PROMEEC (INDUSTRY)
2006 IN LAO PDRPROMEEC Post-Workshop
Brunei Darussalam 27-28 Feb. 2007

Dr.Daovong Phonekeo
Deputy Director General
Department of Electricity,
Ministry of Energy and Mines, Lao PDR
1Outline
1. Energy audit
2. Seminar21

1Energy audit

3

Auditing Background• Industry type: Cement• Auditing dates: 2 - 5 October 2006
• Venue:
1. Vangvieng Cement Factories No.1
2. Vangvieng Cement Factories No.2,Vientiane, Lao PDR

42

Photos of the two cement factories

Vangvieng Factory No.1

Vangvieng Factory No.2
5Information ofVangvieng cement factoryNo. 163

General Information of thefactory• Established Year: 1996
• Employees: 244• Energy consumed per year:Electricity: 8,307,924 kWhAnthracite: 15,500 Ton
Fuel: 191,156 L
7

Information ofVangvieng cement factoryNo. 284

General Information of thefactory• Established Year: 2001 October• Employees: 294- Technology engineer: 1- Mechanical Engineers: 5- Electrical Engineers: 3- Maintenance service technicians: 45- Operators:18
9Design capacity- Clinker: 210,000 t/y- Cement: 240,000 t/y- Heat Consumption:
850Kcal/Kg-cl- Electric Power:115 kWh/t cem.
105

Energy consumption (2005)
1. Electricity: 30,957,252 kWh

2. Anthracite: 31,071 T
3. Diesel: No data

11

Power average consumption
137.98 Kwh/t of cement
34064000

32872000

35000000

32584000

30000000
23250900

25000000
20000000
15000000
10000000
5000000
0
2002

2003

2004

2005

Electric power
kWh/year126

Energy consumption(Anthracite)
Item

2002

2003

2004

2005

Clinker(T) 179,220 226,821

224,747 205,157

Coal (T)26,42835,63433,09031,071

Heat

811

864809832

Consumption

Kcal/kg cl

Kcal/kg cl

Kcal/kg cl

Kcal/kg cl

13

Activities of Energy Saving- Policy for Energy saving from the end ofYear 2005
- Beginning from Electricity energy in January
2006. First training held in cement plant No II- Making and monitoring of monthly records,analyzing of records- Goal or objective determination 125 kWh/tcement- Results from January-August/2006
133.49kWh/t cement
147

Electric power used 1-8.2006
Kwh/t cement160
147.32140120

127.96127.21

122.41118.76

118108.84

100

98.66

80

Coal60Used402001234567815

Future plan of Energy Efficiency andConservation in the Cement factory• Raising awareness of Energy Efficiency andConservation to all employees;• Enhancing efficiency on machine and equipment
maintenance to avoid the unscheduledshutdown;• Keeping or increasing the productivities (quantityand quality )• Establishment of Energy Efficiency andConservation Committee to monitor the energy
consumption and energy saving in the factory
168

Pre-audit coordination• Contacting the two Vangvieng Cement
factories that proposed to be audited andasking them to fill up questionnaires fordiscussion during our visit.
• Organising a small team to join the on-the-job
training on energy audit in the factory;• Arranging a seminar on Promotion of Energy
Efficiency and Conservation in Industry inSoutheast Asia on 6 October 2006 including
invitation of 80 participants.
17

List of participants• Ministry of Energy
and Mines, Lao PDR:4• ECCJ, Japan : 3• ACE : 2
• PTM, Malaysia : 2• The factories : 18

Total: 29 people
189

Audit Items & Measurement
Items
HeatElectricity

Measurement

Heat & material balance

Factory 1
Factory 2

Clinker (t/d), coal to kiln (t/d),coal to precalciner (t/d),
Temperature (SP exit gas,cooler exit gas, clinker)

Waste heat recovery

Factory 1
Factory 2

Same as above

Air leakage

O2 Balance (gas analysis)

Big motor load factor

Motor power, pressurebalance

Transformer load factor &power factor
Air compressor
EnergyManagement

Motor power, pressurebalance

Data management

Factory 1

Recording, targeting (SEC)

Factory 2
Employee awareness

Factory 1
Factory 2

SEC reporting, training,
promotion committee
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Measuring Instrument List
Kanomax

PTM

Contact thermometer PTM

Grate cooler air(2ry air),Coal comb air (1ry air)
Ambient air

Power monitor

PTM

Radiation
thermometer

ECCJ Kiln surface (3 locations)
Cooler surface (3 locations)
SP surface

2010

Data collection in Factory 1
Exhaust gas

Raw material
TF
T

coal
F

Shaft Kiln Section

Combustion air
TF

clinkergas flowmaterial flow
21

Data collection in Factory 2
Exhaust gas
Raw material
TT

F

coal

Pre-calciner

F

Preheater Section

1ry air
coalT

T

Cooler exhaust
ventKiln Section
Cooler Section
Tgas flow

TF

material flow

2ry airF

Clinker

22

11Participantsmeasuring thetemperature ofthe kiln23Monitoring of SEC & Key Variables
ProcessCalculation

UnitRaw Mill= Electric Power / Raw Material Charge(kWh/kg-rawmat’l)Burning= Fuel / Clinker production(kcal/kg-cl)= O2% of Kiln Exhaust Gas(%)= Electric Power / Cement Production(kWh/kg-cement)

Cement Mill

24

12

Participants
closely
analyzing
the data

25

Participants
paid attention
at controllingsystem26

13

Recommendations tothe factories

27

Energy Management System
AspectOrganization

Monitoring

Major Activity
Accountability

Employee education (awareness)

Organization

EE&C promotion committee
Appoint an energy manager

MonitoringData recording & Sharing by allemployees

TargetingSpecific energy consumption (SEC)
Key efficiency parameters (O2%)

Technology
Operation &maintenance (O&M)

Technical review (energy audit)
House keeping

Product yield (avoid off-spec product)
Preventive maintenance (avoidunscheduled shutdown)28

14

Energy Saving Measures in Cement FactoryFirst step

Raw material section

Clinker burning section

1)Selection of raw materials1)Prevention of unscheduledshutdown2)Selection of fuel3)Prevention of leakage

1) Management ofparticle fineness2) Management ofgrinding media2)Management of particlefineness3)Management of grinding
media

Finishing section

Secondstep

1)Replacement of fan rotor2)Improvement of
temperature and pressure
control system
3)Improvement of mixing &homogenization system
4)Installation of closed circuit
mill (separator)

1)Use of industrial waste(waste tire, etc)
2)Heat recovery of pre-heater
exhaust gas and cooler
exhaust gas (drying of raw
material and generation ofelectricity)
3)Replacement of cooler dust
collection from multiclone toEP

1)Installation ofclosed circuit mill(separator)
2)Installation of feed
control system

Third step1)Conversion from wetprocess to dry process2)Replacement of ball or tube
mill by vertical roller mill
3)Pneumatic transfer of raw
material to mechanicaltransfer1)Conversion of fuel frompetroleum to coal2)Conversion of SP to NSP
3)Conversion of planetary
cooler to grate cooler

1)Use of industrial
waste (slag, pozzolan)

29

Monitoring of SEC & Key Variables
SectionMonitored Item

UnitRaw MillSEC = Electric Power / Raw
Material Charge(kWh/kg-raw mat’l)

Clinker
Burning

SEC = Fuel / Clinker production
O2% of Kiln Exhaust Gas(kcal/kg-cl)(%)

Cement MillSEC = Electric Power / CementProduction(kWh/kg-cement)

30

15

Recording of SEC on a Graph
Grinding Ball Management
SEC should bemonitored daily, andwhen SEC arrives atcertain level, grinding
balls is compensated.

Raw mill SEC

Ball diameter shrinks astime passes due toerosive effect. This leads
to gradual increase ofraw mill SEC.

Addition of Grinding Balls(kWh/kg-mat’l)Filling level of grinding
balls is also important ingrinding efficiency.
Optimum level of fillingshould be maintained.

Oct.2

Oct.9

Oct.16

Oct.23

Oct.30

Nov.6

Monitor raw mill SEC daily and add grinding balls in right timing→ 10% energy saving expected
312Seminar

32

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Seminar Background• Seminar title: Seminar on the promotion
on Energy Efficiency and Conservation(PROMEEC) for Major Industries inSoutheast• Seminar held: 6 October 2006
• Venue: Don Chan Palace, Vientiane,
Lao PDR

33

Seminar Background• Presenters:• ECCJ: 2, ACE:2, Malaysia: 1,Myanmar:1,The Philippines: 1, Lao
PDR: 3• Participants: 60

34

17

Session 1Policy and Initiatives on EE&C
• Overview of EE&C Programs of
ASEAN/ACE• Overview of Plans and Programs on
EE&C in Lao PDR, Ministry of Energy andMines• Initiatives and Programs of ECCJ on
EE&C in Industry in Japan Mr. Hideyuki
TANAKA, ECCJ
35Session 2
EE&C Best Practices in Industries• Presentation: Case Study 1 (Cement factory andHydropower plant, Lao PDR)
• Presentation: Case Study 2 (Textile, Glass and Food
Malaysia) Best Practices for Energy Efficiency andConservation for the Textile, Glass and Food
Industries in Malaysia• Presentation: Case Study 3 (Oil Refinery, Myanmar)
Best Practices for Energy Efficiency andConservation for the Oil Refinery Industry inMyanmar• Presentation: Case Study 4 (Iron and Steel, Philippines)
Best Practices for Energy Efficiency andConservation for the Steel/Iron, Cement and FoodIndustries in the Philippines
3618

Session 3The Way Forward• Presentation from ECCJ
• Presentation: Updates on theDevelopment of Technical Directory
ACE• Presentation: Updates on theDevelopment of Database/ Benchmark/
Guideline for Industry ACE

37

Thank youfor your attention

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