Industrial Parks Development Corporation (IPDC)

Energy Study and Supply Department

Preliminary Energy Audit Report of Adama Industrial Park
ZLD plant

First Draft

May, 2023
Energy Study and Supply Department
 I. Executive Summary
 Electricity is the major energy source to the plant and the electrical energy consumption
from Tir 2015 to Ginbot 2015 E.C. is 7278.9 MWh and the current minimum production
is 232 m3/day and maximum production is 1,172 m3/day.
 The actual plant specific energy consumption of AIP ZLD is average 28 kwh/m3. But by
design the specific energy consumption of the plant is 20.8 kwh/m3.
 Increase the production or reduce energy consumption, currently the plant working
capacity is around 10% and all motors and pumps which controlled by DOL and Star Delta
is working under capacity, and it consume more energy for low production. Therefore, we
must maximize the production or reduce energy consumption by using load scheduling
method.
 The maximum demand charge is very high, we must reduce this charge by adjusting and
maintaining the plant operation also, we have to discus with EEU about MD charge.
 During the site visit, boiler, MEE, and RO is not working. the details are shown in the table
below.

N Findings Action to be taken Estimated Energy saving Investment

o. Energy Saving (birr) cost
(MWh/year) (birr)
1 Heat loss /no insulation of 98.957 118,056 birr/year The material is
steam pipe from boiler to The bare pipe must be available in
steam header insulated contractor stock
Heat loss /no insulation of The bare pipe must be 31.475 37,550 birr/year
steam header insulated
Heat loss /no insulation of The bare pipe must be 306.977 366,224 birr/year
steam pipe from steam insulated
header to MEE#2
2 High maximum demand Adjust and maintain - No cost
(MD) charge proper operation of the
plant and reduce
multiplication factor
for both energy
meter with
discussion EEU
3 SCADA is not working in It could be functional - - No cost/
ZLD system communicating
with contractor
4 Equalization transfer Install VFD controlling 7,884 Depend on working -
pump is working under system hours one million
load and above birr/year
5 Heat loss in steam valve Steam valve must be - - -
and flange jacketed by insulation

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II. Table of Content

I. Executive Summary .............................................................................................................1

II. Table of Content ..................................................................................................................2
1.0 Introduction ......................................................................................................................3
1.1. Objective ......................................................................................................................4
1.2. Methodology.................................................................................................................4
2.0 Plant overview ..................................................................................................................4
3.0 Energy Consumption Profile .............................................................................................7
3.1. Energy Description .......................................................................................................7
3.2. Production profile ....................................................................................................... 10
3.3. Energy vs production Graph ........................................................................................ 11
3.4. Energy Baseline and KPIS .......................................................................................... 12
4.0 Energy Saving Potential Opportunity .............................................................................. 13
4.1. Identified Area Where the Energy Waste/Lost ............................................................. 13
4.3. Estimated Energy Saving ............................................................................................ 24
4.4. Implementation Plan ................................................................................................... 25
5.0 Recommendation and Conclusion ................................................................................... 26

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 1.0 Introduction
The full working capacity of the AIP ZLD plant is 11,000m3/day of which 3,000m3/day is for
domestic wastes and 8,000 m3/day is for industries wastes. Therefore, the WWTP is comprised of
Common Effluent Treatment Plant (CETP) and Effluent Treatment Plant (ETP). To operate the
WWTP to its full design capacity, seven oil type transformers (33 KV/0.4 KV) with a capacity of
3000 KVA each are installed. Now this treatment plant is working under its design capacity from
232 m3/day - 1172 m3/day and the specific power consumption is average 28 kwh. The plant has
different facilities like Boiler, ETP, STP, MEE, MBR+RO but MEE and RO are not working
during the assessment period.
We made walkthrough audit and we have seen energy is lost in different section like, steam header,
steam distribution line, different rating of pumps and motors.
The main system of ETP consist of following equipment for treating effluent-
 Receiving chamber
 Grit screen chamber
 Equalization Tank
 Primary Clarifier and Dosing System
 Aeration System
 Secondary Clarifier
 Tertiary tank
 Clean water tank
 Sludge Dewatering
 Centrifuge
The main system of STP consist of following equipment for treating sewage-
 Receiving tank
 Screening and De-gritting
 Sequential Batch Reactor
 Filter feed tank
 Multigrade Filter
 Sludge Dewatering
 Centrifuge
 Sewage treated tank.

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1.1. Objective
The main objective of this audit is to maintain optimum energy utilization and
reducing energy consumption without affecting production and quality. Also analyze
the present use of energy in the plant and to improve the energy performance of the
plant.

The specific objective of this energy audit is: -

 To calculate specific energy consumption (energy usage per production).

 To improve the efficiency of boiler.
 To identify steam leakage.
 To analyze the efficiency of motor and system losses in distribution line.
 To improve the compressor and pump efficiency by identifying its leakage
and loss.
 To identify energy saving area potential and recommendation.
 To achieve and maintain optimum energy utilization.

1.2. Methodology
 First, we made short meetings with plant manager and section head
discussion about energy audit and what we want.
 Field visit to each process section of the ZLD plant.
 Interviews has been made with plant manager, senior expert,
electricians, operators.
 Data were collected such as, energy consumptions and production
of the last 20 months.

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 General Energy Audit Methodology
Energy Audit can be classified into the following two types.
i) Preliminary Audit
ii) Detailed Audit

Preliminary Audit
Preliminary energy audit is a relatively quick exercise to:
 Establish energy consumption trends in the organization.
 Estimate the possible saving opportunity.
 Identify the most likely (and the easiest areas for attention) for plausible saving potential.
 Identify immediate (especially no-/low-cost) improvements/ savings.
 Set a ‘reference point’ for basic energy consumption and production.
 Identify areas for more detailed study/measurement.
 Collecting Preliminary energy audit existing, or easily obtained data, such us energy bills,
operational hours, energy consumption trends, property of fuels used, types of fuels used,
stoppage and shutdown histories, etc.

Detailed Energy Audit

Under the detailed energy audit, detailed energy project implementation plan for a facility, it
evaluates all major energy consuming systems.

This type of audit offers the most accurate estimate of energy savings and cost. It considers the
interactive effects of all projects, accounts for the energy use of all major equipment, and includes
detailed energy cost saving calculations and project costs.

In a comprehensive audit, one of the key elements is the energy balance. This is based on an
inventory of energy using systems, assumptions of current operating conditions and calculations
of energy use. This estimated use is then compared to utility bill charges.
Detailed energy auditing is carried out in three phases: Phase I, II and III.

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  Phase I - Pre-Audit Phase
 Phase II - Audit Phase
 Phase III - Post Audit Phase
Under this project, we have followed these basic and standard steps.

Step PLAN OF ACTION PURPOSE/RESULTS

No
Step 1 Phase I-Pre-Audit Phase
 Plan and organize  Resource planning,
 Walk through Audit Establish/organize Energy audit team
 Informal Interview with  Organize Instruments &time frame
Energy Manager  Macro Data collection (Suitable to
Production/Plant Manager type of industry).
 Familiarization of
process/plant activities
 First hand observation& Assessment
ofcurrent level operation and practices
Step2 Conduct of brief  Building up cooperation
meeting/Awareness program with  Issue questionnaire for each
all divisional heads and persons department
concerned (2-3hrs)  Orientation, awareness creation
Step 3 Phase II-Audit Phase  Historic data analysis, Baseline
 Primary data gathering, data collection
Process Flow Diagram,  Preprocess flow charts
&Energy Utility  All service utilities system diagram
Diagram (Example: Single line power
distributiondiagram, water, compressed
air & steam distribution.
 Design, operating data and schedule of
operation
 Annual Energy Bill and energy
consumption pattern (Refer manual, log
sheet, name plate, interview)
Step 4  Conduct survey  Measurements:
and monitoring Motor survey, Insulation, and
Lighting survey with portable
instruments for collection of more
and accurate data. Confirm and
compare operating data with design
data

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Step 5  Conduct of detailed  Trials/experiments:
trials/experiments for selected  24 hours power monitoring
energy guzzlers (MD, PF, kWh etc)
 Load variations trends in pumps,
fan compressors etc
 Boiler/Efficiency trials for (4-8
hours)
 Furnace Efficiency trials
Equipment’s Performance
experiments etc
Step6  Analysis of energy use  Energy and Material balance& energy
loss/waste analysis
Step 7  Identification and development  Identification & Consolidation ENCON
of EnergyConservation measures
(ENCON) opportunities  Conceive, develop, and refine ideas.
 Review the previous ideas suggested by
unit personal.
 Review the previous ideas suggested by
energy audit if any.
 Use brainstorming and value analysis
techniques.
 Contact vendors for new/efficient
technology
Step 8  Cost benefit analysis  Assess technical feasibility, economic
viability, and prioritization of ENCON
options for implementation.
 Select the most promising projects.
 Prioritize by low, medium, long-term
measures

Step 9  Reporting &Presentation to the Top  Documentation, Report Presentation to the

Management top Management
Step Phase III-Post Audit phase Assist and Implement ENCON recommendation
10  Implementation and Follow- measures and monitor the performance.
up  Action plan, Schedule for
implementation
 Follow-p and periodic review

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 2.0 Plant overview

ZLD plant at Adama Industrial Park consists of two main parts: Effluent Treatment Plant (ETP)
and Sewage Treatment Plant (STP) and design capacity,
 Effluent water treatment Plant is 8 MLD, 8000 m³/day.
 Sewage water treatment Plant is 3 MLD 3000 m³/day
Amount of Actual Wastewater Treated

The total productions form Tir 2015 to Ginbote 2014 E.C are as follows:

Final Output Amount Remarks

Treated Wastewater 262,057 m3

Data collected from the facility
(ETP+STP)

The major process consequences of the process of Effluent Treatment Plant (ETP) and sewage
treatment plant are shown below figure-

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 Color removal Coagulant

PAC
air air

Primary dosing

Aeration
Stilling Fine Grit Equalization Primary
Flash
chamber screen chamber clarifier
mixer

Wet well

Returned sludge
Sludge Secondary
thickener Sludge clarifier
sump1 &2
Coarse bar
screen

Tertiary
ETP receiving chamber Hardness
tank/polishing unit
Sludge removal
Decanter

Clear water tank

Raw influent
Hypochlorite

Sludge DMFs
Indicators: storage UF

o Normal water MEE

Salt
o Treated water and back wash water RO 1, 2
o Process flow &3
o Sludge process Treated water tank
o Filtrate to reuse for
production

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3.0 Energy Consumption Profile
3.1. Energy Description

Adama ZLD Plant receives electricity from Ethiopian electric utility 33 KVA and step dawn

to 400V by seven distribution transformers of different capacity of rating and distribute to

different section of the plant as shown below.

Location Rating of transformer

Electric Boiler No 1 3000KVA

Electric Boiler No 2 3000KVA

Electric Boiler No 3 3000KVA

ETP 3000KVA*2

STP 3000KVA

Other facility 3000 KVA

Total 16.8 MW

Table 1 Total Power

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 The energy assessment of Adama ZLD plant has been conducted to identify the potential of

energy savings. The plant major energy consumption is electricity. We collect energy data as

shown below table.

Months ZLD Boiler ZLD Process Total Production Specific
meter reading meter reading Energy Energy
m3)
(KWh) Consumption
Megabit 2015 - 120,120 120,120 15,872 7.57

Yekatit 2015 - 92,400 92,400 16,879 5.47

Tir 2015 595,320 347,160 942,480 32,703 28.82

Tahisas 2015 1,186,680 443,520 1,630,200 29,442 55.37

Hidar 2015 691,680 294,360 986,040 22,920 43.02

Tikemet 2015 144,672 294,360 439,032 27,353 16.05

Mesekerem 2015 447,744 294,360 742,104 31,571 23.51

Nehasie 2014 447,744 294,360 742,104 35,173 21.10

Hamle 2014 447,744 294,360 742,104 31,653 23.44

Senie 2014 447,744 79,685 527,429 32,466 16.25

Ginbot 2014 447,744 79,685 527,429 18,776 28.09

Miyazia 2014 - 79,685 79,685 6,957 11.45

Table 2 Monthly Power Consumption

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Figure 1 Energy Consumption Trend

Specific Energy Consumption

60.00

50.00

40.00

30.00

20.00

10.00

0.00

Figure 2 Specific Energy Consumption

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3.2. Production profile
The full working capacity of the Adama ZLD plant is 11,000m3/day of which 3,000m3/day is
for domestic wastes and 8,000 m3/day is for industries wastes but currently or actual production
is under capacity, see below 12 months data.

Months Production in m3

Megabit 2015 15,872

Yekatit 2015 16,879
Tir 2015 32,703
Tahisas 2015 29,442
Hidar 2015 22,920
Tikemet 2015 27,353
Mesekerem 2015 31,571
Nehasie 2014 35,173
Hamle 2014 31,653
Senie 2014 32,466
Ginbot 2014 18,776
Miyazia 2014 6,957

Table 3 Monthly production

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 Monthly Production
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
-

Figure 3 Production trend

3.3. Energy vs production Graph

1,800,000
1,600,000
1,400,000
1,200,000
1,000,000
800,000
600,000
400,000
200,000
-

Figure 4 Energy vs Production Graph

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3.4. Energy Baseline and KPIS

The total productions and Energy from Tir 2015 to Ginbot 2014 E.C are as follows:

Parameter Amount Remarks

Treated Wastewater
262,057 m3 Data collected from AIP
(ETP+STP)
Electricity 7,278,922 KWh Data collected from AIP

The electrical energy consumption KPI for the wastewater treatment has been calculated and
presented below:
Production in m3 Baseline (KPI) in (kwh/m3) power cost/unit, ETB
Treated Wastewater
28 33.404
(ETP+STP)

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4.0 Energy Saving Potential Opportunity

4.1. Identified Area Where the Energy Waste/Lost

1) Heat loss in steam pipe from boiler to steam header, due to bare of main

steam line.

2) Steam leakage on steam header valve and heat loss in steam pipe.

3) Heat loss in main steam pipe from steam header to MEE#2, due to without

insulation of pipe.

4) In ETP and STP, due to the failure of SCADA system

5) Energy loss in equalization transfer pump, the pump is running under load.

6) MBR efficiency is very low.

7) Energy loss in electric Busbar due to high temperature.

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4.2. Heat loss analysis of uninsulated steam pipe
Case one: Existing conditions from boiler to steam header.
 Electricity cost 1.193 birr/kwh

 Surface temperature without insulation 145oc

 Surface temperature after insulation 65oc

 Ambient temperature 28oc

Existing heat loss

 S=[10+(Ts-Ta)/20*(Ts-Ta)

 Ts=145

 Ta=28

 S= [10+(145-28)/20*(145-28) = 1855 kca/hr m2

 S1=S =existing heat loss (1855 kca/hr m2)

Modified System:

After insulating with 65 mm of asbestos wool with aluminum cladding, the hot face temperature

will be 65 °C

Ts = 65 °C

Ta = 28 °C

Substituting these values:

S = [10 + (65 – 28) / 20] x (65 – 28)

= 480 kcal/hr m2

S2 = S = heat loss after insulation (480 kcal/hr m2)

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 Energy Saving Calculation
Pipe dimension and length = Ø100mm,41 meter

Surface area (existing), A1 = 3.14*0.1*41=13m2

Surface area after insulation, A2 = 3.14*0.23*41=30m2

Total heat loss in existing system S1*A1 = 1855*13=24115

Total heat loss in modified system S2*A2 = 480*30=14400

Reduction heat loss = 24115-14400=9715kcal/hr

Operational hr in a year = 8760 hrs

Total heat loss (kcal/y) = 9715*8760=85,103,400 kcal/year

Electricity, kwh = 98,957.44 kwh/y

Price electricity = 1.193birr/kwh

Monetary saving = 118,056.23 birr/year

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 Case two: Existing conditions of Steam header

 Boiler efficiency 85%

 Electricity cost 1.193birr/kwh

 Surface temperature without insulation 135oc

 Surface temperature after insulation 55 oc

 Ambient temperature 28oc

Existing heat loss

S=[10+(Ts-Ta)/20*(Ts-Ta)

Ts=135

Ta=28

S=[10+(135-28)/20*(135-28)= 1642 kca/hr m2

S1=S =existing heat loss (1642 kca/hr m2)

Modified System:
After insulating with 65 mm of asbestos wool with aluminum cladding, the hot face
temperature will be 55 °C
Ts = 55 °C
Ta = 28 °C
Substituting these values:
S = [10 + (55 – 28) / 20] x (55 – 28)
= 306 kcal/hr m2
S2 = S = heat loss after insulation (306 kcal/hr m2)

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 Energy Saving Calculation
Pipe dimension and length = Ø250mm,3.5 meter

Surface area (existing), A1 = 3.14*0.25*3.5=3m2

Surface area after insulation, A2 = 3.14*0.5*3.5=6m2

Total heat loss in existing system S1*A1 = 1642*3=4926

Total heat loss in modified system S2*A2 = 306*6=1836

Reduction heat loss = 4926-1836=3090kcal/hr

Operational hr in a year = 8760 hrs

Total heat loss (kcal/y) = 3090*8760=27,068,400 kcal/year

Electricity, kwh = 31,475 kwh/y

Price electricity = 1.193birr/kwh

Monetary saving = 37,550 birr/year

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Case three: Existing conditions
 Boiler efficiency 85%

 Electricity cost 1.193birr/kwh

 Surface temperature without insulation 125oc

 Surface temperature after insulation 45oc

 Ambient temperature 28oc

Existing heat loss

S=[10+(Ts-Ta)/20*(Ts-Ta)

Ts=125

Ta=28

S=[10+(125-28)/20*(125-28)=1440 kca/hr m2

S1=S =existing heat loss (1440 kca/hr m2)

Modified System:
After insulating with 65 mm of asbestos wool with aluminum cladding, the hot face temperature
will be 45 °C
Ts = 45 °C
Ta = 28 °C
Substituting these values:
S = [10 + (45 – 28) / 20] x (45 – 28)
= 185 kcal/hr m2
S2 = S = heat loss after insulation (185 kcal/hr m2)

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 Energy Saving Calculation
Pipe dimension and length = Ø150, 47 meter

Surface area (existing), A1 = 3.14*0.15*47=22m2

Surface area after insulation, A2 = 3.14*0.25*47=36m2

Total heat loss in existing system S1*A1 = 1440*22=31680

Total heat loss in modified system S2*A2 = 185*36=6660

Reduction heat loss = 31680-6660=25,020kcal/hr

Operational hr in a year = 8760 hrs

Total heat loss (kcal/y) = 25,020*8760=219,175,200

kcal/year

Electricity, kwh = 254,855 kwh/y

Price electricity = 1.193birr/kwh

Monetary saving = 304,042 birr/year

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 Case Four: Existing conditions
 Electricity cost 1.193birr/kwh

 Surface temperature without insulation 95oc

 Surface temperature after insulation 45oc

 Ambient temperature 28oc

Existing heat loss

S=[10+(Ts-Ta)/20*(Ts-Ta)

Ts=125

Ta=28

S=[10+(95-28)/20*(95-28)=984kca/hr m2

S1=S =existing heat loss (894 kca/hr m2)

Modified System:
After insulating with 65 mm of asbestos wool with aluminum cladding, the hot face temperature
will be 45 °C
Ts = 45 °C
Ta = 28 °C
Substituting these values:
S = [10 + (45 – 28) / 20] x (45 – 28)
= 185 kcal/hr m2
S2 = S = heat loss after insulation (185 kcal/hr m2)

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 Energy Saving Calculation
Pipe dimension and length = Ø200, 12meter

Surface area (existing), A1 = 3.14*0.2*12=8m2

Surface area after insulation, A2 = 3.14*0.3*12=11m2

Total heat loss in existing system S1*A1 = 894*8=7,152

Total heat loss in modified system S2*A2 = 185*11=2035

Reduction heat loss = 7152-2035=5117 kcal/hr

Operational hr in a year = 8760 hrs

Total heat loss (kcal/y) = 5117*8760=44,824,920 kcal/year

Electricity, kwh = 52,122 kwh/y

Price electricity = 1.193birr/kwh

Monetary saving = 62,182 birr/year

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 4.3. Estimated Energy Saving

No. Observation/issue Action to be Estimated Annual Investment

taken Energy Energy cost
Saving saving (birr)
(MWh/year) (birr)
1 Heat loss /no insulation 98.957 118,056 The material is
of steam pipe from The bare pipe available in
boiler to steam header must be insulated contractor stock
2 Heat loss /no insulation The bare pipe 31.475 37,550
of steam header must be insulated
3 The bare pipe 306.977 366,224
Heat loss /no insulation must be insulated
of steam pipe from
steam header to MEE#2
4 SCADA is not working It could be - - -
in ZLD system functional
5 Equalization transfer Install VFD 7,884 Depend on -
pump working under controlling working hours
load system more than one
million
birr/year
6 Heat loss in steam Steam valve must - - -
valve and flange be jacketing by
insulation

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 4.4. Implementation Plan

Task Responsibilities Intervention Start End Day(s) Verified by

required
Formation of Energy Formation and 1 Team
management team taskforce deploying the team members
Plant Manager
Prepare implementation plan and Developing 3
by the Energy management EMT Task force implementation Final plan
team (Energy plan
Insulating all bare steam pipe Management Insulating steam 10
Team) pipe
Jacketing steam valve and Jacketing
flange Energy loss
Make SCADA system The plant operated reduction
properly operational by SCADA system
Install VFD Study and
recommendation
Reduce MD charge
Increase production or Reduce
energy consumption

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5.0 Recommendation and Conclusion
We recommend the following points what we have saw during the site inspection period to save

energy without affecting production.

 Increase the production or reduce energy consumption, currently the plant working

capacity is around 10% and all motors and pumps which controlled by DOL and Star Delta

is working under load and consume more energy for low production. Therefore, we have

to maximize the production or reduce energy consumption by off some motors and pumps.

 The contractor immediately shields all the bare steam pipeline starting from boiler outlet

to MEE system, condensate recovery system and bypass line with jacketing of steam valves

and flange. unless and otherwise AIP with head quarter maintenance expert insulate steam

line and we can save more than 437.4 MWh energy and 521,830 birr per year.

 SCADA System, the SCADA is failed during the audit period. as we know industrial

automation system is increasing the efficiency energy utilization. therefore, we must repair

urgently, and we can save more energy.

 Motor loading, some of induction motor and pumps is running under loading or idle

running, this cause to consume more energy but the production is very less. For example,

the equalization transfer pump capacity is 180m3/h currently this pump working 30m3/h.

this shows that there is energy loss in the system and this cause avoid by installing VFD

control system for this pump and we can save more than 7884 MWh energy and one million

and above birr per year, but it depends on working hours of pump.

 Reduce maximum demand charge, both ZLD Process 7B300000000270 CT-400/1 and

ZLD Boiler 7B300000000193 CT-400/1 energy meter MD charge is very high and reduce

this charge by maintaining proper operation of the plant system.

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Conclusion

During site inspection I have list out the above recommendations and it is a critical point from

energy and process perspectives. Therefore, the plant manager and his team with top management

must be committed to solve the problem. the plant manager establishes energy management team

taskforce to manage energy properly and to increase the energy utilization efficiency. if we

implement the above recommendations, we can save more energy and money.

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