energy efficiency benchmarking study of food manufacturing … 2015... · 2018-10-02 · food...
TRANSCRIPT
Strategic Energy Management For Resilience
1
Energy efficiency benchmarking
study of food manufacturing plants
in SingaporeDr Jahangeer K Abdul Halim
06 October 2015
Agenda
Introduction to Company
Food Manufacturing Benchmarking Study
Typical Equipment / Systems
Typical Efficiencies
Potential Improvement Measures
Conclusions
Introduction to Company
Leading Energy Services Companies in Asia with offices
in Singapore, Malaysia, Sri Lanka and operations in
many other countries
Accredited by NEA and other overseas certifying bodies
Team led by Dr Lal Jayamaha the first KQP (key
qualified person) and first BCA Registered Energy
Auditor to be registered in Singapore
Experienced in all types of facilities having completed
more than 80 projects (commercial buildings, hotels,
hospitals, industrial plant, wafer FABS)
Consultancy Team
Certified Energy Managers (SCEMs)
KQP / QuESS
Energy Auditors
Green Mark Professional
Green Mark Managers
LEED APs
GBI Facilitators
Professional Engineer
Energy Modeling & Simulation Expertise
Main Services
Energy Audits
Design & Energy Consultancy
Energy Retrofits
Consultancy for GREET
BCA Green Mark
Consultancy for LEED
Training in Energy Management
Food Manufacturing Benchmarking Study
Food manufacturing is one of the energy intensive
industries in Singapore
To improve the energy efficiency of food manufacturing
plants
– There is a need to develop a better understanding of the various
major energy-consuming equipment/systems
– Identify suitable benchmarks to assess the current level of
efficiency of these plants
– Such benchmarks will help food manufacturing plants quantify
energy efficiency gaps
– Focus management attention on areas that will generate the
biggest savings
Food Manufacturing Benchmarking Study
In early 2015, LJ Energy Pte Ltd was appointed by
National Environment Agency (NEA) to conduct an
Energy Efficiency Benchmarking Study of Food
Manufacturing Plants in Singapore
The benchmarking study covers ten food manufacturing
plants, out of which, eight of the plants would have a
minimum energy consumption of 30 TJ per year
The benchmarking study is in progress and as of now
study on four plants have been completed
Food Manufacturing Benchmarking Study
The main objectives of the study are to:
a) Develop an energy consumption profile of the food
manufacturing industry by studying the major systems
and equipment of each participating Plant
b) Identify suitable metrics to assess and benchmark the
energy efficiency of major systems and equipment
c) Assess and benchmark the energy efficiency of major
systems and equipment of participating Plants
d) Identify effective measures to improve the energy
efficiency of major systems and equipment, taking into
account factors such as implementation feasibility and
cost
Typical Energy Consumption Details
The percentage breakdown of fuel and electricity usage
by a typical food manufacturing company
The percentages are based on kWh units, with natural
gas/diesel derived based on equivalent energy content in
terms of kWh at 10.77 kWh/Litres.
Energy consumption by fuel type
Typical Energy Consumption Details
The approximate breakdown of electricity usage by the
different end-users.
Energy consumption breakdown
Typical Equipment / Systems
Chillers
Pumps
Cooling Towers
Refrigeration Systems
Process Cooling Systems
Boilers
Air Compressors
Lighting
Packing Machines
Mills & Grinders
Typical Efficiencies of Equipment /Systems
Chillers
Measured chiller Coefficient of Performance (COP)
ranged from 4.4 to 5.1
The benchmark COP for typical operating temperatures is
in the range of 5.8 to 6.4
Typical Efficiencies of Equipment /Systems
Measured typical chiller COP
Typical Efficiencies of Equipment /Systems
Chilled Water and Condenser Water Pumps
Measured specific energy consumption (SEC) of chilled
water pump ranged from 0.017 to 0.02 kWe/kWc
The benchmark specific power consumption is about
0.014 kWe/kWc
Typical Efficiencies of Equipment /Systems
Cooling Towers
Measured specific energy consumption of cooling tower
ranged from 0.014 to 0.017 kWe/kWc
The benchmark specific energy consumption is about
0.009 kWe/kWc
Typical Efficiencies of Equipment /Systems
Refrigeration Systems
Measured efficiency (COP) of cold room refrigeration
systems ranged from 1.4 to 4.4
The benchmark COP for refrigeration systems (water
cooled) are:
– 1.8 for -35oC
– 2.9 for -20oC
– 4.3 for -5oC
Typical Efficiencies of Equipment /Systems
Process Cooling Systems
Measured specific energy consumption of process
cooling system (cooling tower + pump) is found to be
about 0.28 kWe/kWc
The benchmark specific energy consumption for similar
systems is 0.017 to 0.025 kWe/kWc
Typical Efficiencies of Equipment /Systems
Boilers
Measured average boiler efficiency is about 80%
The benchmark boiler efficiency is in the range of 77 to
82%
Typical Efficiencies of Equipment /Systems
Air Compressors
Measured specific power consumption of compressed
air is found to range between 138 to 150 W/CMH
The benchmark specific power consumption in the
similar manufacturing plants is in the range of 80 to 120
W/CMH
Typical Efficiencies of Equipment /Systems
Lighting
Measured lighting power density ranged from 15 to 20
W/m2
Benchmark values (from SS 530) for similar applications
is 10 to 15 W/m2
Illuminance levels are generally in compliance with SS
531
Typical Improvement Measures
Chilled Water Temperature Reset
Loading of chillers to optimise operating efficiency
Improving condenser water supply temperature
Reducing condenser approach temperature
Chiller replacement for older chillers
Chillers
Typical Improvement Measures
Reduction of system pressure drop by removing
throttling
Reducing flow rate where there is excess flow
Installing VSDs and varying flow based on demand
Replacement of pumps with better efficiency pumps
Chilled Water & Condenser Water Pumps
Typical Improvement Measures
Repairing defective cooling towers
Using VSDs to vary fan speed based on load
Operating additional cooling towers where available
Reducing water flow rate to design value
Cooling Towers
Typical Improvement Measures
Use of economisers
Re-insulation of boiler surface
Optimization of boiler auxiliary equipment
Condensate recovery
Replacing leaking steam traps
Boiler combustion fine tuning
Boiler Systems
Typical Improvement Measures
Lowering of compressed air pressure
Elimination of leaks
Better loading of operating compressors
Use of VSD compressors for variable load applications
Use of externally heated dryers
Replacement of old compressors
Compressed Air Systems
Typical Improvement Measures
Use of energy efficient lighting
Use of occupancy sensors
Switching off of light when not in use
De-lamping where applicable
Lighting
Typical Improvement Measures
Replacing with high efficiency motors
Improving motor loading by replacing with smaller motors
Use of VSDs for variable load applications
Motors
Conclusions
The study to establish the energy consumption profile
and benchmarking of performance of the various energy
consuming systems in food manufacturing plants is in
progress
Major energy consuming systems that have been
identified are boilers, chillers, refrigeration plants and
motors
Operating efficiency of the major consuming equipment
are been established and are compared with benchmark
values
Potential saving measures are identified for improving
the efficiency of the various systems
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