Promotion of Energy Efficiencyand Conservation in Major
Industries in South East Asia
EE&C Practices of Steel/Cement/Food
Companies in the Philippines
Presented by:Engr. Marlon Romulo U. Domingo
Senior. Science Research Specialist
Energy Utilization Management Bureau
Department of Energy, Philippines
During PROMEEC MAJOR INDUSTRIES Seminarat Don Chan Palace Hotel, Vientiane, Lao PDR
on October 6, 2006

Introduction
The primary objective of the government’s
energy efficiency program is to makeconsumers realize that the way tocompensate for and lessen the impact of thehigh costs of energy and electricity is byusing it efficiently, judiciously and wisely.
Hence, energy efficiency promotions are
aimed at encouraging efficient use of allenergy forms by all users.

Strategies• Conduct Information and Education Campaign on
benefits of efficient use of energy and best practices.
• Promote the use of energy efficient appliances as wellas introduce energy efficient technologies.
• Provide technical and energy management advisory
assistance.
• Put in place a recognition system for those who
consciously apply the concepts, systems andtechnologies of EE&C.

ENERGY AUDITINSTRUMENTSPhilippine Iron & Steel Industry• Billet Production by Electric Arc Furnace (EAF) there
are 5 companies.
– Plain Carbon Steel (Structural Steel)– Intermediate Class– High Strength Steel• Billet Imports from Russia, Australia, Africa• Rolling Mills produce reinforcing steel bars,
wire rods, and section steels– Continuous type rolling (tandem arrangement, high speed)– Semi-continuous type rolling (reverse type or semi-tandem)– Non-continuous type rolling (cross-country arrangement,small scale)• Steel Sheet Coating

Rolling Mill forReinforcing BarsMajor Equipment• Walking Beam Reheat Furnace using
Bunker Oil• Exhaust Heat Recovery Recuperator• Tandem Horizontal/Vertical RollingMachine• Air Compressors• Water Pumps and Cooling Towers

Walking Beam Reheating FurnaceThis technology was developed because:• It Saves Energy;• Requires Less Manpower;• Improved Product Quality;• Efficient Operability

Desired Flue Gas Data
O2 %CO ppmFlue Gas Temp.
Excess Air Percent
Thermal Efficiency

Bunker Oil
3.0 - 4.0400
220 oC
15 - 20Diesel
1.0 - 2.0400
220 oC
5 - 1084.4 - 83.9

84.7 - 84.3

3rd Quarter of 2003 - 2nd Quarter 0f 2004
Product Line

Total Production(MT)

Total Energy
Consumption (LOE)

Specific Energy
Consumption

Rolling Mill

222,141

13,383,520

60.25

3rd Quarter of 2004 - 2nd Quarter 0f 2005
Product Line

Total Production(MT)

Total Energy
Consumption (LOE)

Specific Energy
Consumption

Rolling Mill

198,408

11,107,116

55.98

SAVINGS(LOE)
1. Replacement and modification ofRecuperator

302,665.02

2. Reduction of idle fuel consumption.
Reduce unproductive use of energy
during change size and delays

164,051.00

3. Installed Additional ceramic Fiber
insulation inside furnace wall ofrecuperative zone side.

4,595.00

SAVINGS(LOE)
4. Installation of water flow meters andmodification of the circulation of water at
the furnace area.
5. Modification of design scale pit motors
to reduce frequent simultaneous startingof AC motors.
6. Installation of thermoplastictranslucent roofing sheets at mill andwarehouse areas.

2,339.42
67,334.80

37,563.19

Steel Sheet Coating

Major Equipment• There are two processing plants, namely:¾Continuous Galvanizing Line (CGL);−Uses Liquefied Petroleum Gas (LPG)
in burners for pre-heating sheets−Bunker Fuel is used in Heating
Furnace for the Galvanizing Kettle¾Color Coating Line (CCL)−LPG is used in the Oven and Dryers

3rd Quarter of 2003 - 2nd Quarter 0f 2004
Product Line

Total Production(MT)

Total Energy
Consumption (LOE)

Specific Energy
Consumption

CCL
CGL

29,18638,279806,439.54
1,265,452.17

27.63
33.06

3rd Quarter of 2004 - 2nd Quarter 0f 2005
Product Line

Total Production(MT)

Total Energy
Consumption (LOE)

Specific Energy
Consumption

CCL
CGL

26,401
34,192

719,753.70
1,017,718.09

27.26
29.68

390
380
370
360
350
340
330
320
310300290kW160,000
140,000
120,000
100,000
80,00060,00040,00020,000-Apri
M lay
JuneJuASe ug ly
pt usem tO bec
No tob rv e
De em rce bem r
Ja benu r
Fe ar
br yuaM tyarchkWhContinuous Galvanizing LinekW vs kWhkWhkW

Table 2

CONTINUOUS GALVANIZING LINEMONTHLY ENERGY CONSUMPTIONMONTHCOVEREDApr 5 - May 6, '04
May 6 - Jun 7, '04
June 7 - Jul 6, '04
Jul 6 - Aug 5, '04
Aug 5 - Sep 6, '04
Sep 6 - Oct 6, '04
Oct 6 - Nov 5, '04
Nov 5 - Dec 7, '04
Dec 7 - Jan 6, '05
Jan 6 - Feb 7, '05
Feb 7 - Mar 7, '05
Mar 7 -Apr 6, '05
TOTAL
AV ERAGE

LOAD
DEMAND CONSUMPTIONPOWER
SURCHARGE TOTAL AMOUNTDUE, P
FACTOR, %KW
KWH
FACTOR, %
P
44.31
41.28
52.28
35.09
32.21
34.4
39.75
42.78
28.58
52.19
51.31
43.01

41.43

381.92376.48363.68360.32366.72360.48370.08365.76325.76356.48340.16356.0

125,920
119,360
132,320
91,040147,040
89,280105,920
120,160
67,040142,880
117,280
110,240360.32

1,368,480
114,040

P/kW

99.80
99.80
99.90
99.90
99.90
99.90
99.90
99.90
99.90
99.80
99.80
99.90

6,621.64
6,527.32
6,348.00
6,289.35
6,401.06
6,292.14
6,145.24
6,073.50
5,409.30
5,879.68
5610.50
5,911.44

681,185.80
667,724.80
718,763.25
538,537.55
809,940.15
546,869.50
743,077.70
817,019.10
521,287.55
985,413.55
776,057.25
759,223.30

5.41
5.59
5.43
5.92
5.51
6.13
7.02
6.80
7.78
6.90
6.62
6.89

99.87

73,509.17
6,125.76

8,565,099.50
713,758.29

6.33

CONTINUOUS GALVANIZING LINE
1. Utilized LPG infrared Heater andreplaced motor-powered Air Blower &Electric Heater.
2. Furnace Damper Revision
3. Rationalized LPG Usage by standard
number of burners fired per CRC
thickness being processed.
4. Recirculate Hydraulic Cooling Water atAlkali Rinsing tank instead of dumping
directly to drainage.

SAVINGS(LOE)

1,123.00
34,944.00
13,428.00
313.33

CONTINUOUS GALVANIZING LINESAVINGS(LOE)

5. Decommision Surface Smoothener
Drive.

12,629.25

6. Preheater Revision

13,635.67

7. Installed automated control of the LPGpilot burner that would automaticallyswitch "OFF" the LPG burner during highfire of SFO burner and switch "ON" duringlow
SUB-TOTAL

30,538.00

106,611.25

Philippine Cement Industry• 15 Cement Plants Nationwide• 100,000 to 500,000 MT/yr• 20 T/hr to 90 T/hr
• Process are mostly Dry process• Semi-dry and Wet process still exist
Milestone• Fuel conversion from Oil to Coal
• Finance rehabilitation in 1980’s• Cement Industry Rehabilitation Program in 1990’s

Cement Industry Rehabilitation
Some developmental/rehabilitation projects adopted bysome of the cement mills:• Installation of additional equipment• Conversion from direct to indirect firing system• Improvement of existing facility• Rehabilitation of small capacity kilns to achieve ratedoutput• Conversion of semi-dry to dry process• Installation of pre-calciner to increase plant capacity• Rehabilitation of clinker cooler to increase kilncapacity

CEMENT PLANT
Improved Specific Energy Consumption

100

2002

2001

2000

1999

0

1998

50
1997

LOE /MT150

4321

Cement Plant Implemented Projects• Modified Suspension Pre-heater with separate line
calciner technology• Installation of Vertical Mill at Raw Mill• Installation of 5 stage New Suspension Pre-heater(NSP)• Compressed Air Pressure Reduction 7Bar to 6.8 Bar• Replacement of DC Motors by Variable Speed Drivefor Damper Control• Upgrade Process Automation

Cement Plant Implemented Projects (cont’d)• Use of High Efficiency Fans and Motors at
Clinker Cooler• Repair vacuum leaks at Kiln Hood Door
• Installation of On-line Oxygen Analyzer at
Calciner Exhaust to Improve Leak Management

Food Industry• Varied production processes in relation todifferent Food Products and Sectors.
(Fish, Meat, Poultry, Grains, Vegetables, Fruits, etc.)• Major Food Industries:
Sugar Milling, Coconut and Vegetable Oil, GrainProducts, Dairy Products, Coffee and Chocolate
Confectionary, Processed Fruits and Vegetables,
Bakery Products, Meat Products, Fish Products

Common Equipment• Lighting• Chillers / Refrigerators• Exhaust Fans
• Water Heaters• Pumps• Boilers• Air Compressors

Energy Conservation Measures• Use of High Efficiency Lighting System• Use of High Efficiency Motors• Efficient Combustion of Fuels• Efficient Operation of Chillers• Reduction of Compressed Air Leaks• Steam Condensate Recovery

Processed Pineapple Co.
Specific Energy Consumption

604030202005

20042003

2002

200102000101999

LOE / MT504321

Processed Pineapple Co.
Implemented Project• STEAM SYSTEM– Insulate Bare Steam Lines and Valves– Eliminate Steam Leaks– Recover Condensate for Boiler Feed Water– Insulate Cooker A & J– Recover Heat from Cookers Condensate– Install Combustion Air Preheater– Install separate Low Pressure Steam LineProcessed Pineapple Co.
Implemented Project (cont’d)• WATER SYSTEM– Consolidate Refrigeration Cooling Tower Sumps– Reduce No. of Sprayers for Inside Fruit Elevators– Recycle Coolers Cooling Water– Recycle Coolant of hydraulic Pack
– Reduce Water Spray Before Slicers– Recycle Water Sealant of Pumps– Recycle Cooling Water for Air Compressors andVacuum Pumps– Repair Water Leaks

Processed Pineapple Co.
Implemented Project (cont’d)• POWER SYSTEM– Install Power Factor Correcting Capacitors at Can Plant– Replace Spotlights with Compact Fluorescent Lamps– Improve Machinery Operation Schedule– Upgrade Photocell Controls for Lighting– Install Micro-Hydro Plant at Water Treatment Plant

Processed Pineapple Co.
Implemented Project (cont’d)• COMPRESSED AIR SYSTEM– Repair Air Leaks– Install Separate Systems for Low Pressure and High
Pressure Lines– Recover Heat from Air-compressors– Install Solenoid Valves for all Air Lines

Contact Us
Energy Efficiency andConservation Division
Department of Energy
Energy Center, Merritt Road,
Fort Bonifacio, Makati City 1201 Philippines
Telefax: +63-2-8402243
Telephone:+63-2-8401401
local 277, 214, 205