Activity Report 2007

International Project for Improving Infrastructure for Rationalizationof Energy Use(Energy Conservation in Major Industries in ASEAN Countries)

March 2008
The Energy Conservation Center, Japan

Preface
In recent years, efforts for preventing global warming have become a common issue formankind, while sustainable economic development is continuingly demanded. Thus, weface a situation in which we must overcome two difficult challenges that completely
contradict each other. What are required for overcoming these difficult challenges aretechnical innovations such as technologies for utilizing energy efficiently, andtechnologies for developing energy with minimum burden on the environment.
In order to contribute to a balanced development of economy and environment indeveloping countries, it is demanded to implement an acceptable and appropriate
assistance to each country by assessing the reality of energy use and environmental
conservation measures, and by thoroughly examining the situation of each country suchas infrastructure and lifestyle.
Under this situation, we entered into a new phase (phase 2) in 2004, with an aim to
implementing energy audits, taking improvement measures, and building theinfrastructure for dissemination, based on the results of energy audit and resultant
technology transfer acquired between 2000 and 2003 (phase 1). The year 2007 was alast year of phase 2, and various activities were made, with an aim to strengthening
infrastructure and disseminating the results acquired in the first and second phases.
As an effective means of achieving these aims, we have made a continuous effort tocreate Technical Directory and Database/Benchmark for each industry.
On the other hand, in the effort to strengthen the infrastructure for disseminating ourachievements, we conducted follow-up surveys in the factories that were audited in thepast, to assess the implementation of recommended improvement measures. In addition,
we made simple energy audits in new factories for propelling the transfer of energy
audit technologies. This year, we implemented audits on the textile industry in Vietnam,
food factories in the Philippines and Malaysia and the steel industry in Thailand.
Additionally, we held seminar-workshops in each country, with the participation not
only of people from the host country, but also people of foreign government authorities
and factory personnel of different industries in other ASEAN countries. They wereinvited to present successful cases of energy conservation measures to share informationin the ASEAN region and create a foundation for dissemination activities. Policies onⅰconcept and formulation regarding Technical Directory and In- house Database werealso discussed in the seminar-workshops, and some illustrative examples were
presented.
We are sure that activities implemented during the last year of phase 2 have beensignificantly meaningful in that they have contributed to the steady development of
infrastructure for promoting energy conservation activities directed to achieving theabove- mentioned goals.
We hope that this project contributes to energy and environmental conservation inindustrial sectors in the ASEAN countries, allowing each country to achieveenvironmentally friendly and sustainable economic development. We also hope that thisproject serves as a bridge of technological exchanges and friendship between Japan and
the ASEAN countries.
March 2008
The Energy Conservation Center, Japanⅱ

Contents
Preface…………………………………………………………………………

ⅰContents………………………………………………………………………

ⅲ

Abbreviations………………………………………………………………….

ⅴ

Overview……………………………………………………………………..

ⅶ

Ⅰ. Purpose and Background of the Project………………………………….

Ⅰ- 1

Ⅱ. Vietnam (textile industry)。……..……………………………………… Ⅱ- 1
1. Activity Overview……………………………………………………… Ⅱ- 1
2. Overview of OJT Audit of T Textile & Garment.……………………… Ⅱ- 5
3. Seminar-Workshop…………………………………………………....... Ⅱ- 9
4. Comment and Advice………………………………………………….. Ⅱ- 10
5. Attachments
1) Audit Report on T Textile & Garment……...................................
Ⅱ- 112) Seminar-Workshop Program……………………………………..
Ⅱ- 35
Ⅲ. The Philippines (food industry).....…………………………………..
1. Activity Overview…………………………………………………….
2. Overview of OJT Audit of S Brewing…..…………………………….
3. Seminar-Workshop……………………………………………………
4. Comment and Advice…………………………………………………
5. Attachments
1) Audit Report on S Brewing………………………………………
2) Energy Conservation Checklists for Brewing Factory…….…….
3) Seminar-Workshop Program…………………………………….
Ⅳ

Malaysia (food industry) …………………………………………….
1. Activity Overview…………………………………………………….
2. Overview of OJT Audit of D Food Industry ……………………..
3. Seminar-Workshop……………………………………………………
4. Comment and Advice…………………………………………………

ⅲ

Ⅲ- 1
Ⅲ- 1
Ⅲ- 5
Ⅲ- 9
Ⅲ- 11
Ⅲ-12
Ⅲ- 32
Ⅲ- 34
Ⅳ- 1
Ⅳ- 2
Ⅳ- 5
Ⅳ- 9
Ⅳ- 10

5. Attachments
1) Audit Report on D Food Industries.……………………………… Ⅳ- 112) Seminar-Workshop Program………………………………………. Ⅳ- 33
Ⅴ Thailand (iron & steel industry)……….……………………….………
1. Activity Overview………………………………………………………
2. Seminar-Workshop………………………………………………………
3. Follow- up Survey of B Steel Industry……………………………… …
4. Discussion on PROMEEC Industry Project……………………………
5 Attachment
1) Seminar-Workshop Program……………………………………

Ⅴ- 1
Ⅴ- 1
Ⅴ- 6
Ⅴ- 8
Ⅴ- 10
Ⅴ- 10

Ⅵ Summary & Post-Workshop
1. Overview of Workshop…………………………………………………. Ⅵ- 1
2. Summary of Activity Report of FY2007 and Policies of FY2008 Activities……………… Ⅵ- 2
3. Evaluation of Phase 2 Activities and Basic Policies for Phase 3…..……. Ⅵ- 3

ⅳ

Abbreviations used in the text are as follows:
EE&C
TD
IHDB
BM
OJT
EMS
SEC
CSR
SCADA
COP
DHCR
EM H/B
S&T
PHE
CIP

Energy Efficiency and Conservation
Technical Directory
In- house Database
BenchmarkOn the Job Training
Energy Management System
Specific Energy Consumption
Corporate Social Responsibility
Supervisory Control and Data Acquisition
Coefficient of Performance
Direct Hot Charge Rolling
Energy Management Handbook
Shell and Tube Heat Exchanger
Plate-type Heat Exchanger
Cleaning In Process

ACE
METI
ECCJ

ASEAN Centre for Energy
Ministry of Economy, Trade and Industry
The Energy Conservation Center, Japan

Vietnam
ECC-HCMC
MOIT
EECO
HUT

Energy Conservation Center in Ho Chi Minh City
Ministry of Industry and Technology
Energy Efficiency and Conservation OfficeHanoi University of Technology

Philippines
DOE
PNOC
PICEROMERALCO

Department of Energy
Philippines National Oil Corporation
Philippines Council for Industry & Energy and Development
Manila Electric Railroad and Light Co.

Malaysia
PTM

Pusat Tenaga MalaysiaⅴThailand
DOE
DEDE
FTI/IIEMTEC

ACMECS

Department of Energy
Department of Alternative Energy Development and Efficiency
Federation of Thai Industries/Institute of Industrial Energy
Metal & Materials Technology Center
Ayeyawady-Chao Phraya-Mekong Economic Cooperation StrategyⅵOverview
The ASEAN countries are continuing to make a rapid progress in economic
development, and energy consumption is anticipated to dramatically increase in the
future. It will therefore become increasingly necessary to utilize energy efficiently andto give due consideration to prevent global warming.
This project has now entered its eighth year, and the activities of our counterpart, theASEAN Centre for Energy (ACE) and relevant parties of the ASEAN countries have
expanded and taken its root firmly. Moreover, changes in consciousness have graduallytaken place toward reducing energy consumption in those countries, facing with therecent rise in crude oil prices and the ratification of the Kyoto Protocol on February
16th 2005.
This year marked the final year of the phase 2 of PROMEEC project. It was regarded asa year for bringing together the results of phase 2 activities over the past three years,
and for confirming implementation and disseminations of those results by means offurther self- help efforts. In other words, this year was to establish infrastructure fordisseminating results of the energy audits implemented in all ASEAN countries over the
past seven years (phase 1 and phase 2).
Specifically, the following activities were implemented in four countries of Vietnam(textile industry), the Philippines (food industry), Malaysia (food industry), andThailand (iron & steel industry):l Follow- up surveys of factories audited in the past and simplified energy audits of
new factories
Implementation status of proposed improvement measures, identification ofproblems and barriers in dissemination and the ir solutions were reviewed.
l Creation of technical directory (TD)Information were shared in the ASEAN countries by introducing effective
technologies and successful cases in textile, food and iron & steel industries, topromote implementation and dissemination of these technologies.
l Construction of in- house database (IHDB)The IHDB was formulated and put into practice in order to support energy
conservation operations. In FY2007, formulation of IHDB in textile and foodindustries, and its actual implementation and dissemination in factories wereⅶ

addressed.
Field surveys including energy audits and seminar-workshops were implemented in theabove- mentioned countries. In conducting surveys in each country, practical guidance
was provided to local relevant parties and activities for further ensuring the technology
transfer, through following up the implementation of energy audit technologies thathave been transferred by Japanese experts in the past. Moreover, in factories where
implementation of proposed measures is slow in progress, discussions were heldconcerning barriers and solutions to implementation. Some useful clues were found for
future implementation and dissemination of such measures.
Not only government and factory personnel in the host country but also government
authorities from other ASEAN countries participated in seminar-workshops andpresented energy conservation activities and examples of improvement measures intheir countries. Seminar-workshops were very effective for sharing and disseminating
information.
Activities of the project in FY2007 began with the Inception Workshop held in Ho Chi
Minh City in August 2007 with participation of representatives (focal points) from theASEAN countries. In the workshop, an implementation plan of FY2007 activities andnecessary preparation for on-site activities were confirmed among representatives.
Thereafter, field surveys including seminar-workshops in four countries were steadily
implemented by the end of 2007. In February 2007, the Summary/Post Workshop washeld as last activity of FY2007 in Bogor, Indonesia. Focal points from the ASEAN
countries took part in this workshop. Reports were made to share information on the
results of activities with the ASEAN countries. Intensive discussion was held on
creation of TD and formulation of in- house DB. Lastly, the workshop was concluded
with a discussion of concerning policies and initiatives for FY2008 and onward.
The following are specific activities implemented in FY2007 in the PROMEEC project(major industries).
Ⅰ October 15 - 19, 2007
Local activities in Vietnam
1. A simplified energy audit was conducted at a textile plant in Ho Chi Minh City. Anⅷ

local audit team was organized with engineers of the Energy Conservation Center in
Ho Chi Minh City (ECC-HCMC). The audit was conducted as an OJT, and audit
technologies were transferred to engineers of ECC-HCMC.
2. Eighty people participated in the seminar-workshop and an active exchange of
information was held through the following presentations and discussions.
(1) Presentation concerning energy conservation policies and programs byrepresentatives from Vietnam and Japan.
(2) Presentation of implementation examples of energy conservation by participantsfrom various industries in Vietnam and other ASEAN countries.
(3) Presentation of results of energy audit conducted at a textile plant in Vietnam.
(4) Presentation by ACE and ECCJ on activities of TD creation and IHDB
formulation.
Ⅱ December 3-7, 2007
Local activities in the Philippines
1. A simple energy audit was conducted at a food factory (beer) in the Philippines.
Only three personnel from the Department of Energy (DOE) participated in the local
audit team, and no one participated from food industry.
2. Thirty- four people participated in the seminar-workshop. Participants were mainly
from companies related to energy services, and active discussion on a technologicalaspect was made. Examples of food industry, which was reported from other
ASEAN countries, were very popular.
Ⅲ December 10-17, 2007
Local activities in Malaysia
1. A simple energy audit was implemented at a food plant (retort food) in Kuala
Lumpur. A local audit team was organized with engineers of the Energy
Conservation Center in Malaysia. The audit was conducted as an OJT, and audit
technologies were transferred to engineers of the Energy Conservation Center.
2. Thirty- four people participated in the seminar-workshop. The seminar wasconsiderably meaningful because there were a number of participants from foodindustry, and presentation of examples from other ASEAN countries was inaccordance with interests of participants.

ⅸ

Ⅳ December 19-20, 2007
Local activities in Thailand
1. An one-day visit was made to B Steel Industry that was audited in 2006, and theimplementation status of proposed measures was followed up.
2. Eighty-six people participated in the seminar-workshop. Themes of theseminar-workshop were “Energy conservation in steel industry” and “Energy
conservation in textile industry. ”
Ⅴ February 26-27, 2007
Summary Workshop/Post Workshop held in Bogor, Indonesia (in conjunction withprojects on buildings and energy management infrastructure development)
There were 22 participants, fifteen of whom came from all the ASEAN countries except
Myanmar, including 6 from ACE, and 3 from ECCJ. First of all, an evaluation on phase2 activities was made, and then successful projects, dissatisfactory projects and theirreasons for success or failure were made clear. Based on the evaluation, basic policy ofphase 3 including project strategy for FY2008 were discussed and agreed.
Lastly, this project has been made possible with full cooperation of ACE, relevantorganizations in each country, and representatives of relevant companies. We would liketo take this opportunity to express our deepest gratitude to them all.

ⅹ

Ⅰ. Purpose and Background of the ProjectThis project aims at contributing to energy conservation and promotion ofenvironmental conservation in the ASEAN countries in order to help dissemination andpromotion of energy conservation technologies in major industries. The purpose has
been achieved through contribut ing to promotion of energy conservation measures inmajor industries in the ASEAN countries.
This project was commenced in 2000 under the leadership of the ASEAN Centre forEnergy, with the objective of reducing ever- increasing energy consumption in theindustrial sector in the ASEAN region. The ASEAN calls this project as PROMEEC(Major Industries), which is an abbreviation of “Promotion of Energy Efficiency andConservation, ” and a cooperative project with the Ministry of Economy, Trade andIndustry ackno wledged by a conference of energy-related ministers of ten ASEAN
countries. The Energy Conservation Center, Japan cooperates in supporting promotionof energy conservation in the industrial sector in the ASEAN countries from technicaland operational aspects through the project.
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 energy conservation in major industrial sectors in
the ASEAN countries.
3. To promote the transfer of energy conservation technologies and good practices
from Japan to the ASEAN countries.
4. To develop capacity in energy efficiency and conservation of concerned engineers in
the ASEAN countries through energy audits and OJT.
5. To formulate technical directory (TD), in- house database (IHDB), and benchmark(BM) in the ASEAN countries for energy management.
This cooperative project should be implemented over three phases mentioned below
according to discussions with the ASEAN countries including ACE. FY2007 marked
the fourth year of phase 2 activities. Based on activities conducted in all ASEAN
countries in phase 1, infrastructure has been established for energy conservation
activities to be deployed in all ASEAN countries on an equal basis.
Phase 1 Transfer of technologies and experiences from Japan to the ASEAN countries

Ⅰ- 1(completed in FY2003)
Phase 2 Implementation of proposed improvement measures in each country anddissemination to other countries in collaboration among Japan and the ASEAN
countries(complete in FY2008)
Phase 3 Promotion of energy conservation by self- help efforts of the ASEAN countries
It has entered phase 2 in FY2004, and creation of infrastructure for promoting
implementation and dissemination was commenced. Specifically, activities in phase 2
revolve around implementing follow-up surveys at factories where energy audits were
implemented in the past, creating a technical directory (TD), and formulating an
IHDB/BM for individual industries. During FY2007, activities in accordance with thisline were implemented, targeting textile industry in Vietnam, food industry in thePhilippines and Malaysia and iron & steel industry in Thailand. Activities include
simple energy audits based on OJT, follow- up surveys at factories where energy audit
was conducted in the past, and seminar-workshops.

Ⅰ- 2

Ⅱ. Vietnam (Textile Industry)
1. Activity Overview
October, 2007
15 (Monday)
ECC-HCMC technical guidance (audit technology)
16 (Tuesday)
OJT audit at T Textile & Garment
17 (Wednesday) (Morning) OJT audit at T Textile & Garment(Afternoon) ECC-HCMC technical guidance (data analysis)
18 (Thursday) ECC-HCMC technical guidance (data analysis/report writing)19 (Friday)
Seminar-Workshop
2. OJT Audit at T Textile & Garment(1) Participants
T Textile & Garment : 1
ECC-HCMC : 15 (Dr Nguyen Van Tuyen, and others)
ACE : 2 (Mr. Zamora, Mr. Ivan)
ECCJ : 3 (Mr. Taichiro Kawase, Mr. Hideyuki Tanaka, Mr. Kokichi Takeda)(2) Outline of T Textile & Garment
Major products : Casual wear, children’s wear, sportswear and intermediate
products (cloth and yarn)
Major facilities : Facilities for spinning, weaving and knitting, dyeing/finishing,and sewing
Employees : 5,400
Area: 216,000m2
Export ratio/destinations for export : 65%/USA (69%), EU (8%), Japan (23%)
Certifications acquired : ISO9000, ISO8000(3) OJT Results
Lectures on textile process and energy conservation technology (textile process,boiler, rotary machine)
Preparation for audit work (audit team formation, pre-questionnaire,confirmation of measuring instruments)
Data collection and measurement (operation record, various measurements)

Ⅱ- 1

Data analysis (saving potential calculation, proposal of energy conservation
measures)Report making on audit results (preliminary report)

Ⅱ- 2

(4) Audit Results
Please refer to attachments in this chapter regarding details on calculating grounds, etc
Energy Conservation Issues

Audit Results and Countermeasures

Energy Conservation Potential

Production Facilities(batch dyer)(batch dyer)(stenter)

Waste heat recovery of hot
wastewater in batch dyer
Thermal insulation of batch
dyer hot surface

Decrease of exhaust gas loss Maintenance is necessary because humidity sensor may bein stenterout of order.

Utility Facilities(boiler)
Reduction in boiler air ratio(boiler)

Recover waste heat of hot wastewater in batch dyer Coal Saving: 279t/y(TG800/1) by installing plate-type heat exchanger.
The average surface temperature was 80℃. Surface heat loss Coal Saving: 9.4t/h
was calculated and turned out to be relatively small. The
reason for small loss was that the duration of hot surface
temperature is not so long in one dyeing cycle. Investment
economics should be examined in more detail if cheap resin
insulation material is available.

Residual oxygen in exhaust gas was high, from 17 to 18%. Coal saving: 34% (#2) and 28% (#6) on
Measures such as sealing at openings and closing of actual coal usage. However, saving isobservation windows are necessary (#2 and #6 boilers). realized only during on-operation.
Moreover, adjustment of excess draft in combustion chamberis necessary, because draft is a little strong.

Waste heat recovery of boiler The average temperature of exhaust gas was 200 ℃ . Coal Saving: 13kg/h. However, saving is
exhaust gas
Discussion was made on installation of air preheater for realized only during on-operation (#2)
Ⅱ- 3

recovery of waste heat. However, the amount of heatrecovery is too little to recover the investment.
(steamsystem)Condensate recovery(compressed
air)Supplysystemcompressed air

Condensate was scarcely recovered. It is necessary to Investment
recoveryisachieved
investigate the recovery potential in each equipment where approximately within a year, although it
steam is used.
varies with the distance between
equipment and boiler room.
of Current system uses dendritic supply system. Further, Please consult with ECC-HCMC
compressor room is far from where a facility is used.
Therefore, it is recommended to consider conversion of thesystem to ring-shaped supply system.

Energy Management(organization)

Energyorganization

management Formulate policies on promotion for energy conservation, Please consult with ECC-HCMC
assign energy-responsible managers, organize energy
committees, and enhance consciousness of employees onenergy conservation(monitoring)

Monitoring & recording of Monitor & record monthly usage of coal, electricity andenergy-related conditions
water, and fo llow-up energy usage per product and steam
generation efficiency

Ⅱ- 4

3. Seminar-Workshop
Date: October 19 (Friday), 8:30-17:30
Venue: Liberty Hotel (Ho Chi Minh City)
Participants:
VietnamMr. Phuong Hoang Kim (Official of EECO, MOIT)
Mr. Huynh Kim Tuoc (Director, ECC-HCMC)
Dr. Nguyen Van Tuyen (Scientific Consultant, ECC-HCMC)
Mr. Hoang Thien Kim (Senior Consultant, ECC-HCMC)
Mr. Phan Nguyen Vinh (Specialist R&D Department, ECC-HCMC), and others
Total of 60 people
ASEAN Centre for Energy (ACE)
Dr. Weerawat Chantanakome (Executive Director)
Mr. Christopher G. Zamora (Administration & Finance Manager)
Mr. Ivan Ismed (Technical Expert)
Malaysia
Mr. Ahmad Zairin (PTM)
Philippines
Mr. Artemio Habitan (DOE)
ECCJ
Mr. Hideyuki Tanaka
Mr. Kokichi Takeda
Mr. Taichiro Kawase(1) Greetings from VIP
ACE
Dr. Weerawat Chantanakome introduced ACE activities, PROMEEC activities,
and seminar-workshop programs and showed his appreciation for activities
implemented by METI/ECCJ.
ECCJMr. Kawase mentioned the meaning of the project, its background, and thecurrent status, and Japan’s cooperation and contribution to the ASEAN

Ⅱ- 5

countries. He showed his appreciation for activities implemented by the
Vietnam government, ECC-HCMC, and ACE.
Vietnam Government
Greetings from Mr. Phuong Hoang Kim of the Ministry of Industry andTechnology (MOIT). He showed his appreciation for activities implemented
by METI/ECCJ and ACE.
(2) Session 1: Policy and Initiatives on EE&C
Overview of EE&C Programs on ASEAN (Mr. Christopher G. Zamora, ACE)
Mr. Zamora introduced the position of ACE in ASEAN, its major EE&C activities such
as EC-ASEAN and SOME-METI, and PROMEEC activities. He also called forparticipation in the PROMEEC award system, etc.
Initiatives and Programs on ECCJ on EE&C in Industry in Japan (Mr. Kawase, ECCJ)
Mr. Kawase introduced energy conservation policies in Japan and ECCJ activities. He
also mentioned topics such as the harmonization of 3Es, energy conservation methods,
designation of factories, qualified person for energy management, national examination,
education/training, and the national convention of good practices of energy conservation
Overview of Plans & Programs on EE&C in Vietnam (Mr. Phuong Hoang Kim, MOIT)
Mr. Kim explained energy consumption is rapidly increasing in Vietnam due to therapid economic growth. Laws concerning energy conservation are under formulation inorder to further promote energy conservation based on high-price of crude oil.
(3) Session 2: EE&C Best Practices in Industries
Case Stud y 1 – EE&C in Cement Industry (Philippines DOE, Mr. Aretemio Habitan)
The cement industry has promoted an introduction of highly-efficient processes mainly
by foreign capital, and now its specific energy consumption (SEC) reaches up to theglobal level. Therefore, general energy conservation measures have already been
implemented, and Energy Management System (EMS) has been established. In EMS,
SEC has been introduced process by process, for example, SEC of kiln section. Thirteen
typical measures are named as Best Practices. Considering few measures such as power
generation exhaust gas heat recovery remain unimplemented, further reduction in SEC
is expected to be difficult in the future.

Ⅱ- 6

Case Study 2 – EE&C in Food Industry (Malaysia PTM, Mr. Ahmad Zairin)
PTM has audited 48 companies so far and identified energy conservation potential of
13 percent. In an audit at the palm oil maker (Cargill Kuantan. Co., Ltd.), energy
conservation potential of 79,861GJ/year was found, and energy conservation of
24,000GJ/year of it was realized. PTM has independently suggested measures for suchas condensate recovery and steam leakage. These low-cost measures are applicable toother companies.
Case Study 3 – EE&C in Iron & Steel Industry (Philippines DOE, Mr. Aretemio
Habitan)Currently, there are 50 facilities nationwide. Thirteen typical measures are named as
Best Practices. Among them, a measure to install heat-resistant curtains at a furnace’s
opening was suggested by a Japanese specialist.
Case Study 4 – EE&C in Glass Industry (Malaysia PTM, Mr. Ahmad Zairin)
An old- model glass melting furnace constructed in 1992 showed SEC of 8GJ/ton ofmolten glass. This SEC has been reduced to the EU average of 4.8GJ/ton of molten
glass by replacing the furnace with a new-type furnace. This is an example that
replacement of old-type furnace for energy conservation was decided based on the EU
average as a benchmark.
Results of Energy Audit in T Textile & Garment (Vietnam, Mr. Phan Nguyen Vinh
(Specialist R&D Department, ECC-HCMC))
Audit results were reported, concerning batch-type dyer, stenter machine and boiler. As
for the batch-type dyer, heat recovery of hot wastewater and thermal insulation on the
hot surface were considered. Energy saving is so little that heat insulation seems not
economical.
EE&C Technology and Energy Audit in Textile Factory (ECCJ, Mr. Hideyuki Tanaka)
The calculation process of boiler heat efficiency was explained, using the measured
results. The residual oxygen in exhaust gas showed 17 to 18 percent, which isconsiderably high partly due to use of a coal- firing boiler. Chamber draft was thought tobe excessive ly high, as were observed burning coal ashes soaring actively from thehearth bed. Recommendations were given to reduce chamber draft gradually.

Ⅱ- 7

EE&C Technology and Energy Audit of Electrical Facilities in Textile Factory (ECCJ,
Kokichi Takeda)
Audit on a hot oil boiler ’s air fan and an air compressor were conducted. Thoughintended information could not be obtained, guidance on common energy conservation
calculation method was given concerning adjusting revolution of fans. As for the aircompressor, air supply piping system was investigated. Currently, the dendritic air
supply system is employed. Recommendation was given to consider replacement of itwith the loop-type air supply system.
(4) Session 3: The Way Forward
Barriers Identified in Energy Audit and its Measures (ECCJ, Mr. Taichiro Kawase)
Mr. Kawase explained six factors as barriers against promotion of energy conservation.
They include policies, human resources, technologies and information, funds,
manufacturing technology, and society & cultures. Taking observations at Thanh Cong
Textile & Garment into consideration, those barriers and measures for overcoming themwere explained
Updates on the Development of the Technical Directory (ACE, Mr. Ivan Ismed)
Mr. Ivan explained the purpose and contents, development method, format of theTechnical Directory (TD), and an actual example of TD format.
Updates on the Development of In-house Database (ACE, Mr. Ivan Ismed)
Mr. Ivan explained the purpose and contents, etc., of the in-house database (IHDB)
using input format of the cement industry as an example. A characteristic of the IHDB isthat it includes production data, energy data, equipment data, and key operation
parameters and energy efficiency ind icators. They are used as reference information forenergy conservation operation.
In- house Database for Textile Industry (ECCJ, Mr. Taichiro Kawase)
Mr. Kawase explained the content of a newly created input format of the textile
industry. In addition, he asked the factories concerned to try this new format. In
particular, he emphasized that the IHDB would be useful as a tool for promoting energy
conservation in the factory, and never be disclosed outside the factory.
(5) Closing Address

Ⅱ- 8

The workshop was concluded with a closing address of Dr. Weerawat Chantanakome(ACE).
4. Comment and Advice(1) Energy conservation activities in the textile factory we visited had been scarcely
implemented. Executives of the factory did not appear to have much interest in energy
conservation. Although policy measures like enforcement of energy efficiency
regulations are steadily established at both governmental and municipal level, they havenot sufficiently penetrated into individual industrial factories where energy conservation
activities are demanded.
(2) Preliminary preparations for audit work by ECC-HCMC were excellent. Answers topreliminary questionnaire were sent in advance to Japanese specialists, and madeformulation of an appropriate audit plan greatly easier. Moreover, measuring
instruments were prepared completely as requested. On the other hand, regrettably
closer arrangements were not made by the factory. For example, gas-sampling nozzles
were not prepared in the stenter exhaust chimney, so that measurement of the humidityof exhaust gas had to be given up.
(3) On my giving an OJT guidance, I felt that the technical level of ECC-HCMC’s
engineers needs to be further enhanced, except for several capable engineers. Although
they have a knowledge on respective equipment such as boiler and rotary machinery,
they have a difficulty in relating them to the production facilities. Knowledge regarding
processes should be strengthened. The lack of knowledes may be considerably
improved by providing education, because people in this country are diligent and highly
motivated.
(4) Presentations of successful cases in Malaysia and in the Philippines were excellent.
Particularly, EMS is well established in the presented cases, and may become good
examples for other industries. All of successful cases were examples offoreign-capitalized companies. It is a future task to spread these successful cases tosmall and medium-sized domestic companies and regiona l industries.
(5) Representatives from Thailand and Indonesia did not participate in the seminar.
Their participation was strongly expected. Particularly, we expect Thailand to tell her

Ⅱ- 9experiences to other countries, because she has an abundant accumulation of successful
cases.
(6) A local team consisted of engineers of ECC-HCMC who had minimum necessary
knowledge, so that transfer of audit technologies was smoothly carried out in the OJT.
In the past OJT, most of participants came from management positions who did not
generally have technical knowledge, and they got bored at times. This year there were
not many people falling asleep in the OJT.
(7) Appropriate facilitation by Mr. Zamora greatly helped the audiences understand thepresentations in the seminar. He interpreted and briefed meanings of every presentation
based on purposes of the project.
(8) When I asked comments from engineers of ECC-HCMC in the end, some of themtold me that they could learn a number of aspects such as knowledge, experiences,organization of audit team, data collection, observations of facilities and data analysis,
and they expected an OJT duration to be extended longer. These comments were very
encouraging to us.
5. Attachments(1) Audit Report on T Textile & Garment(2) Seminar-workshop Program

Ⅱ- 10

Attachment 1

Audit Report on T Textile & Garment

1. Audit Venue
T Textile Garment, HCMC, Vietnam
2. Audit Schedule
October 16, 2007 (Tuesday) 8:30 – 17:00
17, 2007 (Wednesday) 9:10 – 12:30
3. Participants
ECC-HCMC (Energy Conservation Center in Ho Chi Minh City)
Dr. Nguyen Van Tuyen (Scientific Consultant)
Mr. Hoang Thien Kim (Senior Consultant)
Mr. Phan Nguyen Vinh (Specialist R&D Department), and others
16 participants in total
ACE (ASEAN Centre for Energy)
Mr. Christopher G. Zamora (Administration & Finance Manager)
Mr. Ivan Ismed (Technical Expert)
ECCJ (Energy Conservation Center, Japan)
Mr. Hideyuki Tanaka
Mr. Kokichi Takeda
Mr. Taichiro Kawase
4. Factory Responder
Mr. T (Equipment Engineer)
5. Outline of T Textile and Garment
General Information

Major products: Casual wear, children’s wear, sportswear and interim products(cloth and yarn)
Major facilities: Facilities for spinning, weaving and knitting, dyeing/finishing,and sewing
Employees: 5,400
Area: 216,000m2
Export ratio/destinations for export: 65%/USA

Ⅱ- 11

Breakdown (69%), EU (8%), Japan (23%)
Certifications accredited: ISO9001, SA8000
Production Facilities/Production Capacity

Spinning Facilities: Carding frame, Comber, Roving Frame, Ring Spinning,
Cone winder / 9000 tons per year
Knitting Facilities: Circulating knitting, Flat knitting / 10000 tons per year
Weaving Facilities: Sizing, Warping, Weaving (Rapier, Water jet, Air jet) / 8
million meters per year
Dyeing Facilities: Jet dyeing, Scouring, Open-edge, Drying, Mercerizing,
Finishing, Inspection / 10000 tons per year for knitted
cloths & 7 million meters per year for woven cloths
Sewing Facilities: Sewing / 20 million pieces per year
Most of facilities are made in Japan, the United States, Germany, Switzerland, Italy,
Taiwan or Korea
Status of Energy Use
Energies used in T Textile & Garment are fuel oil, coal and electricity. The energy
consumption in 2006 is shown in the table below.
Table 5-1 Annual production and energy consumption (2006)
Products, Energy

VolumeCasual Ware

Pieces

20,000,000

Fuel Oil
Coal

t/y
t/y

7,932,676
4,889

Electricity

MWh/y45,307

Toe
7,989
toe/y
3,086
toe/y
3,086
toe/y

Energy price5,300 VDN/kg
7,050 VDN/kg

US C37/kg
US C10/kg

1,184
VDN/kWhUS
C8.2/kWh1¥=125VDN

6. Activities concerning Energy Conservation Promotion
Judging from answers to questionnaire sent to T Textile & Garment, present situation isⅡ- 12

as follows:
Energy Management
An energy conservation committee has not been organized and an energy manager
has not been appointed. As for energy consumption, data is recorded only for
payments. Employee education, award, and kaizen activities have not been adopted
either.
Energy Conservation Measures
Measures have hardly been implemented except energy conservation options attachedat the time of equipment delivery. Moreover, some of energy-related instruments havenever been checked and maintained since their delivery. It is anticipated that training
from equipment manufacturers has not been given.
Energy Conservatio n Measures with Non-Investment or Small-Investment
Improvement of operations such as reduction in operating temperature has not been
performed, nor has addition of heat insula tion for energy conservation been planned.
Moreover, steam traps are not managed. The oxygen level in boiler exhaust gas is notmeasured routinely, and combustion management including air ratio adjustment is not
performed.
As mentioned above, energy conservation activities have not been performed in thefactory. It is anticipated that priority of energy conservation is relatively low in their
management policies. If the factory takes energy conservation measures to the same
extent as been done in Japan, the energy-related cost would be reduced presumably
by half. The first thing is to help factory manage ment understand how nice effect ofenergy conservation is. Considering energy conservation activities are not so active
even in such an influential textile company like T Textile and Garment, it isanticipated that other textile companies in Vietnam face the same situation.
7. Procedures for Energy Audit
Considering this is an OJT audit, it was carried out according to the following
procedures. We asked and encouraged participants repeatedly to remind that audit work
had to be conducted mainly by the local team.
Lectures of textile process and energy conservation measures
Briefing on targeted equipment, data collection, and measurement

Ⅱ- 13Confirmation of role of the local team (incl. selection of a leader)
Implementation of data collection and measurement
Data analysis and reporting
ECCJ specialists were responsible for the first two items for the purpose of providing
starting information. As all of sixteen members of the local team were ECC-HCMC’s
engineers, a leader was smoothly selected. With coordination of Dr. Nguyen Van Tuyen,
Mr. Phan Nguyen Vinh was selected as a leader, and Mr. Taon as a sub- leader. Twotechnical advisors (Dr. Nguyen Van Tuyen, Mr. Hoang Thien Kim) of ECC-HCMC
worked as interpreter in addition to as engineering advisor, and their effort was highly
helpful. The local team implemented data collection and measurement successfully
without assistance of ECCJ experts. Mr. Phan Nguyen Vinh, the leader, reported audit
results at the seminar-workshop, altho ugh data analysis was made substantially by
ECCJ experts analyzed.
8. Summary of Audit Result
One batch dyer, one stenter machine, two boilers, and rotary machines (fans andcompressors) were selected as audit targets.
Batch Dyer
Two measures (heat recovery of hot waste water and heat insulation of dyer’s hot
surface) were taken into examination. As for the former, ECCJ experts gave a lecture
on how to calculate availability of hot waste water and recoverable waste heat. As forthe latter, surface temperature was measured at various locations for calculating how
much heat is lost from the hot surface. Results of heat loss calculation suggested that
insulation is not economically attractive.
Stenter Machine
Measures for reduc ing exhaust gas loss were examined. It was pla nned to measuregas velocity and humidity at an exhaust gas chimney of one stenter, however,measurement was not carried out, because there were no sampling nozzle s available.
Unfortunately in spite of strong request, permission for perforation of nozzles could
not be obtained. During factory walk-through a humidity sensor happened to befound installed on another stenter. The meter reading of the humidity sensor was
7g-H20/kg-Dry Air, which seemed unusually low. If this reading was true, it could be

Ⅱ- 14

possib le to reduce the amount of exhaust gas up to less than one-fifth of the current
level. However, judging from other information like motor sound, etc, it was thoughtthat the humidity sensor could be in disorder. According to a person in charge of thestenter, this sensor has never been calibrated and kept untouched since its installment
in 1995. Probably the system has been operated with manual condition, because thesystem could not function properly without being examined for ten years. Calibrationof the humidity sensor is strongly recommended.
Boilers
Two boilers (one hot oil boiler and one steam boiler) were audited. Gas analysis of
exhaust gas and measurement of surface temperature were performed in both boilers.
Both boilers showed abnormally high residual oxygen ranging from 17 to 18 percent,which means boiler efficiency was as low as 70 percent. In the OJT, calculation
method of boiler efficiency was instructed in detail.
Rotary Machines (Fan, Compressor)
Flow rate of air fan in the hot oil boiler was measured by hot-wire velocity instrument.
However, energy conservation effect failed to be calculated, because necessary data
were not collected, for example, inlet and discharge pressures and fan performance
curve were not available. Instead, calculation method of energy conservation effectconcerning variable speed adjustment of pumps/fans was lectured. As for compressor
effective energy conservation measures could not be proposed, mainly due to lack of
information. However, the dendritic air supply system, which is currently used, seems
inappropriate because factory has considerably big compound. Recommendation wasgiven to consider a conversion to a ring air supply system.

Ⅱ- 15

Results of Audit (Summary)
Energy Conservation Issues
Production Facilities

Audit Results and Countermeasures(batch dyer)

Waste heat recovery of hot
wastewater in batch dyer

Recover waste heat of hot wastewater in batch dyer Coal Saving: 279t/y(TG800/1) by installing plate-type heat exchanger.

(batch dyer)

Thermal insulation of batch The average surface temperature was 80℃. Surface heat loss Coal Saving: 9.4t/h
dyer hot surface
was calculated and turned out to be relatively small. The
reason for small loss was that the duration of hot surface
temperature is not so long in one dyeing cycle. Investment
economics should be examined in more detail if cheap resin
insulation material is available.
Decrease of exhaust gas loss Maintenance is necessary because humidity sensor may bein stenterout of order.

(stenter)

Energy Conservation Potential

Utility Facilities(boiler)(boiler)

Reduction in boiler air ratio

Residual oxygen in exhaust gas was high, from 17 to 18%.
Measures such as sealing at openings and closing ofobservation windows are necessary (#2 and #6 boilers).
Moreover, adjustment of excess draft in combustion chamberis necessary, because draft is a little strong.
Waste heat recovery of boiler The average temperature of exhaust gas was 200 ℃ .
exhaust gas
Discussion was made on installation of air preheater forrecovery of waste heat. However, the amount of heatrecovery is too little to recover the investment.
Ⅱ- 16

Coal saving: 34% (#2) and 28% (#6) on
actual coal usage. However, saving isrealized only during on-operation.

Coal Saving: 13kg/h. However, saving isrealized only during on-operation (#2)

(steamsystem)Condensate recovery(compressed
air)Supplysystemcompressed air

Condensate was scarcely recovered. It is necessary to Investment
recoveryisachieved
investigate the recovery potential in each equipment where approximately within a year, although it
steam is used.
varies with the distance between
equipment and boiler room.
of Current system uses dendritic supply system. Further, Please consult with ECC-HCMC
compressor room is far from where a facility is used.
Therefore, it is recommended to consider conversion of thesystem to ring-shaped supply system.

Energy Management(organization)(monitoring)

Energyorganization

management Formulate policies on promotion for energy conservation, Please consult with ECC-HCMC
assign energy-responsible managers, organize energy
committees, and enhance consciousness of employees onenergy conservation
Monitoring & recording of Monitor & record monthly usage of coal, electricity andenergy-related conditions
water, and fo llow-up energy usage per product and steam
generation efficiency

Ⅱ- 17

9 Calculation of Energy Saving Effect
9-1 Batch Dyer
More than 100 batch dyers, including big and small, were installed, and three of them
(TG800/1) were audited. An outline flow is shown in Figure 9-1. The machineconsists of three dyers, heat exchangers for heating, pumps for feeding fresh water,
and water circulation pumps. The figure also describes a heat exchanger for heatrecovery of hot wastewater mentioned below.
Figure 9-1 Flow Diagram of Liquid Flow Dye ing Machine (TG801/1)

The dyer operates by batch of two cycles per day with eleven hours per cycle.
Production capacity of cloth per cycle is 800kg. 10kg of dye liquor or washing water
is used per cloth of 1kg (called bath ratio 10). Dyeing, neutralization and washing arerepeated during one cycle according to the recipe in Figure 9-2.

Ⅱ- 18

Generally, the following four kinds of energy conservation measures are consideredwith respect to a batch dyer:
Heat recovery of hot wastewater
Reduction in heat loss from hot surface
Recovery of steam condensate
Reuse of hot wastewater
Heat recovery of hot wastewater and reduction in heat loss from hot surface areconsidered herein.
(1) Heat Recovery of Hot Wastewater
According to the recipe in Figure 9-2, hot wastewater is generated seven times fromoperations ? , ? , ? , ? , ? , ? and ? in one cycle. As shown in Figure 9-1,
hot wastewater is firstly accumulated in the wastewater pit, and after being cooled inheat exchanger, discharged to the canal. At the same time fresh water is preheated in
the heat exchanger to some extent and charged to dyers. A wastewater pit has to beinstalled underground so that hot wastewater flows gravitationally from dyers to pit.
A plate-type heat exchanger is recommended as it is relatively cheap andspace-saving. A filter should be installed upstream of the heat exchanger in order toremove textile lint entraining in the dyers.
Amount of coal saving is calculated as follows:1) amount of hot wastewater
Operations which discharge hot wastewater : 7 operations/cycle(operation : ? , ? , ? , ? , ? , ? and ? )Ⅱ- 19amount of hot wastewater per operation: amount of cloths×liquid ratio = 800kg×
10 = 8 ton/operation
amount of hot wastewater per cycle: 8 ton/operation×7 operations/cycle= 56 ton/cycleamount of hot wastewater per day: 56 ton/cycle×2 cycle/day = 112 ton/day
2) amount of heat recovery
temperature of hot wastewater: 80℃ (see the recipe)
temperature of fresh water: 30℃ (see the recipe)
temperature of hot wastewater at outlet of heat exchanger: 40℃
Temperature of hot wastewater at outlet of heat exchanger is decided by temperatureof fresh water + temperature approach. The lower a temperature approach is, themore the amount of heat recovery increases, and, at the same time, required heattransfer area of heat exchanger increases. In the dyeing industry, temperatureapproach is normally set around 10℃. Therefore, the temperature at outlet wascalculated as 30+10 = 40℃.
amount of heat recovery = 112,000kg/day×1kcal/kg℃×(80-40)℃= 4,480,000kcal/day
3) amount of coal saving
efficiency of steam boiler: 70% (estimated value)calorific value of coal: 7,000kcal/kg
operation days per year: 305 days
coal saving = 4,480,000kcal/day / 7000kcal /kg /0.7*305 days / 1,000= 279 ton/year(2) Reduction in surface heat loss
Heat loss from hot surface has two types; convection loss and radiation loss, and they
can be calculated by the following formula:
Convection loss: qc = α*SA*(t1-t0) kcal/h
α heat transfer coefficient = 2.24*(t1-t0)^0.25
t1 surface temperature (℃)
t0 ambient temperature (℃)
SA surface area (m2)
Radiation loss: qr = 4.88 * e *SA *[{(t1+273)/100}^4-{(t0+273)/100}^4] kcal/he emissivity (0.3 in the case of stainless steel)Ⅱ- 20

Generally, if surface temperature is over 50 degrees, heat insulation is regarded as
economically feasible. If the temperature is under 140 degrees, pastable-type
insulation material made of heat-resistant urethane is preferably used as an insulationmaterial. This insulation material is easy to install and reasonable. An example ofinstallation is shown in the photo below, where two candidate materials are trial- used
for performance evaluation. Please see the website of maker for more information.
(website : http://www.thaisekisui.co.th/ )Test of Insulation Materials
Energy saving effect by heat insulation are calculated as follows:
Measurement of surface area and surface temperature
Surface temperature and surface area of the dyeing machine (incl. dyer, heatexchanger, valves, etc) were measured, and the following approximate value wasobtained. Strictly

Ⅱ-21

speaking, although measurement had to be made further on pipes and valves as well,they were omitted due to lack of time.
Calculation of surface heat loss
surface temperature : 80 degrees (average)
surface area: 83 m2
qc = 2.24 * 83m2 * (80-36) ℃ = 8,180 kcal/h
qr = 4.88 * 0.3 * 83 * [{(80+273)/100}^4-{(36+273)/100}^4] = 7,790 kcal/hq = qc + qr = 15,970 kcal/hAmbient temperature was 36 degrees herein. After heat insulation is done, surface
temperature decreases down nearly to ambient temperature. Therefore, surface heatloss is regarded as almost similar to the previous value before performing heatinsulation.
Amount of coal saving
Surface heat loss occurs when dye machine is operated at high temperatures, i.e.,during operations ? , ? , ? , ? , ? , ? and ? . As shown in the recipe, total
duration of them is 280 minutes per cycle and 9.4 hours per day. Now efficiency of
steam boiler, calorific value of coal, and operation days per year are 70%, 7,000
kcal/kg, and 305 days, respectively, and coal saving is calculated as follows:
Coal saving = 15,970 kcal/h /7,000 kcal/kg /0.7 * 9.4 hours/day* 305 days / 1000 = 9.4 ton/year
Energy saving effect is not so high. Economical justification seems difficult. It
depends on prices of insulation material. Contact and discussion with insulationmaterial supplier is recommended.
(3) Other Measures
Recovery of steam condensate and reuse of hot wastewater are also important energy
conservation measures. Steam condensate is normally recovered to boiler feed watertank in the boiler room. It is expected that investment cost is paid out within three
years unless dyeing machine is far from the boiler house. In case that it is distant long,as an alternative, condensate can be used as hot water source for dye ing machine.
Rinsing water used in operations ? and ? is relatively clean so that it can bereused in other dying processes such as mercerization. In addition, it can be used in

Ⅱ- 22the same facility such as operations ? and ? . In this case, a dyeing test isrecommended to make sure there is no problem in dyeing operation.
9-2 StenterIn the plant, there are ten dryers and six out of them are stenters. Stenter is acontinuous-type cloth dryer, and normally the following energy conservation
measures are adopted;
Reduction in exhaust gas loss
Reduction in moisture of charge cloth
Prevention of excessive drying
Heat recovery of exhaust gas
Measurement of exhaust gas loss was planned herein. It was planned to measure gas
velocity and humidity at exhaust gas chimney, however, measurement was cancelled
because there were no sampling nozzles available, and in addition permission for
performing perforation of nozzles was not given.
During factory walk-through a humidity sensor happened to be found installed onanother stenter. The meter reading of the humidity sensor was 7g-H20/kg-Dry Air,
which seemed unusually low. If this reading was true, it could be possible to reduce
the amount of exhaust gas up to less than one- fifth of the current level. However,
judging from other information like motor sound, etc, it was thought that thehumidity sensor could be in disorder. According to a person in charge of the stenter,
this sensor has never been calibrated and kept untouched since its installment in 1995.
Probably the system has been operated with manual condition, because the system
could not function properly without being examined for ten years. Calibration of thehumidity sensor is strongly recommended.
9-3 Boiler
As shown in Table 9-1, three steam boilers and three hot oil boilers were underoperation. Two of them were selected as target for energy audit.
Table 9-1 Boiler Specification
Boiler nameSpecification

Steamboiler#1

Fluidized
bed boiler

Coal fired

20t/h

7kg/cm2#2

Flue boile r

Coal fired

10t/h

7kg/cm2

Ⅱ- 23

User

Note

Dyer,
Dryer,
etc.

Without
recuperator /economizer

#5

Coal fired

10t/h

7kg/cm2

Hot oil #3
boiler#4#6

Coal fired

3.6GJ/h

250℃

Coal fired
Coal fired

3.6GJ/h
3.6GJ/h

250℃
250℃

Dryer,
etc.

With
recuperator
only

Table 9-2 and Table 9-3 are results of measurement regarding the steam boiler (#2)
and the hot oil boiler (#6). Exhaust gas analysis and surface temperature
measurement were performed.
Table 9-2 Operation Data of #2 Steam Boiler
Fuel

Measuring Items
Kind of fuel

Data
Coal
℃

Supply temperature
Chemical component (weight percent)Higher colorific value(Water 8%)

Lower colorific value (dried state)

7,300kcal/kg × 4.187kJ/kg

Consumption

Total volume
Unit consumption

Water

Feed waterkJ/kg

Total volume
Unit consumptionkg
140kg/t-steam kg/h
kg
(4,000kg/h)

Unit consumption per (7.143kg-s/kg- f)
fuel
Blow water

Temp. at inlet of boiler
Flow rate

Combustion Air volume supplied to boiler
air
Temperature
Inlet of boiler
Steam
Pressure

30℃
kg/h
3

m N/h
35℃
6.5bar(g)=0.75Mpa(a)Dryness of steam
Exhaust gas%

Steam generation
Gas volume
Temperature

4,000kg/h
m3 N/hOutlet of boiler℃

Suction side of fan
Discharge side of fan

℃

Ⅱ- 24

123.6℃Gas analysis

Outlet of boiler

CO2 : 2.51%, O2 : 18.12%, CO:102ppmBoiler, duct surface temperature℃

Boiler load factor%
Table 9-3 Operation Data of #6 Hot Oil Boiler
Measuring Items

Fuel

Oil

Data

Kind of fuelSupply temperature

Coal

Chemical component (weight percent)(Water 8%)

Higher colorific value
Lower colorific value (dried state)

kJ/kg
7,300kcal/kg × 4.187kJ/kg

Consumption

Total volume
Unit consumption

6,000kg/d
250kg/hFeed oil

Total volumekg

Temperature

Feed rate
Inlet of boiler

kg/h
233℃ Actual
temp.
250℃ difference = 7~12℃℃

Outlet of boiler
Combustion Air volume supplied to boiler
air
Temperature
Inlet of boiler

m3 N/h℃

Exhaust gas

m3 N/hGas volume
Temperature

Air heater

Inside of boiler furnace About 400℃
Outlet of boiler℃

Suction side of fan℃

Gas analysis

Discharge side of fan
Outlet of boiler

196℃
CO2 : 3.52%, O2 : 17.0%, CO:
88ppm

Air temp.

Inlet of air heater

35℃

Gas temp.

Outlet of air heater
Inlet of air heater(400 –α) ℃

Outlet of air heater(196 +β) ℃

Boiler, duct surface temperature℃

Boiler load factor

%

Ⅱ- 25

Data analysis of #2 steam boiler
1) Theoretical amount of air and exhaust gas- Components of coal C: 69.7%, H: 5.4%, S: 0.4%, N: 1.5%
- Theoretical amount of combustion air: A0
A0 = 8.89C + 26.7 (H – [0]/8 + 3.33S= 8.89×0.679 + 26.7 (0.054 – 0.07/8) + 3.33×0.004 = 7.418m3 N/kg
- Theoretical amount of combustion exhaust gas: G0
G0 = 0.79 A0 + 1.867C + 11.2H + 0.7S + 0.8N + 1.244W= 0.79×7.418 + 1.867×0.697 + 11.2×0.054 + 0.7×0.004 + 0.8×
0.015 + 1.244×0.08 = 7.880m3 N/kg
- Theoretical amount of dry combustion exhaust gas: GOD
GOD = G0 – (11.2H + 1.244W) = 7.880 – 0.704 = 7.176 m3 N/kg
- Oxygen level in exhaust gas: 18.12 %- Air ratio: m
m = 21/(21-[O]) = 21/(21 – 18.12) = 7.3
2) Boiler Efficiency- Calorific value of dry coal: 7,300 kcal/kg- Moisture in wet coal: 8%- Calorific value of wet coal: 7,300 × 4.186 × 0.92 = 28,120 kJ/kg- Boiler feed-water enthalpy: @30 degrees = 125.8kJ/kg- Steam enthalpy @0.75MPa (absolute) and saturated steam = 2,765.6kJ/kg- Fuel consumption of boiler: 140kg-coal/kg-steam (according to T faxtoryC
information)- Boiler efficiency = [Generated steam enthalpy] / [calorific value of fuel]= (1,000kg / 140kg) × (2,765.6 – 125.8) kJ/kg / 28,120 kJ/kg= 0.6705 (=67.1%)
3) Coal saving by Reducing Air Ratio
Oxygen content at the time of measurement was 18.12% and air ratio was 7.3. In theJapanese energy conservation law, energy management standard is stipulated for
major energy-consuming equipment such as boiler and motor, and it is demanded toobserve. Regarding coal- fired boiler (stoker-type), standard value of air ratio is
stipulated as 1.30~1.45 at 10t/h boiler. Temperature of exhaust gas was measured asⅡ- 26

123.6℃, but seemed to be a measuring error. Considering saturated temperature at
0.75MPa (actual boiler pressure (absolute)) is 167.7℃, exhaust gas temperature
should be higher than 167.7℃. In the following analysis, it is assumed to be 200℃.
Coal Saving at air ratio 2.0
Here, coal saving is estimated to be 34.1% with respect to the present consumption as
estimated below;
Suppose that x kg-coal with respect to 1kg-coal can be reduced;
Theoretical air : 7.3A0 at present operation
2.0A0 at improved operation
Specific heat of air: 1.30kJ/m3 NK
Specific heat of exhaust gas: 1.38kJ/m3 NK
Temperature of combustion air: 35℃
Temperature of exhaust gas: 200℃ (estimated)
The following formula is established as the heat quantity for heating excessive air andcoal-firing exhaust gas of x kg up to 200℃ is equivalent to the combustion calorificvalue of coal of x kg. However, the temperature of exhaust gas should not change.
Heat released in combustion of x kg-coal is used for raising temperature of bothexcess part of air ((5.3 + x) A0 ) and theoretical combustion gas (G0 );[(5.3 + x) A0 m3 N/kg×1.3 kJ/m3 NK + x×G0 m3 N/kg×1.38 kJ/m3 NK]×(200 35) ℃ = x×28,120kJ/kg
x = 0.341kg (=34.1%).
4) Coal saving by waste heat recovery of exhaust gas
Waste heat of boiler exhaust gas is recovered for pre-heating combustion air or boiler
feed water. Pre-heating of combustion air is considered herein.
There are two types of heat exchangers, co-current and countercurrent. In general, as
countercurrent-type heat exchanger is considered herein because it has higher
efficiency. In the calculation, it is assumed that air ratio m = 1.3, actual steam rate =4t/h.
- Prerequisite
Coal rate: Wcoal = 140kg/t-steam×(1 – 0.386)×4t-steam/hⅡ- 27

= 343.8kg/h
Air rate: Gc = mA0 ×Wcoal =1.3×7.418 m3 N/kg×343.8kg/h= 3.315m3 N/h
Air temperature at inlet: 35℃ (=Tcl)
Exhaust gas rate : Gh = [(1.3 – 1) ×A0 + G0 ] ×Wcoal= [0.3 ×7.418 + 7,880] m3 N/kg×343.8kg/h = 3,474 m3 N/hExhaust gas temperature at inlet: 200℃ (=Thl)- Temperatures of air and exhaust gas at outlet of heat exchanger
This is calculated using the formula shown in Figure 9-4A.
Q = Gh ×(Cph/3.6)×(Th1 – Th2) = Gc×(Cpc/3.6)×(tc2 – tc1) [W]Gh = 4t-steam/h×140kg-coal/t-steam×(1-0.386)×(G0 + (m-1)×A0 ) m3 N/kg-c= 3.474.6 m3 N/h
Gc = 4t-steam/h×140kg-coal/t-steam×(1-0.386)×m×A0 ) m3 N/kg-coal = 3,315.8 m3 N/h
Q = 3.474.6 m3 N/h×(1.38kJ/ m3 NK/3.6)×(200 – Th2) ℃= 3,315.8 m3 N/h×(1.3 kJ/ m3 NK/3.6)×(tc2 – 35)
If Th2 is assumed to be the same as current temperature of 123.6℃, Q is101,760W and tc2 is 120℃.
- calculation of required heat transfer area
Temperature difference, △Tm, is calculated as follows using the formula in
Figure 9-4B. △Ta and △Tb are 88.6℃ and 80.0℃ respectively. Therefore,△Tm = (88.6 – 80.0) / Ln(88.6/80.0) = 84.2℃
K (overall heat transfer coefficient) of exhaust gas is assumed to be 30
W/m2 K herein, considering K of gases ranges normally in 12~35W/m2 K.
Q = K×A×△Tm = 30W/ m2 K×A×84.2℃ = 101,760W, and therefore, theheat transfer area A is 40m2 .
- Recovered heat (101,760W) is equivalent to coal saving of approx. 13kg/h.

Ⅱ- 28

Figure 9-4 Countercurrent-type Heat Exchanger5) Coal saving by condensate recovery
A calculation on effect of saving coal is carried out in the case that condensate
generated in the plant is recovered as boiler feed water. Conventionally, open-type
recovery system is used as shown in Figure 9-5. Suppose 1,000kg out of 4,000kg of
boiler feed water to the boiler is coming from recovered condensate of 80℃,
(3,000kg×30℃+1,000kg×80℃) / 4,000kg = 42.5℃
That is to say, amount of coal saving is 7.4kg/h with respect to current consumption.
(42.5 – 30) ℃×4.187kJ/kgK×4,000kg/h/28,120kJ/kg = 7.4kg-coal/hThere are two types for condensate recovery; open-type and closed-type. Condensate
temperature is 100℃ at the highest in open-type. On the other hand, in closed-type, it
is much higher than 100℃ corresponding to boiler pressure, although system is morecostly.

Figure 9-5 Condensate Recovery System (open-type vs closed-type)
Data analysis of #6 hot oil boiler
Coal is fired in #6 hot oil boiler. According to information from T factory, coalⅡ- 29consumption is 250kg/h. Supply temperature of hot oil is 245~250℃, and returntemperature is 233℃. Reduction of air ratio and waste heat recovery of exhaust gas
are examined herein, as in the case of #2 steam boiler. #6 boiler has already beenequipped with an air preheater.
1) Coal saving by decreasing air ratio
Residual oxygen level in boiler exhaust gas is 17%, and air ratio m is calculated as
5.25 according to the following formula;m = 21 / (21-[O]) = 21 / (21 – 17) = 5.25
Suppose that x kg-coal with respect to 1kg-coal can be reduced;
Ambient temperature at inlet: 35℃
Exhaust gas temperature at outlet of air pre-heater: 200℃
(200℃ is an realistic estimation, considering exhaust gas temperature of
400℃)
Specific heat of air: 1.3kJ/m3 NK
Exhaust gas temperature: 400℃ (according to information from T factory)Specific heat of exhaust gas: 1.38kJ/m3 NK
Heat released in combustion of x kg-coal is used for raising temperature of bothexcess part of air ((3.25 + x) A0 ) and theoretical combustion gas (G0 );Calculation of the amount of coal saved: x kg per 1kg of coal
Theoretical air : 5.25A0 at present operation
2.0A0 at improved operation(3.25 + x)×A0 m3 N/kg×1.3 kJ/m3 NK + x×(400-200)℃ + G0 m3 N/kg
×1.38 kJ/m3 NK×(400 - 35) ℃ = x×28,120kJ/kg
x = 0.282kg (=28.2%).
2) Coal saving by waste heat recovery of exhaust gas
Currently, air pre-heater has already been installed, and waste heat of exhaust gas isutilized for preheating combustion air. Combustion air temperature is pre-heated up toaround 200℃. In addition, considering high sulfur content of coal (0.4%), acid-dew
point of combustion gas may be over 100℃. Further addition of air pre-heater may bedifficult to be justified economically.

Ⅱ- 30

9-4 Strengthening of thermal insulation
1) Thermal insulation of valves and flanges
Although heat insulation of pipes around the boiler was well performed, most valves
and flanges were not insulated.
Calculation of energy saving effect by thermal insulation of valves and flanges is
described illustratively in the following example. As for calculation of heat loss invalves and flanges, equivalent pipe length (EQ) is conveniently utilized. Heat loss
from pipe with length of EQ is the same as heat loss from valves and flanges. EQ isreferred to a reference book or a handbook. Figure 9-6 shows heat loss per unit length(m) in a graph for various size of pipes.
Calculation of energy saving effect by thermal insulation:
Suppose 6 valves and 4 flanges are thermally insulated as shown in the following
table .
Equivalent pipe length of non- insulated valves and flanges
Fluid temp.

Pipe size

PipinglengthValves No. &EQFlanges No.
& EQ

Total barepiping EQ

Steam: 150℃

50A

3m

6×1.28m

20×0.49m

20.48mcondensate: 90℃

25A

5m

4×1.21m

10×0.54m

15.24mHeat loss per unit length of pipe : given in Figure 9-6
400W/m at pipe size of 50A and steam with 150℃
100W/m at pipe size of 25A and condensate with 90℃
Calculating conditions ;heat insulation efficiency was 80%,boiler efficiency 80%,
operation time 20h/d×300d/y = 6,000h/yHeat loss at non-insulation (bare steam pipe)= 400W/m×20.48m + 100W/m×15.24m = 9,716W = 34,978kJ/h
Heat loss at insulation= 34,978kJ/h×0.9 = 31,480kJ/h
Coal saving = 31,480kJ/h×6,000h/y/ (28,120kJ/kg×0.8) = 8,396kg/y

Ⅱ- 31

Figure 9-6 Heat loss per unit length (m) of various pipes

9-5 Fan and Air Compressor
1) #6 hot oil boiler air fan
Flow rate of air fan in the hot oil boiler was measured by hot-wire velocity instrument.
However, energy conservation effect failed to be calculated, because necessary data
were not collected, for example, inlet and discharge pressures and fan performance
curve were not available. Instead, calculation method of energy conservation effectconcerning variable speed adjustment of pumps/fans was lectured.

2) Air Compressor
As for air compressor, effective energy conservation measures could not be proposed,
mainly due to lack of information. However, the existing dendritic air supply systemⅡ- 32

seems inappropriate because it has long pipelines over considerably big factorycompound. Recommendation was given to consider a conversion to a ring air supply
system.
Compressed air supply system (dendritic system vs ring system)

Dendritic
systemAir
Compressor

Ring system

Air
Compressor

Ⅱ- 3310. Impression on factory
It seemed that energy conservation activities were not implemented. Paradoxicallyspeaking, this means that there is significantly large potential for energy conservation.
50% of energy conservatio n is not a dream. In case that energy cost accounts for 15%
of total manufacturing cost, if 50% of energy conservation effect is achieved, 7.5% ofcost reduction is achieved (7.5=15x0.5).
Although a part of facilities in the factory such as dyers and boilers was observed, it
was untidy in the factory. Hot oil piping with 250℃ was installed around stentermachines and easily ignitable cloth lint were piled around them. It is very dangerous.
Moreover, coal dust was fluttering in the boiler room and blue oil fumes were risingfrom flanges of hot oil pumps. They may also be risk factors, although ventilation
was good. Employee education on safety management (e.g. 5Ss) is expected before
implementing energy conservation measures.
Assistance to OJT audit by factory management was very simple. Only one person in
charge of facilities responded to us, and we could not talk with executives. Moreover,the person in charge did not participate in the seminar-workshop where audit result
was presented. Therefore, although these impressions may include misunderstanding,it seemed that factory manage ment’s concern about energy conservation was low.
This may indicate that relationship of ECC-HCMC with industrie s is not so close
than expected.

Ⅱ- 34

Attachment 2
Seminar-Workshop Program

AgendaSEMINAR ON THE PROMOTION OF ENERGY EFFICIENCY ANDCONSERVATION (PROMEEC) FOR MAJOR INDUSTRIES IN SOUTHEAST
ASIA
19 October 2007, Liberty Hotel, Ho Chi Min City, Vietnam
8:00

-

8:20

Registration

8:20

-

8:30

Opening Remarks by Dr. Weerawat Chantanakome
Representative from ASEAN Centre for Energy (ACE)

8:30

-

9:35

9:35

-

9:40

Opening Statement by Mr. Taichiro Kawase
General Manager, Energy Conservation Center, Japan (ECCJ)
Welcome Remarks by Mr. Phuong Hoang Kim
Representative from Ministry of Trade and Industry (MTI)

9:40

-

9:15

Group Photo Session and Coffee BreakSession 1 Policy and Initiatives on EE&C
Overview of EE&C Programs of ASEAN:
Presented by Mr. Christopher Zamora (ACE)

9:15

-

9:40

9:40

-

10:05 Initiatives and Programs of ECCJ on EE&C in the Industrial
Sector in Japan: Mr. Taichiro Kawase, EECJ

10:05 -

10:30 Overview of Plans and Programs on EE&C in Vietnam:
Representative from Ministry of Trade and Industry (MTI)
Session 2 EE&C Best Practices in Industries

10:30 -

11:00 Presentation: Case Study 1 Cement (Philippines)
Best Practices for Energy Efficiency and Conservation in Cement
Industry in the Philippines-DOE – Mr. Artemio Habitan

11:00 -

11:30 Presentation: Case Study 2 Food (Malaysia)
Best Practices for Energy Efficiency and Conservation for Food
Industry in Malaysia-PTM – Mr. Ahmad Zairin
12:00 Q & A Session

11:30 -Ⅱ- 35

Lunch
13:00 -

13:25 Presentation: Case Study 3 Iron and Steel (Philippines)
Best Practices for Energy Efficiency and Conservation in
Steel/Iron Industry in the Philippines-DOE – Mr. Artemio
Habitan

13:25 -

13:55 Presentation: Case Study 4 Glass (Malaysia)
Best Practices for Energy Efficiency and Conservation for Glass
Industry in Malaysia-PTM – Mr. Ahmad Zairin
14:20 Presentation: Result of the Energy audit in Textile Factory:
Presented by Local Audit Team Mr. Vinh

13:55 14:20 -14:45 Presentation: Result of the Energy audit in Textile Factory: Mr.
Hideyuki Tanaka, ECCJ (Dyeing Machine & Dryer)

14:45 15:10 -15:10 Presentation: Result of the Energy aud it in Textile Factory: Mr.
Kokichi Takeda, ECCJ (Electric Facilities)
15:20 Q & A Session

15:20 -

15:30 COFFEE BREAK

15:30 -

Session 3 The Way Forward
15:50 Presentation: Barriers identified in Energy audit and Its Measures:
Mr. Hideyuki Tanaka, ECCJ

15:50 -

16:10 Presentation: Updates on the Development of Technical
Directory: Presented by Ivan Ismed (ACE)

16:10 -

16:30 Presentation:
UpdatesontheDevelopmentofDatabase/Benchmark/Guideline for Industry: Presented by Ivan
Ismed (ACE)
16:50 Presentation: In-house Database for Textile Industry: Mr. Taichiro
Kawase, ECCJ

16:30 -

Q & A Session
16:50 17:00 -17:00 Awarding of Certificates of Attendance
17:10 Closing Remarks: ACE, ECCJ and Ministry of Industry, Vietnam

Ⅱ- 36

Ⅲ.

Philippines (Food Industry)

1. Activity Overview
12/3 OJT Audit at S Brewing
12/4 Ditto
12/5 Data Analysis/Report making
12/6 Seminar-Workshop
12/7 Reporting to S Brewing
2. OJT Audit at S Brewing(1) Participants
S Brewing: 5 (Technical Manager and 4 engineers)
PNOC Engineers: 2 (Geothermal related)
DOE: 1 (Mr. Domingo, focal point)
ACE: 2 (Mr. Zamora, Mr. Junianto)
ECCJ: 3 (Mr. Taichiro Kawase, Mr. Kokichi Takeda, Mr. Hiroshi Kuroda)(2) Outline of S Brewing
S Brewing is the largest beer brewery in the Philippines and has five factories
in the country and five factories in the neighboring countries such as China.
Kirin Brewery Co. of Japan takes 20% stakes of the company.
Energy Consumption (2006):
Fuel 6,492 toe/y, Electricity 27.93 million kWh/y
Production Facilities: Two brewing lines
Operation: In operation on weekdays (not in operation on weekends), line forwashing bottles is in operation for 24 hours
Energy Conservation Activities: Energy conservation committee has beenorganized. CSR activities are actively implemented(3) OJT results
Lecture on food processing (beer processing, freezing, drying, sterilization)
Preparations for audit (forming of audit team, pre-questionnaire, confirmationof measuring instruments)
Data collection (SCADA/collection of operation record, various
measurements)

Ⅲ- 1

Data analysis (screening of energy conservation measures/calculation)
Reporting audit results to the Factory (quick report)(4) Energy conservation measures to be considereda. Waste heat recovery in wort kettle and improvement of hot water balanceb. Improvement of COP of ammonia refrigerator (optimal operation of evaporative
condenser)
c. Energy conservation of refrigerant circulation pumps (application of inverters)d. Improvement of boiler efficiency
e. Strengthening of thermal insulation (especially around beer bottle sterilizer)
f. Strengthening of energy management (utilization of in- house DB)

Ⅲ- 2

(5) Audit Results (Summary)
Please refer to attachments in this chapter regarding details on calculating grounds, etc
FieldsEnergy Conservation Issues

Audit Results and Measures

Energy Conservation Potential

Production Facilities
Strengthening of waste
recovery from wort boiler

heat Calculating recoverable heat from kettle vapor and wort (in Recoverable heat (per one batch)case that it is recovered as hot water, it is necessary to
Kettle vapor: 33,687MJ
reconsider hot water balance of the entire factory)
Wort: 49,371MJ
Early repair of kettle vapor condensers is necessary.
Loss of wort heat (per one batch)
12,468MJ (oil equivalent 297L)
Strengtheningofthermal Surface temperature measurements (℃)
Surface of sterilizing tank isinsulation of beer bottle sterilizer
Preheating tank: 40, Sterilizing tank: 56, Cooling tank: 39
insulated: Reduction of heat loss =Hot surface with over 50℃ had better be insulated
121.8MJ/h (oil equivalent 2.9L/h)
Utility Facilities
Improvement
efficiency

ofboilerheat Air ratio is ranging from 1.21 to 1.33. Boilers are operated ina good condition. Temperature of exhaust gas is from 170℃
to 176 ℃ . Waste heat recovery of exhaust gas is notrecommended as there is a concern of acid dew-point
corrosion accompanying with fuel oil burning.
Unrecovered condensate in the factory should be recovered.
Improvement of COP of ammonia Measurement of actual COP on refrigeration supply side: 4.1
refrigerator
and reasonable
Evaporative condenser shows performance as it is designed.
Ⅲ- 3

Evaporative condenser facilities have a large capacity
compared to process requirement, but they are operated
efficiently by adjusting number of condensers in operation(constant-speed piston compressors are installed).
Energy conservation of rotary Application of inverter to #3 glycol supply pump weremachines
examined and performance was confirmed as expected.
Energy Management
In- house DB

Constructing in- house DB in order to monitor data related to Reference examples of referenceenergy conservation operations such as temperatures at heat input formats were provided
exchanger outputs which are index of the heat recovery rate.

Energy conservation checklists

Utilizing checklists for housekeeping items in both operation Example of checklists were provided
and maintenance, and avoiding inefficient operation

Ⅲ- 4

3. Seminar-Workshop(1) Participants: 34
Philippines (26 participants)
Government (DOE: 8, PNOC: 2, PCIERO: 1, MERALCO: 2)
Mr. Annunciacion (DOE), Mr. Domingo (DOE)
Private Sector (13, most of them were energy service consultants.
There were no participants from food companies as the seminar wascoincided with the energy week)
ASEAN (3 participants)
Indonesia: Mr. Guanwan (PERSERO, Indonesia)
Vietnam: Dr. Luong (HUT, Vie tnam)
Malaysia: Mr. Phubalan (PTM, Malaysia)
Others (5 participants)
ACE: Mr. Zamora, Mr. Junianto M
ECCJ: Mr. Kawase, Mr. Takeda, Mr. Kuroda(2) Overview of Presentations
1) “Overview and Activities of PROMEEC Projects” (ACE, Mr. Zamora)
Mr. Zamora introduced the position of ACE in ASEAN region, major EE&C
activities such as EC-ASEAN and SOME-METI, and PROMEEC activities. He also
called for participation in the award system.
2) “Energy Conservation Policies in Japan and Activities of ECCJ” (Mr. Taichiro
Kawase: ECCJ)
Mr. Kawase introduced energy conservation policies in Japan and ECCJ’s activities.
He also discussed topics such as harmonization of 3Es, the Energy Conservation Law,
designation of factories, energy managers, national examination, education and training,
and national convention of successful cases.
3) “Energy Audit Activities at Food Factories in Indonesia” (Mr. Gunawan:
PERSERO ,Indonesia, former KONEBA)PERSERO audited so far 31 food factories including factories of palm oil, flour
milling, and bakery. As a result, it was revealed that there was total energy conservation
potential of 12.86%, and that, as shown below, there are important energy conservationⅢ- 5

opportunities in such areas as drying and waste heat recovery.
Reduction in drying energy:
3.58%
Waste heat recovery of exhaust gas:
2.97%
Replacement of inefficient boiler:
2.52%
Operation improvement of boilers:
1.15%
Increase of output in diesel power generation:
0.97%
Strengthening of condensate recovery:
0.90%
Total including others items:
12.85%
4) “Overview of the Food Industry in Vietnam and Energy Conservation Case in
Brewery Factory” (Dr. Pham Hoang Luong, HUT)
There are 232,000 food factories in Vietnam and most of them are SME. Beverages,
dairy products, cooking oil, confectionary products, frozen foods, and ready-to-cookfoods are major products. Issues of the food industry are old- fashioned domestic
machineries and emission of environment-polluting wastes.
Audit at Phu Minh Brewery Factory in Phu Yen Province was implemented by the
Energy Conservation Centre in Ho Chi Minh City (ECC-HCMC). Production in
FY2006 was 146,100 hectoliter. 53.2% of energy consumption was electricity forrefrigeration. It was found that COP of existing reciprocating compressor was 2.0 andefficiency was low. It was replaced by more efficient screw compressor with COP 4.0,
manufactured by MAYEKAWA MFG. CO.(Japan). Investment was paid out within 3.2
years.
5) “Energy Conservation Activities in the Philippines’ Food Industry” (Mr. Marlon
Domingo: DOE (Philippines))
DOE is promoting energy conservation activities under a catchphrase of “EC ways.”
For example, Mr. Domingo explained activities such as measurement by instrument andelectricity patrol. Few contents regarding food industry were presented except
information on major products of the Philippines’ food industry and an example ofreduction in specific consumption at a pineapple factory.
6) “Energy Conservation Case at Glass Container Factory” (Mr. Phubalan Karunakaran:
PTM (Malaysia))
JG Containers Co. was established in 1972 and produces glass containers for foods
and medical products with 150 ton a day. 85% of energy is consumed for glass melting.

Ⅲ- 6

The specific energy consumption (SEC) of factory showed 8.0 GJ/ton, and this isextremely high compared to the European standard of 5.0 GJ/ton. Audits were
implemented three times in the past, and the following measures were implemented
based on results obtained from the former audits, finally the factory SEC was reduced to
5.7 GJ/ton.
- Modification of melting furnace (addition of furnace control system)- Modification of annealing furnace- Fuel conversion in annealing furnace- Reuse of cullet washing water (installation of filter)7) “Overview of Energy Conservation Measures in Food Factories” (Mr. Taichiro
Kawase: ECCJ)
In the food industry there are a number of products produced. Energy conservation
measures are conveniently dealt with, according to unit operations such as washing,steaming, sterilizing, freezing, and storing. Mr. Kawase explained that energy
conservation measures for drying and freezing, the most energy-consuming processes infood industry, together with theory of mass transfer and heat transfer.
8) “Energy Conservation Activities in a Beer Factory in Japan” (Mr. Hiroshi Kuroda:
ECCJ)
Mr. Kuroda reported energy conservation initiatives taken in Japanese brewing
factories since the first oil crisis, including from daily management to the following
state-of-the-art technologies;- Small once-through boiler system- Cogeneration system- Absorption refrigerator with waste heat recovery- Anaerobic digestion wastewater treatment system
9) “Energy Conservation Activities in Food Factories in Japan (Electricity-related
matters)” (Mr. Kokichi Takeda: ECCJ)
Mr. Takeda reported the following cases as measures related to electricity in foodfactories:- Adjustable speed drive of refrigerant circulation pumps in a beer factory(inverter)- Cooling water circulation pumps in a starch factory- Adjustable speed drive of dust collecting fans in a food factory (inverter)

Ⅲ- 710) “Development and Dissemination of Energy Management Tools” (Mr. Junianto M:
ACE)
Mr. Junianto explained that purpose, preparation method, and format of theTechnical Directory (TD), and also presented an actual example of TD input form. A
similar explanation was given on the In-house DB.
11) “In- house DB Input Format for the Food Industry”, and “Barriers against Promotionof Energy Conservation and Measures” (Mr. Taichiro Kawase: ECCJ)
Mr. Kawase explained that purpose and content of the In-house DB using an
example of input format of the food industry. A characteristic of the In-house DB is thatit includes important operation parameters and energy efficiency index as well as
production data, energy data, and equipment data. They are used as reference
information for energy conservation operations.

(3) Questions and Answers, and Comments
Q: The energy consumption in Japan had already reduced before enactment of theEnergy Conservation Law in 1979. Is it not contradictory to the explanation that the
Law has contributed to energy conservation in Japan?
A: Energy conservation in Japan has progressed by self- help efforts of companies. The
Law was enforced in order to further promote energy conservation.
Q: What is the reason for replacing a reciprocating refrigerator with a screw-type one in
the case of Vietnam (Brewery Factory)?
A: It was replaced with a screw-type having a higher COP, because COP dropped down
to 2.0 due to machine aging.
Q: As for variable speed control of absorption chiller in the case of a beer brewery, wasit installed at the time of delivery or was it added afterwards?
A: The control device was installed at the time of delivery. Variable speed control
signifies adjustment of refrigerant flow rate by adjustable speed drive, for example,

Ⅲ- 8

inverter.
Q: Why is it taking much time to enact laws in the Philippines?
A: There is not a straightforward answer, because each country faces different situations.
In an example of Turkey, it took much time to make sure of a legislative harmony with
EU regulations and to reach an agreement among related ministries concerning financial
sources.
Q: What are systems in the ASEAN countries like with regard to discounts by power
factor?
A: There were explanations from several countries. There is a discount system in
Malaysia and Indonesia. Vietnam is considering its introduction. In Japan, a penalty is
imposed if power factor is less than 85%.
Q What does ice slurry stand for?
A: Dr. Luong (Vietnam) answered. It is one of ice thermal storage methods. It is also
called sherbet.
Q: I would like to know more regarding the explanation that cool temperature of -5℃
is realized by an absorption chiller presented in the report of the brewery’s case.
A: The essence of this technology is to control strictly LiBr concentration to be enoughhigh to attain -5℃ at higher-vacuum condition in a absorption chiller. In such low atemperature as -5℃, an icing problem is the biggest technical problem. To overcome
icing problem, fluid- mechanical design in the absorption chiller was redesigned for
LiBr aqueous solution to smoothly flow under high concentration and high viscosity.
(4) Photo Session and Certification Presentation
Certificates of seminar participation were given to fifteen participants from thePhilippines.
4. Comment and Advice

Ⅲ- 9(1) OJT audit was implemented in S Brewery Co., Ltd., an excellent company which
won the second prize of the Industrial Energy Conservation Competition of PROMEEC.
According to an application to the competition, almost all of energy conservation
measures are adopted. In fact, the implementation of those measures was confirmed asstated in the application. We had an impression that this is an excellent factory in the
ASEAN region. A large board with photos’ of members of an energy conservationcommittee was put up in the factory. An introduction video was casted, more than halfof which is used for CSR activities. It indicates the social status of S Brewery Groupvery high.
(2) Mr. Kuroda, who used to work in a beer brewery, participated in this audit.
According to him, there is still much room remaining for improvement in comparison
with Japanese breweries. There is a possibility of improvement from the standpoint of
optimization of the entire factory. For example, unused waste heat from wort kettle isrecovered in a form of hot water, and transported to bottle-washing unit and utilized asheating source. It reduces steam consumption which is generated in steam boiler. The
measure has already been implemented in Japanese breweries.
(3) The factory has an excellent data collection and recording system, respectively
SCADA system and hand-written operation record sheet. However, it was observed thatthe accumulated data were not fully utilized for activities such as daily operation andpreventive maintenance. For example, activities to optimize operation of refrigerating
system are not so active, while large amount of data are continuously accumulated. It
seemed that some engineers were not sufficiently equipped with necessary knowledge.
The In-house DB may be helpful for promoting energy management, including theabove problems.
(4) When we pointed out the above- mentioned points in (2) and (3), engineers
understood the importance of further pursuit of daily management activities. Mr.
Kuroda handed over checklists on each process for daily management use, because they
requested examples of these activities in Japan. They showed deep appreciation as they
have not used these checklists in the past.
(5) Only two PNOC engineers participated in the audit activity from the Philippine side.
Surprisingly no one participated in from food industry. Our activity was substantially
not an OJT but an energy aud it of S Brewery Co., Ltd. A person in charge of the

Ⅲ- 10Philippine side said that it was very helpful in understanding the actual situation ofindustry. However, it is regrettable because we spent much effort to coordinate andprepare beforehand.
(6) A similar problem was found in the seminar-workshop. Although forty people were
expected to participate, only twenty turned up. They explained that it was due to heavy
rainfall and the energy week, but it became somewhat a small seminar in number.
However, it was a good news that questions and answers were actively exchanged. Mostof participants from the private sector were energy service consultants so that thequestion-and-answer session was very practical. We were able to discuss specific ideas,
not general ideas regarding the audit.
(7) Selection of speakers from Indonesia, Vietnam and Malaysia was excellent. They are
respectively a former engineer of fertilizer factory, a professor of thermal engineering
faculty and an audit manager of the energy conservation center, and all of them havebusiness experience in this field. I thought participants from the Philippine side weresatisfied with the question-and-answer session. I have experiences of OJT audit twice inthe past, but speakers of this seminar were one of the best.

5. Attachments(1) Audit Report on S Brewing(2) Seminar-Workshop Program

Ⅲ- 11

Attachment 1

Audit Report on S Brewing

1. Audit Venue
P factory of S Brewing, McArthur Hi-way, Valenzuela City, Philippines CMC
2. Audit Schedule
December 3, 2007 (Monday) 9:30 – 17:00
4, 2007 (Tuesday) 9:30 – 17:00
5, 2007 (Friday)
9:30 – 13:00
3. Participants:
Philippines Government
Mr. Marlon Rumulo Domingo (DOE)
Mr. Mmichaelle B. Anguluan (PNOC)
Mr. Rex Darell Vergel (PNOC)
ACE (ASEAN Center for Energy)
Mr. Christopher G. Zamora (Administration & Finance Manager)
Mr. Junianto M (Technical Expert)
ECCJ (Energy Conservation Center, Japan)
Mr. Hiroshi Kuroda
Mr. Kokichi Takeda
Mr. Taichiro Kawase
4. Responders
Factory Manager, Technical Manager, and five others
5. Overview of S Brewing
General Facts
S Brewing is the largest beer brewing company in the Philippines. P factory is one offive factories, and is located at the northernmost part of the metropolitan area in
Manila. This factory has the second largest production capacity out of five factories of
the company in the Philippines. Kirin Brewery Co. takes 20% of its share. The
company has advanced into neighboring countries such as China. P factory hires 452
employees. Technical Department has 42 members and 12 out of them are engineers.

Ⅲ- 12

Production Facilities
P factory has two brewing lines and are in operation on weekdays (not in operation on
weekends). The bottle-washing line is in operation for twenty- four hours.
Heating facilities: rice cooker, mash tun, wort kettle, CIP heat exchanger, yeast dryer(all of which are indirectly steam heated
Sterilizing facilities: bottle-sterilizing facilities-2, can-sterilizing facility-1, CIP
facilities-2 (all of which use steam)
Cooling facilities: Glycol cooler (-2℃, S&T), beer cooler (1℃, S&T and PHE), watercooler (6-8℃, S&T and PHE)
Utility Facilities
Steam boilers: 6 (9.4t/h x 5, 12.55t/h x 1, 100psig, fuel (fuel oil and biogas))
Air compressors: 4 (screw x 193kW, water-cooling, piston x 2, 280kW each,water-cooling, centrifugal x 1, 261kW, water-cooling)
Facilities for receiving and distributing electricity: 5000KVA x 9 transformers(34500V/4160V)
Refrigeration facilities:
low-pressure system x 6 (screw, ammonia, suction/discharge 1.93-2.4 bar/12bar,
motor 522kW x 4, 548kW x 1, 360kW x 1, each condenser is evaporative
condenser, each evaporator is S&T),
high-pressure system x 3 (screw, ammonia, suction/discharge 3.79-4.14 bar/12bar,
motor 746kW x 3, each condenser is evaporative condenser, each evaporator is
S&T), high-pressure system is only for manufacturing chilled-water
Energy Consumption (2006)
Fuel: 6492 toe/year, electricity: 27.93 million kWH / year
Energy Conservation Activities
CSR activities have been actively implemented. Energy conservation activities havealso been implemented in accordance with CSR activities. P factory has organized anenergy conservation committee, assigned an energy manager, and has an award
system for energy conservation suggestions. Monitoring, recording and reporting ofenergy consumption are implemented. Facilities are managed by preventive
maintenance. TPM/KAIZEN is in place, and in- house energy audits are implemented,
utilizing own employees or external consultants. In addition, The company has

Ⅲ- 13obtained ISO9000/ISO14000, and has won various awards such as the Don EmilioAward and the ASEAN Energy Conservation Award. As a conclusion, we can say thecompany carries out ideal energy conservation activities.
6. Investigation on Production Facilities
As P factory has implemented most of typical energy conservation measures,investigation was conducted except on the already- implemented measures. As a result,
as for production facilities, heat recovery of wort kettles, improvement of hot waterbalance, and reduction in energy loss around the beer bottle sterilizer were investigated.
As for utility facilities, considerations were given to improvement of boiler heatefficiency, enhancement of COP of ammonia refrigerator, and energy conservation ofrefrigerant circulation pump. Concerning energy management, introduction of thein- house database for utilizing operation data was recommended.
6-1 Heat Recovery from Wort Kettles and Improvement of Hot Water Balance
Wort kettles are the largest source of exhaust heat. Therefore, it will be a key of energy
conservation how to increase the heat recovery rate for effectively utilizing it as a heatsource in other places in the factory. Source of exhaust heat in wort kettles is “latent
heat of vapor producing at the time of wort boiling” and “sensible heat of wort at thetime when hot wort is cooled to fermentation-initiating temperature (pitchingtemperature).”Recoverable Heat Quantity from Wort Kettles☆ Heat recovery from vapor producing at the time of wort boiling (latent heat)
per one batch
Amount of wort at the time of completion of boiling (cast wort): 1,340 hL(←from data of wort cooling given by P factory)
Boiling rate (percentage evaporation): 10%(←general manufacturing method, boiling time is supposed to be 90 minutes)
Amount of wort at the time of initiation of boiling (unboiled wort): x hL
(x-1,340) / x=10/100, x = 1,489
Amount of water evaporated: 1,489hL – 1,340 hL = 149 hL
Heat quantity of evaporation:

Ⅲ- 14

Heat of evaporation =540 kcal/kg (2,260kJ/kg)
149 hL x 540 kcal/kg = 8,046 x 103 kcal (33,687MJ)☆Heat Recovery from Wort Cooling (sensible heat) per one batch
Amount of wort at the time of completion of boiling (cast wort): 1,340 hL(←from data of wort cooling given by P factory)
Temperature of wort:
98℃ at inlet of plate-type heat exchanger(←from data of wort cooling given by P factory)
10℃ at outlet of plate-type heat exchanger(←from data of wort cooling given by P factory)
Heat quantity of wort cooling:
1,340 hL x 1 kcal/kg ℃ x (98-10) ℃ = 11,792 x 103 kcal (49,371MJ)☆Total amount of recoverable heat:
8,046 x 103 kcal + 11,792 x 103 kcal =19,838 x 103 kcal (83,058MJ)☆Heat quantity for heating up wort per one batch
Wort is charged from wort pre-run tank, then preheated by hot wort coming from theenergy storage system. A part of heat quantity of evaporation is stored in the energy
storage system.
Amount of wort at the time of onset of boiling : 1,489 hL
Heating temperature:at inlet of plate-type heat exchanger 72℃ (←from data of P factory)at outlet of plate-type heat exchanger 92℃ (←from data of P factory)
Heat quantity for wort heating:
1,489 hL x (92-72) ℃ = 2,978 x 103 kcal (12,468MJ)
Ratio of heat quantity for wort heating to heat quantity of evaporation:
2,978 x 103 kcal (12,468MJ) / 8,046 x 103 kcal (33,687MJ) x 100 = 37%☆Heat quantity available for other usages
19,838 x 103 kcal - 2,978 x 103 kcal = 16,860 x 103 kcal
It is necessary to design an optimal system so that heat quantity available for otherusages should be made maximum use of, with respect to heat demand in other processes
in the factory. Specifically, it is important to separate heat quantity demand (temperature

Ⅲ- 15and quantity) and water quality demand by usage. A high water quality is demanded forprocessing raw materials, washing equipment, handling water which has a possibility tocontact directly with beer liquor.
Current Situation of Heat Recovery from Wort Kettles☆Heat recovery from hot wort cooling per one batch
Heat quantity of hot wort based on 10℃ (fermentation temperature)
1,340 hL x 1kcal/kg℃ x (98-10) ℃ = 11,792 x 103 kcal (49,371MJ)
Wort is cooled from 98℃ to 10℃ through four stages. Heat of hot wort is recoveredfor preheating boiler feed-water and brewing water respectively in the first and thesecond stages. Then it is cooled in the cooling tower as the third stage, and finallycooled down to 10℃ by brine in the fourth stage.
First stage : recovered to boiler feed-waterWort temperature (98? 90) ℃, recovered heat quantity 1,072 x 103 kcal (4,488MJ),
recovery rate 9.1%
Second stage : recovered to brewing waterWort temperature (90? 45) ℃, recovered heat quantity 6,030 x 103 kcal (25,246MJ),
recovery rate 51.1%
Third Stage : discarded to environment in the cooling towerWort temperature (45? 35) ℃, discarded heat quantity 1,340 x 103 kcal (25,246MJ),
energy loss11.4%
Fourth stage: cooled by brine (supplied from refrigeration system)
Wort temperature (35? 10) ℃, cooling, 3,350 x 103 kcal (14,026MJ),
energy inputted 28.4%☆Instability of Hot Water Balance
Current tank system for recovered hot water causes a phenomenon that hot water runs
short due to imbalance of hot water supply and demand accompanied by delay of wort
boiling. This causes wasteful situation when hot water is produced, but cannot be used.
☆Early Repair of Vapor Condenser
At the time of investigation, heat recovery of kettle vapor was stopped for a long time,
because vapor condenser was left unrepaired due to delay of delivery of replacement
parts. Though this did not affect beer production, significant heat energy was lost.

Ⅲ- 16

Suggestions for Improving Heat Recovery (short-term measures)☆Reexamination of Hot Water Balance in the Entire Factory
Recoverable heat quantity from wort kettles was calculated as 19,838 x 103 kcal
(83,058MJ) per one batch. It is a key of energy conservation how to enhance heatrecovery rate from available heat quantity of 16,860 x 103 kcal (70,590MJ), and to makemaximum use for heat demand in other processes in the factory.
In the factory, strengthening of steam condensate recovery is one of current goals.
Moreover, change in hot water demand is forecasted along with energy conservation
promotion. It is necessary to reconsider hot water balance in the entire factory taking thedemand change into consideration.
☆Early Repair of Vapor Condenser
The vapor condenser which had not been utilized at the time of investigation should be
repaired and re-operated at an early stage. Although it does not affect the beer
production, at least 2,978 x 103 kcal (12,468MJ) of recoverable heat quantity for wort
pre-heating, which is equivalent to fuel oil of 297L, was lost to environment. It is
important to maintain and manage not only vapor condenser but also energy
conservation facilities.
Information on New Technologies (reducing the wort boiling rate from 10% to 4%)☆Background of Reduction in Boiling Rate
Required hot water decreases as energy conservation progresses. In future, hot waterbalance may lean to excessive supply of hot water. In order to promote energy
conservation further, innovative conversion of the brewing process may be required.
Emerging technologies in the world brewery industry are shown below.
☆Internal Heating Wort Kettle
This is a technology to attain a predetermined wort quality at a boiling rate of 4% by aninternal heater which forcefully agitates wort with a circulation pump ,while the boilingrate of 10% has been adopted stereotypically. This technology was studied at the
Weihenstephan University in Germany, and put to practical use by German brewing
machine manufacturer. Evaporation heat is recovered by the energy storage system as
before, and used for pre- heating wort coming from the wort pre-run tank. It is not

Ⅲ- 17

necessary to carry out heat recovery as hot water, because available heat quantity withboiling rate of 4% is approximately equivalent to heat quantity required for pre-heatingwort. This is an energy conservation technology with which recovered heat is used out
in the same process, not resulting in unused exhaust heat.
☆Modification of the Existing Wort Kettle
At the time of introduction of internal heating wort kettle, the existing wort kettle will
be stopped during an extended period for modification work. Fortunately there will belittle adverse effect of modification work on beer production, because there are brewing
facilities with two lines.
6-2 Reduction in Energy Loss around Beer Bottle Sterilizer
Sterilizer (pasteurizer) consists of three parts, pre- heating, sterilization, and cooling.
Beer bottles are sterilized when they pass through hot water shower to reach aprescribed temperature. Each part requires similar treatment time. Generally, a type inwhich water flows counter-currently between a preheating tank and a cooling tank isadopted for energy conservation purpose.
Results of Investigation of the Current Situation☆Pasteurizer :Type : Double Deck Tunnel Pasteurizer 1600 bpm(bottles per minutes)(VORTEX-type made by BARRY-WEHMILLER CO., INC.)
Size of pasteurizer: width 6m x height 2.7m (water part 0.5m) x length 30m
Capacity of beer bottle: 320mL, throughput: 1,500 bpm
Beer temperature at inlet: 0~4℃, beer temperature at outlet: 35℃
Transit time (travel time): 50 minutes
Shower temperature: based on management of sterilizing intensity,and it was approximately a standard temperature.
☆Measurement of surface temperature of pasteurizer
Temperature of pre- heat tank (fourth tank): 49℃, surface temperature: 40℃
Temperature of sterilizing tank (heating): 68℃, surface temperature: 56℃
Temperature of sterilizing tank (retention): 61℃, surface temperature: 51℃
Temperature of cooling tank (fourth tank): 44℃, surface temperature: 39℃

Ⅲ- 18

☆Situations Surrounding Pasteurizer
Steam leak was found at one part of a steam drain pipe. Although there wasscattering of broken bottles on the floor, the factory was managed tidy overall.
☆Heat Loss from Surface of Pasteurizer
Heat loss from surface of pasteurizer is calculated as the following table;
Place

Upper
surfaceSidesurface Side
surface(circulation(steam feeding
pump side)
side)

All surface area A(m2)(Each zone occupies 1/3)

6.0×30.0(6.0×10.0)

2.7×30.0(2.7×10.0)

2.7×30.0(2.7×10.0)

Actual temperature Ta (℃):
pre-heating
Actual temperature Ta (℃):
sterilizing

40

40

40

56

56

56

Actual temperature Ta (℃): cooling

39

39

39

Ambient temperature T0 (℃)
Calculation Natural convection
formula
hc

30
30
30
0.25
Qn = [hc×(Ta-T0) ]×(Ta-T0 )×A (W)

Radiation εEmissivity
Current heat loss

3.26

2.56

2.56

Qe = 5.68×ε×{[(273+Ta)/100]4 –[(273+T0 )/100]4 }×A(W)
0.95
0.95
0.95
(paintwork)(paintwork)(paintwork)
Q1 = (Qn+Qe) = (30,741+33,853)W?
64,593kWh/h? 233MJ/h☆Generally, target of heat insula tion is a surface with 50℃ and hotter. Heat insulationof sterilizing part is supposed to be carried out herein, and surface temperature after heatinsulation is set as 35℃. Thickness of heat insulation is judged on economics, forexample, payout year.
Current heat loss (only sterilizing part)

Q1 = (Qn+Qe) = (19,600+20,221)W ?
39,821kWh/h? 143.4MJ/hHeat loss after heat insula tion

Surface temperature is assumed 35℃
Ⅲ- 19

Q1 = (Qn+Qe) = (2,496+3,508)W ?
6,004kWh/h? 21.6MJ/h
Energy saving

143.4-21.6 = 121.8MJ/h? in terms of fuel oil
121.8MJ/h/41,934MJ/L = 2.9L/h

Reference: Heat Quantity Required for Sterilization
Temperature of beer is set as approximately 2℃ in the state of bottle filled. The bottled
beer is heated up to approximately 60℃ in the pasteurizer for sterilization, and thencooled. It is discharged at approximately 35℃.
Heat quantity for heating the bottled beer:
Beer: 320mL
Bottle : 335g, Specific heat: 0.265 cal/g℃
Throughput: 1,500bpm ? 90,000bph
Heat quantity for heating up to 60℃(320 + 335 x 0.265) cal/℃ x (60-2) x 90,000/h? 2,134 x 103 kcal/h ? 8,935 MJ/h ? 213.1 L/h
Recovered heat quantity :(320 + 335 x 0.265) cal/℃ x (60-35) x 90,000/h? 919.8 x 103 kcal/h ? 3,851 MJ/h ? 91.8 L/hHeat quantity for heating bottled beer ? 213.1 L/h – 91.8 L/h = 121.3 L/h
Suggestions for Improving Heat Recovery (short-term measures)
Based on the above calculations, surface heat loss (233MJ/h) from pasteurizer is 5.6L/hin terms of fuel oil. This is equivalent to 4.6% of heat quantity required for pre-heatingbottled beer. It is possible to reduce most of the heat loss by heat insulation, though it issaid, in general, that heat insulation is economically feasible if surface temperature isover 50℃. Heat insulation of the sterilizing part was carried out herein, and there isenergy conservation effect of 2.9L/h in terms of fuel oil. If temperature is less thanaround 140℃, a pasting-type insulation material made of heat-resistant urethane ispreferably used as an insulation material. This insulation material is cheap and easy toattach. An example of installation is shown in the photo below. Please see the website ofa manufacturer. Careful attention is necessary to attaching work of insulation material,
because the surrounding of pasteurizer is congested with attachments like piping, valves,

Ⅲ- 20

etc. It may be an option to avoid heat insulation of complex-shaped parts.

Performance Test of Insulation Materials
http://www.thaisekisui.co.th/

7 Investigation on Utility Facilities
7-1 Improvement of Boiler Heat Efficiency
Gas analysis and temperature measurement on exhaust gas in two boilers were
implemented. Fuel oil with sulfur content of 1% was being burned. Residual oxygen
level was 3.7-5.2%, and exhaust gas temperature was 170-176℃. The oxygen level was
managed appropriate. It seems that there is no economics of introducing an air
pre-heater, considering high sulfur content and relatively high gas temperature.
Boiler Specifications and Operation Data
Steam pressure
Steam generated (rated)
Fuel
Exhaust gas temperature
Oxygen level in exhaust gas (O 2 %)Air ratio

No.3 Boiler
6.7 bar
9.4 t/hFuel oil
170℃
5.2%
1.33

Ⅲ- 21

No.6 Boiler
6.7 bar12.5 t/h
Fuel oil
176℃
3.7%
1.21

Exhaust gas loss (%)

8.0%

7.5%

Air ratio is estimated from the following formula: Air ratio = 21 / (21-O2 %)Exhaust gas loss was calculated from the figure below. This figure is used in a case offuel oil A, however, it is also applicable approximately to other types of fuel oil.

Necessity in Energy Conservation Measures
The Energy Conservation Law in Japan requires to manage boiler air ratio and exhaustgas temperature under 1.3 and 200℃, respectively. This boiler meets these requirements
so that it is not necessary to adopt energy conservation measures further.

7-2 Improvement of COP of Ammonia Refrigerator
Ammonia refrigeration system has six low-pressure stages and three high-pressure
stages, and eight evaporating condensers are coping with refrigerating system. One or
two of condensers are in operation under normal operation. Condens ing pressure iscontrolled by adjusting number of operating compressors with on-off control.
Reference : COP Estimation on Refrigeration Supply Side
There are two kinds of COP : one is refrigeration supply side and the other isrefrigeration demand side. COP of refrigeration supply side is defined as a ratio of
refrigeration produced in the refrigeration plant to power input to refrigeration
compressor. COP of refrigeration demand side is defined as a ratio of refrigeration
Ⅲ- 22

supplied to process to all power input in the refrigeration plant. Refrigeration supplied
to process should be measured in order to calculate COP of refrigeration demand side.
However it is not so easy.
Condenser pressure / temperature: 12.2 bar(g) / 34.1℃
Evaporator pressure / temperature: 2.14 bar(g) / -8℃
Theoretical COP (Carnot’s reversible cycle): (-8+273) / (34.1-(-8)) = 6.3
COP (standard cycle): 6.3 x 0.83 = 5.2
Calculated COP: 5.2 x 0.8 = 4.1 (COP of refrigeration supply side)

R value

R value (ratio of COP of the standard cycle to COP of the Carnot’s reversible cycle) was
calculated based on the following figure. Refrigeration compressor efficiency was
assumed to be 80%.
Evaluation on Performance of Evaporative Condenser
The fifth evaporative condenser was in operation at the time of investigation (December
4, 2007). Operation data is as follows:
Wet bulb temperature: 24℃
Circulation water temperature: 26.5℃
Temperature approach: 26.5-24 = 2.5℃
Generally, temperature approach in an evaporative condenser is designed to be 3℃,
where temperature approach is defined as temperature difference between cooling waterⅢ- 23

temperature and ammonia condensing temperature. As the evaporative condenser was inon-off operation, it is in operation with load of 100%, compared to rated capacity of asingle evaporative condenser. Considering measured temperature approach is 2.5℃, it isthought that the evaporative condenser showed its performance as designed. Channelingof circulation water was not found nor generation of algae. It is in a good maintenancecondition.
Effect of Increase in Evaporative Condensers in Operation
Currently, one or two out of eight evaporative condensers are in operation, meaning that
there is redundant capacity in the existing facility. If number of evaporative condensers
increases in operation, temperature of circulation water can be lowered. This indicatesthat ammonia condens ing pressure can be lowered, and ammonia compression ratio canbe also lowered, resulting in reduction of compressor power. However, in this facility,
temperature approach has dropped to 2.5℃ as mentioned above. Therefore, it isdifficult to expect a significant decrease in temperature approach even when adding
more condensers in operation. On the other hand, there is a restriction thatcompressor-type is a constant-speed piston and it cannot perform continuous control.
Therefore, it is difficult to carry out energy conservation operation, utilizing sparecapacity of the evaporative condensers.
If compressors in the refrigeration plant are equipped with screws with inverters, it ispossible to perform energy conservation operation utilizing spare capacity of theevaporative condensers. Power required for operating the evaporative condensers
increase, but more saving of ammonia compressor ’s power can be expected. An
estimation method of energy conservation potential in this case is shown below.
Basic formula of evaporative condenser: Q = U x A x ⊿t
Q: Quantity of heat exchange r duty (kcal/h)
U: Overall heat transfer coefficient
A: Area of heat transfer (m2)⊿t: Average temperature difference (℃)
G: Mass velocity in condenser tube (kg/m2h)
Between base operation and energy conservation operation, the following equation is set.
Subscripts are described as 1 and 2 .
Q = U1 x A1 x ⊿t1 = U2 x A2 x ⊿t2
U1 / U2 = (G1 /G2 )^0.8
It can be said that U is approximately proportional to the 0.8 power of ammonia flow

Ⅲ- 24

rate in a condenser tube. If condensers increase from two to three, A1 / A2 become
two-third (2/3). At the same time, flow rate per evaporative condenser also becomes
two-third. The current ⊿t1 is a difference between 34.1℃ of ammonia condensation
temperature and 26.5℃ of temperature of evaporative condenser’s circulation water,that is, 34.1 – 26.5 = 7.6 ℃ . Ammonia condensation temperature under energy
conservation operation is estimated as 26.5 + 6.35 = 32.8℃ based on the following
procedures.
⊿t2 /⊿t1 = (U1 / U2 ) x(A1 / A2 ) = (3/2)^0.8 x (2/3) = 0.92
⊿t2 = 6.9 x 0.92 = 6.35℃
Ammonia property in condensers and evaporators in base operation and in energy
conservation operation are as follows
Base operation
Condenser
Pressure bar(g) 12.2
(Mpa)
Temperature ℃ 34.1

Energy conservation operation
Evaporator

Condenser

Evaporator

2.14

11.6

2.14

-8

26.5 + 6.3 = 32.8

-8The compressor ’s power can be estimated as follows:
L = k / (k-1) x (Ps x Qs) / 0.06 x [(Pd / Ps)^{(k-1) / k}-1] / η
k: Specific heat ratio of ammonia
Ps: Suction pressure (MPa)
Pd: Discharge pressure (Mpa)
Qs: Compressor ammonia handling rate (m3 N/min)η: efficiency of compressor, normally 0.8
Here, Ps x Qs is a constant value herein in an ideal gas state, and this is supposed to beapproximately valid.
Therefore,
L2/L1 = [(Pd/Ps)^{(k-1)/k}-1]2 / [(Pd/Ps)^{(k-1)/k}-1]2= [(12.6/3.14)^{(1.31-1)/1.31}-1] / [(13.2/3.14)^{(1.31-1)/1.31}-1]= 0.96 (4% saving)Ammonia compressor’s power is saved by approximately 4%. However, its effect is loweven if evaporative condensers are increased from two to three. Rather effort had betterbe made for reduction of process-side refrigeration load.

Ⅲ- 25

7-3 Investigation on Energy Conservation of Rotating Machine
Pumps were investigated by focusing specifically on glycol feed pumps. The #3 glycol
pump (to Fassen PHE cooler) has already been equipped with an inverter. In order toevaluate a performance of inverter, realized electricity saving was estimated using themeasured data. Effectiveness of the introduction of inverter was confirmed.
Energy Conservation Effect of Introduction of Invertera) Rationale of electricity conservationb) Calculation example of glycol pump #3
Measured data in this investigation: Motor rating Lo 37.3kW (50HP)
Input power Lb’ 2.64 ~ 2.97kW (at 25Hz)①Calculation of shaft power at point A and estimation of flow Qa and head Ha
One example of measured data of input power at point C : kWc = 2.81[kW]Supposing pump efficiency is constant over normal operation range,
La = kWc/(Nn/No)3 /(ηtc ×ηmc)= 2.81/(25/60)3 /(0.95×0.7)=25.8[kW] = 34.6[HP]Judging from intersection of La curve and pump performance curve,

Ⅲ- 26

Qa≒120[USGPM], Ha≒340[ft]②Calculation of head Hn’ and Hn at points C’ and C
Hn’ = (Nn/No)2 ×Ha = (25/60)2 ×340 = 59.9[ft]Supposing pressure drop in the throttled discharge valve of glycol pump #3 is 30[ft],Hn ≒ 59-30 = 29[ft]③Calculation of flow Qb and shaft power Lb
Qb = √(Hn’/Ha) × Qa =√(59/340) ×120 ≒ [USGPM]
Lb ≒ 29.3[HP] = 21.8[kW] (read from the performance curve)④Calculation of electricity saving?kW = Lb/ηmb’ – kWc = 21.8/0.92 – 2.8 = 20.9[kW]

8 Investigation on Energy Management System
8-1 Utilization of Operation Data and the In- house DB
P factory has introduced SCADA systems. The hand-written recording sheet isemployed in each on-site department. Typical data are raw materials and products,
energy consumption like fuel, electricity, specific energy consumptions, and key processparameters. Accumulated data are recorded and monitored every day. However, it
seemed that there was still much room for more effective utilization of accumulated
data. It is possible to find out a drop in the heat recovery rate due to tube fouling ofvapor condenser or equipment failure in an early stage.
Thus, we recommended an introduction of in-house DB with specific examples. For thereference, we provided an example of input format of the in-house DB (Seeattachment).
8-2 Energy Conservation Checklist
Energy conservation checklist on each process in beer brewing was provided (Seeattachment). In the P factory, energy conservation measures in the packaging processseem to be behind, compared to those in the brewing process. It is expected, in the
future, that energy conservation checklists are utilized as what is called score sheet tocompare energy conservation performance among factories in S Brewing Co, Ltd.
Similarly, as for utility facilities, it is expected to create checklists (score sheets) andutilize them for promotion of energy conservation.

Ⅲ- 27

9 Results of audit (Summary)
Please refer to attachments in this chapter regarding details on calculating grounds, etc
FieldsEnergy Conservation Issues
Production Facilities
Strengthening of waste
recovery from wort boiler

Audit Results and Measuresheat Calculating recoverable heat from kettle vapor and wort (in Recoverable heat (per one batch)case that it is recovered as hot water, it is necessary to
Kettle vapor: 33,687MJ
reconsider hot water balance of the entire factory)
Wort: 49,371MJ
Early repair of kettle vapor condensers is necessary.
Loss of wort heat (per one batch)
12,468MJ (oil equivalent 297L)

Strengtheningofthermal Surface temperature measurements (℃)
insulation of beer bottle sterilizer
Preheating tank: 40, Sterilizing tank: 56, Cooling tank: 39
Hot surface with over 50℃ had better be insulated
Utility Facilities
Improvement
efficiency

ofboilerEnergy Conservation Potential

heat Air ratio is ranging from 1.21 to 1.33. Boilers are operated ina good condition. Temperature of exhaust gas is from 170℃
to 176 ℃ . Waste heat recovery of exhaust gas is notrecommended as there is a concern of acid dew-point
corrosion accompanying with fuel oil burning.
Unrecovered condensate in the factory should be recovered.

Improvement of COP of ammonia Measurement of actual COP on refrigeration supply side: 4.1
refrigerator
and reasonable
Evaporative condenser shows performance as it is designed.
Evaporative condenser facilities have a large capacity
compared to process requirement, but they are operated
efficiently by adjusting number of condensers in operation
Ⅲ- 28

Surface of sterilizing tank isinsulated: Reduction of heat loss =121.8MJ/h (oil equivalent 2.9L/h)(constant-speed piston compressors are installed).
Energy conservation of rotary Application of inverter to #3 glycol supply pump weremachines
examined and performance was confirmed as expected.
Energy Management
In- house DB

Constructing in- house DB in order to monitor data related to Reference examples of referenceenergy conservation operations such as temperatures at heat input formats were provided
exchanger outputs which are index of the heat recovery rate.

Energy conservation checklists

Utilizing checklists for housekeeping items in both operation Example of checklists were provided
and maintenance, and avoiding inefficient operation

Ⅲ- 29

Attachment 1

In-house DB(Reference Input Format)

Data Sheet for P factory of S Brewing Co, Ltd (Philippines)
Data & Time
Heat recovery system in the wort cooler
Cooler type
Wort amount (m3/batch)
No of batch a day
Wort rate (m3/h)
Inlet temp (℃)
Outlet temp (℃)
Water rate (m3/h)
Inlet temp (℃)
Outlet temp (℃)
Performance curve of hot water pump (manufacturer)
Flow sheet of heat recovery system around the wortcooler (SCADA)
COP of new ammonia refrigeration system
Compressor type
No of compressors
Electric power at design (kW)at actual (kW)Suction pressure at design (bar G)
at actual (bar G)
Suction temperature at design (℃)
at actual (℃)
Discharge pressure at design (bar G)
at actual (bar G)
Discharge temperature at design (℃)
at actual (℃)
Evaporative Condenser
Type of condenser
No of condensers
Water temperature at cooling tower basin
at design (℃)
at actual (℃)

Ⅲ- 30

Dry bulb temperature at design (℃)
at actual (℃)
Wet bulb temperature at design (℃)
at actual (℃)
Evaporator
Type of evaporator
No of evaporators
Lowest temperature of refrigerated rooms
at design (℃)
at actual (℃)
Glycol temperature at cooler inlet
at design (℃)
at actual (℃)
Glycol temperature at cooler outlet
at design (℃)
at actual (℃)
Flow sheet of new ammonia refrigeration system(SCADA)
Variable frequency drive (VFD) for glycol supply pump
Pump type
No of pumps
Glycol rate at design (m3/h)
at actual (m3/h)
Performance curve of glycol pump (Manufacturer)
Flow sheet of glycol supply system (SCADA)

Ⅲ- 31

Attachment 2

Energy Conservation Checklists for Brewing Factory(http://www.oee.nrcan.gc.ca/industrial/technical-info/benchmarking/benchmarking_guides.cfm#b)
SOME BREWERY PROCESS-SPECIFIC ENERGY EFFICIENCY OPPORTUNITIESBrewing:*Processing beer at high gravity throughout all major energy-using activities will reduce overall specificenergy consumption. In addition, the brewery will realize a de facto increase of production capacity(better utilization of process vessels and equipment)*Gradual operation of steam valves on the kettle will modulate demand on the boiler. Control of steam
use in wort boiling (programmable -logic controllers [PLC], personal computer [PC] applications) using
steam mass flow control will prevent energy wastage.
*Verification of the evaporation rate may reveal that evaporator is well in excess of the adequate
minimum (generally set by brewing researchers at between 6% to 8%) wasting energy and water.
* Volume-based rather than time-based control on burst rinses and CIP flows will reduce the volume ofwater used
* Reduction in boiling time (while still achieving the required evaporation rate) will give a corresponding
decrease in energy use.
*Recovery of high-grade heat from kettle vapor, using either spray condensers or heat exchangers (spiralor plate), has significant energy conservation potential. However, hot water balance in the brewery must
be carried out beforehand to determine best uses for recovered hot water. With the aid of PC or PLC, it ispossible to obtain optimum recovery of the highest-grade heat possible and storage utilization. Benefits
include energy savings, savings in water use and cost, and effluent cost savings. Heat recovery in thebrewhouse is often a key to mo re effective energy use in the entire brewers.
*Recovered heat from the kettle can be used for hot water preparation, as well as for preheating of wort
before boiling or with steam ejector or mechanical compressor for wort boiling.
*The brewery hot water line should be optimally based on recovered heat utilization rather than on
heating cold water with steam or electricity. To optimize it, hot water balance should be calculated for thewhole brewery.
*Using heat-recovered hot water for functions such as CIP, bottle washing, and sterilization should be
investigated. Hot water storage tank capacities should be calculated carefully to avoid hot water
overflows and sewering.
*Keeping refrigerated areas as dry as possible (avoiding hosing down surfaces) will significantly reduce
the refrigeration load.
*Optimizing CIP, the reduction and re-use of rinse water and a reduction in temperature of cleaning
solutions will bring about energy and water savings.

Ⅲ- 32

*Use of a low-pressure blower instead of high-pressure compressed air for conveying spent grains may be
more economical.

Packaging:*Insulate to economic thickness bottle washers and tunnel pasteurizers and steam and water pipes, valves,traps and the condensate system associated with their operation. Major savings in steam and water
consumption will ensue, with reduced requirements on the HVAC load in the packaging hall and an
improvement in the work environment.
*The (multiple) regenerative water circulation system in a pasteurizer requires optimum balancing.
Consider using a cooling tower for cooling water conditioning to bring additional energy and watersavings.
*Direct steam injection for heating water in pasteurizers and soakers results in loss of condensate.
*Heat from bottle washers and the bottle/can pasteurizer can be recovered.
*Water from soakers and pasteurizers can be recycled.
*Water from the filler vacuum pumps and cooling water from the baler hydraulic pumps can be recycled.
*Review brewery-specific pasteurization requirements to achieve safe minimu m pasteurization units(P.U.). The review may result in a reduction of an unnecessarily high P.U. and in energy savings.
*Installation of a heat recovery system from keg washer will save 40% of keg cleaning energy andrecovery 86% of heat required for heating incoming water.
*Use of low-pressure blowers, instead of air compressors, would enable tank pressurization during
emptying without the use of CO2 and without disturbing the protective blanket of CO2 atop the beer.
*Optimize the rinsing section in the bottle washer; check the sizing and positioning of the nozzles; and tie
the rinsing section function to the actual washer operation to avoid wasting water.
*Optimize packaging operations to achieve the best line efficiency possible. Line efficiency affects
energy consumption to a great extent. Inefficient production results in higher specific energy consumption
due to losses when the line is idle. Additionally, increased efficiency can result in a lesser number of shifts
required to package the same volume of beer.
*Conveyors running without a load waste electrical energy, lubricants and water; contribute to accelerated
wear and tear; and increase the power demand.
*Avoid using water hoses instead of brooms in areas where a broom and shovel will do a perfectly goodjob (e.g., on spilled solids such as spent grains; and on broken glass around fillers).

Ⅲ- 33

Attached data 2

Attachment 3

Seminar-Workshop Program
Seminar-Workshop Program

Ⅲ- 34

IV. Malaysia (Food industry)
1. Activity Overview
12/10: Training on audit technology for food factories
12/12: OJT aud it for D Food Industries (retort food)
12/13: ditto
12/14: Training on data analysis, reporting to D Food Industries
12/17: Seminar-workshop
2. OJT Audit of D Food Industries(1) Participants
D Food Industries , 5 persons (factory manager, 3 others)
PTM, 5 persons (Mr. Zairin, Mr. Phubalan, 3 other engineers)
ACE, 2 persons (Mr. Zamora, Mr. Ivan)
ECCJ, 3 persons (Mr. Hiroshi Kuroda, Mr. Koukichi Takeda,
Mr. Taichiro Kawase)(2) Outline of D Food Industries
Main product: retort food
Employee: over 100
Energy consumption: 350toe/year in 2006,
Production equipment: cooker, sterilizer, filling machine, dryer, packing
machine, freezer for production
Utility equipment: boiler (5t/h, 1unit), compressor (3 units), freezer for
preservation
Operation: operation in daytime only of weekday (weekend off)
(3) Contents of OJTLecture on food processes (retort processes, freezing, drying, sterilization)
Preparation for audit (team formation, preliminary questionnaire,confirmation for measuring instruments)
Data collectio n (collection of operation records, measurement work)
Data analysis (screening of energy conservation measures, engineering
calculation)
Reporting to D Food Industries (quick report)

Ⅳ- 1

(4) Energy Conservation Measures to be Reviewed①Production facilities
Cooker / Sterilizer
Heat insulation of non-insulated parts②Utility facilities
BoilerReduction of boiler air ratio
Enhancement of condensate recovery
Heat insulation of boiler outer surface
Freezing equipment
Energy saving for outdoor cold stores
Air compressors
Addition of receiver tank
Introduction of multiple compressors control
Change in aeration air supply method for water treatment
Decrease of intake air temperature

Ⅳ- 2

(5) Results of Audit (summary)
Please refer to attachments in this chapter regarding details on calculating grounds, etc
Energy Conservation Issues

Audit Results and Countermeasures

Energy Conservation Potential

Production Facilities(cooker/sterilizer)

Insulation of hot surface

Both cooker and sterilizer are not insulation. Surface Natural gas saving: 83,177m3N/ytemperatureisaround100-130℃.

Insulationusing

easy-to-attach plastic insulation material is recommended.
Utility Facilities(boiler)

Reduction in boiler air ratio

O2 content and temperature in exhausted gas were 9.4% andEnergysavingeffectwhen

194℃, respectively. To adjust air/fuel ratio, re-tuning of linkdecreasing O2 content to 4% :mechanism is necessary.

Natural gas saving 12.8m3N/h(reduction rate, 4%)(steam system)

Heat insulation of boiler hot

Surface temperature: front side 46-63℃; rear side 140℃. Natural gas saving 0.78 m3N/h.

surfaceInsulation of rear side is necessary.

Enhancement of condensate Present recovery rate of condensate is estimated as low as 17%,
recoveryRecovery of investment is within aand survey of condensate recovery is necessary in every steam year
consuming equipment.

(refrigeration)

Energy saving for outdoor Insulation is deteriorated (door seal, wall, refrigerant piping).
freezer

Energy saving effect of repairing

Heat invasion due to sunlight is reduced (sunshade, etc.); door seal insulation:
Rearrangement of packages is necessary in cold store; freezer power saving, 3,464kWh/yElimination of unnecessary heat generation is necessary in cold
store.

Ⅳ- 3

(air

Addition of receiver tankcompressor)

Unloading time is long (around 50% of day). Although

Energy saving effect: 6.2kW

addition of receiver tank was considered, energy saving
effect was low and investment recovery was difficult.
Adjustment of number of

To avoid operating 3 units all the time, number ofcompressor in operation

compressors in operation was adjusted by changing

Energy saving effect: 7.2kW

control method.
Decreaseof

temperature

intakeair Due to inappropriate location of suction, suction Energy saving effect: 1.5kW
temperature is as high as 44-56℃, resulting in energy
loss. Investment amount is a little.

(wastewater Change in aeration air Air pressure of 1.0bar is enough, instead of existing air

treatment)

supply method

Energy saving effect: 9.9kW

pressure (5.5bar). A roots-type blower is newly installed
to this end.

Energy Management
Introduction of In-house Constructing in- house DB in order to monitor data such Reference input format wasDB
as condensing temperature in refrigeration system , provided
which are helpful for energy efficient operations.

Ⅳ- 4

3. Seminar-Workshop(1) Participants: 34 persons
Malaysia (24 persons)
Mr. Ahmad Zairin (PTM)
Mr. Phubalan Karunakaran (PTM)
Ms. Norhasliza Mohd Mokhtar (PTM), others
ASEAN (5 persons)
Mr. Iswan Nurbaso (Ea stern Pearl Flour Mills, Indonesia)
Mr. Teodoro Elma (San Miguel Polo Brewery, Philippines)
Mr. Tivakorn Jongmekwamsuk(CP Retailing Marketing, Thailand),othersOthers (5 persons)
ACE
Dr. Weerawat, Mr. Christopher Zamora, Mr. Ivan Ismed
ECCJ Mr. Kawase, Mr. Kuroda(2) Outline of Presentation
1) “Japan’s Energy Conservation Policy and Activities of The Energy Conservation
Center, Japan (Mr. Taichiro Kawase: ECCJ)”
Mr. Kawase introduced Japan’s Energy Conservation Policy and activities of ECCJ.
Also referred to topics regarding harmony of 3E and energy conservation law,designated factories, energy manager system, national examinations, education andtraining, national convention on energy conservation successful cases, etc.
2) “Outline and Activities of the PROMEEC Project” (Mr.Weerawat Chantanakome:
ACE)
Mr.Weerawat introduced a position of ACE in ASEAN, major EE&C activities such
as EC-ASEAN, SOME-METI, etc., and PROMEEC activities. He also invited toparticipate in ASEAN energy award system, etc.
3) “Energy Conservation Measures in the Eastern Flour Mills” (Mr. Iswan Nurbaso:
Indonesia)
Mr. Iswan introduced a flour mill located in Makassar City, Sulawesi Island (former
Celebes), and producing 64,000 tons of flour per month. Its energy consumption is 5
million kWh of electric power per month and 55kL of fuel per month. Since electric

Ⅳ- 5

power occupies 99 percent of the total energy, the company has been coping withenergy saving, targeting unit consumption of electric power to be reduced less than
100kWh/ton.
The company has so far implemented such measures as power factor improvement,
inverter lightings, high efficiency motors, etc. Major measures in process or underplanning are as follows:
・ Transfer from pneumatic air transport to elevator transport (under way)・ Introduction of inverter for the purpose of energy saving during idling time・ Transfer from blower to fan
・ Automation of valve (under way)
・ Simplification of transport piping (removal of bend pipe part?)
・ Recovery of process exhaust heat for boiler water preheating
・ Effective use of surplus cold sources
4) “Outline of energy conservation measures in food factories” (Mr. Taichiro Kawase:
Japan ECCJ)
Due to a wide variety of products in food industry, it is inefficient to consider energy
saving measures product by product. Accordingly, examination of measures iscarried out for unit operations, for example, cleaning/washing, steam boiling,sterilizing/pasteurizing, cooling/freezing, preserving, which are popularly used infood industry. He explained energy conservation measures for drying andrefrigerating that consume energy most, in connection with theories of mass and heattransfer.
5) “Energy conservation measures in a beer brewery in San Miguel Polo Brewery” (Dr.
Teodoro Elma: Philippines)
San Miguel Polo Brewery was awarded second prize in the ASEAN energy
conservation award system last year. The following energy conservation measures
were rated high in selection committee.
・ Waste heat recovery of hot wort (for preheating both boiler feed water and sparge
water)・ Redesign for piping system (steam piping for boiler room, condensate recovery
piping, glycol piping, CO2 recovery piping, air compressor cooling piping)・ Introduction of high efficiency ammonia refrigerator and high efficiency air
compressor
・ Effective use of wastewater sludge digested gas (for boiler fuel)Ⅳ- 6

・ Introduction of variable speed control
・ Recovery of steam condensate
・ Improvement of automatic control system
6) “Energy conservation measures in the frozen food factory of CP Retailing &Marketing (Mr. Tivakorn: Thailand)This is a large scale food processing factory with 2,700 employees, producing 42
tons of frozen food a day, located in 60km northwest of Bangkok. They have been
putting a great deal of effort on energy conservation and awarded Thai Energy
Conservation Prize for 2007. The presentation was well prepared, and its
presentation technique with video show was excellent as well as its content.
66.7% of energy consumption is electric power purchased, and its 62% is consumed
for refrigeration, which is a typical consumption in a frozen food factory. Whilespecific consumption of electric power was targeted at a 10% decrease for 2006, theactual result was a 15.45% decrease. Of course, an electric power demand monitor isinstalled and a peak load is being watched. In the energy conservation activities, it isan honor student from a plenty of aspects. In view of energy management, textbook
menus such as policy, organization, education, SGA and information were all carriedout. He felt the company could be a model for other companies. Also in view ofenergy conservation technology, it classified measures into three steps andimplemented them without fail. Major measures are as follows:・Steady cleaning of heating coil in electric fryer (step 1)
・ Condensing unit with cooling pad (step 2)・ High efficiency electronic ballast (step 2)
・ Reinforcement of heaters for grilling harumaki dumpling (step 2)・ Integration of air compressors and number control (step 2)・ Temperature control of scalding equipment (step 2)・ Improvement of fermentation tank (step 2)
・ Time-scheduled control of air conditioner (step 2)・ Improvement of pork BBQ production process (step 3)・ Automation for harumaki dumpling forming process (step 3)
7) “Energy conservation measures in the glass factory of JG Glass Containers” (Mr.
Phubalan Karunakan: Malaysia)

Ⅳ- 7

JG Glass Containers was established in 1972 and has been producing 150tons ofglass containers for food, medicines, etc. a day. The 85% of energy is occupied byfuel for melting glass. The company’s specific consumption of fuel was 8.0GJ/ton
that was higher than the European and American level of 5.0GJ/ton. Audits had been
conducted three times in the past, and the following measures were carried out, andas a result, the specific consumption of fuel decreased to 5.7GJ/ton.
・ Reform of melting furnace (adding furnace control system)
・ Reform of annealing furnace
・ Conversion of fuel for annealing furnace
・ Reuse of cullet washing water (filter installed)
8) “Energy conservation measures in ready-to-eat lunch box factory” (Mr. Hiroshi
Kuroda: ECCJ)
Mr. Kuroda gave a presentation associated with ready-to-eat lunch box factory run byJapan’s large scale supermarket. Major operations of the factory are production of
cooked rice and ready-to-eat lunch box. The workplace is kept at low temperature forpreventing microbes’ growth. Products are stored in refrigerated store. More than halfof energy is electric power for refrigeration; the calculation method of refrigeratingload and examples of energy conservation measures were introduced in thispresentation. The following are examples of energy conservation measures:
・ Reduction of refrigeration load (minimization of floor washing water and 7
others)・ Evaporative cooler (air is cooled through evaporation of sprayed water)・ Ice thermal storage facility・ Air curtain (prevention of outdoor air intrusion)9) “Development and dissemination of energy management tools” (Mr. Ivan Ismed:
ACE)
An explanation concerning the purpose of Technical Directory (TD), preparation
method, formats, etc. and actual examples of TD sheets were made. In addition, asimilar explanation for in- house database was given.
10) “In-house Database input formats for food industry” (Mr. Taichiro Kawase: ECCJ)
The purpose, content, etc. of in-house database were explained, drawing an exampleof draft input format for food industry. The characteristic of in- house database is tocontain an important operation parameters and energy efficiency indices in addition

Ⅳ- 8

to production data, energy data and equipment data. These are used as an operation
guide toward energy efficient operation.
(3) Questions and Answers, and Comments:
Q: While Japan aims at one percent energy conservation per annum, is there any
penalty? (There is no penalty because it is a target for effort to be made)4. Comment and Advice
OJT Audit
1) Factory manager of D Food Industries expressed his gratitude, saying “So far I
have carried out a maintenance for equipment from the standpoints of production
and safety, I have never considered energy efficiency. I have become aware of thepoint of energy conservation in this opportunity. Thank you for offering me with aplenty of proposals.”
2) Mr. Zairin of PTM said, “In the reporting to factory, I learned measures inrefrigeration demand side concerning energy conservation of refrigeration system.
Inasmuch as I have so far heard only of energy conservation of refrigeration
supply side, it was a very good reference to us. ” The measures of demand side(refrigeration used side) seem an important target in the technology transfer
activities in the future.
3) When appealed that PTM’s cooperation was important for implementing the
proposed measures, Mr. Zairin promised that PTM would continue cooperation.
In connection with this issue, the factory and PTM requested the Japanese side togive a quantitative information on capital investment along with energy saving
amount. ECCJ experts replied that they would make an utmost effort to include
them in the final report.
4) It seems that there are many small and medium sized factories in Malaysia, suchas D Food Industries, which have not initiated any energy conservation
activities.

Ⅳ- 95) In this audit the audit team proposed effective measures for compressed air
system. It is largely owing to the excellent measurement service provided by
PTM with three power monitors. This success should be enjoyed in other ASEAN
countries. In order for that, it is helpful for ACE to purchase minimum- necessary
instruments and utilize them if demanded.
6) This time, ECCJ experts made a sufficient preparation in advance of OJT audit.
For example, they surveyed the present situation of energy conversation measures
in Japan by taking a look into domestic retort food factories. Thanks to these
efforts, they could propose heat insulation for cooker and pasteurizer, etc. withconfidence.
Seminar-Workshop
1) A variety of examples were presented by four ASEAN countries. All presentations
are dealing with instant food (RTE, ready to eat), on which information is difficult
to collect in internet or literatures. They could become a good reference for the
Malaysian participants. We would like to say thanks to the Malaysian focal pointand concerned ACE personnel for excellent preparation.
2) The presentation made by CP Retailing & Marketing (Thailand) was impressive ofboth contents and presentation skills. It is nearly on a par with the advanced
factory group of food sector in Japan. Although Thai’s domestic average value
seems to be still lower, it is realized that Thailand had at least some exemplary
students at home who can disseminate their technologies to other factories.
3) In the presentation of this seminar, we had several of good practices worthwhile ofregistration in ASEAN technical directory. In particular, the examples presented byIndonesia, the Philippines, Japan and Thailand are expected to be compiled in TD.
We would like ACE to do the job for implementation.

5. Attachments
1) Audit Report on D Food Industries

2) Seminar-Workshop Program

Ⅳ- 10

Attachment 1

Audit Report on D Food Industries

1. Audit Venue
D Food Industries
2. Audit Schedule
December 12, 2007 (Wednesday) 10:00 – 16:30
13, 2007 (Thursday) 10:00 – 11:30
14, 2007 (Friday) 10:00 – 12:00
3. Participants:
PTM (Malaysia Energy Conservation Center)
Mr. Ahmad Zairin Ismail (Deputy Director)
Mr. Phubalan Karunakaran (Program Manager, Industrial Energy Efficiency)
Mr. Nor Hisham Sabran (Technical Assistant)
Mr. Mohd Ibrahim Bachik (Energy Engineer)
Ms. Norazean Mohd. Nor (Technical Assistant)
ACE (ASEAN Energy Center)
Mr. Christopher G. Zamora (Administration & Finance Manager)
Mr. Junianto M (Technical Expert)
ECCJ (Japan Energy Conservation Center)
Mr. Hiroshi Kuroda
Mr. Koukichi Takeda
Mr. Taichiro Kawase
4. Factory Responder
Mr. M (General Manager)
Mr. H (Senior Engineering Executive)
Mr. S (Factory Manager), others
Total: 5 persons
5. Outline of D Food International
General Information
Operation : started in 1988
Product : retort food of Brahims brandⅣ- 11

Employees : over 100
Energy consumption: 350 toe/year (2006)
Location : vicinity to PTM (several hundreds of meter distant)
Production Facilities/Production Capacity
Cooker: 400kg kettle x 8 units
Pasteurizer: Retort equipment (hot water storage type, made in Japan)
Filling machine: 4 units made in Japan, addition of 1 unit scheduled
Refrigeration equipment: Freezer/refrigerator for indoor storage x 4 units,
freezer/refrigerator for outdoor storage x 4 units
Utility Facilities
Boiler: 1 unit for production and 1 unit for outdoor storage
Boiler for production: Installed in 1987, 2 pass smoke-tube type, natural gas
burning, capacity 4.5t/h, steam pressure (rating 12bar,normal 8-10bar)
Air compressor: 3 units
Refrigerator: Installed individually in each freezer/refrigerator
Energy Consumption (2006)
Natural gas: 114,048 Nm3/y (unit price 0.5 RM/Nm3 )Electric power: 925,056 kWh/y (unit price 0.29 RM/kWh)
Energy Conservation Activities

Not implemented yet, while implementing activities for environment and safety,
they have not carried out energy conservation activities.
6. Survey for Production Facilities
6-1 Cooker/Pasteurizer
Both cooker and pasteurizer were not thermally insulated. It makes bad working
environment with high temperature of the room. Surface temperature ranges inaround 100-130℃. Heat insulation contributes not only to energy conservation but toimprovement in working environment. Addition of insulation is strongly
recommended because high energy saving potential is forecasted and insulation is
implemented on these equipment in Japan.

Ⅳ- 12

According to a person in charge, the equipment supplier did not recommended
insulation, although the reason is not clear. Since pasteurizer was repeatedly usedfrom high temperature pasteurization to following rapid cooling, there is a risk ofrepetitive stress fatigue. We recommended them to consult the supplier one more time.
According to comments by the Japanese supplier, “While no insulation is made on
delivery, there are heat insulated cases according to customers’ request. In accordancewith a type of pasteurizer, there are many cases not to be insulated for the part where
many accessories and measuring instruments are attached complicatedly, ” they say.

Hot water storage tankpasteurizer (autoclave)(1) Energy Saving Effect by Insulation of Pasteurizer Hot Surface
The pasteurizer is composed of the part of hot water storage tank and the part ofautoclave. Heat loss of hot water storage tank is calculated. The following equations
are applied for calculation of heat loss;
Q = Qn + Qe
Qn = [hc x (Ta – To)0.25 ] x (Ta – To) x A (W)
Qe = 5.68 x εx {[(273+Ta)/100]4 – [(273+To)/100]4 } x A(W)
Here, Q: Heat loss from hot surface (W)Qn: Heat loss by convection from hot surface (W)Qe: Heat loss by radiation from hot surface (W)Ta: Surface temperature (℃)
To: Temperature of outside air (℃)
A: Surface area (m2)

Ⅳ- 13

hc: Surface heat-transfer coefficient (W/m2K), use 2.56
ε: Emissivity(-) use 0.95 (stainless 0.35)
Outside air temperature 35℃ (dry bulb temperature)
Surface temperature: 120℃ (before insulation), 40℃ (after insulation)
Heat loss before insulation (suffix is 1)
Qn1 = [hc x (Ta – To)0.25] x (Ta – To)= 2.56 x (120 -35) 0.25 x (120 – 35) = 660.7 W/m2
Qe1 = 5.68 x ε x {[(273+Ta)/100]4 – [(273+To)/100]4= 5.68 x 0.35 x {[(273+120)/100]4 – [(273+35) /100]4 }= 295.2 W/m2h
Q1 = Qn1 + Qe1 = 660.7 + 295.2 = 945.9 W/m2
Heat loss after insulation (suffix is 2)
Qn2 = hc x (TA –To)0.25] x (Ta – To)= 2.56 x (35 – 30) 0.25 x (35 – 30) = 19.1 W/m2
Qe2 = 5.68 x ε x {[273+Ta/100]4 – [(273+To)/100] 4 }= 5. 68 x 0.35 x {[(273+35)/100]4 – [(273+30/100)] 4 }= 11.3 W/m2
Q2 = Qn1 + Qe1 = 19.1 + 11.3 = 30.4 W/m2
Energy saving effect by insulation
Dimension of hot water storage tank (estimation): L 5m x D 1.2m
Surface area: 5 x (3.14 x 1.2) = 18.8m2(surface area of two heads is not included, however insulation is recommended)
Reduction of heat loss: ΔQ = (945.9 – 30.4) x18.8 = 17,211 W
Pasteurizer operation: 16 batches/day, heating time: 40min/batch

Ⅳ- 14

Annual heating time: 40/60h/batch x 16 batch/d x 250d/y =2668h/y
Boiler efficiency: 85%
Natural gas low heating value: H1 = 43.96MJ/m3 N
Annual reduction of heat loss:
17,211W/m2 x 18.8m2 x 2668h/y= 863.2 x 106 Wh/y = 863.2 x 103 kWh/y = 3,108 x 103 MJ/yAnnual natural gas saving: 3,108 x 103 MJ/y / 0.85 / 43.96 = 83,177 m3N/y(2) Comment on heat insulation work
In order to make insulation work easy, we recommend to first insulate the part of hot
water storage tank. As for the autoclave, insulation should be made for the part where
insulation work is not difficult. In addition, not- insulated parts of cooker and hot
water piping should also be insulated. In general, economical justification is expected
when the surface temperature is 50℃ or higher. As an insulation material, thepaste-type plastic insulation material such as heat resistant polyurethane is usedpreferably for hot surface with less than 140℃. The paste-type is simple to work andcheap in price. An example of the insulation work are shown in the following photo.
Please refer to manufacturers’ websites. For the autoclave, insulation work should be
carried out carefully because many accessories are attached.

7. Survey of Utility Facilities

Ⅳ- 15

7-1 Reduction of Boiler Air Ratio
Though exhaust gas temperature ranges relatively high as 187 to 208℃, it seems that
installation of air pre- heater is difficult to be economically justified under the present
condition of low operation load and long duration of off-operation.
Boiler operating condition
Boiler steam pressure:
Fuel consumption rate:
Exhaust gas O2:
Exhaust gas temperature:

8-10kg/cm2 (on-off control)
320 m3 N/h (Dec. 13, 2007)
9.4%
194℃

Energy Saving Effect
The measured value of O2 content in exhaust gas was 9.4%. When natural gas isburned, generally O2 content can be decreased to as low as 4%. Re-tuning of
mechanical link is necessary before changing the air ratio. It is safer to ask the boiler
manufacturer to re-tune, rather than to do by yourself.
Low heating value of natural gas: H1 = 43,96MJ/m3N
Present air ratio: m = 21/(21-9.4) = 1.82
Theoretical air rate: A0 = 0.268 x H1 = 0.268 x 43.96 = 11.78 m3 N/m3 N
Theoretical exhaust air rate: G0 = 0.293 x H1 = 0.293 x 43.96 = 12.88 m3 N/m3 N
Actual exhaust gas rate: G = G0 + (m – 1) x A0
= 12.88 + (1.82 – 1) x 11.78 = 22.54 m3 N/m3 N
7.213 m3 N/h
Air ratio after improvement: m = 1.2 (responding to O2% = 4%)
Actual exhaust gas rate: G = G0 + (m – 1) x A0
= 12.88 + (1.20 – 1) x 11.78 = 15.24 m3 N/m3 N
4.877 m3 N/h
Fuel saving :Precondition of calculation:
Exhaust gas temperature: 200℃
Exhaust gas specific heat: 1.306 kJ/ m3 NK
Outside air temperature: 30℃
Natural gas saving rate Ox m3 N/h:{[(320 – Ox) m3 N/h/320m3 N/h] x (7.213 – 4.877) m3 N/h

Ⅳ- 16

+ Ox m3 N/h/320m3 N/h x 7,213m3 N/h} x 1.306kJ/ m3 N･K
x (200 – 30)℃ = 43.96MJ/m3 N x 103 x Ox m3 N/h
Ox = 12.8m3 N/h
Saving effect: 12.8m3 N/h / 320m3 N/h = 0.04 (4%)
7-2 Strengthening of Condensate Recovery
In order to estimate the condensate recovery rate in the entire factory, heat balance
was examined around the boiler water supply tank. As a result, the recovery rate ofcondensate was calculated to approximately 17%. To increase the recovery rate, allsteam-consuming equipment should be individually inspected concerning an
opportunity of condensate recovery. Cooperation with PTM is strongly
recommended.
Calculation of Condensate Recovery Rate
As shown in the following figure, Soft water and condensate return from the factory
enter into the boiler water supply tank, while boiler feed water leaves. Temperaturesof the surfaces are measured as follows;
Soft water line: 29℃
Condensate return line: 66℃
Boiler feed water line: 35℃
If condensate recovery rate is R, the following formula is set up.
(1 – R) x 29 + R x 66 = 1 x 35
R = 0.17, therefore, recovery rate is 17%.

1-R
Soft waterR
condensate

Boiler water supplytank1
Boiler watersupplyThere are two types of condensate, clean and dirty. The clean condensate is acondensate generated from the steam used for indirect heating. It does not contact
directly with process fluid, and becomes an object of recovery into the boiler water
tank.

Ⅳ- 17

7-3 Heat Insulation of Boiler Hot Surface
The surface temperature of not- insulated rear side (exhaust side) was 140℃. A
paste-type plastic insulation material is recommended because surface temperature ofboiler rear side is below 140℃. The front side (burning side) and shell are insulated,
and the surface temperature ranged from 43℃ to 63℃. No more insulation isnecessary for the front side and shell.
☆Calculation of heat loss from boiler hot surface
Front side
Location(burner side)

Rear side(exhaust gas side)

Shell

Area, A (m2 )

3

25

4.9

Measured temperature
Ta (℃)

61

51

139

Ambient
To (℃)

30

30

30

temperature

Equation
Heat loss (present)hc(naturalconvection)ε(emissivity)

Qn = [hc x (Ta –To)0.25] x (Ta – To) x A (W)

Qn (W)Qe (W)
Qn + Qe (W)

562
650
1212

2877
3495
6372

4418
5390
9808

kW/h
MJ/h
(MJ/m2 h)

1.2
4.36(1.45)

6.4
22.94(0.92)

9.8
36.31(7.21)

2.56

2.56

2.56
4

Qe = 5.68 xεx {[(273+Ta)/100] - [(273+TO)/100]4 } x A(W)
0.95
0.95
0.95
(painted surface)(painted sur face) (painted surface)Heat loss(after insulation)

Qn (W)Qe (W)
Qn + Qe (W)

94
151
245

kWh/h
MJ/h

0.245
0.9

Ⅳ- 18

Fuel
savingNaturalsavinggas= 35.3-0.9= 34.4/43.96

34.4
0.78

m3N /h

7-4 Energy Conservation for Outdoor Freezer/Refrigerator
Inasmuch as audit permission was not provided for refrigeration equipment inproduction area, only the outdoor refrigeration equipment was investigated, which iscomprised of four container-type cold stores. The size of one cold store is 5m length
x 3m height x 2m width, and each store is equipped with an individual condensing
unit.
Findings and Energy Saving Measures
Insulation and door seal were severely deteriorated. The low temperature with around
8℃ was observed in the joint part of foundation/wall and the vicinity of door seal.
Moreover, the surface of wall, which not exposed to wind, was wetting with a dew
condensed. The surface temperature seemed to reach a dew point. As the progress indegradation of insulation is anticipated, a repair for insulation is necessary.
It was observed that the temperature of wall surface rose to 45 to 57℃ undersunshine in particular on the south and east sides. We recommended to install
sunshades to the south and east sides. A simple sunshade is satisfactorily used ,forexample, like a bamboo blind.
The insulation of cold piping around condensing unit was severely damaged andwetted deeply with water. Early repair for insulation, in particular, cold refrigerant
piping is required.
There is a room of improvement in the package stacking in the cold store. The
packages were stacked without clearance among packages. In order to accelerate heattransfer from cold air to packages, reasonable clearances should be provided.
Otherwise, it takes long time to cool up to the prescribed temperature.
From the standpoint of energy conservation, it is important to minimize the heatgeneration in the cold stores. The room lighting should be turned off when closing. in

Ⅳ- 19

addition, the inside fan should be a two-speed type, and run in the low speed orturned off when it is unnecessary.
Energy Saving Possibility for Outdoor Freezer

Ⅳ- 20

Calculation of Energy Saving Effect
In the first step, calculate the reduction of heat input entering into the cold store (ΔQ , namely refrigeration load). In the second step, calculate the power saving in
refrigeration compressor ( Δ P). Power saving is calculated by the following
equation:
ΔP =ΔQ +ΔQ /COP
The first term of the right side is a saving corresponding to reduction ofrefrigeration load, and the second term is a saving of compressor power
accompanied by the reduction of refrigeration load. The approximate value of COP
can be given by dividing the COP value shown in the following figure by thecompressor efficiency. 80% is typically used as compressor efficiency.

Condensing temperature
air cooling: air temperature + 10℃
water cooling: water temperature + 5℃

COP
Evaporating temperature = cold store temperature – 5℃

Ⅳ- 21

Repair of Insulation of Door Seal Part
Equations for heat loss from hot surface can be used approximately for low
temperature surface.
Q = Qn + Qe
Qn = [hc x (Ta – To)0.25 ] x (Ta – To) x A (W)
Qe = 5.68 x ex {[(273+Ta)/100]4 – [(273+To)/100]4 } x A(W)
Here, Q: Heat loss from hot surface (W)Qn: Heat loss by convection from hot surface (W)Qe: Heat loss by radiation from hot surface (W)Ta: Surface temperature (? )To: Temperature of outdoor air (? )A: Surface area (m2)
hc: Surface heat-transfer coefficient (W/m2K), use 2.56
e: Emissivity(-) use 0.95 (stainless 0.35)
In the door seal part of cold store, surface temperature was 8? and much lower than
the temperature of outdoor air of 29? . Normal repair work of insulation can easily
improve the surface temperature toward outdoor air temperature. In the following
calculation, it is assumed that wall temperature becomes 2? lower than outdoor air
temperature.
Outdoor air condition : 29? (dry bulb temperature) & 75% (relative humidity)
External surface temperature: 21? (before repair) & 27? (after repair)Heat loss before insulation repair
Qn1 = hc×(Ta ‐ T0)0.25]×(Ta ‐ T0)= 2.56 x (29 – 21) 0.25 x (29 – 21) = 34.4 W/m2
Qe1 = 5.68×e×{[(273+Ta)/100]4 - [(273+T0)/100]4 }= 5.68×0.95×{[(273+29)/100]4 - [(273+21)/100]4 }= 45.7 W/m2
Q1 = Qn1 + Qe1 = 34.4 + 45.7 = 80.1 W/m2
Heat loss after insulation repair
Qn2 = hc×(Ta ‐ T0)0.25 ]×(Ta ‐ T0)= 2.56 x (29 – 27) 0.25 x (29 – 27) = 6.1 W/m2

Ⅳ- 22

Qe2 = 5.68×e×{[(273+Ta)/100]4 - [(273+T0)/100]4 }= 5.68×0.95×{[(273+29)/100]4 - [(273+27)/100]4 }= 11.7 W/m2
Q2 = Qn2 + Qe2 = 6.1 + 11.7 = 17.8 W/m2
Energy saving effect by insulation repair
Insulation repair area
1 m2/store x 4 store = 4 m2
Reduction of refrigeration load ⊿Q = 80.1 – 17.8 = 62.3 W/m2
Cold store temperature -20℃ ?
Evaporating temperature -25℃
Outdoor air temperature 29℃ ?
Condensing temperature 39℃
COP (excl compressor efficiency)
1.7
Reduction of compressor power ⊿P = ⊿Q + ⊿Q / COP= 62.3 + 62.3/1.7 = 98.9 W/m2h= 866 kWh/m2y
Old store (４room total)（4m2） = 866 x 4 = 3,464 kWh/yⅣ- 23

7-5 Energy Saving in Air Compressors
Outline of Compressed Air System
Information concerning compressed air system was not provided. Based on name-plateinformation and interview with factory engineers, we obtained the following outline ofcompressed air system.

Compressed air supply flow chart
Factory

Research bldg.
Air compressor room

Air compressor specification and load/unload conditions

Load/unload conditions: Load 0.55MPa, unload 0.75MPa
Start/stop: Manual
Load atstart/stop
0.55 MPa,by control
Unloadpanel
at 0.75
in workshop
MPaStart & stop : manual on local panel

Ⅳ- 24

Data Collection of Compressed Air System
In order to grasp the load distribution and distribution of load/unload, power
consumption of three air compressor motors were measured by PTM engineers.
Measurement was implemented for nineteen hours with one minute interval byusing three portable-type power monitors.
Measurement of electric power and time

Note: Measurement interval (1 min.), AC1, AC2: actual power
AC3: Calculated value (1.7321 x (A1 + A2 + A3)/3 x 436 x 0.7/1000[kW])Load distribution when operating 3 units

Loading & unloading when operating 1 unit

Review on Measured Data
Load factor of 3 air compressors ranges from 48.5 to 50.1% and compressed air
system has relatively wide allowance. Nevertheless, all 3 compressors are always
operated except for nights and holidays.

Ⅳ- 25

Air compressor is operated in unloading mode during 49.9-51.5% of one day.
Power usage during unloading time is completely wasted energy.
Number of air compressors in operation is the following; 1 compressor (AC1)
operation: 63.0%, 2 compressors (AC1,AC3) operation: 24.5%, and 3 compressors(AC1,AC3,AC2) operation: 5.6%.
3 compressors operation continues for as short as 1-7 minutes, and irregularly.
One compressor (AC2) is operated even in night time and on weekend/holidays
during which about 14.4kW of electricity is consumed for aeration of the activatedsludge unit in the wastewater treatment facility.
Power Consumption during Unloading Operation
Power for load operation = 39.67x0.490+14.70x0.501+20.19x0.485 = 36.59[kW]Power for unload operation = 17.11x0.510+7.41x0.499+11.91×0.515 = 18.56[kW]Total kW0 = 36.6+18.6 =55.2[kW]Unloading power ratio: 18.6/55.2 = 0.337 (33.7%)
Energy Conservation Measures for Reducing Unloading Operation
In order to reduce unloading operation which is a major source of energy loss, thefollowing 4 measures are considered.
・ Addition of receiver tank・ Change in pressure control system (adjustment of number of operating
compressors)
・ Change of aeration air supply method in the activated sludge unit
・ Reduction of intake air temperature
Reduction of Unloading Loss by Addition of Receiver Tanks, etc.
3 compressors operation occupies only 5.6% of total time, and continues only inseveral minutes. Accordingly peak shaving is effective like receiver tank. When
receiver tank is installed, 2 compressors (AC1 and AC3) are normally operated,while AC2 is standing-by.
Energy saving effect (kW1 ) is estimated to be about 6.15[kW] as shown below;
kW1 = (39.67 x 0.79 + 20.19 x 0.26) + (17.11 x 0.21 + 11.91 x 0.74)= 36.6 + 12.4 = 49.0[kW]Ⅳ- 26

Unload power ratio: 12.4/49.0 = 0.25 (25%)
Power saving: ΔkW = kW0 – kW1 = 55.2 – 49.0 = 6.2[kW]about 11% energy saving
Power saving of 6.15[kW] seems too small to justify an installation of new receiver
5[m3 ] .
For the reference, rough calculation of receiver tank capacity is shown below;
V = R/(ΔP x 104 ) x ΔQ x t x 1.293 x 273.16
Provided that
R: gas constant 2.987, γ[kg/m3]: air density at temperature :T[K]γ=1.293 x 273.16/T
ΔP[MPa]: unload pressure – load pressure
ΔQ[m3 ]: air volume supplied from tank for t[min]AC2 delivery capacity: 2.424[m3 /min]
ΔP = 0.75-0.55=0.2[MPa]t = 2[min],
ΔQ = 2.424[m3 /min] x 2[min] = 4.848[m3 ]V = 2.987/(0.2 x 104 ) x 4.848 x 2 x 1.293 x 273.16 = 5.11 ≒ 5[m3 ]Change in Pressure Control System
Considering that order of operation time is AC1, AC3, AC2, this order is mostefficient from the standpoint of energy efficiency. In this case, AC1 is a base load
compressor.
If the allowable frequency of start-stop in the electric motor is assumed to within
10 times per hour, percentage of stoppable times in AC2 and AC3 arerespectively about 80% and about30%.
Accordingly, kW2 of this case is as follows:
kW2 = (39.67x0.49+14.7x0.2+20.19x0.7)+ (17.11 x 0.23 + 7.41 x 0.95 x 0.2 + 11.91 x 0.74 x 0.7)
= 36.5 + 11.5 = 48.0[kW]Unloading power ratio: 11.5/48.0 = 0.24 (24%)
Power saving: ΔkW = kW0 – kW2 = 55.2 – 48.0 = 7.2[kW]About 13% energy saving

Ⅳ- 27

Change of aeration air supply method in the activated sludge unit
The activated sludge unit is operated for 24 hours, and compressed air with 5-7
bar(g) is provided as aeration air. However pressure requirement for aeration is
only 1 bar(g) because liquid height of aeration tank is several meters. We
proposed to change air supply from air compressor to new air blower with about
one bar(g) of discharge pressure.
Energy saving effect is given as a difference of power decrease in air compressor
and power increase of new air blower as shown below;☆Power decrease of air compressor
Currently, power required for supplying compressed air to the activated sludge
unit is about 14.4kW. If this air supply is replaced by blower air supply, it
becomes feasible to stop one compressor (AC2), while 2 compressors operation(AC1, AC3) continue to be operated. Load factors of AC1 and AC3 become
respectively about 54% and about 8%. Power consumption in this case (kW3 )becomes as follows;
kW3 = (36.5 – 14.4) + (17.11 x 0.46 + 7.41 x 0 + 11.91 x 0.92)= 22.1 + 18.8 = 40.9[kW]Unloading power ratio: 18.8/40.9 = 0.46 (46%)
Power saving : ΔkW = kW0 – kW3 = 55.2 -40.9 = 14.3[kW]about 26% energy saving☆Power increase of new air blower
Required power of air compressor is estimated by the following equation;
L = k/(k-1) x (Ps x Qs)/0.06 x [(Pd/Ps)^{(k-1)/k} - 1] /?
k ： ratio of specific heat of air (1.4 at 15℃)
Ps ：suction pressure (MPa)
Pd ：discharge pressure (MPa）Qs ：air rate（m3/min）? ：compressor efficiency (usually 0.8)
Assuming air is ideal gas, Ps x Qs is constant value. This is approximately applied
to both air compressor and blower.

Ⅳ- 28

Considering liquid depth of aeration tankis about 6m and control margin of airpressure control is 4m, blower discharge pressure is assumed to be 0.1 MPa(g),compared to 0.55MPa(g) of existing compressed air pressure.
L1 = 14.4
L2/L1 = [(Pd/Ps)^{(k-1)/k} - 1]2 / [(Pd/Ps)^{(k-1)/k} - 1]1= [((0.1 + 0.1)/0.1)^{(1.4-1)/1.4} - 1] / [((0.55 +0.1)/0.1)^{(1.4-1)/1.4} - 1]
= 0.219 / 0.708 = 0.31
L2 = 14.4 x 0.31 = 4.5 kW⊿L = 14.4 – 4.5 = 9.9 kW
Annual power saving: 9.9kW x 8,760 = 86,724 kWh
It is reminded that Activated sludge unit is run day and night throughout the year.

Reduction of Intake Air Temperature☆Measurement of air temperature☆Calculation for compressor power reduction rate

Power requirement of air compression is approximately proportional to absolutetemperature at the suction condition. Therefore intake-air temperature should be as
low as possible. According to measurement data shown in the above figure, suction
temperatures of AC2 and AC2 are very high compared to AC1. When suction
temperature is lowered to 30? , energy saving effect is estimated in the following;

Ⅳ- 29

AC2: {(273+56)-(273+30) / (273+56) = 26/329 = 0.079

AC3: {(273+44)-(273+30) / (273+44) = 14/317 = 0.044
kW4 = 55.2 - (14.70 x 0.501 + 7.41 x 0.499) x 0.079- (20.19 x 0.485 + 11.91 x 0.515) x 0.044 = 55.2 – 1.5 = 53.7 [kW]Power saving rate?kW = kW0 – kW4 = 1.5[kW]about 3% energy saving

8. Energy Management
It turned out in this audit that D Food Industries has not carried out any energy saving
activities so far. In the meeting of reporting audit result, one of factory management
told to realize how wastefully they used energy, and to start an energy conservation
activity from now on. We emphasized an importance of energy management such as
daily housekeeping and timely maintenance of equipment and facilities. Before taking
technological measures accompanying capital investment, we advised to start from thefollowing activities as a first step.
･ Declaration of energy management policy with written document･ Appointment of person responsible for energy management･ Collection, recording and analysis of energy-related data
･ Target setting for goal of energy conservation activity･ Employee’s awareness to energy conservation through education, etc

Ⅳ- 30

9. Results of audit
Please refer to attachments in this chapter regarding details on calculating grounds, etc
Energy Conservation Issues

Audit Results and Countermeasures

Energy Conservation Potentia lBoth cooker and sterilizer are not insulation. Surface

Natural gas saving: 83,177m3N/y

Production Facilities(cooker/sterilizer)

Insulation of hot surface

temperatureisaround100-130℃.

Insulationusing

easy-to-attach plastic insulation material is recommended.
Utility Facilities(boiler)

Reduction in boiler air ratio

O2 content and temperature in exhausted gas were 9.4% andEnergysavingeffectwhen

194℃, respectively. To adjust air/fuel ratio, re-tuning of linkdecreasing O2 content to 4% :mechanism is necessary.

Natural gas saving 12.8m3N/h(reduction rate, 4%)(steam system)

Heat insulation of boiler hot

Surface temperature: front side 46-63℃; rear side 140℃. Natural gas saving 0.78 m3N/h.

surfaceInsulation of rear side is necessary.

Enhancement of condensate Present recovery rate of condensate is estimated as low as 17%,
recoveryRecovery of investment is within aand survey of condensate recovery is necessary in every steam year
consuming equipment.

(refrigeration)

Energy saving for outdoor Insulation is deteriorated (door seal, wall, refrigerant piping).
freezer

Energy saving effect of repairing

Heat invasion due to sunlight is reduced (sunshade, etc.); door seal insulation:
Rearrangement of packages is necessary in cold store; freezer power saving, 3,464kWh/yElimination of unnecessary heat generation is necessary in cold
store.

Ⅳ- 31

(air

Addition of receiver tankcompressor)

Unloading time is long (around 50% of day). Although

Energy saving effect: 6.2kW

addition of receiver tank was considered, energy saving
effect was low and investment recovery was difficult.
Adjustment of number of

To avoid operating 3 units all the time, number ofcompressor in operation

compressors in operation was adjusted by changing

Energy saving effect: 7.2kW

control method.
Decreaseof

temperature

intakeair Due to inappropriate location of suction, suction Energy saving effect: 1.5kW
temperature is as high as 44-56℃, resulting in energy
loss. Investment amount is a little.

(wastewater Change in aeration air Air pressure of 1.0bar is enough, instead of existing air

treatment)

supply method

Energy saving effect: 9.9kW

pressure (5.5bar). A roots-type blower is newly installed
to this end.

Energy Management
Introduction of In-house Constructing in- house DB in order to monitor data such Reference input format wasDB
as condensing temperature in refrigeration system , provided
which are helpful for energy efficient operatio ns.

Ⅳ- 32Attachment 2

Seminar-Workshop Program

Ⅳ- 33

V. Thailand (Steel and Textile Industries)
1. Activity Overview
December, 2007
19 (Wednesday) Seminar-Workshop
20 (Thursday)
Bangkok steel follow-up surveys
2. Seminar-Workshop(1) Participants: 86 persons
Thailand (77 persons)
Mr. Thammayot Srichuai (Deputy Director General, DEDE)
Mr. Yosapong Khupthaboot (Head of Energy Regulatory in Building,
DEDE)
Mr. Sarat Prakobchart (Senior Engineer, DEDE)
Many persons from private industries (textile, steel industries, etc)
ASEAN (4 persons)
Mr. Maximino Marques (DOE, Philippines)
Mr. Purnomo (Bhineka Karya Manunggal, Indonesia)
Mr. Phan Nguyen Vinh (ECC-HCMC, Vietnam)
Dr. Nguyen Van Tuyen (ECC-HCMC, Vietnam)
Others (5 persons)
ACE: 3 (Dr. Weerawat, Mr. Ivan, Ms. Evangeline)
ECCJ: 2 (Mr. Kawase, Mr.Tanaka)(2) Outline of Presentations
1) “Outline and Activities of PROMEEC Project” (Ms. Evangeline: ACE)
She introduced major EE&C activities such as the position of ACE in ASEAN, thePROMEEC activities as well as the activities of EC-ASEAN and SOME-METI.
Also she invited to participate in the ASEAN award system, etc.
2) “The energy conservation promotion scheme and activities of the Thailand Energy
Ministry ” (Mr. Yosapong Khupthaboot: DEDE, Thailand)
Concerning energy situation in Thailand, Mr. Yosapong reported that energyⅤ- 1consumption increased 5% per annum for the past 5 years, industry andtransportation are major consumption sectors, the energy cost occupied a 17% of
GDP in 2006, petroleum occupied 88% of the energy cost and its import dependency
was 63%.
With regard to energy conservation activities, major activities of DEDE were
responsible for standards and regulations, technical assistance, financial incentives,
information service and awareness raising. In the field of technical assistance, there
are self- effort promotion of energy conservation by industry, improvement on SEC
in the fields of industry and building, demonstration of new technologies, promotionof ESCO business. In self- help promotion by industry, house-keeping type activities
were implemented in around 2000 facilities. As financial incentives, instruments
such as revolving fund and tax reduction were mobilized. Tax reduction is applied
for tax reduction for energy conservatio n investment, tax deduction for realizedenergy saving, tax exemption for imported facilities. In the field of information
service, there are, for instance, publication of handbook and guideline, e- learning
program, energy clinic service and energy display center.
3) “Energy Conservation Measures in the Steel Industry and Experiences in
PROMEEC ” (Mr. Hideyuki Tanaka: ECCJ, Japan)
Mr. Tanaka mentioned technologies adopted since 1985, and explained energy
conservation effect of DHCR and regenerative burner which have recently become
widespread showing successful examples. He also explained a process and energy
efficiency of shaft furnaces adopted in Japan. He reviewed audits of steel factories
performed in PROMEEC activity, drawing examples of Thailand and thePhilippines.
4) “Development of Electric Furnace Operational Technology in Thailand ”(Dr. Kritsada Prapakorn: MTEC, Thailand)
Researchers of MTEC presented their study of energy conservation technology ofelectric furnace by stabilization of slag- foaming. It was reported that development ofelectric-arc stabilization detector, effect of slag composition, and maximization ofchemical energy ratio are investigated in order to stabilize slag- foaming. Moreover,development of neural system and expert system with respect to electric furnace
operation is carried out.
5) “Energy Conservation Measures in a Steel Factory in the Philippines” (Mr. Marquez:

Ⅴ- 2

DOE, the Philippines)
Mr. Marquez explained an activity implemented in steel factory which is located insouth Luzon, the Philippines, and produces galvanized steel sheet and coil of 3.5
million ton per year. Energy management team was organized, which comprises ofmanagement- level leader and several staffs. The team proposed and implemented
various energy conservation measures steadily. Most of them were very common
measures such as variable speed control of motors, conversion to high efficient
motors, reduction of boiler air ratio, and conversion to high-efficiency lamps. As aresult of activity, great energy saving was achieved, for example, fuel oil 52kL/y,
LPG 2,596 ton/y, and electricity 6.58 million kWh/y.
6) “Energy Conservation Measures in the Textile Industry and Experiences in
PROMEEC ” (Mr. Taichiro Kawase: ECCJ, Japan)
Mr. Kawase overviewed major energy conservation measures in the textile industry,
and introduced actual audit cases including exhaust heat recovery from hot waste(dyeing) and from dryer exhaust gas (textile dryer) experienced in Japan and theASEAN region. In addition, he reported specific energy consumption data in theJapanese textile industry, concerning fuel, electricity and water. He explained an
importance of monitoring energy efficiency indicators, and asked to establish an
in- house database system as a guide for energy-efficient operation of equipment andfacilities..
7) “Case Study of Energy Conservation Measures in a Textile Factory in Indonesia” (Mr.
Purnomo: Bhineka Karya Manunggal, Indonesia)
Mr. Purnomo explained an activity implemented in textile factory which is locatedin west Jawa, Indonesia, and produces cotton/polyester-based textile products. The
factory is so called integrated textile factory, which covers from spinning and dyeing,
to weaving. Production capacity is spinning 400 ton/month, weaving 1.4 million
yard/month, dyeing 1.1 million yard/month, and printing 0.2 million yard/monthrespectively. A cost reduction program (CRP) was planned, and a project team wasorganized with Mr. Purnomo as its leader. It started its activities in 2003. Most ofenergy conservation measures are concentrated in utility facilities.
･ Applying inverters to twenty-eight motors of spinning instruments･ Attaching roof windows to some buildings for utilizing daylight･ Downsizing of surface aeration motor of activated sludge unit
･ Shortening of steam pipes

･ Periodic cleaning of condensers and evaporators of air-conditioning system
8) “Case Study of Energy Conservation Measures in a Textile Factory in Vietnam” (Mr.
Phan Nguyen Vinh: ECC-HCMC, Vietnam)Ⅴ- 3
Mr. Phan Nguyen Vinh reported the result of energy audit implemented in Vietnam
last October. The audit was projected for the OJT as one of the PROMEEC activity,and Mr. Phan served as a leader of the audit team. The venue of the OJT audit wasThanh Cong Textile and Garment located in Ho Chi Minh City, which was anintegrated textile manufacturing factory. This large factory has 4,600 employees andits production capacity is 22,500 ton/year and energy consumption approximately
20,000kL/year. The audit team proposed several energy conservation measuresconcerning high-pressure batch dyer, continuous textile dryer and boilers. According
to him, some of measures proposed in the audit have just started.
9) “Development and Dissemination of Energy Management Tools ” (Mr. Ivan Ismed:
ACE)
In the PROMEEC activity, development of energy management tools was projected,
such as Technical Directory (TD), Energy management guideline (GL) and in- house
database (IHDB). Mr. Ivan explained the purpose, input form and actual examples
concerning the TD. Furthermore, he explained the progress in development of the
IHDB using a draft input form prepared for the cement industry. Included are
information necessary for factory energy management, for example, raw material
and product, energy consumption, equipment and facilities, and key processparameters and energy efficiency indicators.
10) “In-house DB Input Format for the Textile Industry” (Mr. Taichiro Kawase, ECCJ,
Japan)
Mr. Kawase explained about newly-drafted input form targeting for textile factory.
He asked the participants of seminar to apply the new form to their factories,emphasizing that the IHDB is useful as a tool for promoting energy conservation in
the factory.
(3) Questions and Answers
Q: Why is thermal efficiency of regenerative burner higher than conventional
recuperator? How deep does regenerative burner penetrated into reheating furnaces andⅤ- 4ladle furnaces in Japan? How long is an investment recovery?
A: Mr. Tanaka gave a detailed answer using cases of NEDO demonstration project.
Judging that such fundamental questions are raised, it seems that regenerative burners
are not widely known in Thailand.
Q: What is a barrier in implementing energy conservation measures in the textile
industry in the Philippines?
A: Support of factory top management is most important.
Q: Does heat insulation of batch dyer hot surface have any adverse effect on equipment
or operation?
A: Any adverse news is not reported in spite of numerous application cases in Japan.
Q: The audit manual prepared for textile factories is very interesting. Can I have themanual?
A: The manual has now been developing in the FTI/JETRO cooperation project. You
are asked the more in detail to FTI/IIE.
Q: Can I have information on energy consumption in the textile processes in Japan?
A: Recent data was not available because most jobs in the textile industry has shifted toChina, etc. Regretfully, data in the today’s presentation were given 10 years ago by theJapan Textile Finishers’ Association.
(4) Comments and Advice
1) More than fifty persons participated in the seminar, most of whom came from theindustries including iron and steel, and textile. It was successful six presentations
were made by other ASEAN countries and Japan. Energy conservation activities
presented by Mr.Yo sapong (DEDE), were worth listening, because each activity
Thailand implemented could become a leading model for other ASEAN countries.
Question and answer session was so active. We can evaluate this seminar had asuccess more than expected. The achievement owes much to careful planning andpreparation by Mr. Sarat, a substitute focal point, and others.
2) Some successful cases, which were presented in the seminar, are worth registering in
the technical directory. In particular, some cases of the Philippines and Indonesia

Ⅴ- 5should be registered. I would like to ask ACE to do so.
3) “Research on energy conservation technologies of electric furnace by improving
slag-foam stabilization” was introduced by Thailand researcher. Although this theme isimportant for energy conservation operation, it may deviate a little from the scope of
PROMEEC project. It is reminded that the purpose of PROMEEC is establishment ofenergy management system and its dissemination.
3. Follow-up Survey of B Steel Industry(1) Participants
BSI: 10 persons (Mr. Somchai, manufacturing manager, and nine engineers)
DEDE: 4 persons (Mr. Sarat and three engineers)
ACE: 2 persons (Mr. Ivan and Ms. Evangeline)
ECCJ: 2 persons (Mr. Tanaka and Mr. Kawase)(2) Overview of Factory
The factory is located in the southern coast of the Gulf of Thailand, the 30
kilometers south-southeast of Bangkok. Rolling mill operation started in 1964
and electric furnace operation started in 1973.
Major facilities:
Two electric furnaces with capacity of 25 ton/batch (annual capacity 300,000 t/y),
two continuous casting machines, two continuous heating furnaces, two rollingmills,
Production:
steel bar: 450,000 t/y, galvanized steel sheet: 130,000 t/y
Employees: 600(3) Follow-up Results
There was an explanation from the factory concerning the implementation statusof measures suggested in the audit of the previous year.
1) Heat Insulation of Wall Surfaces of Continuous Heating Furnace
Heat insulation has not been implemented so far, due to delay of permission
from the factory management. According to the factory, energy saving effect ofheat insulation was estimated by the Iron and Steel Institute of Thailand (ISIT).

Ⅴ- 6

Desirably calculation of heat insulation effect had better be done by engineers of
the factory.
2) Heat Loss at Exit Opening of Continuous Heating Furnace
It was suggested in the previous audit to install an insulating cover at an exit
opening. However, this has not been implemented. Prompt implementation is
expected as it is easy to install and has a short investment recovery time. The
furnace pressure was adjusted as suggested in the previous audit. It is now +0.4mm
WC (water column) at a hearth position, while it was negative pressure in theprevious audit. As a result, aspiration of cool air decreased, and also hot gas
blowing was not observed around the exit opening.
3) Heat Insulation of LD Pre-heater
Heat insulation has fully been implemented. Specific energy consumption of LD
furnace decreased from 5.32 litter/ton to 5.05 litter/ton.
4) Measures which have been implemented by the company’s own initiative
The most effective measure was energy conservation by increasing EAF supply
voltage. Voltage on the secondary side was increased by adjusting the tap locationof primary transformer. As a result, processing time per batch was reduced and heatradiation loss was reduced, resulting in saving of electricity and diesel oil.
(4) Comments and advice
1) In the previous audit, most of suggestions belonged to operational improvement,
however they are not implemented as expected. One reason of low implementationis that report of the previous audit had not reach the factory. In the PROMEEC
project, audit report is prepared by ECCJ, and then distributed to factory throughACE and focal point in each country. At the same time audit report is disclosed on
the home page of ACE. It may be one of solutions for ECCJ to unofficially send a
draft report to factory, in parallel with the formal ACE route mentioned above.
2) There was a question about what is appropriate for an insulating material. T here wasa question of how and where to open a sampling hole with respect to measurementof the oxygen content in the continuous heating furnace. These are very basic
knowledge for all engineers of industries including iron and steel industry to learn.

Ⅴ- 7

It shows a lack of basic knowledge of engineers, and more education is necessary.

3) The BSI are developing energy-conservation-related technologies in cooperation withMTEC (supervised by the Ministry of Science and Technology) and the Thailand
Institute of Iron and Steel, etc. Development themes are “stabilization technology of
EAF slag formation” and “tundish preheating technology”. It is expected that
understanding of process principles concerning electric furnace and heating furnace
is deepened through the process of technology development. It will contribute to theproper implementation of energy conservation measures mentioned in 1) and 2),
and other measures.

4. Discussion with Focal Point on PROMEEC Industry Project
ECCJ experts and Thai focal point including DEDE engineers exchanged opinions on
the role of Thailand in the PROMEEC industry project. The following is major content:(ECCJ) Thailand has accumulated a number of technologies and experiences in both
energy conservation technologies and energy management, and is a step ahead of other
ASEAN countries. We think it is a time now to disseminate the accumulated knowledge
experiences to other ASEAN countries. For example, Dispatching Thai engineers to
OJT audit activities in other countries and to carry out measurements are expected.
(DEDE) There is a cooperation program called ACMECS consisting of countries in the
Mekong basin. Please refer to the website of the Thai Foreign Ministry for details. It ismainly funded by Thailand. It may be possible to invite engineers from other countries
and hold a seminar in a training center under DEDE (Note: this training center isdifferent from the training center of person responsible for energy (PRE) of Thailand).
(ECCJ) In the beginning, there was a request from the Thai focal point that they want tocarry out production process-related audit in the glass factory. In the end, consideringthat process-specific energy conservation measures are beyond the scope of the
PROMEEC project, audit of the glass factory had to be given up. We explained thatprocess-specific technologies are under the NEDO’s jurisdiction.
(DEDE) We understood the aim of the PROMEEC project in the discussion.

Ⅴ- 8

(ECCJ) We heard that “All Participation Project” completed successfully. What was the
problem found?
(DEDE) In reality, there is a problem of sustainability. In the factory audit, almost all
the jobs were conducted substantially by the dispatched outside experts. After they ha vegone, its activities have stopped in many factories. In order to raise sustainability wethink that EM H/B is helpful in maintaining sustainability. (note:EM H/B is energy
management handbook, which was provided in the other Thai/Japan cooperation
project)(ECCJ) The OJT audit of this project was also carried out by ECCJ experts in reality. It
is not sustainable as long as ECCJ experts do. We hope that an audit is carried out by ahost nation’s initiative, but there is not a good idea. In the PROMEEC activity in
Vietnam, engineers from the ECC-HCMC participated in the OJT audit. In the
PROMEEC activity in Malaysia, engineers from the PTM participated in the OJT audit.
We believe it contributes to increase sustainability if those engineers would participate
in the next OJT audits with self- help efforts.
(ECCJ) Based on discussions today, we expect you to disclose opinions concerning thefuture role of Thailand in PROMEEC activities and achievement of after-projectsustainability at the next post-workshop or the inception workshop.

Ⅴ- 9Attachment 1

Seminar-Workshop Program

Ⅴ- 10

Ⅴ- 11

VI. Summary & Post-Workshop
1. Overview of Workshop
Focal points from nine countries except Myanmar, representatives of ACE and ECCJ,
and twenty-two persons from the host country participated in the workshop.
We frankly exchanged views and discussed on achievements and evaluation of thephase 2 of the PROMEEC project, including evaluation on activities of this year,
following the discussion on how to direct the phase 3 activity. As a result, we had theconclusion that (1) many achievements were made through steady implementation, and(2) dissemination of energy conservation technologies were transferred in the phase 2,(3) further efforts for improvement are required in order to achieve a goal targeted in thephase 2. Furthermore, based on the conclusion, a consensus was formed by participants
concerning future initiatives including a basic implementation plan for next year.
According to the consensus, individual proposals which each country plans in FY2009
will be submitted by the first week in May from each focal point to ACE as done lastyear. Then, these proposals will be reviewed at ECCJ-ACE to form an implementation
plan, which will be finalized at the inception workshop scheduled to be held in earlyJuly this year.
(1) Summary & Post Workshop
February 26 (Tuesday) ~ 27 (Wednesday), 2008
Hotel Salak the Heritage, Bogor
J1. Ir. H. Juanda No.8, Bogor-16121, Indonesia(2) Participants
The total of 22 persons participated in the workshops. Fifteen were from ten
ASEAN countries, four from ACE, and three from ECCJ.
Representatives of ASEAN countries: 9 persons
Mr. Sarat Prakobchat (DEDE, MOE, Thailand, workshop chairman)
Mr. Amir Sharrifudin (Prime Minister’s Office, Burnei)
Mr. Lien Vuthy (Head of Energy Efficiency & Standard Office, MINE,
Cambodia)Ⅵ- 1

Ms. Indarti (Head of EC Division, MEMR, Indonesia )Mr. Khamso Kouphokham (Chief of Administration Division, MEM, Lao PDR)
Ms. Norhasliza Mohd Mokhtar (Program Manager, PTM, Malaysia )Mr. Jesus C. Anunciacion (Chief Science Research Specialist, DOE, Philippines)
Mr. Abdul Rashid B. Ibrahim (Deputy Director, EMA, Singapore)
Mr. Phuong Hoang Kim (Official on Energy and Environment, MOIT, Vietnam)
ACE : 6 persons
Dr. Weerawat Chantanakome (Executive Director)
Mr. Christopher Zamora (Administration and Finance Manager)
Mr. Ivan Ismed (Project Officer)
Ms. Maureen C. Balamiento (Database and IT Specialist)
Mr. Junianto M. (IT Staff)
Ms. A. Desita Ekaputri (Statistics & Database Specialist)
Other representatives from Indonesia (DGEEU and ACE): 4 persons
ECCJ: 3 persons
Mr. Kazuhiko Yoshida (General Manager)
Mr. Yoshitaka Ushio (General Manager)
Mr. Hideyuki Tanaka (Technical Expert)
2. Summary of FY2007 Activities and Policy of FY2008 Activities
The followings were reported from countries which implemented activities in FY2007.
Please refer to the other chapters concerning each country’s activities for details. Then,
ECCJ explained policy of FY2008 activities, and they were acknowledged by allparticipants.
Country and industry
sub-sector

Achievement and evaluation

Policy of FY2008

Vietnam (textile)
the Philippines (food)
Malaysia (food)Thailand (steel)

1. Local audit team wasorganized in three countries.
They actively performed
OJT audit and deepened abasic understanding on theprocess.
2. Seminar-workshop was
implemented aiming at

Proposals of FY2008 activities
will be selected based on thefollowing standpoints (policy):
1. Enhanced OJT- organization of local audit
team- preparation before OJT audit(replytopre-survey

Ⅵ- 2disseminationofachievements.
Activediscussions were made.
3.
Thirty-five
goodpractices
were
newly
registered in TD anddisclosed on the ACE
website. Contents of the
IIHDB
were discussed
concerning food and textile
fields,andACE
isformulating it in line withthe discussion.
4. Points of Improvement- As for participants fromother countries, not only the
number but also theindustrial sub-sector should
be considered.
- Works for improvement
and formulation of TD and
IHDB should be speededup.

questionnaire)- Countries where above twopoints are guaranteed.
2. Strengthening of basic
knowledge on the process
principle
3. Energy management tools- actual application in 3
sub-sectors (cement, textile,food)
And formulation of IHDBs foriron & steel sector, etc- Enhancement of TD
4. Duration of activity in eachcountry- maximum 7 working days
- 4 working days in case ofenergy audit at one location- 2 working days in case offollow-up survey at one
location- 1 working day in case of
seminar workshop.
5. Priority of selection- maximum 3 countries- countries which were notvisited this year.

3. Evaluation of Phase 2 Activities and Basic Policies for Phase 3(1) Evaluation of Phase 2 Activities
Activities in the Phase 2 were completed as planned, and the results were accumulated
as achievements. In particular, significant progress has been made that consciousness
about the importance and effectiveness of energy conservation has been strengthenedin the concerned parties throughout ASEAN countries. In addition, various tools andⅥ- 3

information systems were developed and disseminated for the purpose of sharing
information and experiences accumulated in the PROMEEC project.
However, there is still room remaining for improvement from the standpoint of project
aims of the Phase 2 such as establishment of self- help efforts and dissemination oftechnological experiences to the whole nation. In particular, future leaders and trainers,
who are target persons of the OJT training, are not trained in a systematic way.
Moreover, there are no projects planned in which they are made maximum use of, or no
education and dissemination by themselves are not implemented now. There are nopolicy supports including financial support for assisting their activities. As for follow-up
survey of the cooperative factories and establishment of energy management tools,
support to ACE by each country is insufficient. This is a big problem againstsustainability of the PROMEEC project.
(2) Basic Policies for Phase 3
In order to start the Phase 3, the above- mentioned issues need to be improved first of all.
Activities of FY2008 should be carried out, considering these issues into consideration.
It is important to choose activities to be strengthened and to clarify barriers against
these activities and to eliminate them.
1) National policy measures for expanding achievements of the Phase 2 with self- help
efforts. A bilateral cooperation with an advanced country including Japan may beconsidered if necessary.
2) Regional cooperation among ASEAN countries on the basis of mutual cooperation.
3) Selection of activities to be strengthened with clear criteria.
4) Collaboration among three projects in the award system (e.g. Focal Point – BOJ(Building) member – BOJ (EM) member)5) Quantification of goals and results, and visualization of achievements for the
purpose of quantitative evaluation.
Based on the above- mentioned discussions, a basic plan was confirmed and agreed.
First priority is given to effort for improving the current activities toward the Phase 3. It
is confirmed that selection of activities to be concentrated on, and strengthening of thecollaboration among three projects and setting of a quantitative target are important.

Ⅵ- 4