MS: 0.5Mpa steam CW: Cooling water PW: Purified water

Figure. I-4-5

Simple Flow of Evaporator(1) Caustic soda evaporators of Co. A
Contractor:
Asahi Engineering Co., Ltd.
Type:
Double-effect evaporator
Concentration: 32.5%NaOH → 50%NaOH(2) Caustic soda evaporators of Co. B
Contractor:
Toyo Engineering Co., Ltd.
Type:
Double-effect evaporator
Concentration: 35%NaOH → 50%NaOH

I-23

5.
5.1

Energy Conservation Survey and Measurement Results
Measurement Results
The results of the measurements of brine electrolyzers, caustic soda evaporators, etc.
of the two companies are respectively shown below.
We carried out measurements by reading the existing installed measuring instrument
meters. We also used mobile measuring instruments to measure heat insulation effects.
These mobile instruments were prepared by the employees in charge from the twocompanies. Their response was expeditious and cooperative.
(1) Energy consumption of Co. A (electricity and steam)1) Electricity for electrolysis
The operation data at the time of the survey was as shown below.
Table I-5-1 Data Shown on Control Panel of Central Operation Room
(14:00 PM November 25, 2003)
Electrolyzer
Monopolar
Bipolar No. 1
Bipolar No. 2
Bipolar No. 3
a.

b.

Electrolytic
current (kA)
154
12.1
12.1
12.1

Full voltage
(V)
206
497
495
483

No. of Electrolyzers
60
2 Units (75 Cells/Unit)
2 Units (75 Cells/Unit)
2 Units (75 Cells/Unit)

Average electrolytic cell voltage• Monopolar
3.43 V• Bipolar No. 1
3.31 V• Bipolar No. 2
3.30 V• Bipolar No. 3
3.22 VElectric consumption in electrolyzers (DC-kWh/t-100%NaOH)• Monopolar
2419 (96492 × 3.43/3600/40/0.95 × 1000 = 2419)• Bipolar No. 1 2335 (96492 × 3.31/3600/40/0.95 × 1000 = 2335)• Bipolar No. 2 2328 (96492 × 3.30/3600/40/0.95 × 1000 = 2328)• Bipolar No. 3 2271 (96492 × 3.22/3600/40/0.95 × 1000 = 2271)
Here: Faraday constant:
96492 (Asec/mol)
Mass per NaOH 1mol: 40 (g/mol)Power efficiency:
95%(value reported in theinterview)I-242) Steam for caustic soda evaporator
The data shown on the control panel of the central operation room at 14:00
on November 25, 2003 was as shown below.
Steam consumption
3.52 t/h
NaOH production
7.5 m3/h
Unit consumption of steam for caustic soda evaporators was 0.626t-Steam/tNaOH.
(3.52t-Steam/h)/(7.5 m3/h)/(1.5 t/m3)/0.5 = 0.626t-Steam/t-NaOH
Here: specific gravity of 50% NaOH solution: 1.5 t/m3
(2) Energy consumption of Co. B (electricity and steam)1) Electricity for electrolysis
The operation data at the time of the survey was as shown below.
Table I-2-2
Electrolyzer
Monopolar

Data Shown on Control Panel of Central Operation Room
(13:30 PM November 27, 2003)
Electrolytic
current (kA)
80

Full voltage (V)
108 (107–109)
Cell Voltage =3.72V(Ave.)
Normally 102V (reported)

No. ofElectrolyzers
29

a.

Average electrolytic cell voltage• Monopolar
3.72 Vb.

Electric consumption in electrolyzers (DC-kWh/t-100% NaOH)• Monopolar
2652 (96492 × 3.72/3600/40/0.94 × 1000 = 2652)
Here: Faraday constant:
96492 (Asec/mol)
Mass per NaOH 1mol: 40 (g/mol)Power efficiency:
94% (value reported in theinterview)2) Steam for caustic soda evaporator
The data shown on the control panel of the central operation room at 14:00
on November 25, 2003 was as shown below
Steam consumption
1.80 t/h
NaOH production
3.2 m3/h (2.4–4.0 m3/h)

I-25

Unit consumption of steam for caustic soda evaporators was 0.750t-Steam/tNaOH.
• (1.80t-Steam/h)/(3.2 m3/h)/(1.5 t/m3)/0.5 = 0.750t-Steam/t-NaOH
Here: specific gravity of 50% NaOH solution: 1.5 t/m3
5.2

Other Survey Contents
Prior to the energy audit, we obtained the answers to the questionnaires we had sent
the two companies in advance. Their answers are summarized below.
(1) Price of electricity, etc.
Both of the companies purchase electricity and steam from other companies.
Supplier: NPC (National Petrochemical Co., Ltd.)• Power charge: Co. A On peak : 2.6 B/kWh, Off peak : 1.1 B/kWh
Ave. : 2.1 B/kWh
Demand Charge : 74 B/kWh
Co. B 1.9 B/kWh (flat rate)• Steam charge:• De-mineralized Water:• N-Gas:635 B/t
Purchased
Used for production of solid soda

(2) Operation status
Both of the companies executed a planned shut down of operation for 20 days in
February.
The current operation status is 100% load due to the active demand for vinyl
chlorideThus, brine electrolyzers are in a certain degree of high-load operation aroundthe clock.

I-26

6.

Energy Conservation Proposals and Expected Effects

6.1

Point of view of energy conservation measures
In studying the potential for energy conservation of the existing equipment in theprocess of caustic soda production, it is important to review them from the following
aspects.
a. Possibility of reduction in energy consumption through the improvement ofoperation conditions, etc.
b. Reduction in energy discharged from the plant unit
• Effective use of steam condensate• Reduction in heat loss from the outside wall of the equipment• Effective use of latent/sensible heat of chlorine and hydrogen generated inbrine electrolysis cells.
c. Possibility of reducing energy consumption of general power machine andequipment
As the result of our energy audits from the mentioned specific aspects, we found thatenergy conservation management was exercised regarding the following points.
(1) Caustic soda factory of Co. A
1) Factors affecting electricity unit consumption of electrolytic cells
Electrolytic voltage in electrolizer represents electricity unit consumption
for electrolysis. NaCl concentration of feed brine to electrolizer , one of thefactors controlling such electricity unit consumption, is in a state ofsaturated concentration at a given temperature. The level of impure
substances is at a standard level for Japan.
2) Steam unit consumption of caustic soda evaporators
The standard evaporation ratio (quantity of water that can be vaporized by
1ton of steam) for double-effect evaporators is maintained.
3) Effective use of steam condensate in caustic soda evaporators
It is supplied to other plant in the factory as hot water and heat is effectively
used.
4) Reduction of heat loss from outside walls of equipment
We mainly checked by eyes and hands the temperature and condition of theouter walls of the caustic soda evaporators. The temperature was low andthere was no defect in heat insulation materials. The equipment was
extremely well-managed.

I-275) Effective use of latent/sensible heat of chlorine and hydrogen generated inbrine electrolyzers
There was heat recovery equipment installed. Currently it is not actuallyused, however, because of no heat balance expected at high load. It is
maintained so as to be used at the time of low load.
6) Others
Inverter control of cooling fans of cooling towers had been introduced tosave electricity consumption.
(2) Caustic soda factory of Co. B
1) Factors affecting electricity unit consumption of brine electrolyzers
Electrolytic voltage in electrolizer represents electricity unit consumption
for electrolysis. NaCl concentration of feed brine to electrolizer , one of thefactors controlling such electricity unit consumption, is in a state ofsaturation at a given temperature. The level of impure substances is at astandard level for Japan.
2) Steam unit consumption of caustic soda evaporators
The standard evaporation ratio (quantity of water that can be vaporized by
1ton of steam) for double-effect evaporators is maintained.
3) Effective use of steam condensate in caustic soda evaporators
It is effectively used in the process of dissolving salt, which is raw material
for production of caustic soda.
4) Reduction of heat loss from outside walls of equipment
We mainly checked by eyes and hands the temperature and condition of theouter walls of the caustic soda evaporators. Although we found some areas
not insulated, most of other areas of the walls were properly insulated. The
parts where we pointed out for improvement were immediately insulated
after our advice. The response of the staff members in charge was honest
and quick showing that their attitude toward energy conservation was
positive and serious.
5) Effective use of latent/sensible heat of chlorine and hydrogen generated inbrine electrolyzers
There was heat recovery equipment installed. Currently it is not actuallyused, however, because of no heat balance resulting from high load. It is
maintained so as to be used at the time of low load.

I-286) Others
Turning on and off of lighting in the storehouses of raw salt and other placesis thoroughly controlled.
Improvement plans for potential energy conservation based on the results of thecurrent survey were proposed. Their expected effects are described below.
6.2

Reduction of Electricity Unit Consumption for Electrolysis(1) Caustic soda factory of Co. A

Cell voltage (V)1) Relationship between current density and cell voltage“Current density vs. Cell voltage” in electrolyzers of this factory compared
to standard values for Japan is shown in Figure. I-6-1 and Figure. I-6-2.
This factory has cells of both mono-polar and bi-polar types.

□:Shift run◆:Flat run○:Caustic soda factory of Co. A(Spot data Nov. 26, 2003)

Current density (kA/m2)
Figure. I-6-1

Relationship Between Current Density and Cell Voltage(Monopolar cell)□:Shift run◆:Flat run

Cell voltage (V)○:Caustic soda factory of Co. A(Spot data Nov. 26, 2003)

Current density (kA/m2)
Figure. I-6-2

Relationship Between Current Density and Cell Voltage (Bipolar cell)I-29

Spot data of this factory as of November 26, 2003 are shown in the figures.
The electricity unit consumption for electrolysis at that time are compared
to corresponding average values of Japan.
a)Monopolar cell
Current density (kA/m2): 4.5
Cell voltage (V):
3.43 (Average value for Japanese factories(J: 3.5)
Electricity unit consumption (kWh/t): 2.419 (J: 2,468)b) Bipolar cell
Current density (kA/m2): 4.2
Cell voltage (V):Line #1:
3.31 (J: 3.30)
Line #2:
3.30 (J: 3.30)
Line #3:
3.22 (J: 3.30)
Electricity unit consumption (kWh/t)
Line #1:
2,334 (J: 2,327)
Line #2:
2,327 (J: 2,327)
Line #3:
2,271 (J: 2,327)
As learned from the above data, values of both monopolar and bipolarcells of this factory are almost in the same range as the average values
in Japan. The solid lines in Figure. I-6-1 and I-6-2 (Relationshipbetween current density and cell voltage) show Japanese average valuelines.
2) Plans to reduce electricity unit consumption and expected effects
In the interview, it was reported that recoating of anodes and cathodes werecarried out at appropriate intervals. Thus, as a challenge in further reducing
electricity unit consumption in the future, a shift run was recommended(operation at a low electrolysis current during the daytime and at full load
during the night time unlike a flat run in which operation is continued at thesame electrolysis current) that had been practiced in the past.
In order to introduce a shift run, it will be necessary to increase the numberof electrolytic cells if output of caustic soda continue to be about thedesigned production capacity of the facilities like what it is now. In that case,the number of electrolyzers to add must be studied in relation to the
production plan with considerations to equipment costs.
This plan, if implemented, will produce great advantages when the rate
difference of purchased electricity between nighttime/holidays and daytime/
weekdays further expands.
Here, we refrain from any quantitative assessment of the merits because

I-30

such potential merits are much subject to the conditions.
(2) Caustic soda factory of Co. B
1) Relationship between current density and cell voltage
Cell voltage, which is the base of electricity unit consumption forelectrolizer, is shown in “Current density vs. Cell voltage” in Figure. I-6-3,
in comparison with standard values for Japan.

Cell voltage (V)□:Shift run◆:Flat run○:Caustic soda factory of Co. B(Spot data Nov. 27, 2003)

Current density (kA/m2)
Figure. I-6-3

Relationship Between Current Density and Cell Voltage(Monopolar cell)

Here is a calculating formula for electrolysis energy unit consumption.
Electrolysis energy unit consumption = [Electric power used for electrolysis]/[Output of caustic soda]
Electricity used for electrolysis (MWh/t) = [Electrolytic current (kA) ] ×[Cell voltage (V)]/[Rectifier efficiency rate (-)]
Output of caustic soda = [Electrolytic current (kA)]/[96492(coulomb/F)] ×[3600 (sec/h)] × [40 (gram-NaOH/mol)] ×[Current efficiency (-)]
In a more simplified form,

0.670 × (Cell voltage)

Electrolysis electricity unit consumption =(Current efficiency) × (Rectifier efficiency)

With the current efficiency set at 0.95
Electrolysis electricity unit consumption = 0.70 × (Cell voltage)/(Rectifier efficiency) (MWh-DC/tNaOH)

I-31

Here, if both current efficiency and rectifier efficiency are set at fixed rates
respectively, electricity unit consumption becomes proportional to cell voltage.
Knowing cell voltage is enough for us to know an approximate value ofelectricity unit consumption.
Current density means electrolytic current per unit electrode surface area.
Generally “Cell voltage vs. Current density”, rather than electrolytic electricity
unit consumption itself, is compared in comparison of performances ofelectrolyzers.
The solid line inserted in Figure. I-6-3 “Current density vs. Cell voltage” showsa line of Japanese average values.
Spot data of this factory as of November 27, 2003 is shown in the figure. The
electricity unit consumption for electrolysis at that time is compared to acorresponding average value for Japan.
Current density (kA/m2): 4.2
Cell voltage (V):
3.72 (Average value for Japanese factories(J):3.45)
Electricity unit consumption (kWh/t): 2.624 (J: 2,433)
These values are quite high compared to the average values in Japan.
Cell voltage has elements such as theoretical electrolytic potential, membranepotential, anode excess voltage, cathode excess voltage, potential drop by
membrane, potential drop by electrolyte and potential drop by bubble resistance.
In terms of maintenance, in order to maintain the initial performance, it isnecessary to change membranes at regular intervals and retain the activity ofanode and cathode.
2) Plans to reduce electricity unit consumption and expected effects
Measures proposed to this factory for reduction in electrolytic electricity
unit consumption, or reduction in cell voltage and their expected effects arebriefed below.
We studied measures to reduce electrolytic electricity unit consumption,
conducting a hearing survey to the staff of the factory. We found that the
problems were increased excess voltage of anodes and delayed renewal of
membranes. Thus, we propose the following improvements.
a) Renewal to new ion-exchange membrane: Reduction by 25–43 kWh/tb) Recoating of anodes (reactivating treatment of anodes): Reduction by
183 kWh/tc) Increasing the number of tightening bolts of equalizing bars andflexible bars: Reduction by 3–9 kWh/t

I-32

7.
7.1

Guideline for Promotion of Energy Conservation and Energy audit Manual
Outline of Caustic Soda Production Process
The caustic soda production industry is a basic material industry where soda, chlorine,
etc. are produced mainly from salt. It has a long history and it is not exaggerating to
say that it has grown along with the economic growth. It is an essential,
infrastructural industry that is deeply associated with products used in daily life.
This manufacturing industry is said to be an electricity intensity industry because
large quantities of electricity are consumed when salt water is electrolyzed.
The production methods have been changing from mercury process to asbestos
diaphragm process and further energy efficient ion-exchange membrane process.
The whole manufacturing process consists of the following processes.
•
Salt water purifying process - dissolve raw salt into water until saturated andremove impure substances in salt solution•
Electrolytic process - electrolyze clarified saturated salt water with direct current
electricity•
Concentration process - Heat and vaporize 30% diluted caustic soda solution
refined in electrolyser to 50% concentration using steam in vacuum evaporator•
Pressure feed process - After drying and dehydrating chlorine generated inelectrolyzer, compress and send to next process in a liquefied or gaseous state.
•
Purifying process - Purify hydrogen and send to next process•
Synthesizing process - Directly burn chlorine and hydrogen and make water
absorb combustion gas to produce synthetic hydrochloric acid•
Final sodium hypochlorite producing process- Disperse remaining chlorine gas
dissolved in dilute salt water after electrolysis and make caustic soda absorb
discharged chlorine gas to produce sodium hypochlorite
As mentioned previously, in this production process, electricity used in electrolizers
and steam used in concentration of caustic soda are main targets of energy
conservation.
Ion-exchange membrane method process flow chart is shown in Figure. I-7-1.

I-33

Flow Sheet (Ion Exchange Membrane Method)
Cooling Water
Hydrogen Gas
NaOH Solution*2 Hydrogen

Hydrochloric acid

Na2CO3 Solution

BlowerSalt stock yard
Saturated salt solu,

Cooling Water

Cl 2 or H 2

CaCl2 Solution

Steam

HeaterC.w

Desulfurization

FilterreactorClarifierAbsorber

Mist

Storage tankcatcher

Electric power
Chlorine*2 Hydrogen
Catholyte
Filter pressDil,sulfuric acid

Pure chlorine gas
Blower(Compressor)
Sulfuric acid pump

Steam

Drying tower

Steam Edjector
Ion Exchange
Membrane Cell

Flash tank

Mud

Cooling water
Pure waterDil,chlorine gas

Separator
FilterSteam
Caustic Soda
Solution

Drain

EVAPORATOR
Air
Stock tank

Figure. I-7-1

Ion-exchange Membrane Method Process Flow
I-33

(1) Salt water electrolysis cells
Saturated NaCl solution of about 25% after impurities are removed in the salt
water purifying process is supplied to electrolysis cells. In the cells, direct
current is applied and salt and water are electrolyzed.
In the reaction, chlorine gas is generated on the anode side and caustic soda andhydrogen gas is generated on the cathode side as shown in the formulas below
Anode:
Cathode:2NaCl → Cl2 + 2Na++2e2H2O+2Na++2e- → H2+2NaOH

Electrolysis cells:

2NaCl + 2H2O →Cl2+ H2+2NaOH

There are 3 types of methods for electrolytic production of caustic soda;
Mercury method, diaphragm method and ion-exchange membrane method.
Currently, the ion-exchange membrane method is the mainstream production
method. Two types of cells, mono-polar cells and bipolar cells are used for thismethod.
These cells are explained in Figure. I-7-2 and -3.
This salt water electrolysis process is the core part of the entire caustic soda
production process. Electrolyzers are extremely important and electricityintensive equipment. Ion-exchange membrane is made of fluorine polymer andprevents products on anode and cathode from mixing up.
Electric consumption depends on potential difference between anode andcathode (i.e. cell voltage) multiplied by current applied and time.
Accordingly, the point of energy conservation (electricity saving) is how muchcell voltage can be lowered in the operation.

I-34

Mono-polar cell

Figure. I-7-2

Bipolar cell

Electrolysis Cell Types for the Ion-exchange Membrane Method

Mono-polar cell

Figure. I-7-3

Bipolar cell

Electric Current Flows in Electrolysis Cells for the Ion-exchange
Membrane Method

I-35

“Current Density and Cell Voltage” for the standard ion-exchange membraneelectrolysis cells in Japan are shown below.

“Current Density vs. Cell Voltage” (Monopolar cell)□ ; Shift run

Cellvoltage(V)◆ ; Flat run

Current density (kA/m2)
Figure. I-7-4

Relation between Current Density and Cell Voltage(Typical Example for Monopolar Cell Used in Japan)“Current Density vs. Cell Voltage” (Bipolar cell)□ ; Shift run◆ ; Flat run

Cellvoltage(V)

Current density (kA/m2)
Figure. I-7-5

Relation between Current Density and Cell Voltage(Typical Example for Bipolar Cell Used in Japan)

I-36

(2) Caustic soda concentration process
Liquid product on the cathode side in ion-exchange membrane electrolytic cells
is dilute solution containing about 30%–35% of caustic soda. As theconcentration of commercially available caustic soda is 50%, it is necessary toconcentrate it through vaporization.
In order to concentrate to 50%, dilute caustic soda is heated with vapor of about
0.5MPa and drawn into vacuumed evaporators of about 0.005–0.010MPa.
For concentration, multiple-effect evaporators, which are designed for reusing ofsteam evaporated from dilute solution, are used. The number of effects is 2 to 3
normally and evaporators with multiple effects are called double-effect andtriple-effect evaporators.
The point for energy conservation (vapor saving) in this process is to maintainthe vacuum degree and to prevent leakage of sealing water of pumps and generalservice water.
While vapor unit consumption changes depending on the number of effects ofevaporator, evaporators’ performance is commonly expressed in steam economy(evaporation ratio).

Evaporation ratio (steam economy) (n)Note: Steam economy (evaporation ratio)
Theoretically, 1 ton of vapor can evaporate 1 ton of water. In effect,
however, it is not always the case due to radiation of heat, etc. Therefore,
it is used as a gauge to show real efficiency.
A general pattern of the relation of “No. of Effects and Evaporation
Ratio” is shown below.

Upper limit
Lower limit

No of effects of evaporator (n)Figure. I-7-6

No. of Effects and Evaporation Ratio

Vapor unit consumption for double-effect evaporator (N=2) is calculated below.
In the above figure, evaporation ratios are normally 1.6–1.7.
Assuming the concentrations of dilute caustic soda solutions at 32.5% and 35%,
vapor unit consumption when they are respectively concentrated into 50% is asfollows;

I-37

32.5% → 50% :[(100-32.5)/32.5-(100-50)/50]/1.6 = 0.67 (t-steam/t-100% NaOH)
35% → 50% :[(100-35)/35-(100-50)/50]/1.6 = 0.54 (t-steam/t-100% NaOH)
When supply vapor concentrate (hot water) is used in other plants, around 10%of these values are normal values.
7.2

Energy Conservation Measures
Energy conservation measures implemented to date in the caustic soda manufacturingindustry include the following:(1) Downsizing of pumps(2) Recovery of heat exhaust from other plants(3) DDS (Daily Start & Stop) of chlorine compressors (in the case where more than
one compressor are installed)(4) Shift to inverter control rotary machine and equipment(5) On-and-off operation of cooling tower fans
(6) Lowering cell voltage by reactivating cathode(7) Recovery of latent/sensible heat in chlorine and hydrogen gases(8) Adoption of low electric resistance membrane(9) Lowering cell voltage by reactivating anode(10) Shift from flat run to shift run

7.3

Special Notes for Promotion of Energy Conservation
Points to be kept in mind for promotion of energy conservation in the process of
caustic soda production by the ion-exchange membrane method are as follows;(1) Ion-exchange membrane is a very delicate product and therefore should be
handled very carefully. Particularly, impure substances mixed in salt water tofeed to electrolytic cells must be controlled so as not exceed their standard level.
Accumulated impure substances may not only cause increases in cell voltage but
also significantly affect current efficiency.
(2) It is necessary to plot cell voltages, etc. of individual electrolyzers in the control
chart
everyday to grasp the trends.
(3) Recoating cycle of electrodes should be determined and practiced.
(4) In renewal of ion-exchange membrane, consultation and advice of membranemakers should be sought because they have various types of membranes
including low-voltage type, low oxygen type, etc.
(5) Whenever a renewed electrolyzer is set in motion, bolts used at the connectionof the conductor should be retightened at the point in time where the celltemperature is balanced. Further bolt tightening can minimize contact resistanceof electricity.

I-38

Out of the slide pictures of energy use status by Japan Caustic Soda Industry
Association that we used in the explanation in the field, some we consider
necessary are attached at the end of this report.
4 energy conservation example cases of the ion-exchange membrane method areshown in the ensuing pages.

I-39

Energy Conservation Technology Directory
Name[Kind of industry]
Chemical (caustic soda)[Technology category]

Caustic soda production process[Energy source]Electric power

Energy-saving ion-exchange membrane electrolyzer[Practical application]

1994

Energy-saving production equipment

This newly developed electrolyzer is an energy-saving compact brine electrolyzer causing structurally little potential
drop and thus achieving high current density in comparison with the conventional bipolar ion-exchange membraneelectrolyzers. This equipment can provide an about 6% electricity cut compared with the conventional method.

[Generaldescription]

Electric current flows as shown in Figure. 1.
Electric conductivity of Ni is 6 times as thatof Ti and electric current running on Ti is
minimized and thus, structurally it is possible
to reduce potential drop.

[Principle/
action]Electrolyte flow
Current
Anode membrane

Cathode membrane
Improved part

Figure. 1 Component Elements Section[Details of
Improvement]
Structural
explanation

Anode

CathodeNickel plate

Titan plate

DesignSchematic
diagram

Improved part

Electrolyte flow

Figure. 3 Electrolyte Flow

Figure. 2 Bipolar Elements Assembly[Effects from
improvement]

Table 1 Energy Conservation Effects of the Improved Equipment Versus the Conventional Bipolar
Ion-exchange Membrane Method Electrolyzer
Operation condition: Production scale 100,000 tNaOH/y, Current density 3 kh/m2

Reduced electricity unit consumption
Reduced energy consumption in crude oil[Economic effects]

Equipment cost

[Note]

Investment: 120 million yen
Recovery period: 2 years

Saving from improvement: 62 million yen /year

With this technology, economical high current density operation possible up to 6kA/m2[Embodiment]
Major business establishments
There are working samples using this technology.

Figure. I-7-7[Reference materials][Inquiry]“Soda industry technical information (No. 449) October 1994)”

Japan Chemical Industry Association → ECCJ (JIEC)

Energy-saving Ion-Exchange Membrane Electrolyzer

I-40

Energy Conservation Technology Directory
Caustic soda production process

Chemical (caustic soda)[Technology category]

Name[Kind of industry][Energy source]
Fuel (steam)Brine electrolysis heat recovery line preheater[Practical application]

1992

Energy-saving equipment[Generaldescription]

Installation of preheating equipment that preheats brine to feed electrolyzer using sensible heat ofchlorine and hydrogen gases generated from diaphragm process brine electrolyzer[Details of[Before improvement]
Improvement]
Conventionally, feed brine water was heated with steam by carbide heat exchanger.
Structural
explanation
DesignSchematic
diagram[After improvement](1) Steam consumption was reduced through heat exchange with the heat of chlorine andhydrogen gases generated from brine electrolyzer (particularly diaphragm processelectrolyzers).
(2) Preheating system flow is shown in Figure. 1.
(3) For the heat exchange system, a shell and tube heat exchanger is used. Thematerials of the mainparts of the equipment are shown in Table 1.
Table 1

Materials of the Main Parts of Brine Preheater
Shell side

Tube side

Chlorine gas–brine

TP 35 (Titan)

TTH35W (Titan)

Hydrogen gas–brine

SS40V (SS material)

TTH35W (Titan)

Evaporative
condensing
process

Electrolytic
vesselPurified brinestorage tankBrine purifying process

Improved part
Figure. 1 Preheating System Flow

[Effects from
improvement]

Table 2Heat Recovery Effects by Brine Preheating Equipment
Effects

Reduced energy consumption in crude oil[Economic effects]

Equipment cost

Investment: 90 million yen
Recovery period: 3 years

Note
Production: chlorine 55,000 t/y(hydrogen 17,500 km3)

Energy recovered (in steam)

Saving from improvement: 30 million yen/year[Note][Embodiment]
Major business establishments
There are working samples using this technology.

[Reference materials][Inquiry]“Soda industry technical information (No. 449) October 1994)”

Japan Chemical Industry Association → ECCJ (JIEC)

Figure. I-7-8

Brine Electrolysis Heat Recovery Line Preheater

I-41

Energy Conservation Technology Directory
Name[Kind of industry]
Chemical (caustic soda)[Technology category]
Energy-saving equipment[Practical application]

1985

Principle of ion-exchange membrane method and breakdown of energy loss

Brine

[Principle/
action][Energy source]Electric power[The developed active cathode is designed to reduce excess voltage of cathode that causes big energy loss in theindustrial salt ion-exchange membrane electrolysis in the process of caustic soda production. Attention was
focused on the fact that excess voltage of electrode depends on electrolytic potential and its surface area. Then,the surface of electrode was dramatically enlarged by the coating method with the result of significant reduction
in electricity.

Chlorine gas

Hydrogen gas

Table 1 Breakdown of Energy Loss of Ion-exchange
Membrane Electrolyzer

Alkali[Generaldescription]

Caustic soda production process
Improvement of active cathode for ion-exchange
membrane method electrolyzer

Electricity unit consumption (kWh/tNaOH)

Percentage (%)

Ion-exchange membrane resistanceAnolyte resistance
Catholyte resistanceAnode overvoltage
Cathode overvoltage
Conductor resistance
Total
Ion-exchange
membrane
Saturated brine

Figure. 1

Improved part
Water

Principle of Ion-exchange Membrane Method[Details of
Structure of active cathode
Improvement] (1) Figure. 2 shows mesh cathode and Figure. 3 shows a pattern diagram of its sectional structure. By applying
special coating on the stainless or nickel cathode base, hydrogen overpotential is reduced.
Structural(2) Coating layer is porous alloy of Ni-C-S.
explanation(3) In the normal industrial scale, operation current density is 20–40A/dm3. Active cathode excess voltage is
0.2 V lower than conventional cathode.

DesignCarbonSchematic
diagramNi-s alloy
Coating layer
Base material
Figure. 1[Effects from
improvement]

Table 1

Mesh CathodeFigure. 2 Pattern Diagram of Section
Structure

Improved part

Example of Energy Conservation Improvement Effects (Production scale: 100,000 t/y base)
Reduced electricity unit consumption
Reduced annual electricity consumption
Reduced energy in crude oil[Economic effects]

Equipment cost

Investment: 2.6 million yen
Recovery period: 3.5 years

Saving from improvement: 72.9 million yen /year[Note][Embodiment]
Major business establishments
There are working samples using this technology.

[Reference materials][Inquiry]“Complete Collection of Energy Conservation Case Examples (1988)” P.197

Japan Chemical Industry Association → ECCJ (JIEC)

Figure. I-7-9 Improvement of Active Cathode for Ion-Exchange Membrane
Method Electrolyzer

I-42

[Kind of industry]
Chemical (caustic soda)[Technology category]
Operation improvement[Generaldescription]

Name

Energy Conservation Technology Directory
Caustic soda production process
Reduction of electrolytic electricity of brine electrolyzer[Energy source]Electric power[Practical application]

1977

This is an energy-saving operation method of reducing electrolytic electricity by lowering current load
for brine electrolysis at the time of low operation in the process of caustic soda production.
• Electrolytic electricity used in brine electrolyzer (W) is proportional to cell voltage as shown by formula in ccell voltage is in almost linear relation with current (I) as shown by formula in d. In addition, production (P) is[Principle/
action]proportionate to product of current and number of cells (n). (formula in e)

Here, W: electrolytic electricity (AC-kWh/t), 670: Electricity chemical equivalent (kA/t), V: Cell voltage(V), ηc: Current efficiency ηk: Current transformation efficiency, I: Load current (kA), a. b: Constants,
P: Production, n: Number of cells, K: Coefficient

Improved part

[Details of
Improvement]
Structural
explanation
DesignSchematic
diagram(1) Formula in e shows that when production volume is fixed, an increased number of cells can lower load current
and formulas in c and d show that electricity can eventually be reduced. However, simply lowering current
level will cause;• Unit consumption of steam for condensation to increase due to reduced electrolyte concentration• Current efficiency to go down due to increased electrolyte resistance resulting from drops in electrolyte
temperature• Wear and tear/deterioration of diaphragm resulting from change in pH in diaphragm cell and drops in current
efficiency, etc
For the countermeasures of these possible outcomes,• Reduction in electrolyte concentration was prevented through adjustment of diaphragm and thoroughmanagement of electrolytic cell
• Temperature of electrolyte was raised by about 2 degree (°C) and current efficiency was maintained throughpreheating of feed brine by using waste heat from the drain of hydrogen gas generated.

[Effects from
improvement]

Table 1

Energy Conservation Effects Example
Reduction effect

Note
Reduction rate 7.4%

Reduced annual electricity consumption

Reduced energy in crude oil[Economic effects]

Equipment cost

[Note]

Investment: 130 million yen
Recovery period: 2 years

Saving from improvement: 64 million yen /year

Although this is an example of improvement of diaphragm process electrolyzer, this improvement is applicable to electrolytic highpurity chrome and manganese dioxide production processes as well as ion-exchange membrane method brine electrolyzer.

[Embodiment]
Major business establishments
There are working samples using this technology.

Figure. I-7-10[Reference materials][Inquiry]“Complete Collection of Energy Conservation Case Examples (1980)” P.803

Japan Chemical Industry Association → ECCJ (JIEC)

Reduction of Electrolytic Electricity of Brine Electrolyzer

I-43

Attachment:
Attachment I-I

Attachment I-2

Attachment I-3

Energy Consumption Status of Co. A
Annual utility consumption, Monthly utility consumption,
Daily utility consumption and unit energy consumption
Energy Consumption Status of Co. B
Recent trend of production
Utility consumption: Annual consumption, Monthly
consumption, and Daily consumption
Energy Use Status of Caustic Soda Industry in Japan(Excerpts from presentation slide pictures used in the field)

I-44

Attachment I-I

Energy Consumption Status of Co. A

Recent Trend of Utility Consumption- Annual Utility Consumption
600,000
Steam (t)500,000

Elec. (MWh)Well Water (t)400,000

City Water (t)300,000

N.G (×10Nm3)
NaOH Product (t)200,000
100,000
0
2001

2002

2003 (1-10)- Monthly Utility Consumption (2003)
60,00050,000Well Water (t/m)

40,000

Elec.(MWh/m)
City Water (t/m)
N.G (×10 Nm3/m)

30,00020,00010,000

Steam (t/m)

0
1

2

3

4

5

6

7

I-45

8

9 10
Month

- Daily Utility Consumption (Oct. 2003)
2,000
1,800
1,600
Well Water (t/d)
Elec. (MWh/d)

1,400
1,200
1,000
800
600
400
200

Steam (t/d)

0
1

5

9

13

17

21

25 29
Date

Unit Energy Consumption
Year

2001

2002

2003
(1—10)‘03/11/25
Spot data

Item
Electricity

MWh/t-100%NaOH

2.233

2.433

2.117

2.384

Steam

t/t-100%NaOH

0.731

0.680

0.632

0.625

Catholyte

t-50%NaOH

208,707265,819

238,96441.6

Product NaOH
SteamElectricity

t-100%NaOHt
MWh99,136
72,510232,997

86,39158,783323,389

77,66349,098
252,939

5.63
3.52
49.6

2.5

Electricity2(MWh/t-100%NaOH)

1.5

Steam (t/t-100%NaOH)

1
0.5
0

2001

2002

2003

I-46

'03/11/25

Attachment I-2
Energy Consumption Status of Co. B

Recent Trend of Production
Item

2001

2002

2003(1-10)

Caustic Soda (t-50%NaOH/y)
Gas Chlorine (t/y)

54,00023,00055,00022,00046,00011,00060,000Caustic Soda

50,000t/y
40,00030,00020,000Gas Chlorine

10,000
0

2001

2002

2003 (1-10)

Recent Trend of Utility Consumption- Annual Utility Consumption
80,00070,00060,000
Steam (t)50,000

Elec. (MWh)40,000NaOH Product (t)30,00020,00010,000
0
2001

2002

2003 (1-10)

I-47

- Monthly Utility Consumption (2003, 1-10)
8,000
7,000
6,000
5,000

Elec.
(MWh/m)4,000

Steam (t/m)

3,000
2,000
1,000
0
1

2

3

4

5

6

7

8

9 10
Month

- Unit Energy Consumption

Electricity

MWh/t-100%NaOH

2.558

2.543

2003
‘03/11/27(1—10) Spot data
2.654
2.652

Steam

t/t-100%NaOH

0.936

0.849

0.859

0.750

Catholyte

t-50%NaOH

54,00055,00046,0006.51

Product NaOH

t-100%NaOH

31,00032,00028,000

2.4

SteamElectricityｔ/ y
MWh / y14,502

13,577

12,027

3.52

69,06969,92361,045

8.64

Items

3
2.5
2
1.5
1
0.5
0

2001

2002

Electricity(MWh/t100%NaOH)

Steam(t/t-100%NaOH)

2001

2002

2003

I-48

'03/11/27

Attachment I-3 Energy Use Status of Caustic Soda Industry in Japan(Excerpts from presentation slide pictures used in the field)

添付資料Ⅰー３

Benchmark / Guideline
at Caustic Soda Industry
Contents
1. Composition of Variable Cost
2. Benchmark for Caustic Soda Industry
3. Check Items for Plant Operation and
Maintenance （Examples in Japan)
January, 2004

The Energy Conservation Center, Japan
ECCJ
1

1. Composition of Variable Cost
60%

Electrolysis

50%

Salt

40%

Elec. of others

30%

Steam

20%

Chemicals

10%

Technical fee
for electrode0%

Pure Water

Target for cost reduction!
ECCJ
2

I-49

94%

Composition of Energy Consumption
Other Electricity:
Steam:１２％

１１％
Electrolyzer: ７７％

ECCJ
3

2. Benchmark for Caustic Soda Industry (1/2)
・ Electrolysis① Monopolar cell (Current Efficiency: 0.95 )Current density 3 〜 4.5 (kA/m2)⇒ Cell voltage = 3.2 〜 3.5 (V)⇒ Unit consumption = 2.260 〜 2.470 (DC-MWh/t)② Bipolar cell ( Current Efficiency: 0.95 )Current density = 4 〜 6 (kA/m2)⇒ Cell voltage = 3.2 〜 3.5 (V)⇒ Unit consumption = 2.260 〜 2.470 (DC-MWh/t)
ECCJ
4

I-50

1) Monopolar cell
Current density vs Cell voltage

Cellvoltage(v)□: Shift run◆: Flat run

Current density (kA/m2)
Current density ⇒ Cell voltage ⇒ Unit consumption(DC-kWh/t-NaOH, Ceff,; 0.95)
2
Example: 2.1kA/m ⇒ 3.0V ⇒2,116, 4.2kA/m2⇒3.5V⇒2,468
ECCJ52) Bipolar cell
Current density vs Cell voltage□: Shift run◆: Flat run

Cell
Voltage(v)

Current Density (kA/m2)
Current density ⇒ Cell voltage ⇒ Unit consumption(DC-kWh/t-NaOH,Ceff,;0.95)
2
Example: 2.1kA/m ⇒ 2.9V⇒ 2,045, 4.2kA/m2⇒3.2V⇒2,257
ECCJ
6

I-51

Electrolyzer:

Cell Voltage

Electricity Unit Consumption

Electricity Unit Consumption= [Electric Power Consumption] / [Product Volume of NaOH]= [(Electrolysis Current (kA))×(C. V.) / (R. Eff.] /[(Electrolysis Current (kA)) / (96492 (Coulomb/F))
×(3600 (s/h))×(40（g-NaOH/mol))×(C. Eff.)]= 0.670 ×（C. V.) / (C. Eff.) / (R. Eff.)= 0.74 ×（C. V.)(AC- MWh/t- NaOH)= 0.71 ×（C. V.)(DC- MWh/t- NaOH)(AC- MWh/t- NaOH)

Here, C. V.: Cell Voltage (v)C. Eff.: Current Efficiency (-) = 0.95
ECCJ

R. Eff.: Rectifier Efficiency (-) = 0.95 (AC), 1.0 (DC)7

Benchmark for Caustic Soda Industry(2/2)
・ Steam at evaporator
Double Effect Evaporator(Steam condensate is not used at other plants.)
Unit consumption:
Catholyte NaOH conc. = 32.5 〜 35 (wt.%)
Product NaOH conc. = 50 (wt.%)⇒ ０.6 〜 0.8 (t-steam/t- 100%NaOH)
ECCJ
8

I-52

3. Check Items for Plant Operationand Maintenance （Examples in Japan)
1) Operation conditions and factors
2) Feeding brine specification
3) Check items for plant operation（Brine refinement & Electrolyzer）
4) Check ＆ action after maintenance5) Grasp method of change at Electrolyzer
by the day6) Recoating cycle of cathode & anode
ECCJ
91) Operation Conditions and Factors
Hydrochloric Acid
Over addition /High density

Depletedbrine pHToo low pH

Conversion to H
from Na in carvone
base of Membrane

Abnormity ofcell voltage

O 2 / Cl 2 conc.
Under addition /Low density
Brine supply
Brine supply stop /Circulation fluid flow or stop

NaCl / NaOH

Under feeding /Lowing of NaCldensity

Depletedbrine conc.

Permeate
flow rate

O 2 / Cl 2 conc.

Highertemperature

Temperature

Membraneswelling

Cl 2 conc.

Over feeding /Raising of NaCldensityLowertemperature

Depleted brain
pH
Depletedbrine conc.

Permeate
flow rate

Temperature

Membraneshrinkage

Impurities

Purified water
Under feeding

Efficiency

Depleted brain
CLO

Ca, Mgaccumulation

Note:: Factor: Variation

NaOH conc.

Cell voltage: Membranecondition: Result

Over feeding

NaOH conc.

Cell voltage: Phenomenon

ECCJ

10

I-53

2) Feeding Brine Specification
Item

NaCl
Na2SO4NaClO3

Unit Standard
Item
Value
g/L 300〜310 Al
g/L <5SiO2Unit Standard
Value
ppm ＜0.1

g/L

<20

Fe

ppm ＜0.2

Nippm <0.01

TOC

ppm <10I（Iodine) ppm <0.2

Sr

ppm

<20
as Ca
<0.06

Ba
Hg

ppm

<0.5

ppm

<15

Ca + Mg ppb

ppm ＜5

Source ; Chlorine Engineers Corp,,Ltd

ECCJ

11

3) Check Items for Plant Operation（Brine Refinement & Electrolyzer)
Continuous data
AnalysisFeed Brine

NaClO3> Once/d

Electrolyzer(individual）

NaCl > Once/d Na2SO4 > Once/d
Ca Continuously Catholyte> Once/d
Mg
Na2SO4 > Once/d

NaClO3 > Once/w
Depleted Brine

NaOH Continuously Brine Flow rate
NaCl Continuously NaOH Recirculation Flow
Electrolyzer (Individual）

NaOH> Once/w

NaCl> Once/d

NaCl /> Once/w
NaOH

F-Cl2

> Once/d

Cl2

ECCJ

Cell Volt
Cell Temp.

> Once/w
12I-54

4) Check and Action after Maintenance
Assembling
completion

Air tightness test
at 0.2kg/cm2G,
To check the

Tie rod & bus bar forcell main bodyshould be tightening.

leakage from gasket

Electrolyzer
START

Catholyte &depleted brine
over-flow check,
Cell temperaturecheck (70℃ up)

Confirmation ofcell temp. riseCl2 conc. Check(97%up)Once again
tightening

1 hour laterCl2 conc.
& cell volt
check

Normal operation
ECCJ
135) Grasp Method of Change
at Electrolyzer by the day
Prepare the data table for following factors byonce a week, and make plans for the
maintenance.
① Cl2 concentration② Cell voltage③ Cell temperature④ Cell life (Progress number of days)⑤ Kind of membrane⑥ Maintenance record
ECCJ
14

I-55

6) Recoating Cycle of Cathode & Anode
Cathode:Electric Potential measurement(Electrode maker)
Give the instructions by the result(User)
Anode:
Recoating : 1〜２ times/life
Usual life: Standard type = 10 years
Long life type = 15 years
All renewal
ECCJ
15

I-56

II. Food Industry

Participants in the Workshop of ASEAN Major Industry Energy Audit(Persons concerned from EMA and the food industry and members of
ACE and ECCJ) at the workshop venue in Singapore (January 6, 2004)

II.

Food Industry

1.

Summary of ProjectThis project was implemented as part of the Infrastructure Improvement Project for
Rationalization of International Energy Use with an aim to contribute to energy
conservation, environmental preservation and sustainable development of economy in
ASEAN countries that have recently achieved remarkable progresses in economic
growth.
This project is designed to promote energy conservation in the major industries of
ASEAN countries with ACE (ASEAN Center for Energy) as the core organization andwith cooperation of ASEAN countries. As one of the countries and industries subject toenergy audit for the current year, the food industry of Singapore was chosen. Then,
audit plans were developed based on discussions with EMA (Energy Market Authority),
the department in charge, of Singapore. Energy audits were implemented at the sites of
two companies of the food industry over 6 days for the periods from December 1
through 5, 2003 and January 6 through 9, 2004 with persons in charge from EMA ofSingapore. The results of the energy audits along with an overview of the political andeconomic situations of the country is reported as follows;

1.1

Subjects of Energy Audit and Organizations involved(1) Country and companies subject to energy audit
Country:
Republic of Singapore
Company: Co. C (Dairy products processing industry) andSuper Coffeemix Manufacturing Ltd. (SCM)(2) Organizations involved and participants
1) Republic of Singapore
a. Energy Market Authority (EMA)
Mr. Abdul Rashid B Ibrahim
Deputy Executive Director
Mr. Zulkarnain B H Umar
Engineer, Consumer Education
Ms. Latha Ganesh
Executive Engineer
Mr. Melvin Tom
Engineer, Consumer Educationb. National Environment Agency (NEA)
Mr. Pang Hian Kiat Eddie
Engineer, Resource Conservation
Mr. Andy Wongc. Industrial Committee of Energy Efficiency
Mr. Vincent Low Loke Kiong(Super Solution Pte Ltd)Mr. Yeo Chee Kiong(Precision O&C)

II-1

d.
e.

Mr. Colon koh(Precision O&C)
Mr. Francis Plang(Precision O&C)
Mr. Leow kok Chong(Honeywell Pte Ltd.)
Food factory of Co. C
5 people including Plant Manager
SCM
Mr. Muhamad Muhtazam Noor Din Technical Assistant
Mr. William ONG
General Manager
Mr. Dan Khoo Yew Meng
Technical Manager

2) ASEAN: ASEAN Center for Energy (ACE)
Mr. Christopher Zamora
3) Japan: The Energy Conservation Center, Japan (ECCJ)
Participants from the International Engineering Department of ECCJ
Hiroshi Shibuya
General Manager
Kazuo Morishita
Technical Expert
Hideyuki Tanaka
Technical Expert (the 2nd site survey only)
1.2

Political and Economic Conditions in Singapore(1) National indicatorCountry name:Area:
Population:
Capital:Language:
Religion:
Brief history:

Republic of Singapore
682.3 km2 (Almost the same size as a total of Tokyo 23
wards (617 km2)
About 4,131,000 (Including foreign residents living in
the country for more than one year)
Singapore
National language: Malay, Official language: English,
Chinese, Malay and Tamil
Buddhism, Taoism, Christianity, Islam and Hinduism
1959: Acquired autonomy from England and became anautonomous state of Singapore.
1963: Joined as a state at the time of establishment ofFederation of Malaysia.
1965: On August 9, after secession from Malaysia,
became independent as Republic of Singapore.

II-2

(2) Political system and domestic policy
Form of government:
Head of state:

Parliament:
Government:

Domestic policy:

Constitutional republic (Established on August 9, 1965)
President (6-year presidential term, S.R. Nathan, theincumbent president was inaugurated in September
1999 as the 6th president of the country.)
Unicameral Parliament, 84 seats; (members elected bypopular vote to serve 5-year term)(1) Prime Minister: Goh Chok Tang (People’s Action
Party [PAP] assumed office inNovember 1990)(2) Foreign Minister: S.Jayakumar (took office inJanuary 1994)
In 1990, Prime Minister Goh succeeded to the post after
Lee Kuan Yew, former Prime Minister (currently Senior
Minister) who had been in office for 31 years. In thenational election carried out in November 2001, PAP
acquired 82 seats out of the total of 84 (share of thevote: 75.29%). The nation’s domestic policy has been
extremely stable. Goh Chok Tong expressed his
intention to step down from the post before the next
general election is conducted in 2007 or before that.

(3) Political situation in Singapore
Since the establishment of the country to date, People’s Action Party, as theruling party, has been in power, making up the comfortable majority of theparliament and thus, the domestic policy continued to be in a stable condition. In
November 1990, Goh Chok Tong took over the post from Lee Kuan Yew, who
had been Prime Minister consecutively for 31 years.
• In the nation-wide election in November 2001, PAP comfortably won
acquiring 82 seats out of the 84 in total (about 75% share of thevote)appealing to people’s sense of insecurity resulting from an economic
slump and a series of terrorist attacks on U.S. that they had recently
experienced.
• Prime Minister Goh expressed his intention to step down from the post atleast 2 years before the next general election scheduled for some time before
early 2007, to transfer power to Lee Hsien Loong, the eldest son of Senior
Minister Lee Kuan Yew and currently Deputy Prime Minister.

II-3

(4) Basic foreign policy
Singapore puts priority on the alliance of ASEAN countries and the power
balance among great powers in East Asia. Singapore underlines militarypresence of the US in the Asia and Pacific region and its political commitment(though as member of the Non-Aligned Countries).
• Singapore has developed strategic foreign policy looking realistically at thecountry’s disadvantageous aspects (small land and population without
resources). It has focused its efforts in securing access to world economy bymaintaining and advancing its multi-lateral free-trade system while creatinga stable international environment in East Asia. Singapore pursues also theintegration of ASEAN and the regional cooperation based on the amicable
relationship with ASEAN member countries including ASEAN+3, ARF,
APEC, etc. Singapore underlines military presence of the US in the Asia
and Pacific region and its political commitment for the post-cold war period(though it is one of the Non-Aligned Countries).
• Singapore has put importance on the promotion of bilateral free trade
agreements other than WTO negotiations as part of its efforts in establishingand enhancing a free trade system. It has already concluded FTA with NZ,
Japan, EFTA (Switzerland, Liechtenstein, Norway, Island), Australia andUS (Not effective yet for Australia and US), and is now in the course ofnegotiation with Canada, Mexico, India, etc.. and started studies with EU,
Korea, Sri Lanka, Jordan, Bahrain, etc.
(5) Economy
Major industries: Manufacture (Electronics, transport equipment, petroleum
products and metal products), commerce and finance
Table II-1-1

Basic Economic Data

Item
GDP

Year
100 MlnUS$

19991379352000
1570002001
152066

2002
15572
7

Per capita GNP

US$

20598

22769

20544

20887

Economic growth rate

%

6.9

10.3

-2.0

2.2

Commodity priceincrease rate
Unemployment rate

%

0.0

1.3

1.0

-0.4

%

4.6

4.4

3.4

5.2

Current account100 Mln 25737
22894
28914
33490
US%
(Exchange rate 1.0 Singapore dollar (S$ = about 68 yen (as of July 2002))

II-4

Major trade items:
Exports: Electric and electronic products, oil-related products, telecommunications/audio equipment, chemical products
Imports: Electric and electronic parts, crude oil, chemicals
Table II-1-2

Year
Exports toJapan:
Imports fromJapan

Trades with Japan

Trade value(in units of million S$)
2000
2001
2002
39955
28794
26080

17949

16712

15990

Trade items
Machinery and equipment,
petroleum products
including gasoline
Electronic parts including
semiconductors, businessmachine1) Economic overview
After the secession and independence from Malaysia (1965), Singapore has
proactively promoted “Industrialization centering on the foreign
investment”, etc. In January 1996, it “left” the list of developing nations
designated by the Organization for Economic Cooperation andDevelopment (OECD).
• In 1998, its real GDP growth rate dropped to a negative figure (-0.9%)
for the first time since 1985 being affected by an overall economic slow
down in the region, etc. as a result of the Asian currency crisis in 1997.
However, after that, supported by favorable winds such as the recovery
of Asian economy, the world-wide expansion in the needs forelectronics products, the recovery of domestic consumption, etc. it
posted high growth rates of 6.4% and 9.4% in 1999 and 2000
respectively.
• In 2001, however, the demand for electronic products diminished due toan economic slowdown in the US, etc. Thus, as a result of significant
drops in exports, the growth rate in the manufacturing industry
seriously worsened (-11.5%) and the GDP growth rate resulted in an
all-time worst (-2.4%) since the foundation of the country.
• Although the negative growth still continued in the first quarter of 2002,
it picked up in the second quarter due to dynamic growths in the
manufacturing industry, particularly in the chemical-related divisionand recorded the first positive growth rate (3.9%) in 5 quarters. GDP
continued to grow and ended up with a positive growth rate of 2.2% for
the full year of 2002.

II-5

•

For the economic growth for 2003, the government of Singapore had
initially projected at 2–5%. However, due to the prevalence of Severe
Acute Respiratory Syndrome (SARS) in the country and the region
during the period from March to May, its tourist and transportindustries were severely damaged causing the growth rate of the second
quarter of 2003 drop to -4.2% and thus, the government revised its
projected economic growth downward to 0–1% in August. In the third
quarter of 2003, the growth rate recovered up to 1.0% (a preliminary
figure) reflecting strong overseas demand.

2) Economic measures• In January 1999, the government of Singapore announced the “Industry
21” program, as its basic industrial policy up to 2010. The government
upheld, as its goal, the creation of a world-class hub of the knowledgebased industry centering on the manufacturing and service industries.
As strategic industries, the following 9 fields are targeted; electronics,
petrochemistry, life science, engineering, educational service, medical
service, logistics, telecommunications/media and regional integrated
service. In 2000, as industrial policies for individual fields, “Infocom
21 Program (Information-communication, net business)”, “Singapore
Genome Program (life science)” “Science and Technology 2005
Program (science and technology)” ,etc. were announced.
• While the world economy was drastically changing with the accelerated
globalization, the rise of China as a competitor, etc. the government ofSingapore, which had faced with a severe recession in domestic
economy, set up the Economic Review Committee (ECC chaired by
Lee Hsien Loong, Deputy Prime Minister and Minister of Finance) togive a fundamental review of its development strategies and propose a
blueprint for economic restructuring. After repeated discussions over
one year, the Committee publicized its final report in February 2003.
Although the report covered a broad range of issues and topics, its
central theme was to strengthen each field’s function as a hub in Asiaand in the world. In this respect, the report included policy proposals,
which would directly/indirectly help economic restructuring, regarding;(1) Taxation system reform, (2) Development in the educational
industry, (3) Improvement in medical/health service, (4) Development
as a financial center, (5) Progress as a digital hub, (6) Development of
the high value-added manufacturing industry, (7) Establishment of
distribution networks, etc. Most of these proposals are reflected on the2003 budget.

II-6

1.3

Energy Situation in Singapore
Singapore imports all of the primary energy (petroleum, gas) used home. Althoughpetroleum accounts for a dominant proportion, import of gas has increased year by
year. Solar power generation accounts for only about 0.2% of the total energy
consumed in the country.
Energy situation in Singapore is shown in Table II-1-3. In the industrial sector, thechemical and petrochemical industries consume more than 70% of the total energy
consumed in the sector. As the food processing industry is included in the item forothers of the industrial sector, there is no specific data on its actual energy
consumption. Although the food processing industry is an important industry in
Singapore, it is one of minor industries in terms of energy intensity.
Table II-1-3

Classification
SupplyEnergy Situation in Singapore(unit: 1,000 toe)

2000
Sector
Total
total
64
24591

2001
Sector
Total
total
64
29158

SectorDomestic
production
ImportSolar energy
generation, etc.
Oil
23344
25088
Gas
1183
4007
ConPower generation
5088
6612
14305
18553
sumption Oil refining
6177
7409
Conversion to others
3040
4532
Industry
Iron and steel
93
4001
89
3962
Chemical/
2895
2888
petrochemical
Others1013
985
Transport
Air transportation
2414
4388
2413
4559
Roads
1949
2120
Others25
26
Other
Agriculture
3
1898
3
2084
sectors
Public use
813
990
Residence546
555
Others536
536(Data source: IEA 2003 Edition, Energy Balances of Non-OECD Countries, 2000-2001)

II-7

2.

Overview of the Food Industry (Food Processing Factories) Subject to Audit
In advance of the implementation of the planned energy audits of the food industry(Food processing factories) in Singapore, ECCJ requested to ACE to select two foodprocessing factories. The department of the Singapore government in charge, in
response to the request from ACE, determined on the two food processing factories
mentioned previously.
These 2 factories requested for conclusion of a nondisclosure agreement prior to theiracceptance of our first site survey. Actually, we concluded a nondisclosure agreementwith only Co. C. The conclusion of a ND agreement with “Super Coffeemix
Manufacturing Ltd. (SCM)” was not necessary and they accepted our energy audits.
Accordingly, we note here that the report described hereunder, particularly data on Co.
C, is limited to the matters concerning energy conversation.
Brief outlines of the respective 2 food processing factories are given below.

2.1

Outline of Co. C (dairy food processing industry)(1) General information
Factory location:
Products:
No. of employees:
Work system:

City of Singapore
7 items of diary product640
3 shift- team operation, 24 h/d, 5.5 d/w (From 7:00 AM on
Monday through 7:00 PM on Saturday)(2) Production volume and energy consumption
1) Production volume (2003)
7 production items and their annual production volumes are shown in thetable below.
Table II-2-1

Diary Products and Annual Production Volumes
Production volume
No. of cartonsML
1750000 ctns
25.7
1500000 ctns
29.5
1800000 bottles
0.23
7200000 cups
1.1
–
5.0
–
15.0
2200000 cups
0.26

Product nameSweeten Condensed Milk
Evaporated Milk
Vitagen Cultured Milk Drink
Cup Yogurt
Juices
Pasteurized Milk
Jelly & Pudding

II-82) Energy consumption (2003)
Annual energy consumption by Co. C is detailed in the table below.
Table II-2-2
Type

Volumeconsumed

Electricity

9800000 kWh

Diesel oil

3200000 L

LPG
2.2

Annual Energy Consumption
Average unit
price (S$)

Use

0.122 General use
0.406 Boilers, forklifts, etc.

7000 kg

15 Sterilization of empty cans

Outline of SCM(1) General information
Factory location:
Products:
No. of employees:
Work system:

2 Senoko South Road, North of Singapore
2 items: Coffee mix and cereal95
One team operation, 8 h/d, 5 d/w(2) Production volume and energy consumption
Although the company had processed cereal in the factory till June 2003, as it
outsourced the production to China, it currently does only packaging of coffee
mix and cereal there. Only electricity is used for energy in the factory.
Table II-2-3
Month
2003

7
8
9
10

Monthly Energy Consumption by SCM
Production volume(Million Sachets)
55.0
55.0
60.0
56.0

II-9

Electric consumption(kWh)2863912826472829872887403.

Plan of Energy Audit
The primary purpose of the planned audits in Singapore was to grasp the actual
situations of the production process, energy consumption and the use of exhaust heat in
the selected 2 food factories and to propose improvement plans to advance their energy
conservation efforts. The purposes also included conducting workshops on the sites tointroduce energy conservation technologies, activities, etc. in Japan to raise, promoteand disseminate the awareness of the energy conservation among those concerned in
Singapore. Furthermore, these energy audits were aimed at giving support to energy
conservation leaders on the side of ASEAN in establishing the standardized energy
audit method after these energy audits were carried out, based on our acquired
understanding of the actual situations of the same industry in ASEAN countries, thelevels of their energy audit skills, etc.
For implementation, a survey was conducted twice for the respective facilities.
In the first site survey, the first work shop was conducted. The points for energy auditsof food factories and energy conservation technologies practiced in the food processing
industry in Japan were introduced to help and boost their understanding.
In the actual auditing, a local audit group arranged by ACE took specific measurements
at the respective sites under the instructions of the experts dispatched from Japan while
the points to be checked in energy auditing that we had asked in a preliminary
questionnaire to these factories were confirmed.
In the second site survey, energy conservation improvement plans determined based on
the results of the first survey were explained to the persons concerned of EMA (Energy
Market Authority), a department of the government of Singapore in charge, and the
managing persons of the respective companies. Then, we visited the sites again andconducted energy audits for the respective facilities to confirm the results of the firstenergy audits and our subsequent proposals.

3.1

Energy Audit Procedure
The energy audit group visited the two companies that accepted energy audits in twodays for the first site survey and in one day for the second site survey each.
In the first survey, the auditing staff from ACE and ECCJ explained to Plant
Managers of the two companies the background and meaning of the current energy
audit. In the site survey, the filled-out questionnaire was collected and a site
inspection and an energy audit were conducted.
Photo shooting was strictly prohibited in both companies and no information on theactual condition was obtained.

II-10

3.2

Selection of Equipment Subject to Audit and Reviewing of Responses to
Questionnaire
As the two companies use the two different manufacturing processes, we decided todetermine the equipment for energy auditing after reviewing the current condition of
the respective companies.
However, the advance questionnaire from ECCJ had been returned from only one
company and it contained only part of the company profile and no information onenergy management. Therefore we planned to confirm at the site survey but actually
they were not prepared to provide us with information that met our request. As bothcompanies had not practiced energy management in terms of unit consumption andcollected necessary data, we decided to conduct energy auditing focusing on energy
conservation of individual equipment and installations.
Equipment selected for auditing and the questionnaire items confirmed are shown
below.
(1) Co. C (Diary products processing industry)
1) Selection of equipment for energy auditing
The factory of Co. C that we visited has been in operation for 40 years andrepeatedly expanded its production scale to date. It has 7 product lines anddata on each product line has not been collected in the field. Due to the time
constraints, we limited our current energy audit to the product lines ofcondensed milk, evaporated milk and pasteurized milk produced in large
quantities.
Energies used in the dairy product factory is as follows :• Electricity (Purchased power):
Cooling system, air compressor, refrigerator, air-conditioner,
pump, fan, conveyer, lighting, equipment motor, etc.
• Steam:Heating, pasteurizing, vacuum equipment, steam cleaning, etc.
We picked up for auditing the steam system, cooling system, air compressor
and electricity receiving/transforming installation that consume large
quantities of energy.
As we could not obtain necessary data to confirm the questionnaire items
for the reason mentioned previously, we report here what were clarified in
discussions.
2) Major energy consuming equipmenta. Sweeten Condensed Milk
Production capacity: 200,000 L/d (estimate)

II-11

b.

c.

d.

Powder milk dissolving tank, homogenizer (110 Bar, 60 Hp),
Pasteurizer (plate heat exchange), Vacuum condenser (2), Middle tank(5), Filling equipment (350 CPM), Labeler, Packing machine, Palletizer
Evaporated Milk
Production capacity: 145,000 L/d (estimate)
Powder milk dissolving tank, Balance tank, Pasteurizer, Homogenizer(250 Bar, 100 Hp), Pre-cooler (plate heat exchange), Cooler (plate heatexchange), Middle tank (3), Filling equipment (245 CPM), Rotarysterilizer, Labeler, Packing machine, Palletizer
Pasteurized Milk
Production capacity: 134,400 L/d (estimate)
Dissolving tank (2), Pre-pasteurizer (plate heat exchange),
Homogenizer (75 Hp), Middle tank (3), Pasteurizer (plate heatexchange, 6000 L/h), Homogenizer (50 Hp), Middle tank (12,000 L ×5), Cooler (plate heat exchange), Filling equipment (500 L/h × 2),
Packing machine, Cool storage
Utility facilities
c Boiler (steam pressure: 10 Bars × 188℃)• UK made × 2@4.5 t/h
Installed in 1997/2002• Singapore made × 2@2.27 t/h Installed in 1998/1989• Exhaust gas recuperator:
Feed water temperature 30 → 70°C
Installed in 2002
d Air compressor (discharge pressure: 8.43 kg/cm2)
No.of compressors in operation is under sequencer control.
• 4 compressors (KSESAR): @50 HP 5.95 m3/min• 3 compressors (IR ML):@25 HPe Refrigerating machine (ammonia machine)• 1 unit (MYCON): 75 kW• 2 units (MYCON): @55 kW• 1 unit (MYCON): 45 kW
f Evaporative condenser
4 units
g Chilled water pump
There are 3 lines and one pump in each line is constantly inoperation.
• 2 pumps (Vitagen line):@35 m3/h 7.5 HP• 2 pumps (Juice line):@60 m3/h 15 HP• 2 pumps (Milk line):@40 m3/h 10 HP
h Ice thermal storage tank
1 tank: 1,200,000 kcal as Ice (15 ton)
1 tank: 800,000 kcal as Ice (10 ton)II-12

i Refrigerating chamber
One 4°C ice chamber in the factory, Air condensing unit + unit
cooler
4°C and -20°C ice chambers outside the factoryj Transformer
2 units: @2.0 MVA Power factor: 96%
3) Other items confirmed
a. Electric rate (in units of S$)• Basic charge (@kW): Contract rate: 7.3, For electric use
exceeding the contract volume: 10.99• Charge at a metered rate:
Off-peak time (23:00–7:00): 0.0725+0.0015
Peak time (7:00–23:00):
0.09590+0.0142• Other charges: Service charge: about 2.5%
Tax: 4.0%
b. Boiler feed water costc. Vitagen Cultured Milk Drink
Sterile filling machines are sterilized with steam every morning (9:00–
11:00)
d. Refrigerating chamber.
Although the standard temperature is set at 4°C, the temperatures
recorded in each chamber were respectively, -0.6, -0.5, 1.0, 1.0°C. The
lower temperatures are intended to prevent rises in temperature causingfrom the influx of fresh air at the time of shipping by trucks.
The temperature must be kept below 4°C in accordance to HACCP.
e. Sweeten Condensed Milk
• Although the equipment is 40 years old, it is still in use withrepairs and maintenance.
• Steam ejector vacuum condenser (Maximum 4,200 L/batch,
Vacuum degree: 2.0–2.9 inHg) consumes vapor at a rate of 700–
1000 kg/h.
• The operation of steam ejector (3-staged ejector + auxiliary
ejector) was checked.
• The naked pipe surface temperature was measured. 130°C• The naked end-flange surface temperature was measured. 90°C
• Empty cans to fill the contents are sterilized with LPG direct
flame (one can was picked up at random and the temperature
over 149°C) was confirmed.
f. Evaporated Milk
Rotary sterilizer (FMC made) consumes steam at a rate of 125 kg/h.

II-13

g.

Steam system
Drains of the Sweeten Condensed Milk and Evaporated Milk
production lines are not collected. They once tried collection of drains
but due to the high position of the boilers installed on the 8th floor, it
was not successful.

(2) SCM (Coffee blending and packaging)1) Selection of equipment subject to audit
The SCM factory we visited did only blending and packing of coffee mix
and cereal mix.
The energy used in the entire process was electricity. However, datacollection in the production site was not practiced and as they received
electricity in the same line as the Head Office, it was impossible to estimate
their unit electricity consumption.
• Electricity (Purchased power):
Air conditioning, air compressor, conveyer, lighting,equipment motor and electricity used in the offices
We picked up for auditing the air conditioning system, air compressors,
lighting, electricity receiving installation that we assumed would consume
large quantities of energy.
As we could not obtain necessary data by the questionnaire entries for thereason mentioned previously, we report here what were clarified in
discussions.
2) Major energy consuming equipmenta. Coffee mix
Blending (2 lines), Packing (5 lines)
b. Cereal
Blending (1 line), Packing (3 lines)
c. Air compressor (screw type)
Preset pressure (6.0 kg/cm2)• 2 units: @125HP (only one unit is in operation)• 1 unit:
50 HP Out of service• 1 unit:
30 HP Out of service
Only one large-size compressor is in operation to supply air. Unload
operation is frequently repeated.
d. Air conditioning equipment
Pre-set conditions: Room temperature 20°C Humidity 55–62%RH• Production line:
3 units: @ fan 30 kW 2 units are simultaneously inoperation at the time of production and only 1 unit
is in operation at the non-production time.

II-14

e.

f.

• Blending line:
2 units: @ fan 30 kW One unit is constantly in operation
Air condensing apparatus• 5 units: @40 HP × 2 Comp Linked with the respective air
conditioners
Transformer• 2 units: @2.0 MVA, Power factor = 99%

3) Other items confirmed
a. Electric rate (in units of S$)• Basic charge (@kW): Contract rate: 7.33, For electric use
exceeding the contract volume: 10.99• Charge at a metered rate (@kWh):
Off-peak time (23:00–7:00): 0.06960 + 0.00150
Peak time (7:00–23:00):
0.09810 + 0.0142• Other charges: Service charge: about 3.5%
Tax: 4.0%
3.3

Audit Schedule
The two factories that we visited for energy audit were located in the city ofSingapore and in the northernmost town about one hour away by car from Singapore
city. The one in Singapore city was conveniently located and the staff of the factory
was so nice that the planned audits proceeded as scheduled.
(1) First site survey: December 2003
December 1 (Mon.)

December 2 (Tue.)

December 3 (Wed.)
December 4 (Thu.)

December 5 (Fri.)Workshop on the efficient use of energy and energy
conservation (16 participants in total from EMA, NEA,
Co. C, ACE, ECCJ, etc.)
Visit the factory of Co. C
Check of the energy management status andinspection/energy audit of the factory
Energy audit and wrap-up meeting in the Co. C
Visit the factory of Super Coffeemix Manufacturing Ltd.
(SCM)
Check of the energy management status andinspection/energy audit of the factory
Visit the factory of SCM Co.
Summary and wrap-up meeting

II-15

(2) Second site survey: January 2001
January 6 (Tue.)

January 7 (Wed.)

January 8 (Thu.)

January 9 (Fri.)Workshop: Points of auditing of food factories andreporting on the results of the 1st site survey etc. (12participants in total from EMA, NEA, Co. C, ACE,
BCCJ, etc.)
Visit the factory of Co. C
Recheck of the energy management status, detailed
explanation on the results of the 1st site survey andestimations of potential energy conservation.
Visit the factory of SCM
Recheck of the energy management status, detailed
explanation on the results of the 1st site survey,
estimations of potential energy conservation andreporting to the bureau chief of EMA.
Workshop: Benchmark/databaseforenergyconservation and energy-saving potential for eachfactory (10 participants in total from EMA, NEA, SCM,
ACE, BCCJ, etc.)

II-16

Energy Audit of Co. C(1) Specification and operation method of steam generating equipment
1) Boiler
A total of 4 boilers are installed on the top floor (8th) and normally 2 units
having better efficiency in a. in Figure II-4-1 are in operation.
An exhaust gas recuperator installed in 2002 preheats feed water from 30℃
to 70°C. (Installation cost: 74,000S$ to be recovered in 1.5 years). Boiler
piping diagram is shown below.

Cochran Boiler
10,000lb/h

Feedwater tank
給水タンク

排ガスgasExhaustMech Mal
Boiler5,000lb/hExhaust排ガス
gas

Recuperator
レキュピレータ
Cochran Boiler
10,000lb/h

Mech Mal
Boiler5,000lb/hFigure II-4-1

Boiler Pipinga.

4.54 t/h × 10 bar × 2
Cochran Boiler Installed in 1997/2002 UK manufacture
3-path fire tube boilerb.

2.27 t/h × 10 bar × 2
Mech Mal Boiler Installed in 1988/1989 SG manufacture
2-path fire tube boiler

II-17

Boilerroom steam header
ボイラー室蒸気ヘッダー

4.1

Equipment Subject to Energy Audit

Makeup
water
補給水

4.

(2) Specification and operation method of steam-utilizing equipment
Stem is used in the sterilizing, heating and condensing processes. The maximum
required steam pressure is 6 Bar.
1) Steam piping
The steam piping of this factory is very complicated because facilities wereexpanded many times. The data on the main steam piping is as follows:• 8in (200A): 460ft (140.2 m)• 6in (150A): 211ft (64.3 m)• 4in (100A): 277ft (84.4 m)• 3in (180A): 242ft (73.8 m)
There are many branch pipes and steam piping not in use other than themain piping.
Steam piping schematic diagram and table of flowing capacity in relation to
piping diameter and flow speed are shown below
Boilerheaderボ イhouse
ラ ー 室steam
蒸気ヘッ
ダー

Factory
header
第 2工II
場steam蒸気ヘッ
ダー

５ 階floorへ
5th

５ 階floorへ
5th

３ 階floorへ
3rd

３ 階floorへ
3rd
第 1工 I場steam
蒸 気 ヘheader
ッダー
Factory

FMC
FMC

SCM
SCM

EVAP
EVAP

Figure II-4-2

Steam Piping Schematic Diagram

II-18

Table II-4-1 Flowing Capacity in Relation to Piping Diameter Bore and Flow Speed
Flow rate (m/s)

Flow volume by FR (kg/h) (Pressure: 9kg/cm2 Specific volume: 0.1943m3/kg)

10
6094
3503
1613
947
407
252
111

Pipe diameter (A)

200
150
100
80
50
40
25

15
9142
5255
2419
1421
611
378
166

20
12189
7007
3225
1894
814
503
222

25
15236
8758
4032
2368
1018
629
277

30
18283
10510
4838
2842
1221
755
332

2) Vacuum condenser
In the condensing process of Sweeten Condensed Milk, steam ejector
vacuum condensers are used. Milk is vacuum-condensed using a 3-stage
steam ejector system at 27 inHg (50–75 mmHg). The maximum production
volume/batch is 4200 L. The maximum production capacity per condenser
is 16 batches/d.
Accordingly, the maximum daily production volume is;42,000 L/batch/condensor × 16 batches/d × 2 condensers = 134,000 L/d
The operation of the vacuum condenser was changed because theproduction volume per batch was increased.
a.

Initially planned operation condition
As a first step, the 1st , start and 3rd ejectors are put in operation andwhen the pressure in the condenser becomes 20 in (250 mmHg), the
2nd ejector is put in operation. When the inner pressure of thecondenser becomes 23 in (175 mmHg), the 1st and start ejectors are
stopped and the condensing is continued until it is completed.

b.

The current operation condition
All ejectors are put in operation from the beginning, and when thepressure in the condenser becomes 27 in (50–75 mmHg), the firstejector is stopped and the condensing process is continued until it iscompleted.
The factory’s vacuum condenser piping is shown below.

II-19

大気
air

蒸気
steam

大気
air

Start ejector
スタートエジェクター
2nd
ejector
第2エジェクター

3rd ejector
第3エジェクター

1st condenser
第1コンデンサー

2nd
condenser
第2コンデンサー
第1エジェクター
1st ejector

Vacuum真空濃縮器
condenser

Figure II-4-3

Vacuum Condenser Piping3) Steam condensate recovery system
Condensate from Sweeten Condensed Milk and Evaporated Milk production
line were not collected. Although it had once been tried, it was not
successful because of the high position of the boilers installed on the 8th
floor.
(3) Specification and operation method of cooling system
0°C cold water produced in the ice thermal storage tank by the combination ofammonia refrigerating machines and evaporative condensers is used for thecooling process through 3 lines of cold water piping. Normally, in dairy plants,
large quantities of refrigerated water are used to store raw milk. However as Co.
C does not use raw milk as raw material, their facilities are comparatively of asmall scale. They have a single-distribution line cooling system in their old
factory other than this 3-distbitution line cooling system
Cold water piping and cold water distribution diagrams are shown below.

II-20

Evaporative
エバコン
condenser

Evaporative
エバコン
condenser

Evaporative
エバコン
condenser

Evaporative
エバコン
condenser

Ice thermal
storagetank BUCO
氷蓄熱槽
BUCO

HPレシーバータンク
HP
receiver tank

Ammonia machine
冷凍機
Ammonia
machine冷凍機
Ammonia
machineAmmonia
machine冷凍機
冷凍機

Ice thermal 氷蓄熱槽
storage tank
ICE ICBBANKBANK

Figure II-4-4

Cold Water System Piping

Vitagen系
No.1
ポンプ
Vitagenline統No.
1 PumpVitagen+Yogurt
Vitagen + Yogurt
プ
ロセス
process

Vitagen系
No.2
ポンプ
Vitagenline統No.
2 PumpIce thermaltank
氷 蓄 熱storage
槽 BUCO
BUCO

Juice系
ポンプ
Juiceline統No.No.1
1 Pump

Juice
Juice
プ
ロセス
process

Juice系
ポンプ
Juiceline統No.No.2
2 Pump

Milk系
No.1
ポンプ
Milk
line統No.
1 PumpIce蓄
thermaltank BANK
氷
熱 槽 storage
ICE BANK

Milk
Milk
プ
ロセス
process

Milk系
No.2
ポンプ
Milk
line統No.
2 PumpFigure II-4-5

Cold Water Piping Diagram

1) Refrigerating machinea. 75 kW Reciprocal ammonia refrigerating machine × 1
Japanese made

II-21

MYCON

b.
c.

55 kW Reciprocal ammonia refrigerating machine × 2
Japanese made45 kW Reciprocal ammonia refrigerating machine × 1
Japanese made

MYCON
MYCON

2) Ice thermal storage
Two ice thermal storage tanks, a. and b. are installed. They are respectivelyof different types. As the production facilities are in operation for 24 hours,
cold water is constantly used. Heat storage operation is not controlled underpredetermined schedules but let go until it reaches the limit.
The accumulated ice is measured by a thickness-sensitive sensor and whenthe maximum amount is detected, the operation of the refrigeratingmachines is stopped.
a. 1,200,000 kcal as Ice (15 tons):
One tank
BUCO
b. 800,000 kcal as Ice (10 tons):
One tank
Ice Bank
3) Cold water piping system
Cold water is distributed through three lines of piping to cool the respective
production processes of Milk, Vitagen and Juice .
a. Vitagen line (Level 3): Cold water pump × 2 (@35 m3/h 7.5 HP) supply
at 0°C, return at 7.0°C
b. Juice line (Level 3): Cold water pump × 2 (@60 m3/h 15 HP) supply at
0°C, return at 5.0–10°C
a. Milk line (Level 5): Cold water pump × 2 (@40 m3/h 10 HP) supply at
0°C, return at 5.0–10°C(4) Specification and operation method of air compressor
The number of compressors in operation out of the 7 installed is controlled by
the pressure in the receiver tank (discharge pressure: 8.44 kg/cm2). The sameenergy conservation method as that employed in Japan had already been adopted.
The air compressor piping is shown below.
a. 50 HP screw compressor × 4 5.95 m3/min Kaesar
b. 25 HP screw compressor × 3 IR ML

II-22

Cooler
クーラー

Kaesar 50HP

IR ML 25HP

Kaesar 50HP

IR ML 25HP

Kaesar 50HP

IR ML 25HP

ドライヤー

Cooler
ク
ーラー

ドライヤー

Dryer

Dryer

Kaesar 50HP

レ
シ ー バ ーtank
タ ンNo.
ク No.1
Receiver1

レ
シ ー バ ーtank
タ ンNo.
ク No.2
Receiver2

Figure II-4-6

Air Compressor Piping(5) Specification and operation method of electricity receiving/ transforming
facilities
The electricity consumption status at the time of our visit was as follows:(Actual results of October 2003)
Annual electric consumption: 9,800,000 kWh
Monthly electric consumption: 850,000 kWh
Contract demand:
1,650 kW
Maximum electricity use:
1,736 kWPower factor:
96%
Leveling of power consumption is quite advanced.
a.
4.2

2.0 MVA

transformer × 2

Energy Audit of SCM(1) Specification and operation method of air handling unit
There are two air-conditioning systems in the factory; one is for the production
room and the other one for the blending room. They are in operation throughout
the year because of the necessity to control humidity. The air conditioning
system consists of a condensing unit and direct expansion cooling coil air

II-23

conditioning equipment The outlet temperature of the air-conditioning
equipment is assumed at 10℃ to keep room temperature at 20℃ and humidity
at 55–65% RH.
1) Air handling unit
5 air-conditioners of the same specification are installed. The huge space ofthe factory is air-conditioned by these 5 machines.
Directly reading current meter values• Production room
300A (400 V) = 208 kW
2 air conditioners are in operation• Blending room
90A (400 V) = 62.3 kW
1 air conditioner is in operation
As we could not obtain information on the specification, it is assumed asfollows;
Blower:Capacity 54,000 CMH
Power 30 kW
Cooling coil:
210,000 kcal/h
Schematic diagrams of air conditioning system are shown below.

コンデンシング
Condensing unit
(30kW × 2)
ユニット（30kW×2)

コンデンシング
Condensing
unit(30kW × 2)
ユニット（30kW×2)

Blendingroom
調合室

Air conditioning
equipment
空気調和機

Air conditioning
equipment
空気調和機

Blending room
air conditioner
調合室系統空調機
2 sets (1 constantly
in operation)（2set常時1台運転)

Figure II-4-7

a.

b.

Production
room
製造室

Production room air conditioner
製造室系統空調機
3 sets (2 for manufacturing time and one for night time)（3set常時2台運転夜間1台運転)

Air Conditioning System

Air-conditioning for the production room
Out of the 3 direct expansion system cooling coil air conditioning
machines, 2 sets are used during the manufacturing time and only one
set is used during the night time.
Air-conditioning for the blending room
Out of the 2 direct expansion system cooling coil air conditioning
machines, 1 set is in operation during the manufacturing time and thenight time.

2) Condensing unit
40 HP × 2 Comp. air-cooled condensing unit: 5 sets
They are respectively linked with air conditioning machines.

II-24

(2) Specification and operation method of air compressor
Out of the 4 air compressors currently possessed, only 1 compressor of 125 HP
is in operation. As there is a lot of unused capacity, unloading is repeatedbetween the maximum pressure of 8.3 kg/cm3 and the minimum pressure of 7.6
kg/m3 (at about 15- second intervals)
Directly reading current meter values
At loading:
180 A (400 V) = 125 kW
At unloading:
140 A (400 V) = 97 kW
a. 125 HP Screw compressor: 2 (1 is brand new and unused )b. 50 HP Screw compressor:
1 (Out of service now)c. 30 HP Screw compressor:
1 (Out of service now)31
d. 2.5 m Receiver tank:
Air compressor piping is shown bellow.

プロセス
Process

125HP
125HP

125HP
Unused125HP未使用
3

Receiver tank (2.5 m )レシーバータンク（2.5m3）
50HP50HP休止
Out of service

30HP30HP休止
Out of service

Figure II-4-8

Air Compressor Piping(3) Specification and operation method of lighting equipment
For lighting in the factory, ceiling lights of 400w are used and there are switches
for respective lights. Currently, all lights are turned on during the operation timeand spotlighting is used at the packing machine area.
(4) Specification and operation method of electricity receiving/transforming
facilities
The electricity consumption status at the time of our visit was as follows:(Actual results of October 2003)

II-25

Monthly electric consumption: 289,000 kWh
Contract demand:
850 kW
Maximum electricity use:
749 kW
Power factor:
96%
Load factor:
52%
Electricity is received in two lines with 2 sets of 2.0 MVA transformers

II-26

5.

Energy Measurement and Survey Results

5.1

Audit and Measurement Results of Co. C(1) Energy management
ISO 9002 has already been conformed to and monitoring and monitoring records
are properly managed. However, data collection that is essential for energy
management is no enough. Utilization of collected data is not proper either.
The establishment of a method of energy management and goal setting, thedetermination on monitoring items based on the established method and thegoals set, and the assessment of the results will be challenges for them.
(2) Steam-related equipment
1) Boiler pressure
While the boiler pressure is set at 10 kg/cm2, the user’s maximum demandpressure is 6 kg/cm2. Even with the long extended pipeline, it will bepossible to lower the present pressure. To realize it, the following measures
should be considereda.

Enhancing thermal insulation of steam piping
The layout of the existing steam piping is very complicated due to the
expansions of the factory, etc. In the on-site survey, we found that thethermal insulation of the main piping was almost properly done andrepaired. However, the heat retention of valves, flanges, etc. is notenough or there is no thermal insulation. In addition, we could not
grasp the actual condition of the branch piping at all. If heat loss frompiping is prevented and drain from piping is reduced, the current piping
may be all right for increased flow rates resulting from the lowered
steam pressure.

b.

Removal of unused piping
As it is a factory with a long history behind, removal, renewal andaddition of equipment have been repeated. Unused piping, etc. isconsidered to be everywhere, causing heat losses. They should be
removed.

2) Vacuum condenser
We were explained that the steam consumed in the condensing process of
Sweeten Condensed Milk was 700–1000 kg/h. However, the feed volume
per batch was not constant and it appeared that workers adjusted the volume

II-27

by their experience. As the current operation is intended to reduce thecondensing time, it should be reviewed from a standpoint of energy
conservation. The matters to be studied are summarized below.
a.

Start ejector
The start ejector is normally installed to exhaust air in the system at the
beginning of the operation. Thus, it should be stopped when thecondenser’s internal pressure goes down below the standard level. (Asthe steam outlet is open to air, the system vacuum degree is subject tothe starter ejector while it is working)b.

Establishment of operation conditions and management criteria
It is necessary to grasp steam consumption by measuring feed volume
and setting an operation schedule and management criteria. We checkeda chart where steam consumption was plotted by the hour. But it was
old data and we heard that it was not relevant to the current condition
because the feed volume increased.

c.

Review of steam ejector
While a steam ejector system can provide required vacuum degrees in ashort time, it consumes large volumes of steam and should be reviewed
in terms of energy conservation. If appropriate operation conditions are
established, it may be possible to gain required vacuum degrees byvacuum pump.

d.

Prevention of air from entering the system
It is undesirable that the air sneaks into the system during the system atwork in terms of productivity and energy conservation. It is necessary
to understand the present condition and take preventive measures.

II-28

Not in normal operation
Air

Air

Start ejector

Steam

2nd ejector

3rd ejector

1st condenser

2nd condenser
1st ejector

Prevent air inflow

Vacuumcondenser

Figure II-5-1

Review from a energy
conservation standpoint

Establish operation
management criteria

Improvement of Vacuum Condenser

3) If it is assumed that about 20 steam traps are installed in each line, a total
number of drain traps and drain recovery systems for the 5 lines combined
will be more than 100 in the entire factory. On the site, steam leakage wasoften observed. It is important to carry out regular checkups and repairs.
As drain recovery is not carried out in the lines of Sweeten Condensed Milkand Evaporated Milk, it should be recovered as much as possible with the
installation of drain recovery tanks, etc.
(3) Cold water system
In Singapore, although there aren’t incentives in electric rates for the thermal
storage system as in Japan, it is necessary to reduce electric consumption
through the efficient operation of cold water system. Costs of refrigerating waterand the measures to reduce costs are discussed below.
1) Operation of ice thermal storage tank
The log sheets of the cold water system show that accumulated heat (cold)
increases from about 7 A.M. and storage is completed at about 2 P.M. We
checked it on the site and found that heat (cold) storage and heat (cold)
release were controlled only by the thickness of the ice produced, not underII-29

a predetermined schedule. In other words, when the freezing machine’s
capacity is not used up as a result of the changing production demand, heat(cold) is stored and when the capacity is used up, heat (cold) is released. We
heard that thermal storage was in operation 3 hr/d actually.
Judging from the survey results, this thermal storage system is intended for“supply of 0℃ water” rather than “storage”. Thus, the freezing machine has
reserve capacity to the load of the process and is not effectively functioning
for “peak-cut” of electricity use and reduction in freezing equipment cost
expected from the introduction of a thermal storage system. In addition, offpeak electric rates are not so advantageous compared to the peak rates forproactively promoting thermal storage and save electricity costs.
It appears that 2 different types of thermal storage tanks are connected inparallel with each other by piping and controlled under their common
operation method. They should normally have different operation methods
and management criteria. Although we could not confirm it, we assume that
improvements are worth making.
2) Cold water piping system
There are 3 cold water piping systems for: Vitagen line (level 3), Juice line
(level 3) and Milk line (level 5). Only the system for Vitagen is an openloop piping having a cold water return tank and other systems are closedloop piping. The respective cooling water pumps are in operation
throughout the production time and consume large quantities of electricity.
a.

b.

Cooling water pump control
Cold water is supplied to the respective heat exchangers to cool
products and tanks. Its flow volume is controlled either automatically or
manually. Although we could not grasp changes in flow volume, theeffects of inverter control should be studied.
Preset chilled water temperature
For a cooling purpose, 0°C chiller water and about 30°C cooling towerwater are used in the process. Cooling tower water is used for the
primary cooling of high-temperature products and chiller water is used
for the secondary cooling so as to save energy.

(4) Receiving/transforming equipment
1) Operation of transformer
Based on the electric charge slip for October 2003, the capacity of theelectricity receiving equipment is calculated as follows: 1736 kW/0.96 =1,808 kVA. Electricity is received via 2 MVA transformers.

II-302) Improvement in power factor
The current power factor is about 96% and may be further improved.
5.2

Audit and Measurement Results of SCM(1) Energy management
Equipment directly related to production is maintained well and operated in agood condition. However, efforts for energy conservation are not sufficient andno management criteria and no goals for monitoring and energy conservation
have ever been set. As we could recognize potential energy conservation evenfrom a short-time audit, we believe that great effects can be expected if a proper
energy management methodology is established, and goal setting, thedetermination on monitoring items based on the methodology and the goals set
and the assessment of results, etc are implemented.
(2) Air conditioning
A strict humidity control is required because raw materials and products handled
in the factory are powder and fine particles. Currently the entire spaces of the
production room and the blending room are respectively air-conditioned. As
regards the air conditioning of the production room, if local air-conditioning is
introduced for the area of packing machines, energy consumption can be reduced.
Humidity in the production room is not even, causing overcooling in some areas.
Further energy conservation can be expected from the equalization of the air
distribution and the installation of multiple sensors.
(3) Air compressor
In the first site survey, we made comments on the management of the number ofcompressors to put in operation. At the time of the second survey, a plan to shift
from the operation with only one compressor of 125 HP to the controlled
operation with 3 compressors of 30 HP, 50 HP and 50 HP was underway.
(A plan to purchase a new compressor of 50 HP and transfer 2 compressors of
125 HP to affiliated companies)(4) Lighting
Currently no energy conservation in lighting is studied. It is comparatively easy
and cheap to take improvement measures and worth while to study them.

II-31

(5) Operation of transformer
Based on the electric charge slip for October 2003, the capacity of the electricity
receiving equipment is calculated as follows: 749 kW/0.88 = 851 kVA.
Electricity is received via 2 MVA transformers.
If equal load on each transformer is assumed, their respective load factors are
851 kVA/2/2 MVA = 0.21 (21%)
The operation efficiency is 96–97%. When the load factor goes below 40%, itshould be considered to stop the operation of one transformer.
1) Improvement in power factor
The current power factor is about 88% and may be further improved.

II-32

6.
6.1

Energy Conservation Proposals and Expected Effects
Proposals to Co. C and Expected Effects(1) Review of boiler pressure setting
The maximum steam pressure required in the process is 6kg/cm2. It is possible tolower the set boiler pressure to 8 kg/cm2 by enhancing heat insulation of thesteam piping. If boiler pressure is lowered to 8 kg/cm2;
Assumed to be unchanged• Boiler efficiency:
2• Steam latent heat for 10 kg/cm : 477.2 kcal/kg
484.5 kcal/kg• Steam latent heat for 8 kg/cm2:
1,300,000 S$• Fuel cost (annual):• Annual fuel saving = approx. 1,300,000 S$ × (1-477.2 kcal/kg / 484.5 kcal/kg= 19,600 S$/year(2) Enhancement of heat insulation of piping and prevention of heat loss
Steam saving amount is estimated regarding the main steam piping the length ofwhich is clearly known.
85%• Boiler efficiency:
9,200 kcal/L• Calorific value of light oil:
0.406 S$/L
• Light oil unit price:
2.2 S$/m2 (0.0022 S$/L)• Feed water unit price:6552 hr/y• Annual operation time:477.2 kcal/kg• 10kg/cm2 steam latent heat:
4,0827 kcal/hr (See the table below)• Reduced heat loss:
Table II-6-1

Piping Size

Unit

Pipe

Heat Loss from
Bare portion
kcal/hr.m 650
Thickness of
Insulationmm
50
Heat Loss after
Insulation
kcal/hr.m 65
Reduced Heat Loss kcal/hr.m 585

Estimation of Heat Losses of Steam Piping
80A

100A

150A

200A

Valve Flange Pipe

Valve Flange Pipe

Valve Flange Pipe

Valve

Flange

813

273

850

1080

332

#### 1950585#### 2856

748

50

50

50

50

50

50

50

50

50

50

50

81
731

27
246

85
765

108
972

33
298

130
195
#### 1755

59
527

170
286
#### 2570

75
673

Length of Piping

ft

242
74

460
140

Number of Valveand Flange
Total Heat Losskcal/hrAssumption;
Number of Valves
Number of Flange

1 Valve for each 30 m of Piping
1 pair Flange for each 10 m of Piping

2
1793

7
1808

211
64
5
4529

II-33

14
4172

460
140
2
3752

6
3377

Enthalpy of 10kg team
Total Steam Loss

5
#####

14
9414
40827

478 kcal/kg
85 kg/hr

Annual fuel cost saving amount= 40827 kcal/hr / (9200 kcal/L × 85%) × 6552 hr/y × 0.406 S$/L = 13900 S$/y
Annual feed water cost saving amount= 40827 kcal/hr / 477.2 kcal/L × 6552 hr/y × 0.0022 S$/L = 1230 S$/y••

Enthalpy of 70°C feed water: 70 kcal/kg
Enthalpy of 10 kg/cm3 steam: 634 kcal/kg

Steam cost (estimate) = 0.406 S$/L / (9200 kcal/L × 85% /(634 kcal/kg - 70 kcal/kg)) + 0.0022 S$/kg= 0.0315 S$/kg
Although we could not confirm the entire piping system in the current audit, we
suspect that there is more heat loss from branch steam piping. Thus, the potential
for energy conservation by strengthening heat insulation of the piping may be
about several times of the above values.
(3) Improvement of vacuum condenser
Steam ejectors for the vacuum condenser consume large quantities of steam. The
effects expected from the replacement of steam ejectors by vacuum pumps havebeen estimated. However, as the operation conditions for the current vacuum
evaporator are not clear, the following assumptions have been used. The system
structure with vacuum pumps is shown below.
大
気
Air
蒸気
Steam
第
2nd
2エejector
ジェクター

真Vacuum
空濃縮器

condenser

Figure II-6-1

Roots
vacuumルーツ
真 空 ポpump
ンプ

22 kW
22kW

Water
seal
pump
水封式
真空
ポンプ

30 kW
30kW

第 3エ
3rdジejector
ェクター

第2nd
2コ condenser
ンデンサー

Study of Vacuum Condenser Using Vacuum Pumps

II-341) Vacuum pumps to be used
a. Operation• In 15 minutes from the starting of operation of vacuum ejectors,
40°C saturated steam pressure (55.32 mmHg) is reached. Steamconsumption during that time is assumed at 900 kg/hr.
• After 15 minutes, the 1st ejector is stopped and only the 2nd and3rd ejectors are put in operation. Steam consumption during thattime is assumed at 300 kg/hr. When 20°C saturated steam pressure(17.54 mmHg) is reached, the condensation is completed.
b.

Initial state of raw material• Temperature 60°C
• Latent heat of vaporization 563.3 kcal/kg• Specific heat 1.0 kcal/kg°Cc.

Estimation of condensate water volume
As we could not confirm the required volume of condensate water on
the site, we have estimated as follows:
Calculations of volumes of feed raw material, partly-finished productand required condensate water for production of 4,200 L of product:
X60L• Feed raw material (60°C):• Partly-finished product (40°C): X40L
The required condensate water is gained from the following formulae(A)(X60 -X40) × 563.3 kcal/kg = X40 × (60°C -40°C) × 1.0 kcal/kg°C(X40-4200L) × 563.3 kcal/kg = 4200L × (40°C -20°C) × 1.0 kcal/kg°C (B)From (A) and (B),
X60 = 4503L, X40 = 4349L
The required condensate water volume= X60 - X40 = 4503L - 4349L = 154L
This amount corresponds to steam of 191.6 m3 in a standard state.
d.

Calculation of necessary air volume displacement of vacuum pump
If space capacity of the evaporator is assumed at 5.0m3, the required air
volume displacement will be calculated as follows;
Air volume displacement= (191.6 m3 + 5.0 m3) / 15 min × 1n (760 mmHg / 55.32 mmHg) × 60 min/h= 2008 m3/he.

Vacuum pumps to be used
In the light of vacuum, a combination of a roots vacuum pump and awater seal vacuum pump is employed.
According to the maker’s catalog, their respective electric motor
powers are:

II-35

Roots vacuum pump:
22 kW
Water seal vacuum pump:
30 kW
The installation cost if about 9,300,000 yen in Japan’s market price(approx. 143,000 S$)
2) Estimated effectsa.

Reduction in steam consumption
Steam cost:
0.0315 S$/kg as already calculated in theprevious item (2)Annual operation hours: 6552 hr/y (273 d/y)
No. of batches:
32 batches/dReduction in steam consumption= (900 kg/h - 300 kg/h) × 15/60h × 32 batches/d × 73 d/y= 1,31,0400 kg/yReduction in steam cost
= 1,310,400 kg/y × 0.0315 S$/kg = 41,277.6 S$/yb.

Electric consumption of vacuum pumps
Electric cost:
0.112 S$/kWh (from the survey report)
Electric consumption of vacuum pumps= (22 kW + 30 kW) × 15/60 h × 32 batches/d × 273d/y= 113,568kWh
Electric power charge= 113,568 kWh/y × 0.122 S$/kWh = 13,855.3 S$/y
Total cost reduction effect is(41,277.6 S$/y - 13,855.3 S$/y = 27,422.3 S$/y)(4) Inverter control of cooling water pump
In the factory, 3 pumps (5 kW, 7.5 kW, 11 kW) for 3 cooling water lines areconstantly in operation. We have estimated effects of the introduction of inverter
control with an assumed average load factor at 60%.
We assumed a constant pressure in piping for inverter control as the figures
below shows.
It is desirable that a pressure sensor is installed as distant as possible. (point C in
the illustration)

II-36

⊿ Pac
⊿ Pab
VSD

PC
a

PC
b

PC
c

P (Pressure)M

Pump
Performance
CourvePower∝ RPM3

100

a
b
c

100

Q (Water Volume %)Figure II-6-2

Inverter Control of Cooling Water Pump

1) Estimated effects
a. Reduction in electric consumption
Electric consumption rate under valve control at 60% load factor:
90%
Electric consumption rate under inverter control at 60% load factor:
30%
Reduced power consumption= (5 kW + 7.5 kW + 11 kW) × (90% - 30%) × 552 h/y= 92383.2 kWh/yReduced power charge= 92383.2 kWh/h × 122 S$/kWh = 11270.8 S$/y

II-37

b.

Investment in equipment
Inverter (3 sets)
Controller
Remodeling of power board
Installation cost
Total

350,000 yen
750,000 yen?
200,000 yen
1,300,000 yen (= 20,000 S$)(5) Improvement of transformer efficiency
If the 2 transformers (2 MVA × 2) are in an evenly load-balanced state;
Load factor is: 1808 kVA / 2 / 2 MVA = 0.45 (45%) and efficiency is 97-98%.
Under the condition of load factor below 40% each, one transformer should be
stopped.
1) Estimated effects
If it is assumed that the load factor drops below 35% and the efficiency
decreases by 1%,
Annual electric consumption: 9,800,000 kWh/yPower factor:
96%
Average electric power cost: 0.122 S$/kWh
Reduced electric consumption:
9,800,000 kWh/y / 96% × % = 102,083 kWh/yReduced electric power charge:
102,083 kWh/y × 0.112 S$/kWh = 12,454 S$/y.
(6) Improvement of power factor
The electric power charge for October 2003 includes a charge for reactive power.
The yearly total amount of the charge for reactive power will be measurable. It is
worth reviewing.
Reduced electricity charge = 147,386 S$ × 12 = 17,686.32 S$/y
6.2

Proposals to SCM and Expected Effects(1) Local air conditioning
The production room has an area of 2500 m2 and its ceiling is 6.7 m high. It is ahuge space (Space capacity: 16,750 m3). In that space, it is a limited area towhich raw materials, etc. in fine particles are actually exposed. If this area ispartitioned and locally air-conditioned, energy consumption may be reduced.
The basic concept is as follows;

II-38

Current
status現状

After improvement
改善後

Air conditioning
equipment
空気調和
機Packaging
包装機
machinearea 周 辺

Air conditioning
空 気 調 和equipment
機

Generalconditioning
全air
体空
調

Drifting
air きconditioning
成行
空調

Production
製room
造室

Figure II-6-3

Production
製room
造室

Basic Concept of Local Air Conditioning System

1) Estimations of the area for local air conditioning and electricity used for air
conditioninga. Estimations concerning the area for local air conditioning
Floor area:
720 m2
Necessary ceiling height: 4.5 m
Cubic capacity of the area for local air conditioning= 720 m2 × 4.5 m = 3,240 m3b.

Estimations of electricity used for air-conditioning
Operating durations of the air conditioning equipment were estimatedbased on the assumption of yearly manufacturing days and daily
manufacturing hours at 260 days/y and 8 hours/d respectively.
Two units are in operation (during manufacturing):
Operating hours for 2 units = 260 days × 8 hours/d = 2,080 h/y
One unit is in operation (during non-manufacturing):
Operating hours for one unit
= 365 days × 24 hours/d - 2,080 h = 7,045 h/y
We assumed load factor of 70% and that load of manufacturing
equipment would not significantly affect load on air conditioning
equipment because they are packaging and conveying equipment.
Current air conditioning electricity= (208 kW × 2,080 h/y + 104 kW × 7,045 h/y) × 70%= 815,724 kWh/yLocal air conditioning electricity= 815,724 kWh/y × 3,240 m3 / 16,750 m3 = 157,788 kWh/yReduced electricity= 815,724 kWh/h - 157,788 kWh/y = 657,936 kWh/yII-39

2) Estimated effects
The above calculations show that a significant energy conservation effect is
expected. However, as measures for the currently air-conditioned area andprevention of incoming heat must be taken into account, the effect should be
estimated at 50%
Reduced electric consumption = 657,936 kWh/y × 50% = 328,968 kWh/yReduced electric charge = 328,968 kWh/y × 0.122 S$/kWh = 40,34 S$/y
(2) Equalization of temperature distribution
If a damper is set at each blowout outlet of the duct and the temperature iscontrolled by individual temperature sensors, an even temperature distribution
may be possible. In addition, by introducing inverter control of revolution
frequencies of fans of air conditioners, further energy conservation can be
expected (VAS control). The basic concept is shown below.

VSD

Inverter

インバーターM

給気ダクト
Air supplyduct
Air conditioning
空 気 調 和equipment機

静圧 セpressure
ン サ ー sensor
StaticRoomtemperature
室温計
indicator

Room
temperature
室温計
indicator

ゾ ー ンAA
Zone

Figure II-6-4

Roomtemperature
室温計
indicator

ゾ ー ンBBZone

ゾ ー ンCC
Zone

Basic Concept of Equalization of Temperature Distribution(3) Improvement of operation of air compressor
Change to a no. of units-controlling operation with 3 air compressors of 30HP50HP-50-HP is planned.
(4) Energy conservation of lighting
Lighting fixtures are fixed on the ceiling of the production room and all lights
are on during manufacturing. It will be possible to save energy by grasping thecurrent energy consumption for lighting and setting of appropriate standards ofillumination.

II-40

(5) Improvement of transformer efficiency
While the capacity of the receiving equipment is 749 kW / 0.88 = 851 kVA, thecurrent transformer load factor is only 20%. By shifting to one-transformer
operation (Out of the two, one is reserved for backup), the efficiency increases
by about 1%. If electricity consumption and power factor are assumed
respectively at 285,000 kW and 88%,
Reduction in electric consumption= 285,000 kWh × 12 m/y / 88% × 1% = 38,864 kWh/yReduction in electric charge = 38,864 kWh/y × 0.122 S$/kWh = 4,941 S$/y(6) Improvement of power factor
Although we were reported a 99% power factor in the site survey, the value
estimated from the electric power charge slip is 88%. However it does notinclude a charge for reactive power. (It is necessary to check electric power
charge system)
6.3

Summary of Energy Conservation Effects(1) Summary of energy conservation effects for Co. C.
Table II-6-2
Proposals

Review of boiler pressure
settingEnhancement of heatinsulation of piping andprevention of heat loss

Improvement of vacuum
condenser
Inverter control of coolingwater pump
Improvement oftransformer efficiency
Improvement of power
factor
Total

Energy Conservation Effects for Co. C.
Estimated
effects
19600 S$/y
15130 S$/y

Equipment
investment
Not
required
Estimation
not possible

27422 S$/y

143000S$

11270 S$/y

20000S$

12454 S$/y

Estimation
not possible
Estimation
not possible

17686 S$/y103562 S$/y

II-41

Remarks

Was estimated only about
the main piping. Further
effects to be expected from
improvements on branchpiping.
Replace steam ejectors byvacuum pumps

(2) Summary of energy conservation effects for SCM
Table II-6-3
Proposals
Local air conditioning
Equalization of temperature
distribution
Improvement of operation of
air compressor
Energy conservation oflighting
Improvement of transformer
efficiency
Improvement of power factor

Energy Conservation Effects for SCM
Estimated
effects
40134 S$/y
Estimation
not possible
In progress
Estimation
not possible
4941 S$/y
Estimation
not possible

II-42

Equipment
investment
Estimation notpossible
Estimation notpossible
In progress
Estimation notpossible
Estimation notpossible

Remarks

7.
7.1

Guideline for Promotion of Energy Conservation and Audit Manual
Outline of Production Process
The production process of food factories is often distinguished from manufacturing
processes of other industrial products in the following points;•
A large number of production items•
Variation in ingredients•
Micro organism management
The batch process is generally used. In the food manufacturing industry, it is difficult
to determine energy unit consumption that is used for energy management except infood material manufacturing industry (flour, sugar, fat and oil, etc.), beer brewery,beverage manufacturing, etc. In addition, as the same product is not always
manufactured in the same process, macro-management based on the comparison ofunit energy consumption among competitors is often inapplicable. In this sense, itwill be necessary to understand the current energy consumption status by factory,building, production line, etc. and prioritize improvements of the respective processes
based on the potential for energy conservation and financial and human resources inorder to achieve improvement one by one. The goals of improvement will be
determined based on the analysis of daily log data. The manufacturing processes ofthe major products of the factories we visited for audits are shown below.
(1) Processes used in the dairy products factory of Co. C
1) Sweeten Condensed Milk
Major energy consuming processes are as follows;a. Steam
Vacuum condenser, pasteurizer
b. Electricity Homogenizerc. Cold water Cooling for inter tanks
Powdered milk/sugar/oil/water

Raw mater ｃal tank

Homogenizer

Pasteurizer

Vacuumcondenser
No. 1

Vacuumcondenser
No. 2

ShipmentLabeler
Middletank
No. 1

Middletank
No. 2

Middletank
No. 3

Middletank
No. 4

Figure II-7-1

Middletank
No. 5

Filler
350cpmCartoningmachineProcess of Sweeten Condensed Milk

II-43

Palletizer

2) Evaporated Milk
Major energy consuming processes are as follows;a. Steam
Pasteurizer, Rotary sterilizer
b. Electricity
Homogenizerc. Cold water
Cooler, Cooling for inter tanks
Powered milk/
oil/water

Mixing ｃtank

Cooler No. 2
Cooler No. 1

Balance ｃtankPasteurizer

Inter
tank
No. 1

Homogenizer

Inter
tank
No. 2

ShipmentLabeler
CartoningmachineSterilizer
250cpmFillerFigure II-7-2

Inter
tank
No. 3

Palletizer

Process of Evaporated Milk

3) Pasteurized Milk
Major energy consuming processes are as follows;a. Steam
Pasteurizer, Sterilizer
b. Electricity
Homogenizerc. Cold water
Sterilizer, Cooling for inter tanks, Cooler
Powered milk/oil/water

Sterilizer
Mixingtank
No. 1

Pasteurizer

Homogenizer

Mixing ｃ
tank
No. 2

Inter
tank
No. 1

Inter
tank
No. 2

Inter
tank
No.3
Homogenizer

Cooler

Inter
tank
No. 1

Inter
tank
No. 2

Inter
tank
No. 3

Inter
tank
No. 4

Refrigerating/shipment

Inter
tank
No. 5
FillerFigure II-7-3

Container
packing machine

Process of Pasteurized Milk

II-44

(2) Processes used in SCM
The major energy consuming process is shown below.
1) Coffee mix/packaging process
a. Electricity
Air conditioning, Air compressorRawmaterialA

RawmaterialB

RawmaterialC

RawmaterialD

Rawmaterial
E

Weighing/
Mixing machine

Packagingmachine A

Packagingmachine B

Figure II-7-4

7.2

Packagingmachine C

Box packing/Shipment

Process of Coffee Mix

Guideline for Promotion of Energy Conservation and Audit Manual
On the site, we explained identification of problems by checklist and guideline forpromotion of energy conservation using slide pictures. Relevant and necessary slides
are excerpted from those used on the site and attached hereto as Attachments.

II-45

Attachment
Attachment II-1 Check Items at Factory Energy Audit (Excerption frompresentation slides used in the field)
Attachment II-2 Guideline for Promotion of Energy Conservation (Excerption
from presentation slides used in the field)

II-46

添付資料Ⅱー１

Check Items
at
Factory Energy Audit

The Energy Conservation Center, Japan

ECCJ

1

Items to be Checked for Factory Energy Audits
1. General Management (1/2)
1. Energy management• Organization setup and personnel training• Consistency with environmental management• Energy conservation targets and investment budget• Mid-and-long term planning• Use of public preferential system• State of energy conservation implementation

2. State of measuring
and recording• State of installation and use of measuring instruments• State of maintenance and checks for measuring instruments• Implementation of periodic measurements and recording

3. Maintenance andmanagement ofequipment• Periodic and daily checks• Repairing leaks (water, air and steam)• Thermal Insulation• Equipment cleaning (filters, strainers)

4. Energy consumption
management• State of daily record keeping• Daily consumption volume and daily load curve• Monthly consumption volume and year- on- year comparativegraphs

ECCJ

2

II-47

1. General Management (2/2)
5. Managing major
products by energy
intensity• Energy intensity against shipping value• Energy intensity against production volume

6. Environment related
management• Prevention measures against global warming
State of reduction measures against CO2 emission• Utilization state of the energy conservation, recycle support
law (energy conservation measures, promotion using recycle
resources, measures against ozone layer destruction:
introduction of freon-free type equipment, etc.) → presence of
project application, projected time
• Using state of “LCA” (Life Cycle Assessment)(procurement → production → use → disposal/recycle)•Disposal of wastes: measures for volume reduction,
segmentation, resource recycling• Waste water treatment• LCA: Evaluation of effect on environment in an overall flow
(materials procurement, production, uses, disposal andrecycle)7. Process
improvement• Operation improvement• Line reviews• Use of continuous production, higher efficiency, etc.

ECCJ

3

2. Air Conditioning and Cooling Systems (1/2)
1. Operation
management• Optimization of setting temperature and moisture• Reduction in intake of outside air• Management of unit numbers in operation of heat source
equipment• Change in temperature setting at cold water outlet• Operation on schedule• State of shutoff of outside air inflow and ventilation• Radiation heat insulation for high temperature equipment

2. Energy conservation
measures• Enhancement of building insulation, shield against insolation• Use of outside air• Recovery of exhaust heat, heat pumps• Revolution control (VAV etc.)• Local cleaning, local exhaust ventilation• Reduction in air-conditioning volume• Use of ice thermal storage system

ECCJ

4

II-48

2. Air Conditioning and Cooling Systems (2/2)
3. Operation
management forcooling equipment• Operating power of refrigerators• Inlet/outlet pressures of refrigerant• Inlet/outlet temperature and pressure of water

4. Operation
management for
auxiliary equipment• Operating power of cooling towers• Water quality control (Electric conductivity)• Pump operation power (water volume, lifting range)• Higher efficiency

5. Cold
insulation/freezing
equipment• In/out control• Thermal insulation control

ECCJ

5

3. Pumps, fans, compressors, co-generations, etc.
1. Operation
management forpumps and fans

2. Operation
management forcompressor systems• State of valve opening/closing• Route modification (piping and ducts)• Flow-rate and operating pressure• Design margin check• Control of revolution and number of units in operation• Type review (screw/reciprocal/ blower)• Capacity and model matching• Reducing discharge pressure and final working pressure• Dividing high/low pressure lines• Ventilating systems and surrounding temperature• Review of piping size and route• Air receiver installation• Number control of units in operation• Capacity optimization control• Countermeasures to leakage• Use of waste heat

ECCJ

6

II-49

4. Boilers, Industrial Furnaces, Steam Systems,
Heat Exchangers, Waste Heat, Waste Water, etc. (1/2)
1. Managing
boiler/furnace
combustion• Managing air ratio and exhaust gas

2. Boiler/Furnace
operation & efficiency
management• Load factor & state of starting/stopping

3. Boiler/Furnace
insulation and radiatingheat prevention• Furnace wall and duct temperature

4. Boiler/Furnace exhaustgas temperature
management andwaste heat recovery
5. Operation
management for
steam• Burner, fuel and draft systems• Automatic combustion control system• Regenerative combustion system• Fuel conversion• Controlling number of units in operation• Heat efficiency, heat balance, heat distribution• Water quality and blow management• Insulation and insulation materials (thermal storage loss)• Seals on openings and furnace internal pressure• Exhaust gas temperature• Heat recovery (Feed water and air pre-heat)• Exhaust gas circulation• Dryness and carry-over• System setting in steam pressure and temperature• Steam flow-rate

ECCJ

7

4. Boilers, Industrial Furnaces, Steam Systems,
Heat Exchangers, Waste Heat, Waste Water, etc. (2/2)
6. Managing steam leaks
and thermal insulation• Piping system, tanks, etc.

7. Optimizing steam
piping systems• Route and piping size
• Eliminating unneeded pipes• Integrating multiple steam lines

8. Load leveling in steam
system• Accumulator installation• Modification from steam ejector to vacuum pump
• Measures for load side
• Steam pressure recovery (back pressure turbine)• Steam trap management• Drainage recovery point and system

9. Recovery and useof steam drainage• Load side equipment

10. Operation management
for heat exchangers• Model adequacy• Adequacy of use and heating medium• State of system maintenance (fouling and pressure loss)• Temperature of heating medium and materials heated

11. Reducing waste heat
and waste water• Recovery heat from hot water• Streamlining waste air ducts•Circulating cooling water for reuse• Managing impurity concentration in water

ECCJ

8

II-50

5. Power Receiving/Transforming Equipment, Motors, Lighting
and Electric Heating Systems (1/2)
1. Power receiving
equipment management• Managing demand, load factor and power factor• Managing consumption• Charges management (contracted power)• Use of nighttime power

2. Substation facilities
management• Transformer capacity and voltage• Demand factor and load adjustment• Unneeded loads shutoff

3. Motor capacity andoperation management• Equipment capacity, voltage, number of units in use• Revolution control• Non-load operation stop

4. Operation managementof lighting systems• Use of high efficiency lamps and fixtures• Use of automatic flashing and localized lighting• Light installation location and divided circuitry• Proper illumination management• Turn off lights when unnecessary and use daylight• Cleaning or changing lighting fixtures

5. Operation managementof electric heating
systems• Improvements in supply voltage and power factor• Material preheating at product in/out• Temperature and heating management• Insulation management• Load factor improvement• Continuous operation• Reuse of exhaust heat
9ECCJ

5. Power Receiving/Transforming Equipment, Motors, Lighting
and Electric Heating Systems (2/2)
6. Load levelingmeasures• Reviewing operating pattern (operating time, operation rate,load factor, etc.)• Adaptation with proper equipment (accumulator, absorbing
type cold/hot water equipment)

7. Electric power
adjusting contracts,
etc.

• Charges management (use of nighttime electricity)- Heat storing contract- Contracts in accordance with seasons and time zones- Peak time adjusting contract

8. Co-generation
introducing plans• Equipment type, capacity, fuels• Seasonal load fluctuation• Using rate, heat/electricity ratio• Checks, spare powers, measures against pollution

9. New energies etc.

• Fuel cell
• Photovoltaic generation• Solar heat

ECCJ

10

II-51

添付資料Ⅱー２

The Present Conditions ofFood Industries in JapanThe Energy Conservation Center, Japan1

ECCJ

Summary of Main Findings of“Walk Through” Audit
Energy management•
To establish good energy management•
To use of monitoring and targeting methodology
Steam System•
To strengthen insulation on piping and valves•
To stop steam leakage•
To reduce steam pressure
To study the use of waste condensate••
To check and maintain steam traps
Power Receiving and Transformer•
To check power factor and load of transformer
To record and check the power consumption•
Fans and Pumps•
To study on adoption of inverters for Fans and Pumps
ECCJ

2

II-52

Summary of Main Findings of“Walk Through” Audit
Refrigeration•
To study of enhanced utilization of ice storage•
To reexamine the set temperature of cold room
Compressed air
To check air leakage•
Lighting•
To study the appropriate luminance at the
separated zone
ECCJ

3

Voluntary Action Plans for EE&C of
Japan Dairy Products Association
Type ofbusiness

Target for battle against
global warmingCountermeasures

1. Regroup / integration of dairy
Dairy
Energy intensity should
factories beyond individual corporate
products
be cut down 0.5% of 1997
frameworks, regroup of transportation
per annual rate of 5 years
method of milk and dairy products[Japan Dairy average between 1998
2. Introduction of energy saving
Products
and 2002,
equipment like boiler/co-generation,
Association]and 1.0% of 1997 shall besaving of energy in refrigerator,
cut down from 2003 tode-CFC2010.
3. Reduction of product defective(Actual achievement
fraction and product scrap, etc. by
was +1.3% in 1998.)
quality and distribution management
4. Review of frequency and a small
amount of deliveries
etc.
ECCJ

4

II-53

Energy Intensity of Food Processing
Factories (1/2)
Type of industry
Plant name
Unit
Fiscal year
Production
kl/yElectricity consumption mWh/yFuel consumption
ml/ySteam consumption
Electricity intensity
kWh/klFuel intensity
l/kl
Steam intensity
t/kl

Beer brewing
All over plant
1,999
2,000
2,001
1,999

Type of industry
Plant name
Unit
Fiscal year
Production
kl/yElectricity consumption kWh/yFuel consumptionl/ySteam consumption
Electricity intensity
kWh/klFuel intensity
l/kl
Steam intensity

Beverage (Soft drink)Kashiwa plant
Akashi plant
2,000
2,001
2,002
2,000
2,001

2,002

117,607
1,785,611

118,725
1,901,395

104,183
1,913,723

229,234
5,495,589

217,497
5,734,760

207,667
5,708,868

2,293,136

2,442,520

2,643,038

5,414,044

5,876,083

5,295,269

15.18

16.02

18.37

23.97

26.37

27.49

19.50

20.57

25.37

23.62

27.02

25.50

2,857,000

2,737,000

Kobe plant
2,000

2,001

2,580,000

410,000

386,000

359,000

117,000

107,000

101,000

143

141

139

41.1

39.1

39.2

113

100

95

0.26

0.26

0.26

5

ECCJ

Energy Intensity of Food Processing
Factories (2/2)
Type of industry
SapporoPlant name
Unit
Fiscal year
2,000
Production
t/y74,451
Electricity consumption mWh/y
10,993
Fuel consumption
kl/y
2,490
Steam consumption
Electricity intensity
kWh/t
147.7
Fuel intensity
l/tn
33.44
Steam intensity
Type of industry
Plant name
Unit
Fiscal year
Productiont/yElectricity consumption mWh/yFuel consumption
kl/ySteam consumption
Electricity intensity
kWh/t
Fuel intensity
l/t
Steam intensity

Atsugi
2,000

Dairy products
Noda
Nagoya2,000
2,000

Fukuoka Yokohama
2,000
2,000

81,27974,82970,79160,55924,203

20,814

14,974

13,253

13,308

10,418

3,297

1,307

1,620

1,545

1,057

256.1

200.1

187.2

219.8

430.4

40.56

17.47

22.88

25.51

43.67

Meat processing
All over plant
2,000
2,001
2,002
132,000
157,081

135,000
154,470

149,000
161,990

19,59920,22826,385

1,188

1,146

1,087

148

150

177

6

ECCJ

II-54

Improvement Items Proposed by Professional Auditors
Total proposed items=11,795

Energy management system
Implementation of measurement & recording
Quality management of used energy
Energy intensity management ofmajor products
Maintenance management for equipment

GeneralGeneral management
management
items
items(3,784(3,784items)
items)

Load leveling measures
Improvement of processes
Energy saving measures
Operation management for air-conditioning& freezing equipment

Air-conditioners,
Air-conditioners,
freezing
freezingequipment
equipment(1,616(1,616items)
items)

Operation management for cooling equipment
Operation management for
auxiliary equipment
Cold insulation & freezing equipment
Operation management forpneumatic equipment
Operation management for pumps & fans

Pumps,
Pumps, fans,
fans, compressors,compressors,
co-generation,
co-generation, etc.
etc.
(1,700(1,700items)
items)

Introduction plans for co-generation

ECCJ

7

Combustion management for boilers& industrial furnaces
Thermal insulation & radiation prevention
Operation, efficiency management
for boilers, industrial furnaces
Exhaust gas temperature management& exhaust heat recovery
Recovery & utilization for steam drain
Management for steam leakage &heat insulation
Operation management for steam

Boilers,
Boilers, industrial
industrial furnaces,
furnaces,
steam
steam systems,
systems, heat
heat
exchangers,
exchangers, exhaust
exhaustheat,
heat,
exhaustexhaust water,water, etc.
etc.
(2,235
items)(2,235 items)

Reduction in waste heat & exhaust water
Optimization of steam piping system
Operation management for heat exchangers
Load leveling for steam system
Operation management forlighting equipment
Management for power receiving equipment
Management for transformers

Power
Power receiving,receiving, transformers,
transformers,
motors,motors, lighting,lighting, electric
electricheating
heatingequipment(2,460equipment (2,460 items)
items)

Motor capacity & operation management
Operation management for electricheating equipment

Ratio to total of proposed items (%)

ECCJ

8

II-55

Audit Result(Average energy-saving rate by industrial Sector)
Audit effect (Energy-saving rate: mean value)
Food manufacturing
Apparel manufacturing
Printing & publishing
Waste disposal
Wood product manufacturing
Rubber product manufacturing
Paper & pulp industry
Chemical industry
Textile industry
Fur manufacturing and processing
Petrochemical manufacturing
Water works
0

2

4

6

8

10

12

Energy-saving rate (%)
ECCJ

9Flow Chart of Energy Management
Establish Organization
Establishmentof organization
Bench Mark
Activity

Setting a Target

Grasp the current Energy use

Get information from
Other Industries or Countries

Management of Energy Intensity

Planning Improvement Measures
ion
Act

PDCA
Cycle

Do

Implementation & Improvement

Plan

Check

ECCJ

10

II-56

Energy Efficiency Improvement in SteamBoilerDistribution

End userType

Pressure

Suitable pressure

Pipe size

Steam trap
and air vent

Drainage

Insulation

Right steam trapping
and air venting

Minimize film
formation

Maximize
condensate return

Temperature
control

Rating matching
Type of burner
Burner controls
Combustion Monitoring
and Control
Adequate water
treatment

Insulation

Heat recovery
from flue gases
On-line cleaning
Heat recovery
from blow-down
ECCJ

11

Recommendation for Steam System

Boiler・ Measurement of Boiler Efficiency
Boiler efficiency is calculated from the amount ofsteam generating, and fuel consumption.
When the amount of direct steam generating
cannot be measured, it judges from the amount ofwater supply.
・ Optimum Air Ratio = 0.21/(0.21-O２)
O2: Measured by Handy Type Oxygen Analyzer
・ To Minimize Supply Steam Pressure
Minimum pressure to satisfy process temperature
・ To Reduce Heat Loss from Boiler Parts
Valves, piping, water level gage, etc
12
ECCJ

II-57

Recommendation for Steam System

Steam Distribution
・ Minimize Leakage
If there is one 2mm hole on 5kg/ cm2 steam
piping, the amount of steam leakage will go up
to 8kg/hr.
・ Maximize Condensate Return・ Improve Insulation Piping and Fittings
25A
80A
100A
Pipe Valve Pipe Valve Pipe Valve

Piping Size
Heat Loss fromkcal/h/m
Bare portionmm
Thickness of Insulation
Heat Loss after
kcal/h/m
Insulation
Reduced Heat Losskcal/h/m

225

272 550825 700 1,100

50

50

50

50

50

50

35

42

60

90

75

115

190

230 490735 625

985
13

ECCJ

Air/Fuel Ratio for Boilers
Standard Air/Fuel Ratio
Ｔａｒｇｅｔ Air/Fuel Ratio
Solid Fuel
Fixed Fluidized
Bed
Bed

Electric Power
Industry Use

75~100−−

Amount of Evaporation

Loadfactor(Unit: %)OthersCategory−−

Liquid
Fuel

Gas
Fuel

(−)
Byproduct Gas
such as Blast
Furnace Gas

1.05~1.2 1.05~1.1
1.05~1.1 1.05~1.1

1.2
1.15~1.2>= 30t/h50~1001.3~1.45 1.2~1.45 1.1~1.25 1.1~1.2
1.2~1.3 1.2~1.25 1.05~1.15 1.05~1.15

1.2~1.3
1.2~1.3

30t/h >>=10t/h50~1001.3~1.45 1.2~1.45 1.15~1.3 1.15~1.3
1.2~1.3 1.2~1.25 1.15~1.25 1.15~1.25−−

10t/h >>=5t/h50~100−−−−1.2~1.3 1.2~1.3
1.15~1.3 1.15~1.25−−

5t/h >

50~100−−−−1.2~1.3 1.2~1.3
1.15~1.3 1.15~1.25

−
−
14

ECCJ

II-58

Waste Gas Temperature for Boilers
Standard Air/Fuel Ratio
Ｔａｒｇｅｔ Air/Fuel Ratio
Liquid
Fuel

Gas
Fuel

Byproduct Gas
such as Blast
Furnace Gas

−
−

145
135

110
110

200
190

200
180

200
170

200
160

170
140

200
190

50~100

200
180

200
170

200
160

170
140

−
−

10t/h >>=5t/h50~100

−
−

−
300

200
180

200
160

−
−

5t/h >

50~100

−
−

−
320

250
200

220
180

−
−

Load
factor(Unit: %)Solid Fuel
Fixed Fluidized
Bed
Bed

Electric Power
Industry Use

75~100−−>= 30t/h50~10030t/h >>=10t/hOthersCategory

Amount of Evaporation

(℃)

15

ECCJ

Equipment for which the Power Factor
should be Improved
Equipment Name

Capacity (Units: kW)

Cage-Type Induction Motor

75

Coil-Type Induction Motor

100

Induction Furnace

50

Vacuum Melting Furnace

50

Induction Heating Equipment

50

Arc Furnace---

Flash-Bat Welder(excluding portable types)

10

Arc Welder (excluding portable types)

10
10,000

Rectifier

16

ECCJ

II-59

Target Efficiencies for High-efficiency,
Totally Enclosed Type Electric Motor(0.2 – 37kW)
Standard Efficiency at Full Load (%)
6 Poles
2 Poles
4 Poles

Output
(kW)
0.2
0.4
0.75
1.5
2.2
3.7
5.5
7.5
11
15
18.5
22
30
37

ECCJ

50Hz

60Hz

50Hz

60Hz

50Hz

60Hz

73.8
78
81.8
84.4
86.5
88
89.3
90.4
91.2
91.8
92.4
92.9
93.3
93.5

75.3
79.4
82.4
84.8
86.3
87.8
89
90
90.8
91.5
92
92.3
92.6
92.8

72.6
77.5
81.4
84.4
86.6
88.4
89.8
90.8
91.6
92.2
92.6
93
93.3
93.5

75.4
80
83.2
85.8
87.6
89.2
90.3
91
91.8
92.2
92.6
92.8
93
93.2

−
74.6
80
83.5
85.8
87.4
88.8
89.8
90.8
91.6
92.2
92.7
93

−
78
82
85
86.8
88
89.3
90.3
91.2
91.8
92.4
92.8
93

−

−

17

Power Factor of Induction Motor

Power Factor (%)

100
90
80
70
60
50
40
30
20
10
0

0.75kW
3.7kW

0

25

50

75
100
Output (%)

ECCJ

125
18

II-60

Refrigeration• Chilled Water Pump Control
Inverter control is good for continuous runningmachinePower Consumption Rate of Fan or Pump

Power （ %）120
Brake Horse Power in Theory

100
80

Invertor control

60
Discharge Dumper

40
20Suction Vane

0
0

50

100

Pump & Fan:Power∝RPM3

Load （%）
ECCJ

19Compressed Air System
・ Compressor Selection:
Type:

Small size = Reciprocal typeMedium size = Screw type
Large size = Turbo type
Selection: Lubrication or oil-less,Number of compression stage,
Level of vibration and noise,
Capacity and Control method

・ Control of number of compressors in operation:
High compressor efficiency is kept during partial load

・ The first to start is saving on the process side.
- Control optimum air pressure, reduce leakage & blow-off.
20

ECCJ

II-61

To check air leakage• To check air leakage
Specified pressure

L: Air leakage per centt1
×100(%)
t1 + t 2

Pressure descent
Pressure ascent
Pressure

L=

Working pressure range

Small leakage
Large leakage
Time

Pressure change in Air Compressor

21

ECCJ

Lighting
Brightness (lm)The electric power for lighting canbe reduced about 50% by the
saved type lighting system ofenergyFL type

Hf typeHigh efficient lamp＋
Lighting management using day light＋
Proper illumination maintenance system

Illuminance distribution at
daytime near windows

Brightness change of lighting fixture by time
Brightness (%)

LightsProperilluminance

Properilluminance
Cleaning

01

Cleaning

2

3

Average life 22

ECCJ

II-62

Installation Record of Industrial
Co-generation (Up until March, 2003)
Installation Percentage
by Industrial Sector(Total installations =1,600)
14%
3%
4%

18%
17%

5%
6%
9%
10%

14%

Power Generation Percentage
by Industrial Sector(Total Generation =5.074MW)

Food
ChemicalMachine/Precis
ion MachineElectric equipment
Iron & Steel/
Nonferrous metal
TextilePaper/Pulp
EnergyCeramic industry
Others

ECCJ

4% 8%
24%

5%
7%
7%

13%
9%
11%

12%

23

II-63

Please be reminded that publicizing of any part of this reportrequires prior permission from the International Project Department
ofNew

EnergyandIndustrial

Technology

Organization (NEDO)
Phone

044-520-5190

Fax

044-520-5193

Development