Download Energy efficiency benchmarking study of food manufacturing plants

Strategic Energy Management For Resilience
Energy efficiency benchmarking
study of food manufacturing plants
in Singapore
Dr Jahangeer K Abdul Halim
06 October 2015
1
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
Energy consumption by fuel type

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.
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
Chillers

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
Typical Improvement Measures
Chilled Water & Condenser Water Pumps

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
Typical Improvement Measures
Cooling Towers

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
Typical Improvement Measures
Boiler Systems

Use of economisers

Re-insulation of boiler surface

Optimization of boiler auxiliary equipment

Condensate recovery

Replacing leaking steam traps

Boiler combustion fine tuning
Typical Improvement Measures
Compressed Air Systems

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
Typical Improvement Measures
Lighting

Use of energy efficient lighting

Use of occupancy sensors

Switching off of light when not in use

De-lamping where applicable
Typical Improvement Measures
Motors

Replacing with high efficiency motors

Improving motor loading by replacing with smaller motors

Use of VSDs for variable load applications
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
THANK YOU
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