2006 Achievement Report

International Project for Increasing
the Efficient Use of Energy
International Project for Improving Infrastructure
for the Efficient Use of Energy(Programs for Promotion of Energy Conservationin Major Industries in ASEAN Countries)

Report on the Results

March, 2007
The Energy Conservation Center, Japan

Preface
In recent years, prevention of global warming has become a common issue for mankind on one
hand, while sustainable economic development is actively demanded on the other. Thus, we aretrapped in a situation in which we must overcome two challenges that completely contradict
each other. Necessary for overcoming this situation are technical innovations, such as thedevelopment of technologies for the efficient use of energy, technologies for utilizing energy
with minimum burden on the environment, and energies having little impact on the environment.

To contribute to the balanced development of economy and the environment in developing
countries, we need to implement assistance that is acceptable and appropriate to each country, byassessing the reality of energy usage and environmental conservation measures, and thoroughly
examining the state of infrastructure development, lifestyles, and other national conditions in
respective countries.
Under this situation, we entered a new phase of activities in 2004, with an aim to implementing
energy audits and improvement measures, and strengthening the mechanism for greater
dissemination, based on the results of energy audit surveys and energy audit technology transfers
implemented between 2000 and 2003, which targeted one industry each in the ten ASEAN
countries. We have continued on with those activities in 2005 and 2006.

As an effective means of achieving our objectives, we have made on-going efforts to compile aTechnical Directory and a Database/Benchmark/Guideline for each industry.

Meanwhile, in the effort to strengthen the mechanism for implementing and disseminating ouractivities, we have conducted follow-up surveys in plants that have been audited in the past, toassess the implementation status of recommended improvement measures, as well conducted
walk-through energy audits in other plants to ensure the transfer of energy audit techniques. This
year, we focused our attention on the cement industry in Lao PDR, the steel industry in Thailand,
and the cement and oil refining industries in Myanmar.
Additionally, we held seminar-workshops in each country, with the participation not only ofpeople from the host country, but also of governmental authorities and plant personnel ofdifferent industries in other countries as well. They were invited to present successful cases ofenergy conservation measures, to enhance information sharing in the ASEAN region and create afoundation for dissemination activities. The seminar-workshops also provided a forum fordiscussing the concept and formulation policies regarding the Technical Directory and database,and some specific examples were presented.
We feel that the activities implemented during the third year of the project have been highlymeaningful, particularly in the sense that they have promoted the steady development of afoundation for

promoting energy conservation

activities

directedto achieving theabovementioned goals.

We hope this project will contribute to energy and environmental conservation in industrial
sectors in the ASEAN countries, and thereby allow each country to achieve environmentallyfriendly and sustainable economic growth. We also hope this project will serve as a bridge oftechnical exchange and friendship between Japan and the ASEAN countries.

March 2007
The Energy Conservation Center, Japan

Contents
Preface
Contents
Overview
Abbreviations

Ⅰ.

Purpose and Background of the Project

Ⅰ- 1

Ⅱ.

Lao PDR (Cement Industry)

Ⅱ- 1

１.

Activity Overview

Ⅱ- 1

２.

Energy Conservation Survey at Lao Cement

Ⅱ- 4

2.1 Overview of Lao Cement’s cement Plants

Ⅱ- 4

2.2 Overview of Cement Production Facilities

Ⅱ- 6

2.3 Walk-through Energy Audit at the Cement Plants

Ⅱ- 6

３．Seminar-workshop

Ⅱ- 14

3.1 Overview

Ⅱ- 14

3.2 Results of the Seminar-workshop

Ⅱ- 15

４．Attachments

Ⅱ- 21

Thailand (Steel Industry)

Ⅲ- 1

１.

Activity Overview

Ⅲ- 1

２.

Energy Conservation Survey at the Steelworks of Bangkok Steel

Ⅲ- 4

2.1 Overview of the Steelworks of Bangkok Steel

Ⅲ- 4

2.2 Overview of the Facilities in the Steelworks

Ⅲ- 5

2.3 Walk-through Energy Audit at the Steelworks

Ⅲ- 8

Seminar-workshop

Ⅲ-31

3.1 Overview

Ⅲ-31

3.2 Results of the Seminar-Workshop

Ⅲ-32

Ⅲ.

３.

４．Attachments

Ⅲ-30

Myanmar (cement and oil refining industries)

Ⅳ- 1

１.

Activities Overview

Ⅳ- 1

２.

Energy Conservation Survey of the Myanmar Ceramic Cement Plant

Ⅳ- 3

2.1 Overview of the Myanmar Ceramic Cement Plant

Ⅳ- 3

2.2 Overview of Cement Manufacturing Facilities

Ⅳ- 4

Ⅳ.

３.

４.

2.3 Walk-through Energy Audit at the Cement Plant

Ⅳ- 8

Follow-up Survey of Thanlyin Oil Refinery

Ⅳ- 25

3.1 Overview of Thanlyin Refinery

Ⅳ- 25

3.2 Overview of the Refining Facilities

Ⅳ- 26

3.3 Follow-up Survey of the Oil Refinery

Ⅳ- 27

Seminar-Workshop

Ⅳ-33

4.1 Overview

Ⅳ-33

4.2 Results of the Seminar-Workshop

Ⅳ-34

５．Attachments

Ⅴ.

Ⅳ-37

Ⅴ- 1

ASEAN Initiatives

１.

Overview of the Summary/Post Workshop

２.

Summary Workshop on Major Industries ‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑‑Ⅴ- 3

Ⅴ- 1

2.1 Report from ECCJ concerning Energy Conservation Activities in
Major Industries in FY2006

３.

Ⅴ- 3

2.2 Energy Conservation Activities in the ASEAN Countries

Ⅴ- 5

2.3 Overview of Presentations by the Three Host Countries in FY2006

Ⅴ- 10

2.4 Plans for FY2007 PROMEEC Activities

Ⅴ- 11

Post Workshop

Ⅴ-13

3.1 Progress on the Creation of the Technical Directory (TD)Ⅴ-13

3.2 Progress on the Creation of the in-house Database/Benchmark/Guideline(DB/BM/GL)
４.

Attachments

Ⅴ‑13
Ⅴ-14

Overview
The ASEAN countries are continuing to make rapid progress in economic development, andenergy consumption is expected to dramatically increase in the future. It will therefore become
increasingly important to utilize energy effectively and to give due consideration to preventing
global warming.
This project has now entered its seventh year, and the activities of our counterpart, the ASEAN
Centre for Energy (ACE), and relevant parties of the ASEAN countries have expanded and taken
its root firmly. Moreover, against increasing energy prices accompanying the recent rise in crude
oil prices, gradual changes in consciousness have begun to take place toward reducing energy
consumption in those countries.
FY2006 marked the third year of phase 2 activities. It has been tagged as a year for bringing
together the results of phase 1 activities implemented over the past four years, and for further
strengthening independent efforts to apply and disseminate those results. In other words, phase 2
aims to establish a foundation for applying and disseminating actual improvement measurescentering on those discussed and recommended by each country in the past, based on theachievements and results of energy audits conducted at plants in ten different industries in the
ASEAN countries.
Specifically, the following activities were implemented in Lao PDR (cement industry), Thailand(steel industry), and Myanmar (cement and petroleum industries).
♦ Follow-up surveys of plants audited in the past and walk-through audits of new plants
The implementation status of proposed improvement measures and problems arising on
dissemination were assessed, and improvement measures were proposed for new plants.
♦ Creation of technical directory (TD)Information on effective technologies in the ASEAN countries and cases of successful
implementation of various technologies related to the cement, steel, and petroleum refining
industries were introduced and shared, to promote the implementation and dissemination ofthese technologies.
♦ Creation of database/benchmark/guideline (DB/BM/GL)
Numerical targets were established for energy conservation activities and a framework wasdeveloped for providing guidelines directed to achieving those targets, with the objective of
putting those activities into practice. One of the tasks for FY2006 included the creation of
the database for cement industry.
Surveys including energy audits, and seminar-workshops were implemented in the1

abovementioned three countries. In order to make sure the technology transfer, practicalguidance was provided to local personnel through following up the implementation status ofenergy audit technologies that have been transferred to the countries by Japanese experts in thepast. In plants where implementation of improvement measures does not progress as expected,
discussions were held concerning impediments to their implementation and possible solutions.
Some useful clues were found for the promotion of future implementation and dissemination ofsuch measures.
In addition to the above discussions, seminar-workshops were held in the respective countries. In
addition to personnel from plants in the host country, plant personnel and governmental
authorities from various industries in the ASEAN countries (including plant personnel who took
part in past energy audits) were invited to participate and present activities and examples ofimprovement measures they have implemented. The seminar-workshops attracted a large numberof participants, and provided a significant forum for sharing and disseminating information.
Local activities of the project in FY2006 began with an inception workshop held in July 2006 in
conjunction with the projects on buildings and energy management infrastructure development.
In the workshop, an implementation plan was formulated for smooth commencement of the
project, and necessary preparations on the site were verified. Thereafter, a series of surveys andseminar-workshops were steadily held in three countries up to November 2006, and the summary
workshop/post workshop was held in February 2007 in conjunction with the projects onbuildings

andenergymanagement

infrastructuredevelopment.

Gathering

togetherrepresentatives (focal points) from the ASEAN countries, presentations were given to share theresults of activities implemented in three countries with all ASEAN countries, and discussions
were

held

on

the

creationoftechnical

directory,

and

the

developmentof

database/benchmark/guideline (DB/BM/GL) by each country. The post workshop concluded
with a discussion concerning policies and initiatives for FY2007 and onward.
The following specific activities were implemented in FY2006 in the project of major industry.

I. October 2 – 6, 2006 (business trip from Oct. 1 to 8):
On-site activities in Lao PDR (primary survey)
1. An audit survey and follow-up survey on hydro electric power plant, and an audit survey ofsewing plants have been conducted in Lao PDR in the past. In FY2006, a walk-through energy
audit was newly conducted at a cement plant, and results of the energy audit were presented
and discussed at the plant.

2

2.

Seminar-workshop in Lao PDR
Approximately 60 people participated in the seminar-workshop held in Lao PDR, which
included the activities shown below. An active exchange of information was held throughlively discussions.
(1) Energy conservation policies and programs (Lao PDR and Japan)(2) Presentation of energy conservation examples by participants from various industries in
Lao PDR and other ASEAN countries(3) Presentation of the results of energy audit conducted at a cement plant in Lao PDR(4) Presentation by ACE on policies for creation of technical directory (TD) and development
of database (DB).

II. November 13 – 24, 2006 (business trip from Nov. 11 to 26):
On-site activities in Thailand and Myanmar (secondary survey)
1. In Thailand, a survey of a sodium hydroxide plant has been conducted in the past. In FY2006,
the follow-up survey of the plant was omitted, but an energy audit was newly conducted at asteel plant. In Myanmar, an energy audit and follow-up survey were newly conducted at a
cement plant and a petroleum refinery, respectively, and the result of surveys was presented
and discussed at the relevant plants.

2. Seminar-workshops in Thailand and Myanmar
The seminar-workshop attracted 70 participants in Thailand and 56 participants in Myanmar.
The following activities were implemented, and an active exchange of information took placethrough lively discussions. In the seminar held in Thailand, all presentations pertained
exclusively to steel industry, and made this particular seminar-workshop the first to be held
on a specific industry.
(1) Production activities in the steel industry in Thailand and Japan’s energy conservation
technologies / energy conservation policies and programs in Myanmar and Japan(2) Presentation of energy conservation examples by participants from various industries in
the host country and other ASEAN countries(3) Discussions on policies for creation of technical directory (TD)III. February 27 – 28, 2007 (business trip from Feb. 25 to Mar. 1):
Summary/post workshop held in Brunei Darussalam (in conjunction with the projects onbuildings and energy management infrastructure development)

3

The following summary and discussion sessions were held with the attendance of 20 participants- 11 from the ASEAN countries, 5 from ACE, and 4 from ECCJ. The participants confirmed thatthe goals of activities implemented in the aforementioned three countries have been achieved as
outlined in the implementation plan, which was adopted at the previous inception workshop.

1. Summary Workshop
Session 1: Energy conservation in major industries- Results, achievements, and evaluation of activities implemented during FY2006- Evaluation of activities implemented by each country and measures for future
improvement- Status of the creation of TD and DB in each country- Status of the creation of TD and DB for major industries in ASEAN- Policies for initiatives to be implemented in FY2007 and onward
Session 2: Energy conservation in buildings
Session 3: Development of energy management infrastructures

2. Post Workshop
Session 1: Summary of discussions held in the summary workshop for each project
Session 2: Basic implementation plan for FY2007 and onward

During FY2006, the project focused on providing assistance for building a foundation forsustainable energy conservation activities in each ASEAN country, and higher-grade activities
were implemented that called for greater independent efforts by each country. Owing to thecooperation of all countries in implementing the activities, significant achievements have been
made this fiscal year. At the same time, however, the following issues have surfaced as the
project has progressed. Greater efforts must be made to address these problems in FY2007 andonward.

(1) Starting FY2005, audit surveys were decided to be conducted under the leadership of a coreteam employing an OJT method, but we found that the team was still highly dependent on
assistance from Japanese experts. More self-help efforts are expected from the core team in
making the necessary preparations, including collecting questionnaires and arranging formeasurement instruments.
(2) In regard to the creation of an in-house DB for cement industry which was to be undertaken
during FY2006, a draft database has been prepared, but the plan has not been accomplished,
due to a number of inadequacies. It is necessary to make stakeholders understand the4significance of creating an in-house DB, and to cooperate closely with ACE and focal points
toward the early development of the DB.
(3) Engineers from countries other than the host country participated voluntarily in the FY2006
audit surveys. Their participation was highly significant in terms of promoting the sharing of
the project’s achievements and disseminating them among the ASEAN countries. Further
efforts should be made to increase voluntary participation from other countries as well, in the
future.

Lastly, this project has been made possible with the full cooperation of ACE, relevantorganizations in each country, and representatives of relevant companies. We would like to takethe opportunity of this paper to extend our deepest gratitude to them all.

5

Below is a list of abbreviations used in this report.
EE&C

Energy Efficiency and Conservation

TD

Technical Directory

DB/BM/GL

Database / Benchmark / Guideline

ACE

ASEAN Center for Energy

METI

Ministry of Economy, Trade and Industry

ECCJ

The Energy Conservation Center, Japan

Lao PDR
MEM

Ministry of Energy and Mines

Thailand
DOE

Department of Energy

DODE

Department of Alternative Energy Development and Efficiency

BSI

Bangkok Steel Industry Public Co., Ltd.

Myanmar
MOE

Ministry of Energy

EPD

Energy Planning Department

MOI2

Ministry of Industry No.2 (No.2: Heavy Industry)

Malaysia
PTM

Pusat Tenaga Malaysia (Malaysia Energy Center)1

I.

Purpose and Background of the ProjectThis project aims to contribute to promoting energy conservation and environmental
conservation in Southeast Asia by helping disseminate and promote energy conservation
technologies in major industries. Specifically, it strives to contribute to promoting energy
conservation measures in major industries in the ASEAN countries by supporting the activitiesof those countries. The project was established in 2000 under the leadership of the ASEAN
Center for Energy (ACE), with the objective of suppressing constantly increasing energy
consumption in the industrial sectors in the ASEAN region. Formally, it is called the Promotionof Energy Efficiency and Conservation Project, but commonly referred to as PROMEEC for
Major Industries in ASEAN countries. It is a project that is certified by the conference ofenergy-related ministers of ten ASEAN countries and implemented in cooperation with theJapanese Ministry of Economy, Trade and Industry. The Energy Conservation Center, Japan(ECCJ) also takes part in the project in support of the technical and operational aspects of energy
conservation in industrial sectors in the ASEAN region.

The objectives of the project are as follows.
1. To strengthen cooperative relationships between the ASEAN countries and Japan in the energy
sector
2. To promote energy efficiency and conservation in major industries in the ASEAN countries
3. To promote the transfer of energy-related technologies from Japan to the ASEAN countries
and introduce Japan’s good practices in energy conservation
4. To enhance the capacities of the ASEAN countries through energy audits and on-the-job
training (OJT) in such audit surveys
5. To create the database/benchmark/guideline (DB/BM/GL) in the ASEAN countries
This cooperation project is being implemented in three phases, as shown below, based on
consultations with ACE and the ASEAN countries. FY2006 marked the third year of phase 2
activities. Based on activities that have been implemented in all ASEAN countries by March
2004 in phase 1, a foundation has so far been created for promoting energy conservation
activities in all ASEAN countries on an equal basis.

Phase 1: Transfer of Japan’s technologies and experiences to the ASEAN countries (completed
in FY2003)
Phase 2: ASEAN-Japan joint implementation of improvement measures in the respective
countries and dissemination to other countries

I‑1

Phase 3: Promotion of energy conservation through self-help efforts of the ASEAN countries
In FY2004, efforts were launched to create a foundation for promoting the implementation anddissemination of energy conservation measures based on the foundation created in phase 1.
Specifically, activities revolved around conducting follow-up surveys at plants where energy
audits were carried out in the past, creating a technical directory (TD), and assisting eachcountry in creating a DB/BM/GL for each industry. During FY2006, relevant activities were
implemented, targeting the cement industry in Lao PDR, the steel industry in Thailand, and thecement and oil refining industries in Myanmar.
In the respective countries, local support was obtained in conducting OJT-based walk-throughenergy audits in new plants for steady transfer of energy audit technologies, and in carrying out
follow-up surveys for assessing the implementation status of proposed improvement measuresand problems in plants audited in the past. Seminar-workshops were also held, featuringlecturers invited from various plants of different industries in the host country and other ASEAN
countries. Through dissemination activities, cases of successful implementation of improvement
measures and examples of advanced energy conservation technologies were introduced to the
ASEAN countries. Finally, to promote the creation of the TD and DB/BM/GL in the respective
countries, a working plan was reported as well as already-finished works for the reference.
These activities aimed to provide a basis for developing a foundation for promotion of energy
conservation in each country and to establish a network for dissemination among the ASEAN
countries.
Lastly, the post workshop was held bringing together the representatives from the ASEAN
countries in order to share the achievements and results of activities that have been implemented
in the respective countries and to discuss basic plans for future activities.

I‑2

Lao PDR (Cement Industry)
1. Activity Overview
An audit survey at the hydro power plant was conducted in the phase 1 of PROMEEC activities
in Lao PDR. As the first stage of activities in phase 2, a follow-up survey of the hydro power
plant and an energy audit at the sewing plant were conducted. This year an audit survey wasplanned at the cement plant as the second stage of activities in phase 2. The cement plant was thestate-run Lao Cement Co., Ltd. (LCC), located in Vang Vieng District, approximately 200
kilometers, or about three hours by car, to the north of Vientiane Province.
The energy audit at Lao Cement was carried out over three days, with the participation of four
members from the Lao Ministry of Energy and Mines (MEM) and 20 engineers from Lao
Cement. The results of the audit survey were presented by a Lao Cement engineer at theseminar-workshop held later in Vientiane.
1.1 Date
October 2 – 6, 2006

1.2 Venue
Cement plant:

Lao Cement Co., Ltd. (LCC) in Vang Vieng(located approx. 200km north of Vientiane)

Seminar-workshop:

Dong Chang Palace Hotel in Vientiane

1.3 Schedule
Oct. 2 (Mon.)

Travel to Vang Vieng; energy audit at the cement plant (LCC)

Oct. 3 (Tue.)

Energy audit at the cement plant (LCC)

Oct. 4 (Wed.)

Energy audit at the cement plant (LCC)

Oct. 5 (Thu.)

Energy audit at the cement plant (LCC); travel to VientianeOct. 6 (Fri.)

Seminar-workshop

1.4 Participants
Lao Ministry of Energy and Mines (MEM):
Mr. Khamso Kouphokham

Deputy Chief of EMD, Electrical Engineer

Dr. Xayphone Bounsou

Electrical Engineer

ASEAN Center for Energy (ACE):
Ms. Evangeline L. Moises

Chief, Information & Event Division

Mr. Ivan Ismed

Project Officer

II‑ 1

Malaysia Energy Center (Pusat Tenaga Malaysia; PTM):
Mr. Zul Azri Hamidon

Energy Audit Engineer, Electrical Engineer

Ms. Norazean Mohd. Nor

Technical Assistant, Electrical Engineer

The Energy Conservation Center, Japan (ECCJ), International Engineering Dept.:
Kokichi Takeda, Hideyuki Tanaka, Taichiro Kawase
About Lao PDR(Source: Web site of the Japanese Ministry of Foreign Affairs (February 2007 data))
1. Area:

240,000 sq km (approx. 0.6 times the area of Japan)

2. Population:

5,609,000 (Third National Survey conducted March 2005)

3. Ethnicity:

Lao Loum (lowland) (60%) and 49 other ethnic groups

4. Language:

Lao

5. Religion

Buddhist

6. Government:
assembly

People’s democratic republic (established February 1973); Unicameral
ASEAN membership in July 1997

7. Major industries:
power generation

Agriculture, manufacturing, forestry, mining, and hydroelectric

8. GDP (per capita):$491 (2005) [GDP growth rate 7.3% (2005)]

9. Total trade:(1) Exports $456 million (Oct. 2004 – Sept. 2005)
Garments, metals and minerals, electric power, wood products(2) Imports $686 million (Oct. 2004 – Sept. 2005)
Fuel, industrial products, raw materials for garments

10. Exchange rate: $1 = 9,650 kip (as of Feb. 2007)
11. Economic overview:
The country has introduced a market economy, and is pursuing open
economic policies. It is showing signs of gradual recovery from the Asian
economic crisis.
Long-term goals: Departure from less developed country (LDC) status by
2020, basic resolution of poverty by 2010, etc.
12. Energy situation:
The country supplied approx. 670 ktoe of energy in 2004 (coal: 26.2%,
petroleum: 58.3%, electric power: 15.5%). 3,327GWh of power was
generated by hydroelectric power generation, and while some areas import
power, close to 65% of power generated by the country is exported. The
country appears to be dependent on imports for petroleum, but no precise

II‑ 2information is available. Although not included in the aforementioned
figure, the country consumes approx. one-fourths of total biomass that iscommonly used in the ASEAN countries. Including biomass, households
account for 50% of energy consumption, industries 20%, transportation
26%, and other sectors, the rest.
(Source: Materials presented at PROMEEC meetings, etc.)

II‑ 3

2. Audit Survey on Energy Conservation at Lao Cement
Of the five cement plants operated by three cement companies in Lao PDR, Lao Cement Co.,
Ltd. (LCC), which owns two plants, was selected for this project’s OJT practice.

2.1 Overview of Lao Cement Co., Ltd.
Lao Cement’s plants are located in the outskirts of Vang Vieng District, approximately 200km
north of Vientiane Province, amidst a picturesque setting where the Nam Song River flows
abundantly through a deep limestone valley that closely resembles China’s famous Guilin.
The survey team consisted of 11 members, including 4 governmental personnel (Ministry ofEnergy and Mines) and 7 representatives from ASEAN and ECCJ. Since two plants werelocated on the same premises, the team spent three days in Vang Vieng to provide auditing
guidance.
(1) Name of company:

Lao Cement Co., Ltd. (established in 1993)(2) Location:

Vang Vieng District, Vientiane Province, Lao PDR(3) Period:

October 2 – 5, 2006

(4) Survey members (audit team 1/2):
Lao government (MEM):
Mr. Khamso Kouphokham Deputy Chief of EMD, Electrical Engineer
Dr. Xayphone Bounsou

Electrical Engineer

Mr. Viengsay Chantha

Engineer

Mr. Khamsith Ackhavong Engineer
ASEAN Center for Energy (ACE):
Ms. Evangeline L. Moises Chief, Information & Event Division
Mr. Ivan Ismed

Project Officer

Malaysia Energy Center (PTM):
Mr. Zul Azri Hamidon

Energy Audit Engineer, Electrical Engineer

Ms. Norazean Mohd. Nor

Technical Assistant, Electrical Engineer

The Energy Conservation Center, Japan (ECCJ):
Kokichi Takeda, Hideyuki Tanaka, Taichiro Kawase(5) Lao Cement participants (audit team 2/2):

II‑ 4

Mr. Thongchan Sounaphon

Deputy Director of Plant No.1

Mr. Vichith Souvannarath

Deputy Director of Plant No.2

Mr. Bouasavath Sophetmany

Mechanical Engineer

Mr. Singeunh Leuangvansay

QC Engineer

Mr. Houmphonh Soududuang

Head of Raw Material

Mr. Thong Phoune Bosisakhoune

Deputy Head of Department

Mr. Korsavanthong

Head of Planning

Mr. Amkha Dethosonedy

Head of MTB

Mr. Phovanh Phomany

Head of Electricity

Mr. Bouasone Keopasert

Head of Department

Mr. Sisomphou Khongphalanh

Head of Department

Mr. Litthi Siriboun Heuang

Head of Department

Mr. Phoungeun Phimmasone

Head of Raw Material

Mr. Chanthay VongnakhoneHead of Spare Parts

Mr. Khamla Noiphewphanh

Head of Production Plan

Mr. Keonkothoung

Head of AD

Mr. Vanh Malathong

Head of CMD

Mr. Chanthaehon Inthacvong

Head of CCR

Mr. Nantha Phuyphuthasak

Electrical Engineer

Mr. Oudomsine Khamsisopha

Electrical Engineer(6) Activity schedule at Lao Cement
Table II-2-1 shows the schedule of activities at Lao Cement.

Table II-2-1 Schedule of activities at Lao Cement
Date/Time
Oct. 2(Mon)
2:30 - 6:30
pm

Oct. 3(Tue)
8:50am 6:00pm

Activity
1. Travel from Vientiane → Vang
Vieng
2. Self introductions
3. General explanation of
PROMEEC activities
4. Explanation of the schedule
5. General description of Plant No. 1
6. General description of Plant No. 2
1. Interviews at the plant
2. Lecture on energy conservation
measures and audit methods
3. Tour of facilities

II‑ 5Person in charge

All members
Ms. Evangeline / Mr. Tanaka
Mr. Khamso
Mr. Thongchan
Mr. Vichith
All members
Mr. Kawase
All members

RemarksOct. 4(Wed)
8:50am 6:00pm
Oct. 5(Thu)
8:50am 12:00pm

4. Discussion concerning
preliminary questionnaire
5. Confirmation of measurement
areas and methods
1. Data collection and measurement
2. Lecture on data analysis methods
and heat balance3.
Lectureonelectricity
conservation
1. Discussion on audit results andenergy conservation measures
2. Summary and presentation ofcompletion certificates
3. Travel from Vang Vieng →Vientiane

All members
All members
All members
Mr. Kawase
Mr. Takeda
All members
Mr. Khamso, Ms.
Evangeline/
Mr. Tanaka

2.2 Overview of Cement Production Facilities
Lao Cement is a state-run company, possessing two plants in Vang Vieng District. An
overview of the plants is as shown below. The two plants stand 500m apart on the same
premises, and substancially constitute one large plant.

Plant No. 1

Plant No. 2

Date of construction

Dec. 1994

Jan. 2002

Nominal capacity (tons/year)

90,000210,000

Kiln type

Shaft kiln

Rotary kiln with NSP

Fuel

Coal

Coal

No. of employees

244

294

There are three cement companies in Lao PDR. One is a state-run company, one is a privatecompany, and the other is a semi-private company. Combined, their production capacities
total 600,000 tons/year, with Lao Cement accounting for 50%. However, as domestic demand
equals 1.3 million tons/year, the difference is covered by imports from Thailand, China andother countries. Therefore, the Lao Cement’s primary goal was to increase production byincreasing the number of operating days. Impressively, both plants now operate more than
300 days per year.
The cement facility has been constructed by the Chinese company, but it is interesting to notethat the major equipment and instruments are made by Japan, the United States, the United
Kingdom, and Germany. Three Chinese engineers work in Plant No. 2 still today, to provide
guidance on production technologies. However, they do not provide guidance on energy

II‑ 6conservation.
2.3 Walk-through Energy Audit at Cement Plants(1) Audit procedure
The energy audit proceeded as follows, with the local team encouraged to take the initiativein its execution. Due consideration was given to the OJT perspective and the participationof PTM engineers.
Lecture on an overview of the cement production process and energy conservation
measures
Briefing on audit items and data collection/measurement items
Grouping of members into audit teams
Data collection and measurement
Data analysis and reporting
ECCJ experts were placed in charge of the first two activities, for the purpose of providing
preliminary information. Attachment II-1 and II-2 show materials that were used in thelecture. In consideration of the time factor, audit items were narrowed down to kiln heatbalance, air leakage prevention, and speed control of large-scale rotary machines.
Members were grouped into audit teams by the focal point, Mr. Khamso Kouphokham, andengineers of the plants and PTM. Data collection and measurement were carried out almost
entirely without the assistance of ECCJ experts, though data analysis required help fromECCJ experts. An engineer in the local team (electrical engineer affiliated with Plant No. 2)
gave a report on the results at the seminar-workshop held later. The report of the audit isprovided in Reference II-3.

(2) Status of energy conservation initiatives
Energy conservation initiatives at the cement plant are said to have begun after participationof a Lao Cement engineer in the 2004 PROMEEC Vientiane Seminar (*1). In Lao Cement,
fuel SEC (*2) and electricity SEC are being managed, but they are matters of concern only
to certain executives, and are not satisfactorily disseminated to the actual work site. No
organizational efforts have been made, such as establishing energy conservation committees
and appointing energy managers, nor have small group activities such as kaizen activities(*3) been adopted. The only information posted on bulletin boards was a graph showing
cement production trends.
We found no signs of untidiness in the cement plants that are commonly found indeveloping countries. They gave the impression of being relatively well organized. Plant No.

II‑ 7

1 employs relatively old facility called shaft kiln, but it was well maintained and being usedcarefully. The employees were courteous, and their willingness to listen to the survey teamleft an agreeable impression on the team members. Truly the employees do not possess
knowledge of energy conservation methods at the moment, but we felt that they are fully
capable of promoting energy conservation on their own if taught what they need to know.
*1: Mr. Vichith Souvannarath (Director of Plant No. 2) participated in the 2004 PROMEEC
seminar. He raised a question and obtained information on electric power consumption
rate in cement plants in Japan.
*2: SEC: specific energy consumption*3: Kaizen activities have been introduced by JICA experts in the past.
(3) Overview of audit results1) Kiln heat balance and its utilization
Kiln heat balance was calculated to obtain the gas load of the kiln inside. Using the gasload, it is possible to estimate the maximum amount of clinkers that could be produced.
Kiln heat balance also shows where energy is being consumed, and hence, where energy
conservation opportunities lie. Heat balance was calculated according to an Excel programsupplied by ECCJ. See the following section for equations constituting the program. Data
that are necessary for running the program were either measured on-site or collected fromoperation records. In the limited time available, estimated values were used in part of
input data. Therefore, the accuracy of the calculation results could not be expected to behigh, but we were able to obtain a rough number. For greater accuracy, it would have beennecessary to consult with a process contractor. Maximum potential of clinker production
was estimated under the assumption that it is generally proportionate to the gas load ofkiln inside. Data disclosed by the Japan Cement Technology Association were utilized astarget values of the gas load. As a result, it was estimated that production capacity of kiln
No. 1 could be increased from the present 230 tons/day to 266 tons/day, and the
production capacity of kiln No. 2 could be increased from the present 780 tons/day to 988
tons/day. Table II-2-2 shows the principal data used in the calculation.
Table II-2-2 Principle data used in the calculation
Data
Unit

Kiln No. 1

Kiln No. 2

Kiln type

-

shaft

NSP

Raw material (dry weight)

t/d

370

1200

II‑ 8

Moisture

wt% on wet RM

140Clinker

t/d

230

780

Coal

t/d

44

122

Lower heating value

kcal/kg

5600

5600

Exhaust gas temperature

degC

200

320

Cooler vented air

%

-

10

Waste gas O2

vol%

5

6

Kiln No. 2 heat balance
Heat input

Heat output

Heat of fuel combustion
Sensible heat of fuelSensible heat of raw material

873.8
0
0

Sensible heat of combustion air

0Heat of clinkering
Sensible heat of clinker
Sensible heat of cooler air bypass

Total heat input
873.8
Reference temperature: Room temperature
Unit: kcal per kg of clinker (kcal/kg-cl)
Clinker cooler: Grate-type

470.0
19.2
-

Heat of evaporation of moisture contained in raw
material
Sensible heat of exhaust gas

0
167.4

Sensible heat of cooler vented air
Heat radiation from kiln surface
Heat radiation from pre-heater surface
Heat radiation from cooler surface
Unaccounted-for heat loss
Total heat output

7.3
30.4
8.0
4.0
167.5
873.8

Estimated maximum clinker production capacity
Kiln No. 1

Kiln No. 2

Kiln type

Shaft

NSP

Gas load (m3N/kg-cl)

1.91

1.71

Designed production capacity (t-cl/d)

200

700

Actual production capacity (t-cl/d) @ Oct. 3, 2006
Estimated maximum production capacity (t-cl/d)

230
266

780
988

Gas load in Japan (m3N/kg-cl)

1.65

1.35

Note 1: The above estimates are based on many assumptions. They are to be used for preliminary
examination, and not for detailed examination.
2) Estimation of air leakage rate

II‑ 9Air leakage is likely to occur in the grate cooler, sliding parts around the kiln, suspension
pre-heater, grinding mill, and electric dust collector. No matter where a leakage occurs,
however, it increases power consumption of the fans. Air leakage in the grate cooler orkiln causes increased fuel consumption. The older the facility becomes, the greater the
possibility of air leakage. An effective method for early detection of air leakage is tomeasure oxygen level in questionable areas. In this audit, oxygen levels could not bemeasured due to a malfunction of the gas analyzer. Oxygen level is not only important for
detecting air leakage, but it has great impact on the accuracy of heat balance.

3) Speed control of large-scale rotary machines
In cement plants, rotary machines consume the largest amount of power. In most cases,
they are much larger than necessary and put a considerable amount of power to waste.
Even if they are designed in an appropriate size, energy loss occurs when the control
damper is closed in times of low production volume. A rough estimate of energy loss canbe obtained by observing the opening of the control damper and the load on the rotary
machine drive motor (electric current). Table II-2-3 below shows the data collected andthe estimated reduction in power when speed control is applied.

Fan
no.
(*3)

Service

G6

Cement millEP fanCooler fan
Cooler fan
Cooler fan
Cooler fan
Primary air
fanCoal mill fan
Coal mill fan
Low mill fan
Low mill
EP fan
IDF fan

G14
G15
G16
G17
G23
K1
K2
B26
E13
F23

Table II-2-3 Estimated power reduction
Rated
Rated
Rated
Actualcurrent
voltagekW
current
(Ad)
(Vd)
(name
(Aa)
plate)
(*1)
214.8
380
(1041)
188

Powersavings(kWsaving)

Damperopening
(%)

62

38

102.6
70.6
85
86
56.8

380
380
380
380
380

55
37
45
45
21.6

73
54
48
60
24

31
18
32
26
0

73
61
60
56
100

102.5
201
53.4
214.8

380
380
380
380

(46.5)(87.8)(41.6)(1041)

56
113
29
180

75
145
39
0

50
78
42
100

62.7

6000

630

51

0
∑428

100(*2)*1: Figures in parentheses are rated power values calculated according to thefollowing equation.
Rated kW = head (Pa) x flow rate (m3/min) / 60000 / fan efficiency*2: F23 adopts speed control based on fluid coupling.

II‑ 10*3: G23 is a roots blower, and the others are centrifugal fans.
The amount of power saved by applying speed control is estimated by comparing actual
operation and rated operation along the performance curve. Unfortunately, we were notable to obtain the performance curve for fans other than F23. Therefore, as a simplified
method, we compared electric currents and estimated power savings according to thecurrent method using the equation below. The current method should be used only when
making rough estimations, as it is not too precise.
Power savings = design kW x {1–(actual ampere/design ampere)^3}/fan efficiency x motor efficiency
Fan efficiency and motor efficiency were assumed as 0.7 and 0.8, respectively.

If the yearly number of operating days is assumed to be 300 days,
Annual savings = 428 x 300 x 24 = 3,081,600kWh4) Proposals for Lao Cementa. Increased cement production
As mentioned earlier, Lao Cement’s existing kilns have the potential to increase cement
production 15% to 26%, though these figures are rough estimates. To mitigate as muchas possible the present burden of importing cement to cover for the lack of production
capacity, serious consideration should be given to increasing production. When doing so,
it is important to take one step at a time, while calculating gas load and checking for any
bottlenecks in the production facilities.
b. Speed control
A number of fans operate with the damper in the semi-open position, and waste several
million kilowatt-hours of power. The most effective method of reducing waste of power
is to control speed by means of an inverter. If the inverter is successfully implemented, aunit power consumption improvement of 13 kWh/t-clinker (*4) could be expected. The
introduction of speed control should be promptly considered.
*4: 428kW x 24h / 780t-clinker/d = 13.1kWh/t-clinker
c. Air leakage prevention
Air leakage causes energy waste. Since the most effective method of detecting air
leakage is to measure oxygen level, we recommend the purchase of a portable oxygen
analyzer. A zirconium sensor would be an appropriate oxygen meter, as it has a longservice life and provides sufficient precision. See Attachment II-3 for details on air

II‑ 11leakage estimation method.
d. Management of grinding balls
Grinding efficiency is greatly influenced by the diameter of grinding balls. The balls
wear and become smaller with time, causing grinding efficiency to drop and raw mill
SEC to increase. Conversely, by monitoring raw mill SEC, it is possible to estimate thedegradation of grinding balls and assess their appropriate charging time. The amount ofballs inside the ball mill also influences grinding efficiency. As shown in Fig. II-2-1
below, it is a good idea to plot SEC values daily.

Fig. II-2-1 Management of grinding SEC in a ball mill

5) Creating an energy management system
The effectiveness of an energy management system (EMS) has already been proven indeveloped countries. Table II-2-4 shows the major items composing an EMS.
Table II-2-4 Items for an energy management system
Item
Energyconservation
organization
Energyconservation
monitoring
Energyconservation
technologies
Operation andfacility maintenance

Activity
Organization
Responsibilities
Tracking data
Establishing goals
Technical evaluation
Daily activities

Activity example
Energy conservation promotion committee
Energy managers
Employee training
Data recording and distribution
SEC management
Energy conservation indicators (ex. O2%)
Technical evaluation
Energy audit
Yield (prevention of off-spec products)
Preventive maintenance (prevention ofunscheduled shutdown)

II‑ 12

As mentioned earlier, energy management activities are scarcely implemented at Lao
Cement’s plants. The following activities should provide a good start.
a. Organizing an energy conservation committee
b. Appointing energy managers
c. Providing employee training (ex. participation in outside training)d. Recording energy data and distributing them to relevant departments
Additionally, it is important that plant top managements give their full support to theabove activities.

II‑ 13

3. Seminar-workshop
3.1 Overview(1) Date/Time
October 6, 2006 (Fri.)

8:30am – 5:30pm(2) Venue
Dong Chang Palace Hotel, Vientiane, Lao PDR(3) Presentations in the seminar-workshop
58 participants attended the seminar-workshop. In the seminar, ASEAN Center for Energy(ACE) introduced the ASEAN Energy Efficiency and Conservation (EE&C) program, andthe Lao Ministry of Energy and Mines introduced the present situation of energy
consumption in Lao PDR, in addition to ECCJ’s introduction to its guidance and program for
EE&C in Japan’s industries. They were followed by presentations on examples of energy
conservation activities in the ASEAN region by representatives from Lao PDR, Malaysia,
Myanmar and the Philippines.
A plant engineer reported the results of audit survey conducted at Lao Cement’s plants, as
already mentioned, and ECCJ made several comments regarding the cement production
equipment and electric facilities.
In the workshop, ECCJ discussed barriers and countermeasures to EE&C promotional
activities, and ACE reported on the current development status of the technical directory(TD) and database/benchmark/guideline (DB/BM/GL) for major industries.

(4) Participants
Lao PDR:
Dr. Daovong Phonekeo

Deputy Director General, Dept. of Electricity

Mr. Khamso Kouphokham

Deputy Chief of Energy Management Div, MEM

Mr. Vanthong Khamloonvylayvong

Deputy Manager of Nam Ngum Hydro Power
Plant

Approx. 40 general participants from Lao PDR also attended (metal mining, table salt,
etc.).
ASEAN Center for Energy (ACE):
Mr. Ivan Ismed

Project Officer

II‑ 14

Ms. Evangeline L. Moises

Project Officer

Malaysia Energy Center (PTM):
Mr. Zul Azri Hamidon

Energy Audit Engineer

Ms. Norazean Mohd. Nor

Technical Assistant

Ms. Meena Kumari

Assistant Project Manager

The Philippines:
Mr. Marlon Romulo U. Domingo

Department of Energy, Energy Efficiency
Division

Myanmar:Ms. Daw Hla Hla Kyi

Deputy General Manager, Myanmar Petrochemical
ComplexThe Energy Conservation Center, Japan (ECCJ):
Kokichi Takeda, Hideyuki Tanaka, Taichiro Kawase
3.2 Results of the seminar-workshop
Mr. Khamso Kouphokham (Deputy Chief, MEM; focal point (FP) representing Lao PDR)
presided over the seminar, which opened with the participation of 58 guests.
(1) Opening ceremony (congratulatory speech and opening address)

1) ACE
Ms. Evangeline Moises delivered a speech written by Dr. Weerawat Chantanakome(executive director, ACE) and introduced ACE’s activities, PROMEEC activities and theseminar program.
2) ECCJ
Mr. Hideyuki Tanaka (project leader) gave a brief address, mentioning the significance ofthe project, its development and recent status, and Japan’s cooperation and contribution to
ASEAN.
3) Ministry of Energy and Mines (MEM)
Dr. Daovong Phonekeo delivered an address, citing the declaration on EE&C initiatives
adopted by the ASEAN Ministers’ Meeting, which was held this spring, and emphasizing
the importance of conserving energy in response to increasing crude oil prices. On behalfof the ministry, he also expressed his appreciation of activities implemented by
METI/ECCJ and ACE.
(2) Session 1: Policy and Initiatives on EE&C

II‑ 15

1) Overview of EE&C Programs on ASEAN (Ms. Evangeline Moises, ACE)
Ms. Moises described the role of ACE in the ASEAN region, and introduced major EE&C
activities by EC-ASEAN and SOME-METI, and PROMEEC activities. She also made acall for participation to the award system.
2) Overview of Plans & Programs on EE&C in Lao PDR (Mr. Khamso Kouphokham, MEM)
Lao PDR is at the stage where it will be preparing future plans, including energy
conservation laws and regulations. It should first of all consider the application of energy
conservation

measures togovernmental buildings, formulation of demand-side

management (DSM) promotion plans by Electricité du Laos (EDL), and the developmentof an energy manager system.
3) Initiatives and Programs of ECCJ on EE&C in Industry in Japan（Mr. Hideyuki Tanaka,
ECCJ）
Mr. Tanaka introduced energy conservation policies in Japan and ECCJ’s activities. He
also discussed the harmonization of 3Es and the energy conservation law, the designationof plants, energy managers and national examination, education and training, and thenational convention of excellent successful cases.
(3) Session 2: EE&C Best Practices in Industries

1) Case Study 1 – Hydro Power Plant (Lao PDR, Mr. Vanthong Khamloonvylayvong)
Nam Ngum Hydro Power Plant has received its first PROMEEC audit by ECCJ experts in
2002, and a follow-up audit in 2004. In this presentation, it was reported that the plant ismaking on-going efforts to implement energy conservation and improvement measuresthat were proposed in 2004. Through measures to repair the turbine runner for increasing
the turbine efficiency, to strengthen lighting control, and to enhance operational
management of facilities inside the power station, it has succeeded in increasing power
generation by 15MWh and in saving 53MWh of power during the year. Mr.
Khamloonvylayvong repeatedly expressed gratitude to ECCJ.
2) Case Study 2 – Industries in Malaysia (Malaysia, Ms. Meena Kumari M. Nair)
Mr. Nair gave a report on the energy conservation activities of the Malaysia Energy Center(PTM), emphasizing the achievements of the Malaysia Industrial Energy Efficiency
Improvement Project (MIEEIP). An audit of 48 plants by the PTM audit team showed thatthe plants as a whole have the potential to save energy worth RM108 million (more than 3billion yen). The implementation of appropriate measures could produce outstanding
results.

II‑ 16

3) Case Study 3 – Oil Refinery (Myanmar, Ms. Daw Hla Hla Kyi)
Myanmar Petrochemical Complex is a state-run company operated under the control of the
Ministry of Energy. It received the first PROMEEC audit by EECJ experts in 2000 and afollow-up audit in 2004. The presentation was almost entirely devoted to a description ofrefining processes and an overview of the first audit. Subsequent energy conservation
activities simply consisted of managing excess air in furnaces. Ms. Kyi repeatedly
expressed gratitude to ECCJ.
4) Case Study 4 – Iron/Steel, Cement & Food (Philippines, Mr. Marlon Romulo Domingo)
A representative from the Philippine Ministry of Energy gave a report on energy
conservation activities in the Philippines, particularly of manufacturers who were awarded
the “Don Emilio Abello Energy Efficiency Awards” in 2005, including a steel bar
manufacturer, a galvanized and color sheet steel manufacturer, a cement company, and apineapple processing company. Dramatic improvements in SEC were shown using
numerical data.
5) Results of the energy audit of two cement plants (Lao Cement Co., Ltd.: Mr. Natha
Phyphthasak; ECCJ: Mr. Taichiro Kawase, Mr. Kokichi Takeda)
Mr. Natha Phyphthasak from Lao Cement gave a presentation on past and present energy
conservation activities and future activity plans of the company’s two plants. Lao Cement
has been actively working to improve electricity SEC. As a result of its efforts, it has
achieved an SEC of 133.5 kWh/t-cement in Plant No. 2 to its target of 125 kWh/t-cement.
Although there was no mention of any activity goals during the energy audit of the plants,
it appears that some activities have actually been implemented to a certain extent for sometime.
As future plans, Mr. Phyphthasak talked about employee training, strengthening of
preventive maintenance, productivity improvement, and the establishment of an energy
conservation organization. The advice that ECCJ gave at the conclusion of audit survey
was adopted as a future plan of cement plants.
In regard to the results of audit survey, Mr. Kawase explained the conclusion drawn fromheat balance calculation in the kiln as a quick evaluation. At the same time, he advised Lao
Cement to create an energy management system, citing the significance of employee
training and daily facility management as reasons. Mr. Takeda gave an explanation ofaudit results (quick estimation) related to the speed control of large-scale rotary machines.

(4) Session 4: The Way Forward
1) Barriers and Measures to Implement EE&C in Industry (ECCJ: Mr. Taichiro Kawase)II‑ 17

Mr. Kawase discussed barriers and measures to implementing EE&C, using materials
supplied by ECCJ and citing other presentations that were delivered ahead on the sameday.
2) Updates on the development of the technical directory (ACE: Mr. Ivan Ismed)
Mr. Ismed explained the purpose, method of development, and format of the technicaldirectory (TD), and presented an example of a TD sheet.
3) Updates on the development of the database/benchmark/guideline for major industries(ACE: Mr. Ivan Ismed)
As materials on the industry-based database were not available in time for this seminar, Mr.
Ismed

explainedthepurpose,methodofdevelopment,

andformatofthedatabase/benchmark/guideline for major industries using materials on the PROMEEC
database/benchmark/guideline for buildings instead.

(5) Questions and answers
As mentioned previously, a Q&A session followed each presentation session. Some
examples are provided below.

Q: In regard to hydro power generation in Lao PDR, energy conservation proposals
made after the first audit were implemented only to a small degree. What was the
obstacle to their implementation?
A: (Mr. Vanthong Khamloonvylayvong) Lack of funding was the problem.
Q: The achievement of energy audits become improved in Malaysia, but are they being
implemented?
A: (Ms. Meena Kumari) Some of large companies put into implementation proposals inenergy audits. Most of other companies are still contemplating their implementation,
due to a funding problem.
Q: Good practices in the Philippines are quantitatively evaluated by SEC improvement
rate. According to the presentation, SEC improved from 130 to 70 in the case of thecement plant. However the improvement seems so large that it should bereconfirmed.
A: (Mr. Marlon Romulo Domingo) We will reexamine it later.
Q: Among the companies participating in today’s seminar, are there any companies that
conduct in-house energy audits?
A: Only one company—Lane Xang Minerals Ltd. (gold producer)(6) Closing address

II‑ 18

The seminar-workshop concluded with closing speeches by Ms. Evangeline L. Moises andMr. Hideyuki Tanaka.
(7) Impressions and comments
Mr. Khamso Kouphokham, the Lao PDR focal point, sincerely worked to coordinate
various activities, including arrangement for accommodations, transportation to and fromthe airport, travel and visit to the plants, adjusting schedules with the plants, and arranging
for interpreters and the seminar. The participation of two Malaysian engineers (PTM) in theaudit had great significance, because technical transfer among the ASEAN countries is oneof the goals of the PROMEEC project. Hereafter, we hope to also receive the cooperation of
the Energy Conservation Center of Thailand (ECCT) and the Indonesia’s national energy
conservation company (KONEBA).
Lao Cement’s response to the audit survey was excellent. 20 engineers, including two
deputy plant directors, devoted four days to participating in the audit survey. The plant
director delivered a speech, and all of 20 engineers introduced themselves in English. A
number of them have graduated from universities in the former Soviet Union, including
Czechoslovakia, Ukraine, Georgia, and Russia. They were also highly disciplined, and we
had an impression that they could respond to anything if proper training was given. The
only regret is that Mr. Zamora (ACE) could not participate due to other urgent business.

(8) Proposals for FY2007 PROMEEC activities
1) Extending the audit duration
This project was originally planned for the purpose of supporting follow-up audits. In thecase of follow-up audit, the duration could be as short as two or three days, because theprocesses of the plant are already known and audit items are already decided. The current
five-day schedule is sufficient.
However, the recent audit we made was substantially a new audit, though it was referred toas a follow-up audit. Actually, a half-day was spent on traveling from the hotel in the city
to the plants in the locality, and a half-day on an observation tour for understanding
processes and facilities of the plant. In addition, one full day was spent on preparatory
works prior to audit, for example, a lecture on process principle and energy saving
measures, an explanation of audit procedures including measurement task, and theorganization of audit groups, etc. Another one day was spent on data collection,measurement, and fine observation of equipment and machineries. A half-day was spent onreporting the brief results of the audit to the plant management, and the following half-day

II‑ 19was spent on traveling from the plants back to the city. The final day was dedicated to theseminar-workshop. The survey took up a total of five days, but only two days were devoted
to actual audit activities on the audit site, excluding the preparatory works and reporting to
the plant management.
In some of the ASEAN countries, important industries frequently locate their factories in
the locality distant from the city. It therefore takes time to travel to a plant from the city. If
the distance requires a day’s travel, then it would be necessary to flexibly deal with thecircumstance, for example by extending the audit schedule by one day. If two or more
plants are to be visited, the additional time it would take to travel from one plant to thenext must be considered.
In the case of plant audits in the ASEAN countries, it seems very difficult to obtainnecessary information on processes, etc in advance. Even if preliminary assessment is
attempted through the use of questionnaires distributed in advance, little information canbe obtained from the plant, and much work must be done on-site, after all in most cases.
One of the objectives of this project was to transfer audit skills through on-the-job training(OJT). Therefore, minimum time was also allocated for training the members of audit
team.
Based on the above, the present schedule of five days is sufficient enough in the case of afollow-up audit, but insufficient to a new audit of plants. We propose a longer schedule
when implementing a new audit. The extension of audit duration should be consideredwhen formulating the next year’s activity plans for the project.
2) Strengthen the preliminary preparation
A preliminary questionnaire was sent to the plants prior to visiting this time around, but wefailed to obtain sufficient responses. The currently-distributed questionnaire have beenformulated for contemporary Japanese plants which usually possess a data management
system, and as a result have contained so detailed questions. However, considerations
should be given to creating a new questionnaire that contains the minimum necessary
questions that match actual situations in the ASEAN countries.
Furthermore, the host plant should be informed of the detailed plans of the audit inadvance. At the least, the schedule and audit items should be conveyed to the plant in an
early stage and an approval should be taken from top management of the plant.
ACE and the focal points should bring forward the date for starting the preliminary
preparation. Starting preparation two months ahead of audit survey is seemingly a bit late.
A speedier response is expected from ACE.

II‑ 20

3) Prepare measuring instruments
It is necessary to prepare at least a thermometer with thermocouple sensor, a gas analyzer,
and an electric power monitor. ECCJ’s instruments were old models and deteriorating,aging, or otherwise in an unusable state. Considerations should be given to leasing themfrom Sumikin Management Co., Ltd. and other companies.
Another enticing option is to borrow measuring instruments from ASEAN institutions suchas PTM and ECCT. If handling engineers are accompanied with the package, they could
provide guidance as audit instructors. This scenario would also be consistent with theobjective of the PROMEEC project to promote guidance through engineers within the
ASEAN region.

II‑ 21

4. Attachments(1) “Cement Process and Energy Saving”(2) “Promotion of Energy Conservation Activities in Factories (Electricity)”(3) “Report on Energy Audit of Lao Cement Co.”
(4) “ASEAN PROMEEC Seminar/Workshop Program”
1. “Overview of Plans & Programs on EE&C in Lao PDR”
2. “Initiatives and Programs of ECCJ on EE&C in Industry in Japan”
3. “Case Study 1 – Hydro Power Plant (Lao PDR)”
4. “Case Study 2 – Industries in Malaysia (Malaysia)”
5. “Case Study 3 – Oil Refinery (Myanmar)”
6. “Case Study 4 – Iron/Steel, Cement & Food (Philippines)”
7. “Results of Energy Audit of Two Cement Factories”
8. “Barriers and Measures to Implement EE&C in Industry”

II‑ 22

III. Thailand (Steel Industry)
1. Activity Overview
In the phase 1 of PROMEEC activities in Thailand, an energy audit at sodium hydroxide plant
was conducted two times on Nov. 24-28 of 2003 and Jan. 12-16 of 2004. In the phase 2, nofollow-up survey of the phase 1 activities was carried out, but it was planned to give instruction
in energy audit for other industrial field, i.e. for steel industry. The OJT of energy audit forsteelworks was carried out at Bangkok Steel Industry Public Co., Ltd. (BSI) near the coast
south-south-east of Bangkok, 30 to 40 minutes’ car ride from the city center. On the site of BSI,
energy audit activities were carried out for 3 and a half days; 7 officers from Thai Department of
Alternative Energy Development and Efficiency (DEDE) and 8 staff members of BSI
participated in the audit works.
In the seminar workshop, the result of audit survey was reported by the manager of BSI. The
seminar workshop in Thailand was confined to the steel industry. Representatives from 3
member states of ASEAN also made a presentation on energy conservation activities in the steel
industry in their respective countries.

1.1 Date
November 13 –17, 2006

1.2 Venue
Steelworks:

Bangkok Steel Industry Public Co., Ltd. (BSI)(Approx. 30km south-south-east of Bangkok)

Seminar Workshop:

Twin Towers Hotel, Bangkok

1.3 Schedule
Nov. 13 (Mon) Energy Audit at the Steelworks (BSI)
Nov. 14 (Tue)Energy Audit at the Steelworks (BSI)

Nov. 15 (Wed)Energy Audit at the Steelworks (BSI)

Nov. 16 (Thu)

Energy Audit at the Steelworks (BSI), Preparation for the Seminar Workshop

Nov. 17 (Fri)Seminar Workshop

1.4 Participants
Thailand:
Department of Alternative Energy Development and Efficiency (DEDE), MOE
Dr. Prasert Sinsukprasert

Senior Engineer

III‑ 1

Mr. Sarat Prakobchart

Senior Engineer

ASEAN Center for Energy (ACE):
Ms. Evangeline L. Moises

Chief, Information & Event Division

Mr. Ivan Ismed

Project Officer

Japan: ECCJ, International Engineering Department, Technical Engineer
Koukichi Takeda, Hideyuki Tanaka

About Thailand(1) General Information about Thailand (Source: web site of the Japanese Ministry of Foreign
Affairs (November 2006 data))- Area:514,000km2 (approx1.4 times as large as Japan)- Population: 62,420,000 (2005)- Capital:
Bangkok- Ethnicity:
Majority is Thai; other ethnic groups are: Chinese, Malay, and minorities
living in the mountains.
- Language: Thai
- Religion:
Buddhists (95%), Islam (4%)- History:
The kingdom of Thailand was established in the 13th century by the
Sukhothai dynasty, which was succeeded by the Aytthaya dynasty (14th – 18th
century), Thornburi dynasty (1767-1782) and the present Chakri dynasty
1782–). In 1932, Thailand became a constitutional monarchy by a revolution.
- Political System:
Constitutional Monarchy- Economy: Agriculture occupies 40% of the working population, but less than 10% of
GDP (2004). On the other side, manufacturing industry occupies approx.
15%, but 35% of GDP (2004) and 85% of the export.
GDP per capita: 2,722 Dollars (2004)
Export: Export items: Computers, cars and their parts, ICs, natural rubber (2004)
Partner: 1. USA 2. Japan 3. China 4. Singapore 5. Hongkong
Import: Import items: Crude oil, machines and their parts, electrical appliances andtheir parts, chemical products (2004)
Partner: 1. Japan 2. China 3. USA 4. Malaysia 5. UAE- Economical overview:
The rate of economic growth in 2003 was 6.9%, in 2004 it was 6.1%. In 2005,
economic growth slowed down a little due to the Sumatra Offshore
Earthquake and tsunami disaster, drought damage, and worldwide steep riseof petroleum prices, and the growth rate sank to 4.5%.
(2) Energy situation (Source: IEA 2004 Statistics (2006 Edition))
In Thailand a certain amount of fossil fuels are produced domestically. Production andConsumption of fossil fuels in 2004 were as follows:
Approx. 20 million tons of coal were produced, but approx. 7.5 million tons were inported.
60% of domestic demand were used for electric power generation, and 40% was consumed

III‑ 2

in the industry.
Domestic petroleum production occupied 20% of domestic consumption, and 80% of thedemand were covered by import. Petroleum was refined domestically, and approx. 10 % of
the products were exported. 60% of the domestic demand were consumed by thetransportation sector, followed by households, industry and energy conversion sector.
Natural gas production covered more than 70% of the demand. More than 90% of natural
gas were used for energy conversion, and the rest were mainly consumed in the industry.
Natural gas was partially utilized for non-energetic purposes.
Biomass was consumed for energy conversion, in the industry and in the household.
Electricity was mostly provided domestically, and only a few percent were imported fromadjacent countries. Electricity is mainly used by households and in the commerce, followedby the industry.

III‑ 3

2．Energy Conservation Survey at the Steelworks of Bangkok SteelAmong numerous steelworks in Thailand, the steelworks of BSI producing reinforcing bar
was selected as a site of OJT (on-the-job training).

2.1 Overview of the Steelworks of Bangkok SteelThe steelworks is located approx. 30km south-south-east of Bangkok, near the Thai Bay.
After crossing many rivers, and passing a newly built cable-stayed bridge, we arrived at thesteelworks of the Bangkok Steel company. Seeing some similar bridges under construction,
we had an impression that the infrastructure was being built up rapidly in Thailand.
The Audit Team consisted of 7 officers of the Thai government (DEDE), 2 members of other
ASEAN countries and 2 members of ECCJ, 11 persons altogether.
Since it had been planned to carry out activities only at the steelworks of BSI during our stayin Thailand, we could give an OJT in audit for three and a half days at the steelworks.
(1) Company Name:

Bangkok Steel Industry Public Co., Ltd. (Founded in 1964)(2) Location:

27 Poochaosamingprai Rd. Phrapradang, Samutprakarn 10130,
Thailand(3) Period:

November 13 – 16, 2006

(4) Survey members (audit team 1/2):
Thai Government (DEDE, MOE):
Mr. Sarat Prakobchart

Senior Engineer

Mr. Somchat Tanglikhasit
Mr. Vachira Jindaphet
Mr. Chawalit Boonsang
Mr. Amornsak Rangsakorn
Mr. Pornchai Thernnoo
Mr. Cheerawat Nuannuam
ASEAN Center for Energy (ACE):
Ms. Evangeline L. Moises

Chief, Information & Event Division

Mr. Ivan Ismed

Project Officer

Japan: ECCJ, International Engineering Department, Technical Engineer
Koukichi Takeda, Hideyuki Tanaka(5) Bangkok Steel engineers (audit team 2/2):
Mr. Chaitat Tanormsub

Personnel Department Manager

III‑ 4

Mr. Viroon Kemphet

Steel Factory Manager

Mr. Somchai Khamphoo

Rolling Mill Production Manager

Mr. Taned Dejamornton
Mr. Pongsthorn Rienthong
Mr. Sumrong Boonchalee
Mr. Pornthep Suwanmanee
Mr. Taweechai Sornchui
Mr. Jakaphol Nounkhain
Mr. Anan Thaicharoen(6) Activity schedule at Bangkok Steel
Table III-2-1 shows the schedule of activities at BSI.

Table III-2-1 Schedule of activities at BSI
Date/Time
Nov. 13 (Mon)

Activity
1. Confirmation of the schedule
2. Introduction of the steelworks by
9:40am-5:20pm
BSI.
3. Explanation of mini-mill industry
in Japan, audit procedure, andsuccessful examples in electricalfacilities by ECCJ.
4. First inspection of the steelworks
Nov. 14 (Tue) 1. Discussion of measurements on site
2. Walk-through audit of furnace
9:30am(temperature measurement etc.)-5:20pm
3. Discussion of preliminary
questionnaire
Nov. 15 (Wed) 1. Discussion of energy conservation
measures8:50am
2. Explanation of analysis of heat
-5:20pm
radiation from furnace wall
3. Walk-through audit of electricalfacilities
Nov. 16 (Thu) 1. Discussion of energy conservationin compressors
8:50am
2. Discussion of audit results-2:00pm

2.2 Overview of the Facilities in the Steelworks(1) Overview of the Steelworks

III‑ 5

Person in charge
All members
Mr. Chaitat, Mr. Somchai
Mr. Tanaka, Mr. Takeda

All members
All members

All members

All members +Mr. Hin Navawongse(ISIT)

Remarks

After explanation of the aims and schedule of the visit by the DEDE officers in the audit
team, three managers of BSI briefed the facilities of the steelworks and the result of
preliminary questionnaire, using a company brochure and a power point slide show. The
outline of the company is as follows:

The company was established in 1964. At first, only rolling mills were operated, usingpurchased materials as a raw material. In 1973 electric furnace were introduced, and the
production capacity for reinforcing bars was increased to 450,000 tons per year. At present,a portion of billets are purchased, and the capacity of rolling mills increases to 600,000 tons
per year. In the premise of the steelworks there is a zinc plating plant and a cranemanufacturing plant. The zinc plating plant and the crane manufacturing plant are notincluded in the object of the audit survey. In the week when we visited the steelworks, No.2of the 2 rolling mills was not operated.
Product:

Concrete reinforcing steel bar
Deform bar, Round bar: φ6–φ40
Production Capacity: 500,000t/y
Actual Production: 314,877t/y (2005)(Zinc-plated steel sheets: 130,000t/y (1983, 1992, 1997))

Equipment:

25-ton furnace×2 (furnace capacity : 300,000t/y), CC (continuous castingmachine)×2
Continuous heating-furnace×2, RM (continuous rolling mill)×2
A part of raw materials are purchased from the domestic market.

Employee:

600

Plant operation: Steel production: 3 shifts, Rolling: 4 shifts(2) Concrete reinforcing bar manufacturing plant

1) Manufacturing process
Manufacturing process of concrete reinforcing bar is shown in Fig. III-2-1. Purchased
ferrous scraps are melted in the electric furnace (EAF), and the molten steel is received bya ladle. The molten steel is then conveyed from the ladle through the tundish (T/D) to thecontinuous casting machine (CCM), and molded into billets there. The hot billets arecooled down, and then reheated in the reheating-furnace to nearly 1,200°C; then, thebillets are hot-rolled into concrete reinforcing bars or round bars by the rolling mill. The
products are cooled down, cut into prescribed sizes and shipped in bundles with required

III‑ 6

quantity.
In this process energy is consumed as follows:
Fuels: bunker oil grade C:

For reheating-furnace and preheating of ladles

light oil (kerosene):

Electrical furnace burner

LPG:

Preheating of tundish

Electrical Power:

Electrical furnace (melting scraps),
Receiving and distribution facilities,
CCM, RM, dust collector, motors for operating otherappliances, lighting etc.

Fig. III-2-1 Concrete reinforcing bar manufacturing process

2) Main equipment
Electrical furnace: 25-ton a.c.furnace×2 (DEMAG (1973), SOE (1993)) gutter tappingtype, equipped with oxygen and carbon blow-in pipe, and kerosene
burner.
Continuous casting machine (CC): billet CC (3 strand)×2 (1973, 1993)
Billet sizes:
Reheating furnace:130-7m and 11m

Former furnace (1964, now out of use), Now there are 2

furnaces.

III‑ 7

Furnace #1: 50t/h heating-furnace (1993, DANIELI, pusher-type)Internal dimension: 7,600W×1,600H×20,000L (mm)Heavy oil burner: 6 heating zones, 6 soaking zones,
Rated oil rate: 1,900L/h
Equipped with recuperator (when fuel oil rate is 1,400kg/h and air
ratio m = 1.1, air preheating temperature is 300°C)
Combustion air fan: 20,000m3N/h×67kW motor
Furnace #2: 70t/h heating-furnace (1996, walking beam type)Continuous rolling mills (RM): 2
RM #1

Continuous rolling mill (1993): 50t/h

RM#2

Continuous rolling mill (1996): 70t/h

Dust collector:

Integrated dust collector using bag filter, direct dust-drawing fromelectric furnace (2 furnaces) and dust-drawing from building (2furnaces), 2 dust collectors are tied-in each other through ducts

Blowers:(4,670m3/min (60°C) – DC600kW)×2,(3,115m3/min (60°C) – DC400kW)×2

Air compressor:

1 turbo compressor with vane-control type (IHI, 2003)

2.3 Walk-through Energy Audit at the Steelworks(1) Energy consumption
Energy sources used in the steelworks are, as stated above, bunker oil grade C, light oil(kerosene), LPG and electricity. Changes in production of the concrete reinforcing steel bar
and energy consumption are shown in Table III-2-2. Also energy unit prices are shown in
Table III-2-3.
The table contains “oxygen”: Oxygen is used for burning light oil during the operation of anelectric furnace, and is blown, together with carbon powder, into the furnace; oxygen
contributes to scrap melting and to raising the molten steel temperature, and to reducing
SEC for electricity. Oxygen should be treated as a part of energy sources, but as data forcarbon powder consumption are lacking, oxygen will not be considered in the discussion
below.
Energy unit prices increased in the last 2 years to 1.4 – 1.5 fold, and electricity increased to
1.2 fold as Table III-2-3 shows. Table III-2-4 shows energy consumption situation in thesteelworks.
BSI intends to promote energy conservation particularly by reducing fuel consumption ofheating-furnaces (bunker oil grade C). Obtained data also show that in 2005 only bunker oil

III‑ 8

grade C increased.
Table III -2-2 Production and SEC of Concrete Reinforcing Bar in the BSI Steelworks
FY
Production of concrete reinforcing bars t/ySales volume
Million Baht/yEnergyconsumption
Bunker oil
for steelkL/yGrade-C
heating-furnace, for(43,892kJ/kg,
preheating ladles
spec.grav.0.9554)
Diesel oil
for EAF burners
kL/yLPG
for preheating T/Dkg
3
Oxygenkm /y for EAF injection
MWh/ for operating EAF andElectricityyappliances
Specific Energy Consump
Bunker oil Grade-C
L/t
Diesel oil
L/t
LPG
kg/t
Electricity
kWh/t
Table III-2-3
EnergyBunker oil Grade-C
Diesel oil
LPG
OxygenElectricity

Unit
Baht/L
Baht/L
Baht/kg
Baht/m3
Baht/kWh2003
320,456
(100)
4,000
(100)

314,878
5,500

2005(98.3)(137)

12,708(100)

15,277(120.2)

3,233
37,9008,251
230,508

(100)
(100)
(100)
(100)

2,292
36,0008,212
204,755(70.9)(95)(99.5)(88.8)

39.7
10.1
0.12
719

(100)
(100)
(100)
(100)

48.5
7.3
0.11
650

(122)
(72)
(92)
(90)

Energy Unit Prices
2003
7.548
12.28814.162
4.200
2.194

2005
(100)
(100)
(100)
(100)
(100)

11.14617.81416.130
4.196
2.658

(148)
(145)
(114)
(100)
(121)

Table III-2-4 Percentage of Energy Consumption Process by Process
EnergyEnergy/Use
Heavy oil

Fuel

Ratio (%)

Furnace #1
Furnace #2
CGL
Boiler (CGL Plant)
OthersEAF1 & 2
TundishDiesel oil
LPG
EAF
Motor (>20kW)

III‑ 9

35.4
27.5
4.2
0.5
10.1
22.0
0.3
45.1
38.6

100

Fuel & Electricity
Ratio (%)

51.2
100

Electricity

Cooling system
Air Compressor
Air Conditioning
Lighting
Others

5.7
2.8
1.7
0.6
5.5

100

48.8

CGL: Continuous Galvanizing Line(2) Energy conservation activities at BSIAt BSI, an Energy Saving Team was organized to promote energy conservation.
Energy conservation activities conducted by BSI itself in the past were described as follows:
1) Roof and wall materials (steel sheet) of the rolling mill plant were, partially and atregular intervals, replaced with semi-transparent plastic plates so as to take daylightinto the building. (Reduction of lighting electricity = ∆178MWh/y)2) Material of fan blade in the cooling tower fans were changed from aluminum to glass
fiber-reinforced plastics. (Reduction of motor power supply = ∆35MWh/y)3) Drying air nozzle for concrete reinforcing bar quenching and annealing (QTB) was
equipped with a solenoid valve in order to open the nozzle only when it is used.
(Reduction of air compressor motor power supply = ∆89MWh/y)4) The opening at the entrance of the heating-furnace was reduced to approx. 50%.
(Reduction of fuel oil = ∆7,632L/y)5) De-scaling air nozzle mounted on the reinforcing bar binder was equipped with asolenoid valve in order to open the nozzle only when it is used. (Reduction of aircompressor motor power supply = ∆60MWh/y)6) The hydraulic chain transfer system was changed into an electromotor-driven type, andthe system is operated only when it is needed. (Reduction of electricity = ∆192MWh/y)7) Pinch rolls and roller conveyers for reinforcing bars were changed into pipe conveyers.
(Reduction of electricity = ∆292MWh/y)8) Dust collectors are added, and air compressors are renewed (Air compressors ofvane-type are replaced with turbo-type)

These activities brought a cost reduction of 2,150,000 Baht (approx. 7 million Yen) per year.
(3) Explanation by the Audit Team
Representatives of ACE in the audit team gave a verbal explanation of the METI-ASEAN
PROMEEC project. ECCJ explained the following 3 subjects using a power point slideshow.

III‑ 10

1) “Energy conservation activities conducted by mini-mill industry in Japan”
Parts of the seminar materials which are useful for the steelworks audit were explained
briefly to the participants.
2) “Audit Procedure”
Procedure of steelworks audit and important check points concerning energy management
and equipment observation were explained.
3) “Examples of audit of electric equipment in steelworks”
Examples contained in the seminar materials were explained.

(4) Walk-through energy audit of the steelworks and measurement results
Now that members of the audit team obtained the knowledge concerning the steelworks andthe audit method, all members of the team inspected the site. As mentioned above, thesteelworks consist of two production lines. We inspected only the #1 RM which was being
operated, DEMAG electric furnace and CC, power supply system and dust collecting
facilities. We carried out the on-site audit three times during the visit.
The situation of the steelworks was as follows:

As a result of the walk-through energy audit of the steelworks, we found out several mattersfor which energy conservation measures are necessary(Thermal area)
1)

The electric furnace is charged with scraps three times (50%, 36%, 14%), Tap-tap
interval was 70 minutes, power consumption was 584kWh/t in average.

2)

Tap-temperature of the electric furnace are often raised up to 1,700°C.

3)

The bunker oil grade C is used for preheating the ladle. Exhaust gas is not utilized.

4)

25t ladle on the CCM stand has no lid.

5)

The tundish has a cover, but the opening is too large. The cover seems not so effective.

6)

Molten steel flows uncovered from the ladle to the tundish and then to the mold. Thispart should be covered by a sleeve.

7)

There is no LF.

8)Billets are not cared for. No hot-charge is employed.

9)

Retention temperature of furnace is 1,050°C
Fuel oil consumption was 1,040L/3h, 810L for 3h20min, 2,980L for 14h40min.

10) The exhaust gas has not been measured. According to old data, it was 4%.
11) Scale loss of steel material in the furnace is 25kg/t.
If scale composes Fe2O3, loss of iron would be 1.75%. In Japan, it is typically 0.7%. It
should be reduced to 1%.

III‑ 1112) Preheated air temperature of the furnace is as low as 166.5°C.
(Electrical area)
1)

Power factor (Pf) of the transformer station in the steelworks was 0.87.

2)

In the rolling mill plant (#1RM), semitransparent plastic plates were placed in the roof
and walls at the same distance to take in daylight. Therefore, ceiling lights were turned
off in daytime except for local lighting.

3)

Fan blades in the cooling tower were changed from aluminum into glass fiber. The lifeof these blades is 10 years, and the motor power can also be reduced.

4)

0.65 MPa is minimum required pressure of compressed air because of drying process
for the GTB (hardening of products). There are 4 air compressors. Normally two or
three compressors were operating. One was under maintenance. Actually, the dischargepressure of turbo compressor in operation was 0.48MPa.

5)

A peak time in electricity charge is 6:30pm – 9:30pm

6)

Installing receiver tank in the air compressor system. There was a question concerning
sizing of receiver tank, which was answered later in the seminar.

As mentioned above, nearly 20 team members participated in the energy audit at thesteelworks of BSI everyday. But the audit and discussion were mainly conducted by ECCJ.

(5) Walk-through energy audit of #1 heating-furnace : measurement result and improvement
measures
Temperatures of the heating-furnace surface, temperature of exhaust gas and combustion air
were measured, and compared with the data at the control panel in the operating room.
Data concerning combustion in the heating-furnace #1 is shown in Fig. III-2-2.

III‑ 12

StackOil, 100℃
1520L/ｈ

Hot Air
166.5℃
Recuperator

BilletBilletExhaust gas
742.2℃

1,050℃#1 RHF

Air, 30℃
13,900m3N/hExhaust gas
493℃
O2%: (4%)

Air fanBillet pusher

Fig. III-2-2 Data concerning combustion in the heating-furnace #1

1) Heating-furnace surface temperature
The surface temperature of the heating-furnace was, as Table III-2-5 shows, rather high.
In the same table, the guideline of surface temperature for heating-furnace in Japan isindicated. Compared to these values, the heating-furnace has generally high surface
temperatures. The bottom surface of the heating-furnace was inaccessible, and thetemperature could not be measured.
Table III-2-5 Measured surface temperature of the heating-furnace (average)
Surface of thefurnace
Surfacetemperature
Guideline in Japan(inside the furnace
1,050°C)

Sides
Side

Top
Front
(inlet)
165°C

137°C

left
100°C

110/
100°C

95/
90°C

right
80°C

Rear
(outlet)150°C

Bottom(inaccessible)
120/
110°C

(Standard values in Japan: upper values are standard values, and lower values are target values.)
2) Opening of the heating-furnace

III‑ 13

The furnace has 3 openings. The inlet opening for billet charging has a size of
7m×400mm. The space between side of billet and furnace wall is 400-500mm at one side,and the space between upper side of billet and upper side of inlet opening is 270mm(Billet-size: approx. 130mm x 130m x 6m). Billet was pushed by the pusher to thedirection perpendicular to the furnace longitude, and conveyed to the rolling mill line.
This pusher doors and the billet inlet are equipped with an elevating slide gate. The slide
gate did not close tightly, and opened unnecessarily long time. It took 40 seconds, while
10 seconds would be sufficient. The size of the opening in the gate is approx. 0.5m (H) x
1m (W) by visual measurement. The vicinity of the opening was very hot and inaccessible.
No dimension was not written on the drawing of furnace structure.
3) Calculation of heat radiation from the surface of heating-furnace #1
Condition for calculation: For 4 surfaces with temperature exceeding the target
temperature of the Japanese guideline, the difference between the heat radiation at thepresent temperature and at the target temperature shall be calculated. The result of
calculation is shown in Table III-2-6. According to the result, it is possible to reduce fuelconsumption by approx.1.5%.

Table III-2-6 Calculation of heat radiation from the surface of heating-furnace #1
Location
Area, A(m2)Top
9.01×21.5

Left
21.5×2.7

Right
9.01×2.7

165

Front
9.01×2.2 (lower 0.5m is
foundation)
137

Measured Temp.
Ta(°C)
Target Temp.
Tt(°C)
Ambient Temp.
T0(°C)NaturalCalcuconvection
lationhc
formula Radiation
Emissivity,εPresent heat radiation
Heat radiation at target
temp.
Improvement

100

150

100

90

80

90

30
Qn = [hc×(Ta – T0)0.25]×(Ta – T0)×A (W)
3.26
2.56
Qe = 5.68×ε×{[(273+Ta)/100]4 - [(273+T0)/100]4}×A (W)
0.3 (Aluminum painted surface)
Q1 = (Qn + Qe)= (362,889+120,965)W → 483.9kWh/h → 1,742MJ/h
Q2 = (Qn + Qe)= (49,966+161,498)W → 211.5kWh/h → 761MJ/h∆Q = Q1 – Q2 = 981MJ/h
Fuel oil saving = 981MJ/h /41.934MJ/L = 23.4L/h →∆1.54%(Right side is 80°C and below the target value, hence no improvement is necessary. Left sideshould be improved to this value; No improvement is necessary for bottom side)4) Combustion calculation for the heating-furnace #1

III‑ 14

The combustion situation of the “bunker oil grade C” at 1,520L/h was to be studied.
Based on the composition of “bunker oil grade C” obtained from BSI, and assuming theelement composition as follows, the combustion situation was studied.

Fuel supply:
Combustion air:

1,520L/h →1,452.2kg/h
313,900m N/hComposition of bunker oil grade C:C:

86.22%
H:

11.51%

S:

1.87%

N:

0.30%

Others:0.10%
3Theor. combustion air : A0 = 10.80m N/kg-oil → 15,683.8m3N/h
Theor. wet combustion gas: G0 = 11.442m3N/kg-oil→ 16,616.1m3N/h
Theor. dry combustion gas: G0’= 10.153m3N/kg-oil→ 14,744,2m3N/h
According to these data, air amount (13,900 m3N/h) supplied through the combustion air
fan (design capacity: 20,000m3N/h) is less than theoretical combustion air(15,683.8m3N/h). The air amount corresponding to the difference must enter through the
openings of the furnace. In case that iron scale is formed at a rate of 25kg/t (*1), oxygenamount (or air amount) necessary for oxidation of iron will be as follows.
(*1: It can also be assumed that iron loss is occurring at a rate of 25kg/t. But this loss
would be considerably higher than usual. So the scale amount was assumed, which is lessthan the iron loss).
Heating-furnace capacity:

Capacity is 40t/h when bunker oil grade C is used at a rateof 1,520L/h(Capacity is 50t/h when bunker oil grade C is used at a
rate of 1,900L/h)

Composition of scale:

Fe2O3 100% (Fe = 70%、O2 = 30%)

Iron loss as scale:

700kg/h (= 25kg/t-Billet×0.7×40t/h)

Oxygen amount needed for iron oxidation:

210.6m3N/h

Air = 1,002.9m3N/h, nitrogen amount= 792.3m3N/h

According to the information from BSI, the exhaust gas contains 4% oxygen. It is
assumed that it contains 4% oxygen at present. Then, the corresponding surplus air will
be as follows:

III‑ 15

Surplus air corresponding to 4% oxygen: A1 = 3,655.6m3N/h[Calculating formula: A1×0.21/(14,744.2 + 792.3 +A1) = 0.04]
Total wet exhaust gas: 21,064.3m3N/h (= 16,616.4m3N/h + 792.3m3N/h+ A1)
Total dry exhaust gas: 19,192.1m3N/h (= 14,744.2m3N/h + 792.3m3N/h+ A1)
Hence, the air intruding from outside will be 6,442m3N/h (= 15,683.8–13,900+1002.9+3,655.6), and together with the air supplied by the blower it will amount to 20,342m3N/h,i.e. the air intruding from outside occupies 31.7% of total quantity. (Gases from fire-proof
constructions were ignored). In this situation, combustion management (air ratio
management) cannot be done successfully. Measures such as narrowing the openings in
the furnace body must be taken immediately.

5）Effect of reduction of air ratioa. Actual air ratio
The oxygen concentration in the exhaust gas was not measured, but based on data in thepast, it is assumed that oxygen concentration is 4% at the stack inlet. The actual air rateis, as mentioned above, 20,342m3N/h. This air rate includes also the air used foroxidation of billets. Therefore, although oxygen concentration in the exhaust gas is 4%,
the air ratio is not1.235 (= 21/(21-4)), but 1.3 (= 20,342/A0).
b. It is assumed that scale forming will be reduced to the half if surplus air is reduced tothe half so that the air ratio becomes m = 1.15. In order to achieve this, openings in the
furnace should be reduced as far as possible, combustion air supplied by the air blower
should be increased so that the air rate becomes controllable.
Surplus air:

2,352.6m3N/h (= A0×0.15)

Air needed for scale forming:
Nitrogen:501.5m3N/h (= 1,002.9m3N/h1×0.5)

396.2m3N/h (= 501.5m3N/h×0.79)

Total wet exhaust gas:

18,863.4m3N/h (= G0+2,352.6m3N/h-501.5m3N/h×0.21)

Total dry exhaust gas:

16,991.5m3N/h (=G0’+ 2,352.6m3N/h - 501.5m3N/h×0.21)

Oxygen in exhaust gas:

2.29% (= [2,352.6-501.5]×0.21/16,991.5 (m3N/h))

Therefore, the apparent air ratio will be 1.12 (= 21/(21-2.29)).
Fuel saving achieved from reducing the air ratio from the present value (m = 1.3) to m
= 1.15 can be calculated as follows. Quantity of heat needed to heat decreased amountof exhaust gas will be saved as a result of reducing the air ratio. Besides, as a part ofoxygen in the exhaust gas is used for forming scale, the exhaust gas will be reduced by

III‑ 16

improvement from the present value 20,853.7m3N/h (= 21,064.3 - 210.6) to18,758.1m3N/h (= 18,863.4 – 105.3).
Condition of calculation:
Exhaust gas temperature:742.2°C

Specific heat of exhaust gas:1.381kJ/m3N・K

Outside air temperature:

30°C

Heat of combustion of bunker oil grade C: 43,892kJ/kg
Reduction of bunker oil grade C: Ox = 66.1kg/h
Calculation of Ox:{[(1,452.2-Ox)kg/h/1,452,2kg/h]×(20,853.7-18,758.1)m3N/h+ Oxkg/h/1,452,2kg/h×20,853.7)m3N/h}×1.381kJ/m3N・K×(742.2-30)°C= 43,892kJ/kg×Oxkg/h
Reduction rate: 4.6% (= 66.1kg/h/1,452,2kg/h = 0.0455)
However, the scale formation exhausts a latent energy as heat of oxidation of iron.
Considering heat of iron oxidation (=5.588MJ/kg-Fe), average specific heat of scale=0.9MJ/kg-scale・K) and average specific heat of iron (= 0.699 MJ/kg-Fe・K), andassuming steel material is heated to 1,050°C, then heat of approx. 1,746MJ/h will be
required. This corresponds to approx. 40kg/h fuel oil. Accordingly, fuel oil of 26kg/h (=27.2L/h) can be saved. Thus, reduction of approx.1.8% can be achieved.

6) Recuperator efficiency
As shown in Fig. III-2-2, the recuperator does not seem to be operating efficiently. For afurnace such as the heating-furnace #1 with exhaust gas temperature 742.2°C, at least
35% of waste heat is required to be recovered by the Japanese energy conservation law, inwhich recuperator outlet temperature of 460°C, and preheated air temperature of 310°C
are targeted. This is the case when heavy oil is used, the outside air temperature is 20°C
and air ratio is 1.2.
At BSI, as air infiltrates through the openings of the furnace body, not all combustion air
passes the recuperator. Therefore, the fuel reduction is shown as follows:a. Present situation:
Heat taken away by combustion exhaust gas:Q = 20,717,754kJ/h (= 21,064.3m3N/h × 1.381kJ/m3N/h・K×(742.2-30)°C)
Heat brought in by preheated air:P = 2,466,555kJ/h(= 13,900m3N/h×1.3kJ/m3N/h・K×(166.5-30)°C)
Calorific value of fuel: F = 63,739,962kJ/h (= 1,452,2kg/h×43,892kJ/kg)

III‑ 17

Fuel reduction:

100×P/ (F-Q+P)= 5.4%

Rate of waste heat recovery:

11.9% (= 100×P/Q = 2,466,555kJ/h/20,717,754kJ/h)b. When air preheating temperature is 310°C (here, exhaust gas rate does not change):
Heat brought in by preheated air:P’= 5,059,600kJ/h(= 13,900m3N/h×1.3kJ/m3N/h・K×(310-30)°C)
Fuel reduction:

100・P’/ (F-Q+P’)= 10.5%

Rate of waste heat recovery:

24.4%(= 100×P’/Q = 5,059,600kJ/h/20,717,754kJ/h)

Accordingly, the difference of fuel reduction between both cases will be 5.1%.

c. When air ratio is 1.15 (preheated to 310°C) (here, exhaust gas rate is reduced):
Heat brought in by preheated air:P”= 6,747,832kJ/h (= 18,538m3N/h×1.3kJ/m3N/h・K×(310-30)°C)
Fuel reduction:

100・P”/ (F-Q+P”)= 13.6%

Rate of waste heat recovery:
37% (= 6,747,832kJ/h /18,538m3N/h×1.381kJ/m3N・K×(742.2-30)°C)
By lowering the air ratio, exhaust gas rate is reduced. Thus further reduction of 3.1% canbe achieved. If the air ratio is reduced from 1.3 to 1.15, and whole air infiltrating into thefurnace is preheated, the fuel consumption will be reduced by 8.2%, 124.6L/h (=1,520L/h ×0.082).

7) Air entering through the openings in the furnace
As already mentioned, the size of the openings are as follows: Opening in front of thefurnace (billet inlet), approx. 2.0m2, is always open; billet pusher side opening and billet
outlet opening, approx. 0.5m2 respectively open 50 times per hour, each time for 30
seconds. When measured, the opening time was 40 seconds, but here an average value of
30 seconds is used. This means openings of approx. 0.8m2 are always open.) Thus, on thewhole furnace, openings of 2.8m2 are always open.
It was reported that the internal pressure of the furnace is kept in the level of several
Pascals, but air infiltration may easily exceed 1m/sec. At 30°C, infiltration velocity is
0.71m/sec, which corresponds to 6,442m3N/h. Furnace pressure should be kept +1 to 10
Pa (or water column 0.1–1.0mmH2O) at the elevation of material charge in order toprevent air infiltration from outside and gas blowing out from inside. Furnace pressure
sensor is often located on the furnace ceiling. In this case, buoyancy of hot gas must be
taken into consideration between the material charge and the ceiling. For the

III‑ 18

reheating-furnace, as shown in fig. III-2-3, the buoyancy is approximately 1mmH2O(=10Pa) per 1m of hot gas column at 1,100 – 1,200°C.
Furnace pressure
Increased

Radiatedflame

Reheating Furnace
Billet０ｍｍH2OHearthHearth level = 0 mmH2O

Decreased

Induced air

1m = 1mm H2O in reheating furnace

Fig. III-2-3 Relation between furnace pressure, air inflow and gas
Therefore, although the furnace pressure is positive at the ceiling, it is possible that thepressure becomes negative at the elevation of material charge, if the pressure is regulated
too low, and air can infiltrate easily into inside.
Heat radiation occurs through the openings in the furnace body, but the material inlet isnext to a preheating area with low temperature. The material outlet has a small opening
area and large hot gas blowing out was not observed, and therefore heat radiation throughthere can be ignored.
8) How much fuel can be saved when “hot billets are charged into the furnace?”
For example, when billets are charged into the furnace on the condition of 100°C hotter
than room temperature and at a rate of 40t/h:
Specific heat of normal steel (soft steel): 0.507kJ/kg・K (100–150°C)
Heat brought in by billets:

2,028,000kJ/h(= 40,000kg/h×0.507kJ/kg・K×(130–30)°C)

Fuel saving (per 100°C): 46.2kg/h (= 2,028,000kJ/h/43,892kJ/kg)
Saving rate 3.2%(= 46.2kg/h×100/1,452.2kg/h)

The above saving is achieved per 100°C of the difference between the material charge
and the room temperature, but in reality, specific heat increases slightly with temperatureso that a little more fuel saving can be achieved. At present, billets are cooled down
before charging into the furnace. It would be necessary to keep them hot in an insulatedbox, and to charge them into the furnace at a temperature as high as possible. Handling of

III‑ 19the hot material charge can be made easier by utilizing lifting magnet that is heat-resistant
up to 600°C.
9) Summary of energy saving measures for the heating-furnace #1
The measures mentioned above are summarized below.
Table III-2-7 Energy saving measures for the heating-furnace #1
Measures
1. Reduce heat radiationfrom furnace body(max.temp.: 165°C)
2. Reduce combustion air(air ratio at present: 1.3,
scale forming: 25kg/t, air
inflow from outside:31%)
3. Increase heat recovery
rate of recuperator(return to the original
specification value)

4.

Make openings in the
furnace body smaller,
shorten opening time.

5.

Charge hot billets

Method, Condition
By improving thermal insulation of
furnace body: ∆981MJ/h

Fuel saving and %saving∆23.4L/h∆1.5%

Reduce air ratio to 1.15 (scaleforming could be reduced by 50%)
Close openings in the furnace,change furnace pressure, and control
combustion air rate
Raise the heating temperature to theequipment specification value(preheating air temperature:
300–310°C).
Intensify recuperator maintenanceand preheat whole air.
Reduce air infiltration and supply
necessary air by blower speed
control.
Increase furnace pressure.

∆27.2L/h

Use an insulation box with
heat-resistant lifting magnet.

Air ratio remains
unchanged: 1.3∆77.5L/h
Air ratio reduced:
1.15∆124.6L/h
Heat radiation is
reduced.
Calculation was
not made due tolack ofinformation.
By raisingtemperature by
100°C: ∆48.3L/h

∆1.8%

∆5.1%
∆8.2%

∆3.2%

For the combustion management of heating-furnace it is important to reduce the air ratio,
and in order to facilitate this, it is necessary to reduce uncontrollable infiltration of air.
Recuperator should be able to operate according to the specification or near; for thispurpose, equipment management should be improved as well as operation management.
Thermal insulation of inside and outside of the furnace should be improved to avoid heatradiation. Billets should not be cooled down, but charged into the furnace at atemperature as high as possible. To realize this, thermal insulation box or cover andheat-resistant lifting magnet can be used.
The effects shown in Table III-2-7 were calculated separately, and some of them containassumption; when all of these measures are realized, the result may not necessarily
correspond to the sum of these effects.

III‑ 20

(6) Electric furnace and continuous casting machine1) Specific energy consumption of electric furnaces is very highWe obtained operation data of two 25-ton electric furnace on October 29, 2006.
According to the data, average values of 29 times of heating a day are as follows:
Scraps charge:

3 times, 13.1t＋10.2t＋3.4t = 26.7t

Tap-tap interval:

63.5 minutes

Yield:

84.5%

Oxygen consumption:

46.19m3N/t

Kerosene:

6.75L/t

Electricity:

584kWh/t (melting 431kWh/t＋refining 153kWh/t)

From the viewpoint of energy conservation, consumption of electricity seems to beconsiderably high. Oxygen, carbon powder (no data available) and kerosene are used innormal quantity, but low yield hints that considerable amount of iron was burnt or scraps
are of bad quality. Steel tapping is conducted as gutter tapping. We suggest that theelectric furnace operating speed should be increased, and an EBT (Eccentric Bottom
Tapping) device, pretreatment (separation of impurities) of scraps to improve yield, andpreheating of scraps should be adopted.
2) Heat radiation from the 25-ton ladle and the tundish
During charge of molten steel to the continuous casting machine, the 25-ton ladle is notcovered by a lid. The tundish has a lid, but it covers only the half of the tundish so thatheat radiation occurs. It would be necessary to cover the 25-ton ladle and the tundish
properly. Here, we will make rough calculation of the saving effect by covering them.

a. For the 25-ton ladle:
Assuming that half of the molten steel remains in the ladle during charge of molten steel
to the continuous casting machine, the heat radiated from the upper surface of the ladle
can be calculated roughly in the following manner. Fig. III-2-4 shows a ladle withapproximate dimensions. Only heat radiation from the molten steel surface in the middle
and from the refractory material on the inner surface shall be considered as heatradiation surface.

III‑ 21

φ1,800mm
φ1,600mm

φ1,600mm

Refractory surface
Molten steel surface

φ1,800mm

Fig. III-2-4 Heat radiation from the 25t-ladle
Calculation conditions
Molten steel surface: Temperature T = 1,650°C,emissivity: ε= 0.28, area: 2.0m2
Refractory surface: Temperature T = 1,500°C, emissivity ε= 0.85, area: 0.54m2
Outside air temperature:

T0 = 30°C

Specific heat of molten steel:

0.867kJ/kg・K (molten steel temperature
1,600–1,650°C)

Duration of holding molten steel in the ladle:
32 minutes (= 25t/(3×0.132m2×2m/min×7.85t/m3)(CCM has 3 strands, casting rate: 2m/min)
Equation of heat radiation : 5.68×ε×{[(T+273)/100]4-[(T0+273)/100]4} (W/m2)

Heat radiation from molten steel surface:

435kW, 232kWh (32 min/process)Heat radiation from refractory surface:

257kW, 137kWh (32min/process)Total heat radiation:

369kWh = 1,328,000kJ

Molten steel temperature fall: 61°C (= 1,328,000kJ/(25,000kg×0.867kJ/kg・K))
If the ladle is covered with a lid, the lid will reduce the temperature fall to half so thatmolten steel temperature fall would be approximately 30°C.
b. For the tundish
At present, the tundish is equipped with a lid, but it covers only the half of the tundish.
Heat radiation released from this area is calculated in the same manner as for the ladle.
Calculation conditions for the
Molten steel surface:Temperature T = 1,600°C,emissivity: ε= 0.28, area:
approx. 1.0m2 (Roughly half of the upper surface oftundish.)Refractory surface:

As molten steel level in the tundish is kept almost

III‑ 22constant during the casting, radiation from the refractorysurface can be ignored.)Specific heat of molten steel:
0.867kJ/kg・K (Molten steel temperature 1,600–1,650°C)
Duration of holding molten steel in the tundish:32 minutes

Calculation using the same formula as for the ladle results:
Heat radiation from molten steel surface: 157kW, 84kWh (32 minutes) = 350,333kJ
Molten steel temperature fall:

16°C (= 350,333kJ/(25,000kg×0.867kJ/kg・K))

If the tundish is covered with a lid, the lid will reduce the temperature fall to half so thatmolten steel temperature fall would be approximately 8°C.
According to the results shown above, the temperature fall would be 38°C. Thus, it would
be possible to reduce the electric furnace tap temperature from the current 1,650–1,700°C
by approximately 40°C.
This temperature reduction of 40°C results in savings of 867MJ (=25t×40°C×0.867kJ/kg・K); converted into electric power, it corresponds to 240kWh,
which is equivalent to 9.6kWh/t.
(7) Energy audit for the electricity area
The audit period was just 4 days, but thanks to eager assistance of the steelworks weachieved so excellent results that we can expect a good following-up by Thai staff.
1) Improving power factor
a. Power factor was as low as 0.76 at the primary transformer station of the works, andthey said that the works was paying additional fee for low power factor. Additional fee
is charged if power factor is below 0.85. We recommended to examine the possibility of
introduction pf phase-lead capacitors for improving the power factor, including effective
use of the existing capacitors equipped in EAF. Improvement of power factor may haveelectric energy saving effect due to reduction of line loss and transformer copper loss.
b. Electric furnaces are the main cause to lower power factor. We recommended inparticular to examine measures for improving the power factor of EAF.

✩Calculation of energy saving effect by improving the power factor
・Given condition:
Electricity data of July 30, 2006 were used.
Average power: W＝28,335[kW]III‑ 23

Power factor:

0.76

Reactive power: Q＝W／cosθ x √ (1−cosθ2)＝28,335/0.76×0.65＝24,234 [kVar]
Fee for power factor: TR＝14.02xR [B/M] (data of the year 2004 were used)
R: (maximum 15-minute reactive power) – (corresponding
maximum 15-minute power) x 61.97%.
・Fee for power factor: (rough calculation using annual average power)
Basis for determining additional fee for low power factor:
Q≥28,335×0.6197＝17,559[kVar]
Before improvement of power factor:
TR1＝14.02×(24,234−28,335×0.6197)×12＝1,123,002 [B/y]After improvement of power factor:
Case in which the power factor fee is added:
1≥Q/(W×0.6197)＝Psinθ/(Pcosθ×0.6197)
P: Apparent power∴tanθ≤0.6197

θ≤tan-1(0.6197)＝31.786[°]cosθ≤cos31.786°＝0.85

Accordingly, in the example of the year 2004, the power factor fee is not added if
power factor is 0.85 and above.
・Effect by improving power factor to 0.85 and above:
Result of rough calculation under the above condition: approximately 3.4 million
yen /year (assuming that 3 yen correspond to 1 baht). Therefore, if investment
payback period needs to be 3 years or shorter, an investment of about 10 million yen
can be realized. Here, we recommend that data be examined precisely taking autilization of existing capacitors of EAF in consideration, in order to achieve further
improvement of power factor. The above is a result of rough calculation using
provisional data; actual data should be used for the study of power factor
improvement.
Estimated dimensions of capacitors for improving power factor are shown in Table
III-2-8.

III‑ 24

Table III-2-8 Calculation of required capacity of capacitors for improving power factor
Present values (July 30,2006)
No.

Elt. Power
W[kW]

Power
factorcosθ

Reactivepower
Q[kVar]Required capacity ofcapacitors
Power
Power
factor 0.85
factor 0.95
[kVar][kVar]

28,3350.76

24,234

6,671

14,918

409

0.64

491

238

357

1,501

0.73

1,405

475

912

2,288

0.69

2,400

982

1,648

4,169

0.72

4,018

1,435

2,648

9,801
12,266

0.87
0.80

5,554
9,200

-520
1,598

2,333
5,168

Use

BI6902

Power supply(main power)
RM 2
BI 21–BI 24
Distribution
RM 1
BI 41–BI 44
Distribution
EAF(DEMAG)
EAF(SOE)

BI 10
BI 20
BI 30
BI 40
BI 50
BI 60

(Notes)・For example cases of present load situation shown in the above table, average values ofJuly 30, 2006 were used.
・Calculation formula
Reactive power: Q＝W/cosθ×√(1−cosθ2)
Capacitor for improving power factor from cosθ1 to cosθ2∆Q＝Q１−Q2＝W×(tanθ1−tanθ2)＝W×(√(1−cosθ12)/cosθ1−√(1−cosθ22)/cosθ2)2) Pump
The following pumps were being operated with discharge valve throttled. Electric energy
saving may be realized by eliminating valve pressure loss.
Electric furnace: EAF(SOE) Inter Pump Return No.6 (IM(C) 110kW)
Continuous casting machine:
CCM cooling water pump: flow control valve is being throttled.
Rolling mill: Cooling water pump for RM2: pump No.2 (QTB-RM2)
Rolling mill: Cooling water pump for RM1: discharge valve was fully open.
Other plants:

All pumps should be inspected concerning discharge valve throttling.

✩ Calculation of energy saving effect by inverter speed control
Fig. III-2-5 explains how to achieve electric energy saving by changing pump rotational
speed with an inverter.
a. Determine (Qb, Hn, Lb) at the point C in case that discharge valve is fully opening.
Hn: total pump head excluding discharge valve pressure loss.

III‑ 25

Lb: brake powerb. Calculate quantities (Qa, Ha, La) at point A in the current operation.
The curve OC is a parabolic curve that passes through the origin, and H = Hn/Qb2×Q2
or H = Ha/Qa2×Q2. Extend the curve OC using this formula, and find the intersection
point A or C with the performance curve.
c. Calculate the pump rotation speed Nn when operating the pump at point C using thefollowing formula:
Nn = No × √(Hn/Ha)
d. Calculate the brake power when operating the pump at rotation speed Nn at point C
using the following formula:
Ln = La x (Nn/No)3
e. Calculate electric energy saving obtained by converting throttling of discharge valve
into reduction of revolution in current flow.
∆kW = Lb/ηpb – Ln/(ηtc×ηmc)×ηpa/ηpc
ηtc : inverter efficiency
ηmc : motor efficiency when the inverter is operated at point Cηpa, ηpb, ηpc : pump efficiency at points A , B and C.
Notably, electric energy saving decrease as net head HA increases.

III‑ 26

H(all head）
Hb
H 00 Ｑ0Ha

To close ofvalve

revolution Ｎ 0

R: rated operation point(Qo, Ho, Lo)

○ Ｂ

○○ Ａ
Ｒ

revolution Ｎn
Hn○ C

H=Hn/Qb2×Q2

B: current operation
point(Qb, Hb, Lb)
Discharge valve isthrottled.

HA

０

Qb

Q(flow)

Qo

L(axis power）

Ｎ0La
L 0 Lb

Δ kW

Ln

０

Qa

C: Operation point indischarge valve fully
opened (Qb, Hn, Ln) by
inverter control.

Qb

Ｎn

Qa

Q(flow)

Qo
Fig. III-2-5 Electric energy saving by changing pump rotational speed3) Fans and blowers
a. Rolling mill 1: The combustion air blower of heating-furnace (90kW) is
damper-controlled. Here, electric energy saving could be achieved by applying
inverter-control and thus eliminating loss by damper. However, for applying inverter
it is necessary to investigate the applicability of variable speed control to the existing
facilities taking due consideration of mechanical strength of the blower. The
heating-furnace for the rolling mill 2 has not been examined.
b. For the main dust collector for the electric furnace, energy saving operation isconducted by variable speed control of d.c.-motors (600kW x 2, 400kW x 2). The gas
cooler fans were not examined.

III‑ 27

✩ Study of application of inverter to the combustion air blower of heating-furnace
The combustion air blower is operated in automatic mode, and it is not possible to fix
a particular operating point. For this reason, the blower operation is divided into somecases concerning opening of the blower damper as shown in Table III-2-9, and for eachcase, input electric power, operating time and air flow rate are measured, or estimatedfrom the performance curve.
Table III-2-9

Example of examination of the heating-furnace combustion blower

Operation caseAir flow[Nm3/h]

CASE-1
CASE-2–
CASE-i

Q1
Q2–
Qi

Operatingtime[h/y]
T1
T2
–
Ti

Electric energy saving∆kW[kW]
∆kW1
∆kW2
–
∆kWi

Electric energy saving ∆kW is calculated by the following formula.
∆kW = Lb/ηpb – La ×(Nn/No)3/(ηtc×ηmc)×ηfa/ηfb
ηtc : Inverter efficiency,ηmc : Motor efficiency when operating the inverter at point B
ηpa, ηpb, ηpc : pump efficiency at points A , B and C.
Accordingly, annual electric energy saving will be calculated as follows:∆kWh = ∆kW1*T1+∆kW2*T2+ ・・・・ +∆kWi*Ti［kWh/y］
To be confirmed

4) Air compressors

Load/unload control is not applied to turbo compressors.

a. Normally operates the turbo type air compressor, which is controlled in load/unload
mode. However, to achieve further energy saving, it is necessary to remove an
inefficiency occurring during partial load operation. In order to do so, present
operation should be analyzed concerning how long and how much partial load
operation occurs through measuring air rate, operation period, etc. for at least one
week.
b. Reduction of air consumption (reducing air leakage, applying high-performance air
nozzle, applying air blower in place of air compressor, etc.) and reduction ofoperating pressure should be pursued continuously.

5) Improving automatic sequence in the rolling mills
a. Reducing heat loss by optimizing the open/close timing of heating-furnace door.
b. Reducing idling loss of the tables and rolling mills.

III‑ 28

The tables and rolling mills operate at normal rotating speed also during the idling ofrolling. We recommend that the tables and rolling mills be stopped or operated at a
reduced speed during the idling in order to save electric energy.

3. Seminar-workshop
3.1 Overview(1) Date/time
November 17, 2006 (Fri)

8:30am – 4:30pm(2) Venue
Twin Towers Hotel, Bangkok, Thailand(3) Summary of the seminar/workshop
70 participants attended the seminar-workshop. On the part of Thailand, the activities of
ISIT (Iron and Steel Institute of Thailand) were presented, and the Steelworks of BSI
reported the results of the factory audit. On the part of ASEAN, representatives from
Malaysia, Indonesia and Philippines reported example cases of energy conservation
activities in their respective countries.
ECCJ presented energy conservation activities with regards to measures for furnace facilities
and electric equipment in the electric furnace industry in Japan. This seminar in Thailand
was concentrated on the steel industry; it was the first attempt focused onto one single
industrial sector. In this respect it was different from previous seminars in which informationexchange among representatives from various industrial sectors had taken place.
(4) Participants
Thai-side members:
Mr. Tammayot Srichuai

Director, DEDE, MOE

Ms. Amaraporn Achavangkool

Senior Scientist, Technical and Efficiency
Promotion Division, (DEDE), MOE

Dr. Prasert Sinsukprasert

Senior Engineer (DEDE), MOE

Mr. Sarat Prakobchart

Senior Engineer (DEDE), MOE

Mr. Hin Navawongse

ISIT

Mr. Somchai Khamphoo

Rolling Mill Production Manager

and many other participants.

III‑ 29

ASEAN Center for Energy (ACE):
Ms. Evangeline Moises

Chief, Information & Event Division

Mr. Ivan Ismed

Industrial Project Officer, PROMEECMalaysia:
Mr. Ghazali Talib

Principal Engineer, PTM, Malaysia

Indonesia:
Mr. Zulham Lubis

PT, Krakatau Steel, Indonesia

The Philippines:
Mr. Loreto C. Carasi

Dept. of Science and Technology, Philippines

Japan: ECCJ, International Engineering Department, Technical Expert
Kokichi Takeda, Hideyuki Tanaka

Thai general participants
From the iron and steel sector in Thailand, approximately 40 persons participated in theseminar.

3.2 Results of the seminar-workshop
Altogether 70 persons participated in the seminar/workshop. The seminar/workshop were
proceeded with Dr. Prasert Sinsukprasert in the chair. Handouts at the seminar/workshop areshown in 4. Attachments.
(1) Opening ceremony (Congratulatory speech and opening address)
1) ACEAs SOME meeting was drawing near, Dr. Weerawat of ACE was absent, and Ms.
Evangeline read his message on behalf of him. After brief introduction of ACE and
PROMEEC, projects being conducted by ACE were introduced.
2) ECCJ
Mr. Tanaka, a technical expert, made a speech on behalf of Japanese side (METI and
ECCJ). He talked about the aims and circumstances of this project, recent situation, andJapan’s cooperation and contributions to ASEAN. He also thanked the participants fortheir help regarding the visit of the steelworks.
3) Representative of Thai ISIT
Mr. Hin explained that energy consumption in the iron and steel sector is very high, andthat it is important to make efforts for energy saving. He said that many persons dealing
with electric furnace and rolling mill were participating in this seminar.

III‑ 30

4) Representative of Thai DEDE
Mr. Tammayot Srichuai greeted the participants. Then he told as follows: “60% of
petroleum are imported. Electricity is expensive, and 36% of the electricity supply are
consumed in the industry. The iron and steel sector is consuming the electricity most, butthere is still a large potential for energy saving in this sector. Petroleum consumption
should be reduced by EE&C activities, energy saving campaign etc. Thailand aims at
becoming the center of EE&C activities of ASEAN.” He thanked ACE, ECCJ, ISIT for
their assistance, and BSI for accepting audit activities.

(2) Session 1: EE&C in the iron and steel sector
1) Overview of Steel Industry in Thailand (Mr. Hin Navawongse, ISIT)He outlined the steel industry in Thailand using a handout which is attached to thisdocument. Demand of iron and steel in Thailand decreased in 1998 to the half of thedemand in previous year; in 2005 it increased to nearly 14 million tons. But the demandbegan to decrease again, and in 2006 the demand presumably decreases 15% below theprevious year’s level. Billets, slabs, hot-rolled and plated steel sheet are imported.
In the handout, SEC for each product is shown. Recently, SEC are gradually worsening.
With regards to products, concrete reinforcing bars consumed energy most;approximately 1/5 of total energy consumption was used for this product.
2) Overview and EE&C of Steel Industry in Japan (Mr. Tanaka, technical expert, ECCJ)He outlined recent situation of energy conservation activities and technologies inmini-mill steelworks in Japan.

(3) Session 2: Presentation of EE&C cases in the iron and steel sector
1) Case Study 1 (Mr. Ghazali Talib, PTM, Malaysia)
At first, the representative of Malaysia briefly described the cases studied in the MIEEIP(The Malaysia Industrial Energy Efficiency Improvement Project). Regarding the ironand steel sector, energy conservation activities at the steelworks producing annually
700,000 tons of concrete reinforcing bars and wires were reported. Six million RM are
expended monthly for electricity. Recuperators for heating-furnaces had low efficiency
due to sulfur depositing so that one more stage was added to the existing stage, changing
it into a two-stage type of recuperator. Air compressor was changed from piston-type into
screw-type. Water supply pump in the hardening process was changed into VSD-type,and electric energy saving of 25% were achieved. Then, he told that equipment for

III‑ 31separating iron-rich materials from iron scraps was introduced. This equipment would be
able to reduce cost by 4.4 million RM.
2) Case Study 2 (Mr. Zulham Lubis, PT, Krakatau Steel, Indonesia)
Krakatau Steel is producing reduced molten iron and rolled products in the electric
furnace. Annual production is 2 million tons of steel products. In this steelworks, 30% ofenergy source is N-gas which is mainly used for producing reduced molten iron, 60% iselectricity which is used mainly for EAF, and 10% is petroleum which is used for rollingmills. Energy cost accounts for 22% out of the total cost for producing crude steel.
Regarding as energy saving, the following measures are being taken:
utilizing waste heat of the ladle exhaust gas to preheat slabs,
hot-charging of slabs (530°C),
shortening the transfer time of billets,
use of thermal insulating covers,
adoption of EAF-electrode lift control,
adding oxygen to melting furnace.
Thanks to the above measures, approximately 9.4 million dollars could be savedannually.
3) Case Study 3 (Mr. Loreto C. Carasi, DOST, the Philippines)
Mr. Loreto reported energy conservation activities in 2 steelworks producing concrete
reinforcing bars and a zinc plating plant respectively.
In the steelworks producing concrete reinforcing bars, the following measures weretaken: reducing air ratio in heating-furnaces,
furnace internal pressure control,
avoiding infiltration of outside air through openings,
repair and replacement of recuperators,
reducing heat radiation from furnace body,intensifying the maintenance of burners,
intensifying the monitoring,
replacement or modification of pumps,
avoiding compressed air leakage,
utilizing daylight etc.
Further, energy saving groups are organized. In the zinc plating plant, besides system
improvements, small but many energy conservation measures, similar to ones taken in theconcrete reinforcing bars plant, were carried out.
(4) Session 3: EE&C cases on electric equipment (Mr. Takeda, technical specialist, ECCJ)

III‑ 32

He presented three cases of energy saving measures for electric equipment in the steel
industry.
(5) Session 4: Report on the audit results of BSI steelworks (Mr. Somchai Khamphoo, BSI)
BSI reported the results of energy audit. After the brief explanation on the company
outline, the situation of energy usage was explained. Concrete reinforcing bars are
manufactured using electric furnaces and rolling mills. On the contrary to Japan, fuel isconsumed more than electricity. Fuel is consumed in two heating-furnaces, whereas 50% ofelectricity is consumed in the electric furnace. Therefore, BSI thinks that reduction of fuelin the heating-furnace is urgent. So far, 9 improvement measures including use of daylight,
improvement of the cooling tower, and replacement of air compressor, have been
implemented ,which gave birth to cost savings of about 210 million Baht per year.
As a result of the audit survey, improvement measures such as improving heating-furnace,
preventing air compressor leakage, measures against excessive capacity of EAF cooling
pump, utilization of exhaust gas from the ladle, covering ladle of CCM and tundish,hot-charging of billets were proposed.

Responding to the reporting, ECCJ showed Japanese standards for air ratio of theheating-furnace, rate of waste heat recovery, and surface temperature of the furnace wall.
ECCJ gave information about heat radiation from the furnace walls, compressed air leakage,and calculation method for the receiver tank of compressed air.
(6) Session 5: The Way Forward

1) Technical Directory (Mr. Ivan Ismed, ACE)
Purpose of TD, how to prepare it, format of TD etc, were explained and some examples
were shown for better understanding. Mr. Ivan gave further explanations using examplesof TD sheet. His explanation that already 50 cases in major industry, and 33 cases inbuildings can be seen on the homepage of ACE drew great attention of participants.
2) Database/benchmark/guideline for major Industries (Mr. Ivan Ismed, ACE)
Purpose and importance of DB and future plan for DB were explained.

(7) Questions and answers, and comments
At the end of each presentation there was time for questions and answers. Participants mademany questions. The most important questions will be shown below:
Q:

How much electric power is consumed by the electric furnace? - Data in BSI were

III‑ 33

shown in a previous section.
Q: How much oxygen is used? - Operation data concerning oxygen will be obtained
from BSI afterwards.
Q: How many shaft furnaces are existing in Japan? How much dioxine emitted fromthese shaft furnaces?
A: Exhaust gas is cooled down in the shaft furnace. Subsequently the exhaust gas isburned. It is said that almost all dioxine is removed by dust collector (bag filter).
Numerical data have not been published.
Q: Oxygen concentration in the exhaust gas in the heating-furnace is 6%. Is it too
much? Scale formation is 2% on total material iron. Oxygen of 6% means that air
ratio is 1.4 . It is too high, considering that the Japanese standard is 1.2.

(8) Closing address
Dr. Prasert Sinsukprasert gave a closing address, and the seminar in Thailand finished witha great success.

III‑ 34

4. Attachments(1) “ASEAN PROMEEC Seminar/Workshop Program”
1“Overview of Steel Industry in Thailand”

2“Overview and EE&C of Steel Industry in Japan”

3“Energy Efficiency and Conservation for Industries; Case Studies of EE Improvement in
Steel Industries”

4“Energy Efficiency and Conservation Best Practices at PT. Krakatau Steel-Indonesia”

5“Energy Conservation for the Philippine Steel and Iron Industries: Case Studies”

6“Promotion of Energy Conservation Activities in Factories (Electricity)”

7“BANGKOK STEEL INDUSTRY PUBLIC CO., LTD”

8

“Comments for EE&C in Iron & Steel Factory”

9“Development of a Technical Directory for Major Industries and Buildings for ASEAN
Member Countries”

10 “ENERGY EFFICIENCY AND CONSERVATION (PROMEEC) – INDUSTRIES/BUILDINGS”

III‑ 35

IV. Myanmar (cement and oil refining industries)
1. Activities Overview

Phase 1 of PROMEEC activities in Myanmar began with the implementation of an energy audit
at the Mann petroleum refinery (December 16-21, 2001). The first step of phase 2 (December
8-15, 2004) consisted of a follow-up survey at the Mann refinery and an energy audit at theThanlyin oil refinery followed by a seminar. The second step in phase 2 started this year with afollow-up survey of the Thanlyin refinery and a new audit survey of the Kyankhin Cement Plant(KCP).
1.1

Date

November 19-24, 2006
1.2

Venue

Cement plant (new audit survey):

Myanmar Ceramic Industries, Kyankhin Cement Plant(located approx. 250 km north-northwest of Yangon, near
the western bank of the Irrawaddy river)

Oil refinery (follow-up survey):

Myanmar Petrochemical Enterprise, No.1 Refinery
Thanlyin (located approx. 20 km south-east of Yangon)

Seminar-workshop:
1.3

Sedona Hotel in Yangon

Schedule

Nov. 19 (Sun.):Travel (from Yangon to Kyankhin) and discussions regarding energy
audit works

Nov. 20 (Mon.):Cement factory energy audit (KCP)

Nov. 21 (Tue.):

Cement factory energy audit (KCP)

Nov. 22 (Wed.):Travel (from Kyankhin to Yangon)

Nov. 23 (Thu.):

Follow-up survey (No. 1 refinery, Thanlyin)

Nov. 24 (Fri.):

Seminar-workshop

1.4

Participants

MyanmarMinistry of Energy (MOE)
Mr. U Aye Kyaw

Director

Mr. U Mg Mg Ohn

Thaw Chief Officer

IV‑ 1Ministry of Industry No.2

(Heavy Industry Division, MOI-2)

Mr. U Ohn Myint

Director

Mr. U Thaung Nyunt

Assistant Director

ASEAN Center for Energy (ACE):
Mr. Ivan Ismed

Project Officer

Mr. Junianto M

Manager of Computer Center & IT

Malaysia:
Mr. Nor Hisham bin Sabran:

Energy Expert, PTM Malaysia

Japan:
Technical Experts, International Engineering Department of ECCJ
Fumio Ogawa, Koukichi Takeda, Hideyuki Tanaka
About Myanmar(1) General situation in Myanmar (Source: Web site of the Japanese Ministry of Foreign Affairs(July, 2006 data))• Size:680,000 km2 (approx. 1.8x the area of Japan)• Population: 52.17 million (Government of Myanmar, Statistical Year Book 2002)• Capital:
Naypyidaw (Pyinmana) (approx. 300 km north of Rangoon (Yangon), notformally announced.
Former capital is Yangon.) Relocation to be essentially completed by March
2006.
• Ethnicity:
Burman (approx. 70%) and numerous other ethnic groups• Language: Myanmar (said to resemble Japanese grammatically.)• Religions:
Buddhism (90%), Christianity, Islam, etc.
• Brief history:
After several centuries of occupation by a number of groups, theBurmans established the First Burmese Empire in the later half of the 11th
century (Pagan dynasty, 1044-1287). This was succeeded by the Taugoo andKonbaung dynasties, which lasted until 1886 when it was annexed to the
British Colony of India. Myanmar became an independent republic on
January 4, 1948.
• Government:
Military regime (provisional government)• Economics: Principal industry: Agriculture
GDP per capita: US$107 (estimate for 2005)(2) Energy situation (from IEA 2004 Statistics (2006 Edition))
There is a certain amount of fossil fuel production in Myanmar. Production andconsumption for 2004 are discussed below.
Myanmar mined roughly 1 million tons of coal (bituminous coal and lignite), exporting
around 80% of that amount. Of the rest, 80% is used by industry and the other 20% goes tohousehold use.
All of Myanmar's refined oil is used domestically, with 77% going to the transport sector,
12% to household use and 11% used by industry. Petroleum production was roughly 1
million tons in 2004 but is said to have fallen to around two-thirds of that amount in 2006.
Myanmar also produced around 320 PJ (1015 J) of natural gas, of which roughly 80% was

IV‑ 2

exported. The natural gas is used for power generation and as fuel by the industrial sector.
In Myanmar, natural gas is seen as the key to reducing energy consumption. Myanmar also
generates around 6,400 GWh of electricity, with 47% used by the public and household
sector and 30% by industry, with 23% going to transmission loss, etc.

2. Energy Audit Survey of the Myanmar Ceramic Cement Plant
Myanmar has 3 government-run cement companies and a number of privately-owned companies.
The cement industry is a major industry in Myanmar, consuming large amounts of natural gas
and electricity. Daily production from all companies is 9,000 tons (equivalent to roughly 3.2 to
3.3 million tons annually), but domestic demand is around 15,000 tons per day, therefore an
increase of production is strongly demanded under the circumstances of import restrictions. In
the audit survey, KCP, one of the government-run enterprises, was selected as the PROMEEC
target plant.
2.1 Overview of the Myanmar Ceramic Cement Plant
The factory is located near the western bank of the Irrawaddy river, 250 km north-northwestof Yangon. Travel from Yangon was on the east bank of the Irrawaddy by car, but due to thelack of bridges across the river, the route involved traveling north up the river to the nearest
bridge and then south back down the river. The survey team consisted of government officials
and representatives of the Thayet cement plant (TCP – located approx. 200 km south-east of
Yangon) together with participants of ASEAN and ECCJ, 13 people in total. Arriving in theevening of the first day, we had a meeting for having an overview of the factory, affirming theaims of the visit and formulating an overall plan.
On the second day, we took a look over the entire plant, starting with the limestone quarry. As
discussed below, we made our observations from the viewpoint of reducing thermal andelectrical energy consumption. In consultation with Myanmar Ceramic, we chose theequipment around No. 3 rotary kiln as a target of audit survey, and in the evening conducted
on-site measurements. On the third day, we continued measurement work to collect some
additionally required data on the same site. In the afternoon, we analyzed the collected data,
provided guidance for calculation and made suggestions as to the materials to be presented by
the plant engineer at the seminar-workshop of the 24th day. In the audit survey, 17 Myanmar
participants worked in concert with the ASEAN and ECCJ, making a group of 23 in total, andsuccessfully obtained the expected results.
(Summary of the visit)

IV‑ 3(1) Name of Company:

Myanmar Ceramic Industries, KCP, (MOI-1)(2) Plant location: Approximately 4 miles west of Kyankhin City
(3) Dates:

Nov. 19, 2006: Travel from Yangon, meeting
Nov. 20-21: Audit and discussions
Nov. 22: Travel to Yangon(4) Visiting survey members: Audit team (1/2)
From Myanmar:
MOE:
U Aye Kyaw, Director Energy Planning Department (Myanmar FP)
U Mg Mg Ohn Thaw Chief Officer, Energy Planning Department
MOI-2:
U Ohn Myint

Director

U Thaung Nyunt

Assistant Director, Ministry on Industry No.2

Major Aye Shwe

Chief Engineer, Myanmar Economic Corporation (MEC)U Saw Lwin Assistant Chief Engineer, Cement Plant(Myaingalay), MEC
U Min Aung

Deputy General Manager (Production), TCPU Win Myint Thein

Assistant General Manager (Planning), TCP

U Khin Mg Cho

Assistant General Manager (Planning), Kyaukse Cement
Plant

ASEAN countries:
Mr. Nor Hisham Bin Sabran Energy Expert, PTM (Malaysia)
ACE:
Mr. Ivan Ismed

Project Officer

Mr. Junianto M

Manager of Computer Center & IT

Japan:
Technical Experets, International Engineering Department of ECCJ
Fumio Ogawa, Koukichi Takeda, Hideyuki Tanaka(5) Myanmar Ceramic: Audit team (2/2)
Mr. U Saw Fernando

Deputy General Manager (Planning)

Mr. U Aung Soe Naing

Assistant General Manager (Planning)

Mr. U Myint New

Assistant General Manager

Ms. Daw Khin Khin Win

Assistant General Manager (QC)

Mr. U Aung Baw

Manager (Rotary Kiln Department)

Mr. U Thein myint

Manager (Electrical Department)

IV‑ 4Mr. U Win Naing
2.2

Assistant manager (Planning)

Overview of Cement Manufacturing Plant(1) Plant overview
Product:

Ordinary (Portland) cement
Production volume: 330,000 t/y (April 2005 to March 2006)

Facilities:

Respectively in 1975 and in 1985, two wet-process rotary kilns
manufactured by Kawasaki Heavy Industries were installed. The capacityof each kiln is 400 tons per day.

No. of employees:

Total number unknown; cement plant workers consist of 3 teams
with 18 workers in each team.

Shift system:

12-hour 2 shifts; 24-hour continuous operation(2) Cement manufacturing processes and equipment

1) Manufacturing processes
The limestone quarry is roughly 10 km from the cement plant. The limestone is crushed
into pieces 150 mm or less in size and mixed with locally mined laterite, clay and sandbefore being shipped to the cement plant by rail. The mixture is milled and mixed withwater before being fed as a slurry into the cement kiln. Since the plant start-up, the kiln
has been fuelled by natural gas. The clinker produced is powdered together with gypsum
in a cement mill to form cement. It is then bagged for shipping. The processing sequenceis as follows:
Limestone quarry → Shipped by truck → 1st stage crusher → Belt conveyor
transportation (BC) → 2nd stage crusher → Shipped by rail → Silo → Raw materials
blending → Raw material mill → Silo → slurry formation → Wet-process rotary kiln →Clinker cooling → Cement mill → Silo → Packing → Shipment by truck, etc.
2) Major equipment
The first half of equipment was constructed and brought on service in fiscal 1975, and theremaining half in fiscal 1985. Like Japan, the Myanmar financial year runs from April to
March.
Limestone crushing equipment
1st stage crusher:wo crushers (to 150 mm or less), each with a capacity of 300 t/h(actual capacity: 240 t/h)

2nd stage crusher:

two crushers (to 25 mm or less) each with a capacity of 150 t/h;IV‑ 5(actual capacity: 120 t/h)
Raw material milling equipment
Raw material mill:

wet-type mill: tube mill (2,500 mm (D) x 12.5 m (L))
drive motor: 800 kW (mill rotation: approx. 20 rpm)
capacity:

dry-base: 35 t/h (actual capacity: 32.5 t/h)electricity SEC:

Av. 20.1 kWh/t-material (FY2004, FY2005)

No. of machines:

4

A mixture of limestone, laterite, clay and silica sand is milled.
Slurry:pump motors:

3 (30, 55 and 75 kW)

Clinker burning equipment
Burning equipment:

kiln type:wet-process rotary kiln, 6 supports
kiln motor: 120 kW, 1.2 to 0.4 rpm

size:

inside dia.: 3,300 mm x 125 m (L); refractory
thickness: 180 mm

capacity:

16.7 t/h (400 t-cl/d) (Actual capacity: 320 t/d)

No. of kilns:

4

fuel:

natural gas: 1,430 to 3,500 m3N/hcalorific value: 948 Btu/SCF
distribution air: 36 m3N/min.
combustion air: 120 m3/min., 40°C, 1,200 mmAq
fan motor: 45 kW
ID fan:2,350 m3/min., 180°C, 250 mmAq; motor: 170 kW
dust removal: multi-cyclone

Clinker cooling equipment
Cooling equipment:

horizontal-grate air coolingexternal dimensions:

2.5 x 3.3 x 13.6 m (W x H x L)

(effective size: 1.68 x 12.0 m (W x L); grate area: 20.2 m2)
Cooling air fan:

air rate: 1,100 m3/min., 45°C, 230 mmAq; motor: 75 kW

Exhaust air fan:

air flow: 930 m3/min., 180°C, 150 mmAq; motor: 45 kW

Annual capacity with each unit running for 300 days is 480,000 tons. However,
because one unit is permanently idle due to a lack of fuel (natural gas), annual
production capacity is currently 363,800 tons.
Cement (finish) mill
Finish mill:

mill type:closed-circuit side-drive typesize:

2,750 mm (dia.) x 8.219 m (L)IV‑ 6

drive motor:

800 kW (mill rotation: 19 rpm)

capacity:

22.5 t/h (actual capacity: 20 t/h)

No. of mills:

4

actual crushed material:

clinker: 18.48 t/h
gypsum: 1.18 t/h

3Mill fan:

air flow: 39,000 m /h., 45°C, 300 mmAq; motor: 55 kW

Bag filter fan:

air flow: 36,000 m3/h, 90°C

Cement silo
No. and capacity:

12 silos, 31,000 tons

Bagging equipment (packers)
Capacity:

50 t/h each (actual capacity: 35 t/h)

No. of packers: 4
Shipping methods:

Truck, freight train, ship(3) Energy usage and consumption
The kinds of energy sources used in the cement plant are natural gas, diesel fuel andelectricity. Natural gas is used only in the cement kilns, while diesel is used for vehicles.
Electricity is used for lighting and for other equipment, including electric locomotives.
KCP is particularly interested in reducing its energy consumption in terms of reducing its
use of natural gas. Table IV-2-1 shows the annual change in cement production and energy
consumption.

Table IV-2-1

Cement production and energy consumption

Year
Clinker production (t/y) (ratio)
Cement production (t/y) (ratio)
Energy consumption
Natural gas (in kilns) (MCF/y)(948 Btu/SCF = 37,333 kJ/m3N,
based on Kawasaki Heavy Industries
specifications.)
Electricity (MWh/y)
Energy consumption
Natural gas (kcal/kg-clinker)
Electricity:Rawmaterial
crushing(KWh/t-mat.)
Clinker burning (KWh/t-mat.)
Clinker milling (KWh/t-mat.)
Packaging (KWh/t-mat.)
Plant overall (KWh/t-mat.)2004
284,815 (100)323,712 (100)2005
294,882 (103.5)
354,170 (109.4)

2,058.29 (100)

2,144.79 (109.4)

34,352.5 (100)36,625.0 (106.6)

1,726.34 (100)1,737.7 (100.7)

21.63
23.67
33.18
2.12
104.49 (100)

18.57
23.23
39.89
2.77
105.01(100.5)

IV‑ 7

2006

21.47
24.58
40.56
2.43
115.04 (110.1)

Natural gas calorific value: 948 Btu/SCF = 8,436.4 kcal/m3 = 35,321.5 kJ/m3(If CF is taken as SCF, (273.15 + (60-32) x 5/9)/273.15 = 1.05695, which gives a calorific value
for natural gas of 35,321.5 x 1.05695 = 37,333 kJ/m3N.)

2.3

Walk-through Energy Audit at the Cement Plant

This plant was constructed in 2 phases, by Kawasaki Heavy Industries, Ltd as a contractor anda number of other Japanese companies as a sub-contractor. The operation of the first-phasebegan in 1975 and the second phase commenced in 1985. Due to a lack of natural gas, only 3of 4 production lines are currently operating. KCP is particularly interested in reducing its
energy consumption in fuel (natural gas). KCP also expressed a wish to hear suggestions as towhere electrical power can be saved. So, we inspected the facilities with these points in mind.
The raw materials are transported from nearby limestone and laterite quarries. The plant
produces Portland cement and has an annual production capacity 480,000 tons, thoughproduction currently stands at 360,000 tons per year. The cement is produced using wet
process rotary kilns in which limestone, laterite, clay and sand are milled, then blended before
being fed into rotary kilns, where the mixture is burned to form clinker.

(1) Walk-through energy audit
1) We went to the limestone quarry and inspected the 1st-stage crusher. This crusher crushes
limestone ores, which are unloaded from dump trucks, into pieces 150 mm or smaller. Its
power consumption drops from 25-30 A during crushing to 13 A when idle. We
confirmed that energy management practices were observed. In fact, the 1st-stage crusher
and conveyor belt were stopped manually during breaks of 1 hour or more, such as
during the lunch break. The dust-collector was operated with 50% opening of the damper,
which indicates an opportunity of energy saving of fan power.
2) Electric room in the cement plant
Table IV-2-2
Month & Year
May 2006
June 2006
July 2006
August 2006
September 2006
October 2006

Recent data of power consumption

Electricity
Consumption
2,376,300 kWh
3,151,000 kWh
2,886,700 kWh
2,830,200 kWh
2,630,200 kWh
2,790,800 kWh3) Emergency generator: Diesel generators (2 sets)

IV‑ 8Remarks
Power factor = 0.9

4) Raw material millAfter milling, the mixture is converted to a slurry and fed into slurry tanks. The watercontent of the slurry was set at 43%.
5) Cement mills
4 cement mills were located in the same yard as the raw material mills.
6) Kilns
Of 4 kilns, only Nos 1, 2 and 3 were running. Our impression was that the area aroundthe kilns was quite hot. The fuel used is natural gas, which is supplied at a pressure of 3.5
kg/cm2. The supply was controlled using a flow control valve, and the combustion air
was regulated using dampers, which were fixed at roughly 50% open during normal
operation.
We have no data for the oxygen concentrations in the exhaust gases as no measurements
were taken. The available data we have is one at the start of operations, and we were toldthat the oxygen data was 1.5% at that time, while the location of the measurement was
not known. Because large amounts of CO2 are emitted from the limestone in the kilns,
this data is indicative that the real oxygen content in the combustion exhaust gas is higher
than 1.5%.
7) Clinker cooler
The damper on cooling air duct were 20% opened. Part of this air is vented by theexhaust fan, and the rest goes into the kiln.

(2) Description of energy-saving technology in the cement plant
Prior to measurement work, we used the PPT presentation from ECCJ to explain actualenergy-saving activities in Japan's cement industry and the audit procedure for electricalequipment. Currently, the wet-process kiln disappeared. Some 90% of kilns are NSP (New
Suspension Pre-heater) kilns, and the remaining 10% are SP (Suspension Pre-heater) kilns.
The average fuel consumption (the equivalent in coal) is 105 kg (2,725.6 MJ/t-cement) andthe electricity consumption is 99 kWh/t-cement. The fuel consumption of the wet-processkilns was 1,357 kcal/kg-clinker in the past of Japan (5,681 MJ/kg-clinker). Mr. Takeda
explained about energy saving measures for the fans and blowers, including the calculationof estimated savings in electric power if inverters were installed. Following this explanation,
target equipment for energy audit were selected, and measurement and information to becollected were decided.
(3) Measurement works
In order to take a heat balance and identify an energy saving opportunity, the surface

IV‑ 9temperatures were measured on the kilns and clinker coolers. We were particularly
concerned about the damage of the internal refractory which may cause kiln's externalsurface abnormally high. As for electrical equipment, the fans and blowers around the kiln
were inspected. In order to evaluate the actual efficiency, air intake rates and electricity
consumption were measured and compared with the specifications. The necessary
instruments were provided by several sources; radiation thermometers by ECCJ, infrared
thermometers by the Myanmar DOE, contact thermometers/anemometers/clamp-on power
meters by Malaysia's PTM.
2 days were spent on 2 times of temperature measurements around the kiln. Then, using
these data and the information which were provided by KCP, the heat balance of the kiln
were calculated. Some part of calculation was carried out by KCP engineers. The result waspresented in the seminar by themselves. The infrared radiation thermometers supplied Mr.
Aye Kyaw of the Myanmar focal point were particularly helpful for temperature
measurements. These were digital models donated by UNIDO and were both quickly
responding and accurate. The radiation thermometer supplied by the ECCJ had some bias toshow a little higher ,and moreover was unable to follow the rotating kiln.
On the next day, we reviewed the measurement data taken on the previous day, and thenstarted the measurement concerning. The power monitor and velocity meters brought by
Malaysia were proven very helpful. As a target equipment, the fans were selected withrelatively narrow-throttled damper (20% or 50% opening), because more energy saving
were expected in these fans. The fan performance curves were promptly prepared forstudying the energy saving potential. The factory engineers were so cooperative as toprepare the necessary data. In addition, luckily enough, the equipment was constructed by
Japanese companies and almost all documents were orderly maintained.

(4) Measurement results
Figure IV-2-1 shows a typical profile of temperature inside the wet-process rotary kiln. Theinternal temperature reaches a maximum of between 1,400°C and 1,450°C. As aconsequence, the temperature goes high around the kiln, which results in considerable
amount of heat radiation to the surrounding.

IV‑ 10Temperature, ℃
2000
Gas temperature
1000
Material
temperature
Cooling

Calcining

DryingPreheating

Sintering
ZoningWater content of raw
material : 38 – 40%

Clinker temp: 80 – 100 ℃

Fuel

Raw meal
Kiln

Cooler

Chain Curtain Zone

ClinkerTemperature Profile in Wet Process Kiln
Figure IV-2-1

Typical temperature profile inside a wet-process rotary kiln

The result of temperature measurement of the surfaces around the kiln are shown in tables
IV-2-3, IV-2-4 and IV-2-5. These data were used for heat balance calculation.
Table IV-2-3 Temperature measurement of the surfaces around the kiln
Length from the
0
31.5
56.5
81.5
120
inlet (m)Interval (m)
31.5
25
25
38.5
Kiln dia (m)Zone
Kiln surface temp.
(°C)
Ave. kiln surface
temp. (°C)

Dimension (m)5

3.36
Drying60-68

3.36
Preheating
155-192

3.36
Calcining248-250

3.36
Sintering234-333

3.36
Cooling336-360

63

175

249

300

348

Table IV-2-4
Cooler surface

125

Temperature measurement of the clinker cooler surface

Front
face
(Kiln
side)
2.5 x 3.3

Side faceKiln
side
5 x 3.3

Rear side

Rear face

Top face

Bottomface

8.6 x 3.3

2.5 x 3.3

2.5 x 13.6

2.5 x 13.6

IV‑ 11

Measured temp.
(°C)

118

86-98

50-74

73

Ave. surface temp.
(°C)

118

94

65

73

Table IV-2-5

42

(35)

Top surface is covered
with dust and bottom isthe same temp. as room

Temperature measurements of the hood surface between kiln and cooler

Hood position
Dimension (m)Measured temp. (°C)
Ave. surface temp.
(°C)

Front vertical face
(Kiln side)

Side face(Cylindrical)

Rear vertical face

φ6.5/φ3.36 (Opening)62

φ6.5 x 2.5L
44, 46, 52, 57

φ6.5
62

62

50

62

(5) Calculation of heat balance and interpretation of the result

1) Heat balance calculation for the wet-process rotary kiln
a. Premises
Ambient temperature:
Fuel data:
Combustion air:

35°C
Natural gas:

2,500 m3N/hCalorific value:

40,914.5 kJ/m3N (KCP data 1,039Btu/SCF)

60 m3/min, 42°C, 5.88 kPa → 55.1 m3N/min,specific heat: 1.306 kJ/m3N • K

Slurry:37.9 t/h, 35ºC, water content: 43% (271.6 kg-H2O/min)

Clinker:

13.5 t/h, 70ºC,
specific heat: 0.192 kcal/(kg-cl • ºC) = 0.804 kJ/(kg-cl • K)
fuel SEC: 570 kcal/kg-cl = 2,386.5 kJ/kg-cl
heat of sintering: -100 kcal/kg-cl = -418.7 kJ/kg-cl
CO2 gas emissions: 0.27 m3N/kg-cl

Clinker cooling air:

669 m3/min, 47ºC, 2.45 kPa → 585 m3N/min

Cooler vent air:

730 m3/min, 135ºC, 1.47 kPa → 496 m3N/min

Kiln exhaust gas:fan: 1,140 m3/min, 120ºC, 2.45 kPa → 812 m3N/min
Note that exhaust gas temperature at the kiln outlet is 130°C and it
cools by 10°C in the duct.
Exhaust gas specific heat: 0.388 kcal/m3NºC = 1.624 kJ/m3N • K

Heat radiation from equipment surfaces (kiln, etc.):
The formulae below are used to calculate the heat loss due to radiation and naturalIV‑ 12

convection. The kiln is assumed to be a horizontal cylinder.
Radiation (Qr): 5.68 x ε x A x {((t1+273)/100)4 - ((t0+273)/100) 4} 3.6/1000 (MJ/h)
Here,

ε:

(radiation factor) is 0.8.

A: Area of radiating surface (m2)t1: Temperature of the hot surface (°C)
t0: Outside air temperature (°C)
Natural convection (Qc): k x (t1-t0) x A x 3.6/1000 (MJ/h)Here, k:Heat transfer coefficient

For a flat surface, k for upper horizontal surface = 3.26 x (t1-t0)0.25
k for vertical surface = 2.56 x (t1-t0)0.25
k for lower horizontal surface = 1.74 x (t1-t0)0.25
For a horizontal cylinder, k = 2.44 x {(t1-t0)/d}0.25
d: outer diameter of the cylinder (m)b: Heat balance calculation• Heat input
Heat of combustion of natural gas:
Qi1 = 2,500 m3N/h x 40,914.5 kJ/m3N = 102286250 kJ/h = 102,286 MJ/h
Sensible heat of combustion air:
Qi2 = 55.1 m3N/min x 1.3kJ/(m3N • K) x (42 - 35)ºC x 60 min/h= 30,085 kJ/h = 30 MJ/h
Sensible heat of slurry:
Qi3 = 0 (No heat input since the temperature is 35°C.)
Sensible heat of clinker cooling air:
Qi4 = 585 m3N/min x 1.3 kJ/(m3N • K) x (47 - 35)ºC x 60 min/h= 547,560 kJ/h = 548 MJ/h
• Heat output
Heat of clinkering:
Qo1 = 13,500 kg-cl/h x (2,386.5 - 418.7) kJ/kg-cl= 26,565,300 kJ/h = 26,565 MJ/h
Sensible heat of clinker (cooler outlet):Qo2 = 13,500 kg-cl/h x 0.804kJ/(kg-cl • K) x (70 - 35)ºC= 379,980 kJ/h = 380 MJ/h
Sensible heat of cooler vent air:
Qo3 = 496 m3N/min x 1.306kJ/(m3N • K) x (135 - 35)ºC x 60 min/h= 3,886,656 kJ/h = 3,887 MJ/h

IV‑ 13Heat of evaporation of water contained in slurry:
Qo4 = 37,900 kg/h x 0.43 x [(100–35)ºC x 4,1868 kJ/(kg• K) + 539 x
4,1868 kJ/kg] = 41,212,297 kJ/h = 41,212 MJ/h
Sensible heat of kiln exhaust gas:
Qo5 = 812 m3N/min x 1.624 kJ/(m3N • K) x (130 - 35)ºC x 60 min/h= 7,516,522 kJ/h = 7,517 MJ/hHeat radiation from kiln
Dividing the kiln into 5 sections and applying the formulae on theprevious page yielded the following results:
Qo6 = 17,780 MJ/hHeat radiation from clinker cooler:
Dividing the clinker cooler into several sections by temperature range andapplying the formulae yielded the following results:
Qo7 = 226 MJ/hHeat radiation from the hood between kiln and clinker cooler:
Dividing the kiln-to-clinker cooler hood into several sections by temperature
range and applying the formulae yielded the following results:
Qo8 = 76 MJ/h
The above data were summarized in Table IV-2-6.

Table IV-2-6 Heat balance table for KCP No. 3 wet-process cement kiln
Heat Input (MJ/h)Heat Output (MJ/h)
1. Heat of combustion of fuel102,286 1. Heat of clinkering
2. Sensible heat of fuel0 2. Sensible heat of clinker
3. Sensible heat of combustion air
30 3. Sensible heat of cooler vent air
4. Sensible heat of slurry
0 4. Heat of evaporation of water inslurry548 5. Sensible heat of kiln exhaust gas
5. Sensible heat of clinker cooling air
6. Heat radiation from kiln
7. Heat radiation from kiln hood
8. Heat radiation from clinker cooler
9. Unaccountable heat losses
102,864

26,565380
3,887
41,212
7,517
17,78076
226
5,221
102,864

2) Refractory degradation of the wet-process rotary kiln
Considering the high surface temperature of the wet-process rotary kiln, we wereconcerned about the condition of the refractory inside the kiln. Figure IV-2-2 shows thearrangement of refractory in the kiln section where high surface temperature was

IV‑ 14

observed. Table IV-2-7 is properties of the refractory materials.

5m, 348℃

38.5m, 300℃
φ3.36m
2m 2m 2m

20m

12m

Fire Clay Brick
SK34, 160mm thick

Name
SK-34
Sk-36
CM-55
CM-RT
DP-6

1m 1m

MgO Cr2O3 Brick
CroMax‑RT,
180mm

Fire Clay Brick
SK34, 180mm thickFigure IV-2-2

5m

MgO

Cr2O3

Brick

High Alumina Brick

Clinkerdischarge
side

DISPOL‑6

CroMax-55,

SK‑36, 180mm thickRefractory arrangement in the kiln section

Table IV-2-7 Properties of the refractory materials
Thermal Conductivity
Chemical Composition (%)
Refractoriness
350°C
350°C
°C (load kg/cm2)
Al2O3
Fe2O3
SiO2
kcal/mh°C
W/mhK
0.9
1.047
1,370<
60>
38<
2.0>
1.15
1.337
1,480<
48>
51<
2.0>
Cr2O3
MgO
1.71
1.989
1,600<
9.0>
17>
55<
Cr2O3
MgO
2.10
2.442
1,630<
6.0>
11>
70<
1.20
1.396
1,500<
45>
54<
2.0>

The high temperature (300°C to 350°C) was observed on the kiln surface, whichindicated that the refractory was likely to be degraded. Consequently, we made a trial
calculation on the thermal situation around the refractory at 6 m distant from the clinker
outlet.

a. Premises
Internal kiln temperature:

1,400°C (= ti)

Surface temperature of kiln's steel casing (= t3, measured at 300°C)
Ambient temperature:

35ºC (= t0)

Heat radiation from kiln surface: a summation of heat transfer of radiation and naturalconvection.
Radiation:

Qr: 5.68 x ε x A x {((t3+273)/100)4 - ((t0+273)/100) 4} (W)Here, ε (emissivity) is 0.8.
A: area of radiating surface (m2)

IV‑ 15

t3: surface temperature of kiln steel casing (°C)
Natural convection:

Qc = k x (t3-t0) x A x 3.6/1000(W)

Here, k: heat transfer coefficient: 2.44 x {(t3-t0)/d}0.25
d: outer diameter of kiln (= 3.36 m)
b. Results
Once heat transfer rate is decided as the above, we can calculate the kiln surface
temperature (t3) or the refractory temperature (t1) respectively by using the kiln
refractory heat transfer calculation shown in the below (Figure IV-2-3). Then thecalculated t3 is compared with the measured value of 300°C, giving the following results:• If refractory temperature inside the kiln is 1,400°C, t3 = 378°C• If surface temperature of kiln steel casing is 300°C, t1 = 927°C
This is the results for a refractory thickness of 180 mm. Generally if the refractory erodes,
casing surface temperature rises high, while if clinker deposits on the refractory, kiln
surface temperature drops low. Accordingly, great care should be taken in the progress ofrefractory degradation if surface temperature is high. Heat radiation from kiln steel casing
increases when surface temperature is high. Regular measurement of surface temperatureis recommended.

IV‑ 16

Q

t3
λ2
t2

r3

Brick λ1

r2

t1

Kiln shell(Steel)r1, r2, r3: (m)t1, t2, t3: ℃
λ1, λ2: Heat
conductivity (W/mK)Q

ti = 1400℃

r1

The heat conduction in a cylindrical walls expressed by the following
formula, and the heat values through the respective layers are equal.
2π (t1 – t3)
Q=
1

r2

λ1

LN (

Figure IV-2-3

1
)+

λ2

r1

r3
LN(

)
r2

Heat transfer calculation for kiln refractory3) Exhaust gas rate from kiln section
While the fuel used in natural gas, there was no detailed information on natural gas at thecement plant. So we used (discussed later) to attempt to calculate the air ratio and oxygen
content in the kiln.
a. Preconditions
Natural gas (fuel) : based on the same data used in the audit of Thanlyin refinery
Amount used:

2,500 m3N/h = 41.67 m3N/min

Components (mole %): CH4: 95.0%, C2H6: 4.0%, C3H8: 0.7%, iC4H10: 0.3%
Calorific power:

1,039 Btu/SCF

b: Calculation of the theoretical amount of combustion air
The theoretical amount of combustion air is 227 m3N/min when natural gas is burned at
41.667 m3N/min as shown in Table IV-2-8.

IV‑ 17

Table IV-2-8
Gas component
CH40.95 moleC 2H 60.04 moleC 3H 80.007 moleiC4H100.003 mole
Total
1.0 mole
N-Gas: 1.0 mole
41.667 m3N/min/22.4
m3N = 1.860 mole/min

Theoretical amount of combustion air(mole, m3N)

Oxygen0.95 mole
0.14 mole
0.035 mole
0.0195 mole
1.1445 mole
1.1445 mole x 22.4m3N = 25.6368 m3N
Air = 25.6368 m3N/0.21 = 122.08 m3N
Air = 1.860 mole/min x 122.08 m3N= 227 m3N/min = A0

CO20.95 mole
0.08 mole
0.021 mole
0.012 mole
1.063 mole
23.811 m3N

H2O, Steam
1.90 mole
0.12 mole
0.028 mole
0.015 mole
2.063 mole46.211 m3N

44.288m3N/min85.953
m3N/min

The air entering the kiln is as follows (see kiln heat balance calculation):
From the combustion air blower

55.1 m3N/min

From the clinker cooler air blower

585 m3N/min

Vent air from the clinker cooler-496 m3N/min

Total = (55.1 + 585 - 496) m3N/min = 144.1 m3N/min

These results show that the amount of air supplied to the kiln is insufficient byapproximately 83 m3N/min (= 144.1 - 227 m3N/min) or more. It seems that around 100
m3N/min of air is infiltrating somewhere, or that there are some kinds of error in the
airflow rate, for example, measurement errors.
c. Calculation of kiln exhaust gas rate
The exhaust gas rate at the theoretical combustion are as follows, based on the kiln heatbalance calculation and Table IV-2-8:
Nitrogen in the combustion air:A0 x 0.79 = 179.3 m3N/min

CO2 produced in combustion:

44.288 m3N/min

H2O produced in combustion:

85.953 m3N/min

CO2 released during calcination:
0.27 m3N/kg-cl x 13,500/60 kg-cl/min= 60.75 m3N/min
H20 evaporated from the slurry:
271.6 kg-H2O/min/18kg-H2O x 22.4 m3N= 338 m3N/min
Total = 708.3 m3N/min
The amount of exhaust gas discharged by the kiln exhaust gas fan is 812 m3N/min,indicating that 103.7 m3N/min of air is leaking from somewhere into the kiln exhaust gas.
This value is equivalent to an air ratio of 1.46. Presumably, this air is being drawn insomewhere between the kiln outlet and the fan. Possible sources of air leakage are
sleeves on the seals at each end of the kiln and the inspection holes below the kiln burner,
as well as the air drawn in through the clinker exit. But the seals on slurry inlet were in

IV‑ 18very good condition. It is possible that air is infiltrating from the periphery of the clinker
cooler, but we could see no evidence of leakage that would make a noise.
d. Clinker cooler heat balance
The heat required for cooling hot clinker (assumed to be 1,200°C) to 70°C is equatedwith the sum of cooler heat radiation and heat brought out by cooler vent air.
• Heat required for cooling the clinker
13,500 kg-cl/h x (1,200-70)°C x 0.804 kJ/kg-cl • K = 12,265,000 kJ/h
Clinker specific heat = 0.804 kJ/kg-cl • K• Heat brought out by cooler vent air
The amount of air entering the cooler is referred to as (585 + Q) m3N/min with atemperature of 42°C. The amount of air infiltration is Q m3N/min. Hot air leaving thecooler is divided into two parts, one of which has 496 m3N/min and goes to the IDF. The
other part has (89 + Q) m3N/min and goes to the kiln. Given an air temperature of 135°C
for the former and X°C for the latter,
496 m3N/min x 60 min/h x 1.306 kJ/m3N • K x (135 - 42)+ (89 + Q) m3N/min x 60 min/h x 1.306 kJ/m3N • K x (X - 42) = 12,265,000 kJ/hSo,
X = 42 + 110,393/(89 + Q)
Assuming that Q is 100 m3N/min, the temperature of air entering the kiln is 626°C, while
if. Q is 150 m3N/min, the temperature is 504°C. In either scenario, the clinker will notcool to 70°C unless a considerable amount of air infiltrate from somewhere. Clearly, weneed to check whether the clinker is really cooled to 70°C, whether the air rates throughfans are accurate, whether there are leaks. In addition, we need to calibrate the measuring
instruments.
4) Reduction of slurry water content
KCP operates its plant with a slurry water content of 43%, which seems a little bit higher
according to the Japanese experience, although the wet-process kilns disappeared inJapan now. For the reference, the figure in the Ceramic Engineering Handbook is 34-37%,
while the guidelines in the NEDO-ASEAN PROMEEC Report (FY2000) allow for
38-40%.
Energy saving effect of reduction of slurry water content is as large as 1% of natural gas
consumption in case of 1% cut in the water content, shown in the following calculation;
Amount of water corresponding to 1%: 271.6 kg/min/43 = 6.316 kg/min
The amount of heat required for water evaporation and to heat the slurry to 130°C:(100–35)ºC x 4,1868 kJ/kg • K+ 2,256.7 kJ/kg + 2.0934 kJ/kg • K x (130-100)ºC= 2,592 kJ/kg

IV‑ 19Heat required for 1% water content:

6.316 kg/min x 2,592 kJ/kg = 16,372 kJ/min

Natural gas calorific value: 40,914.5 kJ/m3N
Reduction in natural gas:
16,372 kJ/min/40,914.5 kJ/m3N = 0.4 m3N/min(= 24 m3N/h)

The reduction in natural gas is equivalent to roughly 1%. Accordingly, a 3% reduction inslurry water content would cut the natural gas consumption by roughly 3%.
5) Potential to increase the production of clinker
Table IV-2-9 shows the correlation between exhaust gas rate and burned clinker
experienced in cement kilns in Japan.
Table IV-2-9

Correlation between exhaust gas rate and burned clinker in Japanese cement kilns

Kiln Type
Shaft kiln
Dry long kiln
Wet kiln
Lepol kiln
SP kiln
NSP kiln

kJ/kg-clinker
3,936
6,226
5,681
3,994
3,337
3,237

SourceYogyo Kogaku H/B
JCA (1961)
JCA (1961)
JCA (1961)
JCA (1981)
JCA (1981)

m3N/kg-clinker
1.65
2.62
2.38
1.68
1.40
1.35

(JCA: Japan Cement Association)

The data provided earlier shows that heat input required for clinker burning at the KCP is7,577 kJ/kg-cl (= 2,500 m3N/h x 40,915 kJ/m3N/13,500 kg-cl/h). This is roughly 1.33
times the figure of 5,681 kJ/kg-cl for Japan's wet-process kilns shown in Table IV-2-9.
Further, the kiln exhaust gas rate is 812 m3N/min, indicating that the gas rate perkilogram of clinker is 3.61 m3N/kg-cl, which is 1.52 times the figure of 2.38 m3N/kg-cl
shown in Table IV-2-9. This indicates that it is possible to burn at least 1.3 times thecurrent clinker burning rate with the current energy consumption of natural gas.

The following suggestions are drawn with regard to fuel reduction:
a. Decrease the heat loss from kiln surface.
Study measure for lowering the surface temperature of the cooling zone in the kiln
where the temperature exceeds 250°C. This can be achieved by changing the refractorymaterial or by increasing the current single layer to double layers and using insulating
materials with lower thermal conductivity.
b. Calibrate the measuring instruments for correcting inconsistency in kiln heat balanceIV‑ 20

The air intake for natural gas burning seems to be too high. Considering that the air rateestimated from the performance curve of air fans is smaller than the theoretical
combustion air rate, it is possible that some amount of air is aspirated from the rear
section of the kiln and from the cooler. Otherwise, there may be errors in the measuring
instruments. Of particular concern is the finding that the cooling air supplied by theclinker cooler is not sufficient to fully cool the clinker. More inspection at the plant are
required.
c. Take measures to lower the water content in the slurry.
The water content of the slurry is between 3% and 9% higher than data experienced inJapan. Reducing the water content by 1% should allow a 1% reduction in fuelconsumption. It should be possible to remove more water by adjusting the slurrytransfer pump specifications and installing a filter before the slurry enters the kiln.

(6) Electrical energy audit
Though the audit was conducted over only 3 days, the enthusiastic response from the plantallowed us to obtain a large number of results, as discussed below. We expect the Myanmar
participants in future to follow-up measures.
1) Fans and blowers
In the audit, many equipment is found to run with dampers throttled . More studies arenecessary for reducing the power loss in dampers. Energy saving can be made on thefollowing equipment:
・Primary Crusher: Dust fan
・Rotary Kilns: Air cooling fan, Discharge cooling fan, Primary air blower, Induced fan,Exhaust fan, (3kilns, Nos 1, 2 and 3)
・Finish Grinding Mill: Induced fan* Sample calculation is given in case that an inverter were installed on the air-cooling fan
for No. 3 kiln. Figure IV-2-4 shows the principle of energy saving in fans and blowers.

IV‑ 21

To throttled damper

Q-H curveat the rated speed of N0

Pressure

B’

Pb’
Pa
A

Pb
Resistance curveof pipeline, etc

B0Q-H curveat the speed of Nn

Qb Qa

Flow

Qb / Qa = Nn / N0, Hb / Ha = (Nn/N0)2
axis power: Ln / La = (Nn/N0)3
Figure IV-2-4

Energy saving effect through inverter installation illustrated on the performance
curve of fans and blowers

Qa is the air flow volume at intersection point A of the performance curve and theresistance curve. The resistance curve is extended according to a square law
characteristic passing the current pressure Pb (measured at point B).
Unfortunately, pressure Pb was not measured in this inspection, so we assumed that Qa= Qo for the purposes of making out the example.
The actual air flow volume measurement Qb (at 42°C) is temperature corrected for the
standard intake conditions (at 20°C).
Qb = 669 x (273 + 20)/(273 + 42) = 622 [m3/min]
The air flow ratio is equal to the rotation ratio, as shown below.
Qb/Qa = Nn/No
Therefore, Nn = No x Qb/Qa = 980 x 622/1100 = 554 [rpm]Electrical power saving is the difference between the current power input at full rotationand the power input at reduced rotation with inverter control.
We assumed that inverter efficiency (ηtb) is 0.9 and the electric motor efficiency (ηmb)
is 0.5. However, we did not take into considertaion the fan/blower efficiency (xηfa/ηfb).
∆kW = Lb/ηmb’ - La x (Nn/No)3/(ηtb x ηmb) x ηfa/ηfb

IV‑ 22

= 54 - 70 x (554/980)3/(0.9 × 0.5) = 25.9 [kW]2) Pumps• Although the slurry pumps are examined for the kiln and finish grinding mill on the site,
the discharge valve opening was not known, so future inspection should be performed.
3) Others• The primary crusher is loaded intermittently, and there is an opportunity in the powersavings when the crusher is idle. The same applies to other equipment that is underintermittent load.
• There is a need for inspections of the power factor in power reception and distribution
facilities as well as for studying an improvement measure.
• There is an opportunity by replacing the mercury lamps used as ceiling lights withsodium lamps.

IV‑ 23

3. Follow-up survey of Thanlyin Oil Refinery
We revisited the Thanlyin oil refinery, which is located close to the confluence of the Yangon
and Bago rivers, about 30 minutes south-east of Yangon by car. An ECCJ team conducted awalk-through energy audit of this refinery in December 2004, and this visit was intended as afollow-up to that audit.
A complete overview of the Thanlyin refinery is provided in the report of the previous visit (seePROMEEC Report for FY2004).

3.1 Overview of Thanlyin Refinery(1) Name of Company:

Myanmar Petrochemical Enterprise (MPE)(2) Plant name:

No. 1 refinery (Thanlyin Oil Refinery, hereafter referred to as TOR.))(3) Date of visit:

November 23, 2006 (Thurs.), 7:50am to 4:30pm(4) Location: On the outskirts of Yangon, approximately 30 minutes by car from the city center.
(5) Survey members:

Audit team (1/2)

From Myanmar:
U Aye Kyaw

Director, Ministry of Energy (MOE), Energy
Planning Dep’t

U Maung Maung Ohn Thaw

Staff Officer, MOE, Energy Planning Dep’t

U Ohn Myint

Director, Myanma Industrial Construction
Services

Participants from other countries
Mr. Nor Hisham Bin Sabran

PTM, Malaysia

ACE
Mr. Ivan Ismed

Project Officer

Mr. Junianto M

Manager of Computer Center & IT

Japan: ECCJ, International Engineering Department Technical Experts
Hideyuki Tanaka, Koukichi Takeda, Fumio Ogawa,(6) TOR respondents: Audit team (2/2)
U Myint Oo

Deputy General Manager

Daw Yin Yin Oo

Deputy General Manager (Production)

IV‑ 24

Daw Khin Khin

Assistant General Manager, COD

U Soe Hlaing

Deputy Assistant General Manager, COD

U Sein Than

Mechanical Engineer Superintendent

U Aye Cho

Electrical Engineer Superintendent

Unlike the previous visit, which was insufficiently prepared, an efficient discussion and tour
were performed, making use of the information given in the pre-audit questionnaire thatwas sent in advance, and to which the responses are done, as well as the additional
information given in e-mail exchange. However, the raw material currently used (crude oil)is very different from that used 5 years ago (condensate), so data in FY2004 and FY2005
were compared. A site inspection was restricted primarily to the CDU (crude oil distillationunit) units and the power plant. Combustion management and energy saving in thepumps/fans were focused as an energy audit.
3.2

Overview of the Refining Facilities(1) Production
The properties of the raw material are that it has a low specific gravity and consists mostlyof naphtha fraction. This is blended with small amounts of relatively heavier fractions. The
raw material is transported from roughly 110 km offshore by 6,500 DWT tanker.
Specific gravity 60/60°

0.75

API Gravity

57

Sulfur content (wt%)

0.005

Based on the actual data, raw material of 114 million IG was processed annually during
April 2003 to March 2004, which means approximately 43,460 kL (9,100 BCD) was
processed on monthly average. BCD is Barrels per Calendar Day. The raw material isprocessed in 2 crude distillation units, as follows:
CDU-B: Approx. 6,000 BCD (at 50% load)
CDU-C: Approx. 3,000 BCD (at 50% load)

Total: Approx. 9,000 BCD

The main products and production yields are shown as a percentage below:
LPG (mixture of propane and butane) : ?%Motor gasoline: 68%
ATF (jet fuel): 13%
HSD (diesel): 12%
Solvents and lubricants (mixtures only), etc : ?%.

IV‑ 25

(2) Energy usage
The only fuel used at the refinery is “off gas” (natural gas). Because the refinery generates
its own electricity, all the energy used can be accounted for in terms of natural gas used.
The amounts of natural gas, steam and electricity used are as follows:
Natural gas:

1.6 billion SCF/ySteam:

360,000 t/yElectricity:

19 million kWh/y(3) Proposed items and improvement effects
1) Technical study
As a preliminary step for the energy reduction study, the operating conditions for the plantshould ideally be as close to optimal as possible. With this in mind, we recommended atechnical study of the CDU with necessary modifications. For example, some
improvement needs to be carried out, such as optimizing the operating pressure andboosting the cooling capacity of the top section of the distillation tower.
2) Recommendation
First of all, a portable Orsat-type analyzer was recommended so as to obtain the excess air
ratio in the furnace exhaust gas. Then, the energy saving of the machinery at low-load
operation was proposed, as well as steam trap maintenance and insulation of bare piping.

3.3 Follow-up survey
On November 23, 2006 (Thurs.), a visiting team of 9, including Myanmar government
representatives, together with 6 staff from the oil refinery conducted a follow-up survey.
To begin with, the refining operation and its energy consumption were confirmed before
going on to conduct an on-site audit. Finally, the visit finished with a discussion of measures
for reducing energy consumption.

(1) Status of production and plant operation
Comparing with 2004 and 2005, both the processing conditions and product structure areunchanged, with condensate from the Yetagun offshore natural gas field being processed as
the raw material in 2 CDUs (B and C).

1) Raw material properties
Condensate production volumes vary depending on the natural gas production
circumstances, while the properties of the raw material also vary slightly. An example ofIV‑ 26

recent properties is shown below:
Specific gravity:

60/60°F 0.7437

API Gravity

58.8

Sulfur content (wt%)

Almost 02) Product output and plant operation conditions
The products distribution is unchanged from the previous audit. The table below lists theamounts of each product produced in FY2004 and FY2005.
Circumstances are also unchanged in that only the CDU plants are running and all
secondary equipment is stopped. However, during the audit 2 years ago, the 2 CDUs were
processing a total of roughly 9,000 BCD, while in FY2005 the production was around
7,800 BCD. The reasons for this are as follows:a. Declines in the supply of condensate
b. Power outages (twice) due to stoppage of the power plant boiler with problemsc. CDU operation halt due to problems in the overhead condensers for CDU-B (probably
caused by leakages)

It seems likely that there has been insufficient preventive maintenance due to a lack ofinvestment funding.
Production volumes have declined as a result (Table IV-3-1).

Table IV-3-1

1
2
3
4
5

Fiscal Year
Condensate charged
Products
NAPHTHAATF (Aviation Turbine Fuel)MK (Medium Kerosene)
GO (Gas Oil)
OthersTotal

Oil refinery production volumes
2004-2005
106,644,732 IG
IG
Yield (%)
77,488,351
72.66
14,085,756
13.21
8,871,982
8.32
1,203,993
1.13
537,993
0.5
102,188,075
95.82

2005-2006
99,850,029 IG
IG
Yield (%)
75,293,447
75.41
11,401,825
11.42
7,668,202
7.7
961,8480.96
447,0190.45
95,792,341 95.94

3) Energy usage
Whereas FO (fuel oil) was also used as primary energy source previously, now energy
used comes entirely from natural gas. As well as being burned directly in the CDU furnace,
natural gas is also burned in the power plant boiler to generate the electrical power.
Accordingly, we can reckon the amount of energy consumed by the refinery almost
entirely in terms of its natural gas consumption. The specific energy consumption isIV‑ 27

expressed as the value of the natural gas consumption (MSCF: Million Standard Cubic
Feet) divided by the amount of production volume in Imperial gallons. Table IV-3-2 showsthat the figures for FY2005 are a significant improvement over those for FY2004, butsome questions remain, as discussed above.

Table IV-3-2
Item
Production volume(IG)
Power (= N-Gas,
MSCF)
CDU-B
CDU-C
SEC

Power
CDU “B+C”

Energy consumption at the Thanlyin Oil Refinery
2001.4-2002.3
2004.4-2005.3
2005.4-2006.3
142,247,290
102,188,075
95,792,341
1,520MSCF

1,373.1MSCF

1,414MSCF

FO: 2,022,417IG
398,376GJ
FO: 718,024IG
141,436GJ
10.685SCF/IG
11,499kJ/IG
FO: 0.0193IG/IG
3,795kJ/IG

N-Gas: 175.5MSCF
184,986.5GJ
N-Gas: 58.4MSCF
61,568.4GJ
13.437SCF/IG
13,326kJ/IG
2.289SCF/IG
2,413kJ/IG

N-Gas: 78.4MSCF
73,696GJ
N-Gas: 27.8MSCF
26,132GJ
14.761SCF/IG
14,639kJ/IG
1.109SCF/IG
1,042.3kJ/IG(4) Inspection of refining units
An on-site inspection of the CDU-C plant and the power plant was conducted. Both plants
were built by Mitsubishi Heavy Industries, but owing to the lack of maintenance since theinstallation, it is already clear that the plants are not functioning in the full capacity.

1) CDU-C plant
The combustion air is introduced into the furnace chamber through a natural draft with nopreheating of the air. The natural gas is burned using 5 burners. The superheated steam
generated in the furnace is injected into side strippers, and side streams are not treated inany more than stripping.
Relatively large P-101 (cold crude charge pump) was observed due to low-load operation
and because its outlet control valve is throttled.
However, pressure gauges located on the inlet and outlet of P-101 did not worked, so acomplete inspection was cancelled.
2) Power plantThis was built in 1979. Steam is generated in a boiler and electricity is generated (3,300
V) in an extraction condensing turbine. A significant number of instruments are no longer
used, for example, pH meter and conductivity meter for BFW (Boiler Feed Water), andfuel/air ratio meter, etc.

IV‑ 28

The following 2 machineries were observed particularly with low-load operation in mind:
P-401 (BFW Feed)

Motor 200 kW, discharge-side LIC C/V 20% opened

FDF C-401

Motor 280 kW, damper throttled to 10%.

The motors for both were 3,300-volt and measurement was also cancelled due to danger.
It was found that there was insufficient maintenance overall. For instance, steam pipeleakages, steam trap deficiencies and insufficient heat insulation were observed.
(5) Implementation of previous suggestions and progress in their self-help improvement

1) Thermal insulation was enhanced on the heat exchangers, towers, product pipelines andsteam distribution pipelines.
2) The amount of steam generated was matched to the needs of the plant.
3) The surplus air to the furnace was kept to less than 5% (air ratio of less than 1.31).
4) Future plans include the installation of additional heat exchangers, condensers andcoolers.
5) Steam trap maintenance and replacement will be carried out as necessary, etc.

(6) Recommendations
The recommendations put forward by this follow-up survey team are as follows:

1) Enhance equipment maintenance.
Prevention of equipment problems and breakdowns; control instrument maintenance;
basic data collection, etc.
2) Implement measures for low-load operation
Stand-by equipment for fans and boiler supply pumps etc.
(7) Study into the possible use of inverters for power plant auxiliary equipment
As an example of a measure for low-load operation, we conducted an on-site check of atypical fan and pump to study whether inverters could be used as auxiliary equipment to thepower plant.

IV‑ 29

Table IV-3-2

Study results [Power plant fan and pump specifications and damper andvalve opening]
Data
Equipment
FDF
BFWP

Motor
Input power
Rating Lo/Axis Lb
[kW]
[kW]

Flow Qo/now Qb[m3/min]PressurePo,Ho/ Pb,Hb[kＰa], [m]

1,450
440*
1.175
0.25*

7.6 5 [kPa]

280

568 [m]

200

142
128
116
104

Damper, Valve
Dcl [%]
28 (Damper,
FIC401)100 (delivery)
10 (LIC-401V)(Notes) • The input power is calculated as 3.21 kV based on the current, and the power factor isassumed to be 0.8.
• The shaft power is calculated as (input power) x 0.9 (assumed motor efficiency).
• The flow rate is estimated using the calculation data of the shaft power on theperformance curve.
• Note also that a fan damper angle of 30° is assumed.
1) Fan (FDF)
The FDF runs with the inlet damper throttled, and if the current operation is maintained in
the future, power saving measures must be implemented.
We recommend to measure the current flow rate and pressure and then to replace the fanwith a low-capacity fan that still allowed some surplus, or to install an inverter.

* Sample calculation if an inverter were installed on the FDF
Qa is the air flow volume at intersection point A of the performance curve and theresistance curve. The resistance curve is extended according to a square law
characteristic passing the current pressure Pb (measured at point B).
Unfortunately, pressure Pb was not measured in this inspection, so we assumed that Qa= Qo for the purposes of making out the example.
The actual air flow volume (Qb) is estimated to be 440 [m3/min].
The air flow ratio is equal to the rotation ratio, as shown below.
Qb/Qa = Nn/No
Therefore, Nn = No x Qb/Qa = 1470 x 440/1450 = 446 [rpm]Electrical power saving is the difference between the current power input at full rotationand the power input at reduced rotation with inverter control.
We assumed that inverter efficiency (ηtb) is 0.9 and the electric motor efficiency (ηmb)
is 0.5. However, we did not take into consideration the fan/blower efficiency (xIV‑ 30ηfa/ηfb).
∆kW = Lb/ηmb’ - La x (Nn/No)3/(ηtb x ηmb) x ηfa/ηfb= 142 - 260 x (446/1470)3/(0.9 × 0.5) = 126 [kW]2) Pump (BFWP: Boiler Feed Water Pump)
The BFWP runs with the flow rate adjustment valve throttled, and if its current operation
is maintained in the future, power saving measures must be taken. We recommend tomeasurethe current flow rate and pressure, and then to replace the pump with a smallersize.
On-site checks were only conducted for the FDF and BFWP in this audit, but an overall
review tailored to low-load operation is needed for other auxiliary equipment.

IV‑ 31

4. Seminar-Workshop
4.1 Overview
A seminar-workshop was held in Yangon, Myanmar on November 24, 2006.
The seminar-workshop began with an opening address given by the Director of the Myanmar
MOE, U Aye Kyaw. The seminar-workshop was attended by a total of 56 enthusiastic
participants and proved to be both successful and highly productive. This year's
seminar-workshops, regardless of the country in which they were held, have all been presided
over by the focal point (FP) from the host country, and in Myanmar this role fell in U Aye
Kyaw. This resulted in him being a very busy man, since he was also acting as Myanmar's VIP.
This seminar-workshop included 3 times of question and answer sessions, and eager
questioning from the floor prompted extensive discussions.

(1) Date/Time
November 24, 2006 (Fri.), 8:00 am – 5:30 pm(2) Venue
Sedona Hotel, GF (Ballroom), Yangon, Myanmar(3) Seminar-workshop presentations
Reports from Myanmar began with an introduction to the general energy-saving activities ofthe MOE, followed by three reports on energy saving campaigns from two oil refineries anda cement plant. Reports from ASEAN were presented by Indonesia, Malaysia and Vietnam.
See the attached data for the program.

(4) Participants
Myanmar-side members:
U Aye Kyaw

Director, Ministry of Energy (MOE), Energy Planning Dep’t

U Maung Maung Ohn Thaw

Staff Officer, MOE, Energy Planning Dep’t

U Aung Kyi

Managing Director, Myanma Industrial Construction Services

U Ohn Myint

Director, Myanma Industrial Construction Services

U Myint Soe

Deputy Assistant Director, Myanma Industrial Construction
Services

U Tin Oo

Staff, Myanma Industrial Construction Services

U Thaung Nyunt

Assistant Director, R & D, Directorate of Myanma Industrial
Planning

IV‑ 32

Daw Hla Hla Kyi Deputy General Manager (Production), Myanma PetrochemicalEnterprise (MPE), Petrochemical Complex, Thanbayakan, (Mann)
Daw Yin Yin Oo

Deputy General Manager (Production), MPE, No.1 Refinery,
Thanlyin

U Saw Fernando

Deputy General Manager (Planning), Myanmar Ceramic Industries,
Kyankhin Cement MillU Win Khaing

General Secretary, Myanmar Engineering Society

U Than Tun

Joint Secretary, Myanmar Institute of Strategic and International
Studies

U Lin

Chairman, Yathar Cho Industry, Ltd.
and many more.

ASEAN Center for Energy (ACE)：
Mr. Ivan Ismed

Project Officer

Mr. Junianto M

Manager of Computer Center & IT

Indonesia:
Mr. Subagyo

PT Kertas Leces, Indonesia

Vietnam:
Mr. Le Tuan Phong

Ministry of Industry, Vietnam

Malaysia:
Mr. Nor Hisham Bin SabranJapan:

PTM, Malaysia

ECCJ, International Engineering Department Technical Expert

Fumio Ogawa, Koukichi Takeda, Hideyuki Tanaka
General participants from Myanmar
A total of 56 attendees including sponsors (list of participant to be received later).
Participants came from a range of fields, including the electric power, cement,
petrochemical, textiles and ceramic industries. Almost all were from state-run
businesses, so there were no distinctions based on their industry, rank or position.

4.2

Results of the Seminar-Workshop(1) Opening ceremony

1) ACE
Because this event coincided with the SOME meeting, Dr Weerawat of ACE was unable toattend, so his message was delivered by Mr Junianto in his place. He began with a brief
introduction of ACE and PROMEEC and also touched on the projects being undertaken byIV‑ 33ACE.
2) ECCJ
A greeting was given by Mr. Hideyuki Tanaka, technical expert representing Japan (METI
and ECCJ). He spoke on the importance of this project, its background and current status,
and Japan's cooperation with and contribution to ASEAN. He also expressed his gratitude
for the cooperation given to this visit to the cement plant and oil refinery, and expressed
his hope that EC activities can be extended to other production facilities in Myanmar.
3) Myanmar, MOE
Mr. U Aye Kyaw gave a greeting in place of the MOE Director General. After discussing
Myanmar's current situation and the importance of this project, he went on to express his
thanks to all the representatives and participants. He then briefly described the content of
the seminar-workshop before formally opening the event.

（２） Session 1: Policy and Initiatives on EE&C
1) ACE Activities on EE&C (Mr. Junianto, ACE)
Mr. Junianto used the attached materials to explain the ACE activities, the current statusof ASEAN, the dialog between the EC and Japan, and future plans.
2) Initiatives and Programs of ECCJ on EE&C in Industry in Japan (Mr. Tanaka, ECCJ)
Mr. Tanaka gave a detailed explanation covering three topics: the current status of energy
conservation in Japan, the energy conservation law, and the implementation of energy
saving measures in the industrial sector in Japan.
3) Overview of EE&C Activities in Myanmar (U Aye Kyaw, MOE)
Mr. U Aye Kyaw also discussed three topics: the current status of energy and energy
policy in Myanmar, the activities that have been undertaken in the past, and Myanmar's
future plans. Until now, a reluctance to engage in follow-up activities coupled with the
low cost of energy have meant that EE&C activities have had little impact. He went on toindicate that future EE&C activities would have clear goals aimed at pointing the way toenergy self-sufficiency. He also stressed the need for better and more effective
coordination between five ministries involving in energy issues.
(3) Session 2: EE&C Best Practice in Industries

1) Case Study 1 – Experience and Application of EE&C in the Leces Pulp and Paper Mill Mr. Subagyo (Indonesia)
This presentation was given by Indonesia's PT Kertas Leces, which underwent a follow-up
survey as part of the PROMEEC activities in fiscal 2005. Reports from this company haveIV‑ 34been presented at successive seminars in the past. A total of 7 people from domestic paper
mills attended in the Myanmar audience.
2) Case Study 2 – EE&C for the Textile Industry in Malaysia - Mr. Sabran (Malaysia)
As an energy-saving activity of Malaysia PTM, Mr. Sabran presented examples of energy
savings at a glass factory and a textiles factory.
3) Case Study 3 – EE&C for the Ceramics Industry in Vietnam - Mr. Phon (Vietnam)
Mr. Phon gave a presentation on the energy-saving improvements implemented at
Vietnam's HAPOCO Ltd, which underwent a follow-up survey as part of the PROMEEC
activities in fiscal 2004.
4) Case Study 4 – Progress Report on Oil Industries previously Audited in Myanmar- Mrs. Hla Hla Kyi (Myanmar)
Mrs. Hla Hla Kyi compared the current situation with the situation in 2001 when the first
PROMEEC energy audit was conducted and discussed the improvements. However, there
was no mention of the results of the follow-up conducted in fiscal 2004. The fact that
there have also been considerable changes to the executive personnel at oil refineries
suggests that there have been problems with management transitions within the oil
refining companies. The content was the same as that presented at the Lao PDR in
October 2006.
5) Case Study 5 – Results of Energy Audit at the No.1 Refinery (Thanlyin)- Daw Yin Yin Oo (Myanmar)
This presentation was based on hastily summarized material from the previous day's visit.
While the specific energy consumption for FY2005 shows a major improvement whencompared with FY2004, close scrutiny over time is needed to determine the validity of the
figures.
6) Case Study 6 – Results of Energy Audit at the Kyankhin Cement Plant– U Saw Fernando (Myanmar)
This presentation covered the details of the guidance provided to KCP when the audit
team visited the factory, for example, the heat balance calculations for the area around theNo.3 rotary kiln (and the potential for lowering the outer casing temperature by repairing
the internal refractory) and the potential energy savings in the fans and blowers for thekiln.
The presentation provided a supplementary explanation of the heat transfer calculations(to lower the outer casing temperature) based on the original data when the refractory
was designed, provided by Mr.Tanaka.
(4) Session 3: The Way Forward

IV‑ 35

1) Barriers and measures for implementing EE&C in industry - Technical expert, Mr. Ogawa
Mr. Ogawa explained the topic using data issued in FY2005 and with reference to content
discussed by the other presenters at the seminar.
2) Technical Directory – Mr. Ivan
Mr. Ivan explained the purpose of the technical directory (TD) and aspects such as its
creation method and format. He also gave an in-depth description of the TD using actual
examples. His explanation referred to an actual sample TD sheet that he provided. He also
attracted great interest with his explanation of how to view 33 existing examples inbuildings and 50 examples in industry on the ACE web site.
3) Database/Benchmark/Guideline for Industry – Mr. Ivan
This explanation covered the purpose and importance of the database as well as futureplans.
(5) Q&A session and comments
As mentioned above, 3 time slots were set aside for Q&A sessions, which were very
actively utilized by the participants. The main points raised in the Q&A sessions are as
follows:
Q:

When the boiler in the pulp and paper plant was changed from fuel-oil-fired togas-fired, did you change the heat tubes also?

A: (Mr. Subagyo) We changed the burners, etc., but not the heat tubes.
Q: Can an inverter be installed on an existing installed motor?
A: I myself have installed an inverter on electric motors that were already installed.
To use an inverter with an existing electric motor, there are several things you haveto check for. These include whether there are temperature increases caused byincreased harmonic loss or insulation problems due to current surges, the effect ofmotor cooling during low-speed operation, and studies into mechanical strength,
including the fans, given repeated acceleration and deceleration. If you check eachof these items, you should have no problems.
Q: Where achievements in energy savings are expressed, more emphasis on themonetary side of things may appeal to decision makers and will be easier for themto evaluate.
A: (U Aye Kya) You can talk about the monetary side of things, but in Myanmar we are
faced with problems such as an absolute insufficiency in natural gas, so reducing
your usage is important since it allows us to use that much more gas effectively inother areas.

IV‑ 36

U Win Khaing added comments such as, “Myanmar wants to play an active role in
the future in the ASEAN Award System,” and “Both the TD and the DB are
wonderful. I want to thank METI, the ECCJ and the ACE. Respective audiences,
surely everyone will want to use

these

a great deal.” With these remarks, hegave a forward-looking and highly encouraging speech.
(6) Closing address
U Aye Kyaw called particularly on U Win Khaing (scheduled to visit Japan in December as
a BOJ member), who then gave a speech. Saying “The PROMEEC project andseminar-workshops such as today's are very significant and clearly address the needs ofMyanmar,” he expressed his gratitude to everyone involved.
There was then an awards ceremony during which certificates were given to thoseanticipating on the day. Finally, U Aye Kyaw once again stressed the importance of theseminar-workshop, affirming that it had been a resounding success and again thanking
everyone involved. He then discussed his hopes for the future before declaring the seminarclosed.

IV‑ 37

5. Attachment(1)“ASEAN PROMEEC Seminar/Workshop Program”
1. “ACE Activities on Energy Conservation & Efficiency”
2. “Initiatives and Programs of ECCJ on EE&C in Industry in Japan ”
3. “Overview of EE&C Activities in Myanmar”
4. “EXPERIENCE and APPLICATION of ENERGY EFFICIENCY and CONSERVATION
in LECES PULP AND PAPER MILL”
5. “Presentation from Malaysia”
6. “Hai Duong Porcelain Company”
7. “Progress Report on Oil Refineries Earlier Audited in Myanmar”
8. “RESULT OF THE ENERGY AUDIT IN NO(1) REFINERY (THANLYIN)”
9. “Presentation from Kyankhin Cement Plant”
10. “Relation between the brick thickness and shell surface temperature”
11. “Barriers and Measures on implementing EE&C in Industry”
12. “Development of a technical directory”
13. “Development of a database for industry/building”
14. “Cement Process & Energy Saving”
15. “Promotion of Energy Conservation Activities in Factories (Electricity)”

IV‑ 38

V. ASEAN Initiatives
1. Overview of Summary/Post Workshop

Summary/post workshop for three projects on energy conservation in major industries, energy
conservation in buildings, and energy management infrastructure development in the ASEAN
countries, was held in Bandar Seri Begawan, Brunei. Representatives from ten ASEAN countries,
the ASEAN Center for Energy (ACE), and the Energy Conservation Center, Japan (ECCJ)
gathered to assess the performance and achievements of three projects in FY2006 and to confirm
future initiatives and policies. In the summary workshop for each project, Japanese members
reported on the results of activities implemented in FY2006, and discussed the present status,achievements, and issues of activities with input from all participants.

1.1 Date
February 27 (Tue) – 28 (Wed), 2007

1.2 Venue
Oil & Gas Discovery Centre, Seria, Brunei Darussalam
1.3 Participants
The summary/post workshop was attended by 20 participants, including 11 members from ten
ASEAN countries, 5 members from ACE, and 4 members from ECCJ. The following is a listof participants.

Brunei Darussalam (2 participants):
Mr. Hj ABD Shawal Yaman

District Electrical Engineer, Dept. of Electrical Service,
Ministry of Development, Nagara Brunei Darussalam

Dr. Kha Sheng Tan

Associate

Professor

and

Head

of

Department

ofEngineering Science, Universiti Brunei Darussalam,
Brunei DarussalamIndonesia (1 participant):
Ms. Indarti

Head of EC Division, Ministry of Energy and Mineral
Resources (MEMR), Indonesia

Cambodia (1 participant):
Mr. Lien Vuthy

Deputy Director, Department of Energy Technique,
Ministry of Industry, Mines and Energy (MIME),V‑ 1

Cambodia
Lao PDR (1 participant):
Dr. Daovong Phonekeo

Deputy Director General, Department of Electricity,

Ministry of Energy & Mines, Lao PDR
Malaysia (1 participant):
Mr. Hyshamudin Ibrahim

Program Manager, Malaysia Energy Centre (PTM),
Malaysia

Myanmar (1 participant):
Mr. U Ohn Myint

Director, Works Planning Dept., Ministry of Industry
No. (2), Myanmar

Philippines (1 participant):
Mr. Jesus C. Anunciacion

Chief Science Research Specialist, EE&C Division,
DOE, Philippines

Singapore (1 participant):
Mr. Zulkarnain B H Umar

Senior Engineer, Energy Market Authority, Singapore

Vietnam (1 participant):
Mr. Phuong Hoang Kim

Official on Energy and Environment, MOI, Vietnam

Thailand (1 participant):
Dr. Prasert Sinsukprasart

Department of Alternative Energy Development andEfficiency (DEDE), Thailand
ACE (5 participants):
Dr. Weerawat Chantanakome

Executive Director

Mr. Christopher Zamora

Administration and Finance Manager

Ms. Maureen C. Balamiento

Database and IT Specialist

Mr. Ivan Ismed

Project Officer

Mr. Junianto M.

IT Staff

ECCJ (4 participants):
Mr. Tsuzuru Nuibe

Senior General Manager

Mr. Kazuhiko Yoshida

General Manager

Mr. Yoshitaka Ushio

General Manager

Mr. Taichiro Kawase

General Manager

V‑ 2

2. Summary Workshop on Major Industries
Summary workshop on major industries was held according to a workshop agenda, chaired by
Dr. Prasert of Thailand.

2.1 Report from ECCJ concerning energy conservation activities in major industries in FY2006
During phase 1, ACE-ECCJ conducted energy audits of major industries in ten ASEAN
countries. In the third year of phase 2 activities, follow-up audits were conducted in majorindustries in three countries listed below, and moreover, some visits were made to other plants
for the purpose of surveying the status of dissemination of guidance provided in phase 1
audits. Additionally, seminar-workshop was held in each country. An overview of activities
implemented in three countries was presented in the summary-workshop.

ASEAN countries visited in the third year of phase 2 and period of visits
Lao PDR

October 2 – 6, 2006

ThailandNovember 13 – 16, 2006

MyanmarDecember 5 – 12, 2006

Table V-2-1 shows the status of activities in each country.
Table V-2-1 Overview of phase 2 activities in FY2006
Country

Lao PDR

ThailandMyanmarTime

Oct. 2〜6

Nov. 13〜16

DEC. 5〜12

1. Follow-up / Energy Audit

CementIron/SteelOil Refining
Cement

2. Seminar-Workshop
1) EE&C Policy

Lao PDR - MEM

Thailand - MOE
ACE
ECCJ

Myanmar- MOE
ECCJ
ACE

Cement (Lao PDR, Myanmar)

Lao PDR - MEM

Items

ACE

ECCJ

Myanmar- MOE

Vietnam-MOI2) EE&C Activities

Ceramics(Vietnam)Chemical (Caustic Soda)
Garment(Thailand)(Cambodia)

Food(Singapore)

Iron/Steel (ECCJ/ASEAN)
Oil Refinery (Myanmar)

Malaysia - PTM
PhilippinesDOST

Myanmar- MPE
Lao PDR-

ECCJ
IndonesiaKrakatau steel

MalaysiaPTM

PhilippinesDOST

Myanmar- MPE

Thailand-Power(Lao PDR)

Pulp/Paper(Indonesia)

Indonesia -Textile(Malaysia)

Malaysia - PTM

Nam Ngum Hydro

Bangkok SteelPT Kertas Leces

Other Industries

Glass
Malaysia-PTM

3) Way Forward

1) What are the Barriers & Measures on the Implementation of EE&C [ECCJ]
2) Development of TD, DB/BM/GL for Industry [ECCJ & ACE]
1) What are the Barriers & Measures for the Implementation of EE & C [ECCJ]
2) Development of Technical Directory, DB/BM/GL for Industry [ECCJ & ACE]

V‑ 3

In the seminar-workshop, Brunei representative gave a presentation on the country’s energy
conservation policies and energy conservation activities implemented by industries.
Representatives from three ASEAN countries in which energy audits were conducted reported
on energy conservation activities implemented in major industries in their respective country.
The other countries did not give presentations. The following section provides an overview ofactivities implemented in three countries.

(1) Activities in Lao PDR
During five-day period of activity, the survey team spent the first four days on
conducting an audit of two cement plants, and the last day on holding aseminar-workshop.
Twenty plant engineers participated in the audit of the cement plants. After giving an
overview of the plant and confirming the content of responses to the preliminary
questionnaire, the survey team conducted a walk-through audit mainly of two kilns andsome large fans. Based on the obtained data, they calculated heat balance inside thekilns and furthered their understanding of cement processes, as well as discussed on
possible energy conservation measures. Two engineers from Malaysia participatedvoluntarily with measurement equipment, and contributed to a measurement in theaudit works. It is epoch-making and highly significant to the objective of the project todisseminate transferred technologies to ASEAN countries.
In the seminar-workshop, 58 people participated in the seminar-workshop, indicating
the high level of interest in energy conservation in Lao PDR. The audit result wasreported by one of cement plant engineers. On the ASEAN side, Malaysia reported on
the efforts of its industries to promote energy conservation, Myanmar on petroleum
refining, and the Philippines on energy conservation activities in the steel industry, andcreated a foundation for an active Q&A session.

(2) Activities in Thailand
During four-day period of activity, the survey team spent the first three days on
conducting an audit of a steel plant and the last day on holding a seminar-workshop.
Ten engineers participated in the audit of the steel plant. The plant is actively pursuingenergy conservation, and has so far implemented various measures, including using
daylight to save lighting energy. The survey here mainly focused on the un-addressed
problem of heat loss from the furnace walls and loss due to the infiltration of air into
the furnace. Using collected data, calculations of power savings were carried out

V‑ 4through on-the-job training (OJT) involving all participants. The early implementationof low-cost measures is expected.
In the seminar-workshop attended by 70 participants, a plant engineer reported on the
results of the audit, and representatives from Malaysia, Indonesia, and the Philippines
presented case studies on energy conservation at steel plants in their country. This was
greatly appreciated by participants from the steel industry, and was the first time aseminar was held focusing on one industry only. It should serve as a reference inplanning future seminars.

(3) Activities in Myanmar
During six-day period of activity, the survey team conducted a follow-up audit and a
new audit survey at an oil refining plant and a cement plant, respectively. A
seminar-workshop was held on the final day. The six-day schedule was established,taking into account the time needed to travel between two plants, but even so, whole
two days were spent on travel.
In the follow-up audit at the oil refining plant, it was revealed that a part of proposals
recommended in the previous audit had not been implemented. This was because thecrude oil had changed from that used during the previous audit, and also because of
equipment failures. Nevertheless, it is worth noting that three out of five proposals
have been implemented even under the above circumstances.
At the cement plant where a new audit survey was conducted, the surface temperatureof the kiln was measured. Using the measurement data, the plant engineers themselvescalculated heat loss. As a result, they were not only able to discover damage occurringto the insulating firebrick inside the kiln, but all participants learned the significance ofmeasurement technologies and heat loss calculations, and the exercise proved to be
extremely meaningful. Of the 11 plant engineers who participated in this survey, four
were from other cement plants. It is hoped that their participation will contribute topromoting the dissemination of transferred technologies throughout the country.
The achievements of the above audit were reported at the seminar-workshop by a plantengineer. Judging from the content and quality of reporting, the technical transfer was
conducted with success. 56 participants took part in the seminar-workshop, and fromother ASEAN countries, Indonesia presented a case study on the paper/pulp industry,
Malaysia on the textile industry, and Vietnam on the ceramic industry.
2.2 Energy conservation activities in the ASEAN countries

V‑ 5(1) Participants of the plant energy audit and seminar-workshop
As shown in Table V-2-2, participants of plant energy audits increased in FY2005
when OJT was adopted, and the trend became even more conspicuous in FY2006.
Numerically speaking, the average number of participants per plant increased from 1.6
to 4.2 to 12.5 in three years. However, it is too soon to interpret this trend as a result of
increased interest in OJT. We must keep a close eye on future developments, butwhatever the reason may be, increase in the number of participants is extremely
welcome.
Meanwhile, the number of participants to seminar-workshops has remained constant inrecent years, with an average of 71.5 to 56.5 to 61.3 participants per seminar-workshop
for the past three years.

Table V-2-2 Number of participants to audits and seminars held in each country
2004
7

Fiscal year
2005
9

2006
4

11

38

50

1.6

4.2

12.5

4

4

3

286

226

184

71.5

56.5

61.3

Item
Energy audit

Number of plants
auditedTotal number ofparticipants
Average number ofparticipants per
plant
Seminar-workshop Number ofseminar-workshops
held
Total number ofparticipants
Average number ofparticipants per
seminar-workshop(2) Overview of best practices in energy conservation reported in the seminar
As shown in Table V-2-3, 12 presentations on best practices were given by 7 countries. The
activities of the hydro power plant in Lao PDR, the steel industry in the Philippines, theceramic industry in Vietnam, and the pulp/paper industry in Indonesia were the same as
those presented in the past. It is not necessarily a waste to make the same presentation morethan once, but cases that have not yet been presented are preferable.

V‑ 6Table V-2-3 Best practices in energy conservation presented by the ASEAN countries

Country

EE&C Activities

Industry

Same presentation done in 2005
Lao PDR Hydro-power
Iron/Steel Ind 2-stg recuperator, VSD for water pump, Screw air compressor
Malaysia
Overview of MIEEIP project (PTM), Food, Glass, Textile,
GeneralIron/Steel
Thailand Iron/Steel Ind Daylight, cooling tower fan blade, air compressor replace, etc
Food Ind
Philippines Iron/Steel Ind

Ceramics Ind

Same presentation done in 2005
VRM, 5-stg NSP, Damper→VSD, Process A/M, Air leakrepair (Kiln), O2 meter for Air leak, Air press 7Bar→6.8
Same presentation done in 2004

Iron/Steel Ind

Slab preheat, slab hot charge, billet insulation cover, etc

Pulp/Paper Ind

Same presentation done in 2004

Oil Refining

Lower tower pressure, tower off gas recovery

Cement Ind
VietnamIndonesia

MyanmarInsulation, cond.recovery, steam leak, Solenoid valves, etc

Cement Ind(3) Obstacles and measures for promotion of energy conservation in major industries
Support of corporate top managements(Current state)
As was pointed out last year, energy conservation efforts have not resulted in significant
progress due to such issues as inadequate policies, shortage of human resources, insufficienttechnologies, lack of funds, and lack of information. The majority of these obstacles havemuch to do with the attitude of corporate top managements. Most of the problems can beeliminated if management provides sufficient support. For instance, in many cases, plants thatare actively supported by top management have been able to make significant progress inenergy conservation, regardless of country.
(Countermeasures)
Future PROMEEC activities must also be directed to reforming the consciousness of corporate
top managements. Put another way, considerations must be given to make top managements
aware of the fact that energy conservation activities produce profits that would strengthen
corporate competitiveness. Corporate top managements constantly think in terms ofinvestment risk. Therefore, they are highly unlikely to approve of proposals that require large
investments. Fortunately, however, many no or low-cost measures still remain to be
implemented in industries in the ASEAN countries. To open their eyes to the effectiveness of
no-cost measures, such measures should be proposed.

V‑ 7Capacity building of the core team(Role of the core team)
One of the objectives of conducting plant audit surveys is to foster a core team that is capableof conducting audits. A core team acquires audit techniques from Japanese experts throughon-the-job training, and is expected to utilize the technology it acquires to contribute topromoting energy conservation in other plants. It is composed of a government team including
a focal point, an ACE team, and a local audit team (engineers of the auditing plant and otherplants).
(Responsibilities of the core team)
1) Selecting the auditing plant (focal point, ACE team)2) Distributing and collecting preliminary questionnaires (focal point, ACE team)3) Inviting participants from other ASEAN countries, and collecting and distributing
presentation materials (ACE team)4) Arranging for measurement equipment (focal point, ACE team)
5) Making accommodation arrangements for audit participants (focal point, ACE team)
6) Making arrangements for OA equipment, copying tasks, and conference rooms at the audit
plant (focal point, ACE team)7) Arranging for the seminar-workshop venue (focal point, ACE team)8) Audit implementation (local audit team; Japanese experts act as advisors)9) Data analysis, preparation of preliminary report, reporting to the plant (local audit team;Japanese experts act as advisors)
10) Presentation of audit results at the seminar-workshop (local audit team)
11) Presentation of the progress of TD/DB at the seminar-workshop (ACE team)
12) Presentation of the energy situation in the host country at the seminar-workshop (focal
point)
13) Making arrangements for OA equipment, copying, and other tasks at theseminar-workshop venue (focal point, ACE team)
14) Preparation of the seminar-workshop venue, compilation of a participant list, collection
and distribution of presentation materials (electronic materials) (ACE team)(Issues for the core team)The general impression we had on supervising OJT-based plant audits is that energy
conservation technologies and audit technologies are not being transferred smoothly to thecore team. The following are some problems we found, though they do not necessarily apply
to other countries.
1) Preliminary questionnaires are left unanswered in many cases. If responses are not

V‑ 8obtained, interviews must be conducted at the plant, which would take up half a day thatshould be used for the audit.
2) Prior to commencing the audit, Japanese experts give an overview of processes and energy
conservation measures, but they do not seem to be fully understood. The government teamand ACE team must gain a good understanding of each industrial process through OJT, as
they are expected to be familiar with technical issues, and the ACE team, in particular, is
responsible for preparing a TD/DB.
3) The role of each team member was not clearly defined in advance of audit surveys. Audit
schedule, including measurement locations and methods, collection of operational data,
and role of each member, was worked out by Japanese experts. As a matter of facts, mostof audit works were conducted by the Japanese experts, while most members of the coreteam were following and surrounding the Japanese experts during the audit surveys. It
does not constitute the on-the-job training.
4) The measuring equipment that have been prepared did not function frequently. They had
better be calibrated before conducting an audit.
5) Hardly any questions are raised, even after an analysis practice was conducted using
measurement data, and after results of the audit are presented. Most people did not seemto gain a clear understanding. Perhaps it might be difficult to explain and make themunderstand in such a short period of time. It is important to select persons with a certain
degree of experience and knowledge as a member of the core team.
(Future countermeasures)
1) The government team, including the focal point, should visit the auditing plant at least
once before audit surveys, in order to discuss with the plant team about the general outlineof the plant, the procedure of audit survey, answers to the preliminary questionnaire, thepreparation for implementing OJT, and other matters.
2) All members of the core team should have sufficient knowledge before audit surveys.
Moreover, it is advisable to appoint technical assistants familiar with the industrial
processes respectively in the government team and ACE team.
3) There appears to be two reasons for the poor response to preliminary questionnaires. One
is that the questions are difficult, and the other is because the ACE team lacks sufficientknowledge of processes. In response to the former, the questions should be made simpler,
and a detailed guideline on filling out the questionnaire should be prepared. Currently adatabase format that answers to this goal is being prepared for the cement industry. The
latter concerning lack of process knowledge can be addressed only by raising ACE’sawareness of its role and implementing steady training.
4) A factor common to the above issues is perhaps low recognition of the ASEAN countries

V‑ 9that they have to address energy conservation issues through their self-help efforts. In fact,a tendency to depend on the Japanese experts can be observed. It is important for eachmember to recognize his respective role, and to realize that they are the ones who musttake the initiative. Since this recognition could be accomplished in the experience of one
audit, it should be repeatedly confirmed on the opportunity of each audit.
(4) Summary of energy conservation activities in the ASEAN countries in FY2006
As also mentioned in last year’s report, energy conservation activities are seemingly
becoming more and more active in ASEAN countries each year. The primary reason is therecent hike in energy prices. This is adding momentum to energy conservation and cost
reduction activities. The other reason is because corporate top managements are becoming
more aware of the issue of energy conservation, thanks to the dissemination of PROMEEC
activities. Energy conservation activities are expected to gain greater momentum hereafter,
as more companies come to realize that energy conservation leads to cost reduction, as wellas contributes to corporate profits and environmental conservation. There are still many
obstacles to promoting energy conservation in the ASEAN countries, but this PROMEEC
program and various energy conservation training programs can be expected to eliminate
such obstacles.
2.3 Overview of presentations by three host countries in FY2006
In the summary/post workshop, representatives of three host countries of energy audit
reported on EE&C activities in their respective countries.
(1) Lao PDR
The Lao representative presented results of audits conducted at cement plants. Content-wise,
it was similar material presented at the seminar-workshop on the plant audit conducted last
October, a part of which were exactly the same materials as the ones compiled by the ECCJ
experts. Judging from the performance of presentation, the focal point proved to have an
excellent understanding of his role in organizing the local team, coordinating activities
during the plant audit, etc.
(2) Myanmar
The Myanmar representative discussed Myanmar’s energy policies, past energy
conservation activities implemented with international cooperation (e.g., UNDP/ADB
assistance, UNESCAP assistance, PROMEEC activities), and future plans (UNESCAP
assistance, PROMEEC and other ASEAN programs). A description was also given of

V‑ 10

FY2006 PROMEEC activities, with a focus on the follow-up audit conducted at the oil
refining plant and the new audit conducted at a cement plant. In the description of thecement plant audit, photos were used to realistically explain the task of measuring thesurface temperature of the kiln.

(3) Thailand
The Thai representative presented results of FY2006 PROMEEC activities, focusing
mainly on the energy audit conducted in the steel plant. It was reported that the audit was
conducted in cooperation with the steel association, and that the audit results have been
uploaded to its web site. The presentation of audit results using the wireless LAN
demonstrated in the workshop venue gave a strong impression.

2.4 Plans for FY2007 PROMEEC activities
In FY2007, METI-ASEAN PROMEEC plans to continue implementing the same activities as
FY2006, through the concerted efforts of ACE, ECCJ, and focal points (FPs) of the ASEAN
countries. As shown in the schedule provided in Fig.V-2-1, site activities are slated to be
conducted in September and November 2007, in two countries and one country, respectively.
Host countries will be selected on the basis of their commitment to organizing a core teamconsisting not only of members from the host country but members from other countries as
well, and to making steady preparations for the survey. They will be determined at the
FY2007 inception workshop. A follow-up survey and energy audit will be conducted in theselected countries through intensive on-the-job training, and thereafter the results will bepresented at the seminar-workshop by the audit team. In principle, the survey will be
implemented in reference to one industry and two plants per country, and will be conducted
over a period of ten days in each country. In implementing the survey, the core team will be
required to make the preliminary preparations, including selecting host plants for the audit,organizing an audit team of more than five members and determining a role of each member,conducting preliminary studies, and filling out a preliminary questionnaire.
In the seminar-workshop, the ASEAN countries will be invited to deliver presentations, inaddition to presentations by the host country on its energy conservation activities. In theworkshop, discussions are planned concerning the compilation of technical directory (TD) andthe progress and status of formulating the database/benchmark/guideline (DB/BM/GL).
Finally, FY2007 activities will close with the summary/post workshop.

V‑ 11Fig. V-2-1 FY2007 PROMEEC activity plan
PROMEEC (Industry) for 2007-2008: Basic Implementation Plan
- Implementation Schedule -(Preliminary)
ECCJ

Year
Month

Activities
Inception Workshop(1) Preparation of Detailed
Implementation Plan & Preparation(2)

1st Site Activity (Follow-up Survey& Workshop (2 Countries))

4

5

6

7

2007
8

9

10

11

February 27-28, 2007
2008
12
1
2
3

Inception W/S

Two Countries(3) Results / Preparation for 2nd Site

(4)

2nd Site Activity (Follow-up Survey& Workshop (1 Country))

One Country

Analyses of 2nd Site Activity(5) Results / Preparation for 3rd Site
Activity
3rd Site Activity (S & P-Workshop),(6) TD dissemination & DB/BM/GL
formulation)

Post W/S(7) Report Writing

V‑ 123. Post Workshop
3.1 Progress on the creation of technical directory (TD)A progress report was given on the creation of technical directory by ACE. So far, 75 entries
have been registered in the TD for industry and 35 entries in the TD for buildings. The system
is near completion, and information provision from ASEAN countries is awaited. An
application form should be posted on the ACE web site to facilitate information provision byanyone visiting the web site. Manufacturers of energy conservation equipment and systems
should also be cultivated as sources of information. These activities require sustainability andreliability, and the number of personnel and budget for them should be allocated inconsideration thereof.

3.2 Progress on the creation of the in-house database/benchmark/guideline (DB/BM/GL)
A progress report was given on the creation of the database/benchmark/guideline for industry(cement industry) which ACE is working on, as well as an overview of the system.
One of project members posed a question concerning the significance of the database tocompanies, and presented his opinion that the system should be designed upon clarifying its
benefits to companies. Another member stated that the significance should be clarified,because if companies do not comprehend the significance of the system, it would be difficult
to gather data from them. Discussions concentrated on this issue, partly because not enoughefforts were directed to this activity by ACE, and partly because the focal point (FP) did notpossess a thorough understanding of the concept of the in-house database. FPs are
consistently concerned about the significance of the database/benchmark/guideline asproviding criteria and standards for implementing governmental policies, so it may bedifficult for them to grasp the concept of the in-house DB. However, PROMEEC activities
aim to create the database/benchmark/guideline from the standpoint of plant management, andthe database is to be used for in-house energy management (thus it is called the in-house DB).
It is important to have the plant understand that the data obtained through the audit are
beneficial to plant management, and that energy management should be implemented basedon continuous data collection and analyses. ECCJ also explained that one of the primary goalsof PROMEEC activities is based on the principle of voluntarily disclosure of data via ACE’s
web site and sharing it among the ASEAN countries. At the same time, it appears necessary toreexamine whether the existing DB format (cement) contains items that correspond to theobjectives of the in-house DB.
The creation of the database/benchmark/guideline is linked to PROMEEC’s energy audit
activities, which are conducted with an aim to promote OJT, seminar-workshop activities, andV‑ 13the awards system (ASEAN Energy Award), and has been clarified as a tool for promoting
energy conservation in the ASEAN countries.
4. Attachments(1) “ASEAN PROMEEC Summary/Post Workshop” (provided by ECCJ)
1“Expected Status of PROMEEC Project in Asia and Cooperation by Japan”

2“Summary of Local Workshops and Energy Surveys in Major Industries at Lao PDR,
Thailand and Myanmar”

3“Major Industry Proposed Plan in 2007-2008”

4“Summary of Local Workshops and Energy Surveys in Buildings (2006-2007) at
Brunei Darussalam, Philippines and Vietnam”

5“Future Plan for PROMEEC- Buildings (2007-2008)”

6“Results of Activities (Intensive Seminar-Workshops / Visits, etc.)”

7“ASEAN Energy Management System –Updated Plan–”

8“Plan of Award System of Best Practices in Energy Management for Industries &Building”

9“Proposed Future Plan”

10 “Achievement and Future Plan”(2) “ASEAN PROMEEC Summary/Post Workshop” (provided by ASEAN countries)
1 “PROMEEC (Industry) 2006 in Lao PDR”
2 “Overview of EE&C Activities in Myanmar”
3 “PROMEEC Thailand 2006 Steel Industry – Activities Summary”
4 “Status of Preparation of Technical Directory for Major Industries and Database forIn-house Use by Industrial Sub-sectors in ASEAN”
5 “Finalized Plan of and Current Progress in Award System of Best Practices in Energy
Management for Industries and Building”

V‑ 14

Any individual or organization who makes part or all of this reportpublicmust

obtainpriorpermission

fromInternational

Engineering Department of Energy Conservation Center Japan.
Phone81-3-5543-3018

Fax

81-3-5543-3022