Nepalese industries offer a huge potential to cut production cost by using energy more efficiently. It is estimated that around 15% of electrical and 30% of thermal energy could be saved in eight energy intensive industrial sector. This presentation contains the result of a study conducted by German Development Cooperation (GIZ) among 200 Nepalese industries in 2012.
Result of Baseline Study of Selected Sector Industries to assess the Potentials for more Efficient use of Energy in Nepal
1. Result of Baseline Study of Selected
Sector Industries to assess the Potentials
for more Efficient use of Energy
Gyanendra P. Upadhyay
Local Long Term Expert, Energy Efficiency
2. Background
๏ Scope for efficient use of energy in Nepalese
industries.
๏ GON and GOG signed agreement for NEEP to
promote efficient use of energy
๏ GIZ and WECS as implementing agencies โ
FNCCI has established EEC
๏ Consulting Company awarded by GIZ to
conduct a baseline study of industries
comprising eight sectors of industries namely
Cement, Pulp & Paper, Food, Metal, Soap &
chemicals, Hotel, Brick, and Cold storage
3. Selection
S.
Sector of Industry
No.
1 Cement
2 Pulp & Paper
Population
Sample size
35
7
26
5
3
Food
139
51
4
Metal
64
21
5
Soap & Chemicals
38
19
6
Hotel
188
39
7
Brick
435
27
8
Cold Storage
23
12
929
200
Total
7. Observations
๏ Two types of cement plants
๏ผ Limestone based
๏ผ Clinker based
๏ Limestone based plants use electrical as well as thermal
energy (coal) as fuel for Sintering process
๏ Clinker based plants use electrical energy
๏ Motors used are old, rewound and of standard efficiency
๏ NEA supply is from 66/33/11 kV with TOD metering
๏ Capacitor banks are installed to improve P.F.
๏ Face problem of voltage fluctuation and low voltage supply
๏ Production hampered by load shedding
9. Observations
๏ Electrical as well as thermal energy from rice
husk in boiler
๏ Capacitor banks used to improve power factor
more than 0.9
๏ Combustion efficiency is not checked for boilers
๏ Steam leakages observed
๏ Insulation not satisfactory
๏ Frequent non-scheduled power cuts result in
production loss
๏ High cost of Generated electrical energy
12. Observations
๏ Food industries consume both electrical and
thermal energy.
๏ Diesel boiler used most for backup.
๏ Use of inefficient motors.
๏ Steam leakages are observed.
๏ Improper Insulation
๏ Power factor not manage well.
15. Observations
๏ Iron and Steel industries are installed with heavy
motors and electrical energy is mainly used for
the drives of rolling mill, billet sharing, pumps,
compressor, blowers and wire plant motors
๏ Motors are old and re-winded
๏ Capacitor banks are used to improve power
factor
๏ Furnace is used mainly with coal, FO and diesel
and workplace is warm/hot indicating insufficient
insulation
๏ Frequent power cuts affect production
17. Observations
๏ Laundry soap is the main product
๏ Small scale pan boiling units use firewood
medium and large units use rice husk fired
boiler
๏ Only few industries uses capacitor bank
๏ Combustion efficiency is not checked
๏ Leakages are seen
๏ Insulation not adequate โ pipes, flanges and
valves are not insulated
19. Observations
๏ Majority of brick industries are BTK (fixed
chimney)
๏ Energy use in brick kiln is coal and coal is
imported from India
๏ Electricity is used for lighting and drives
๏ No significant disturbance in production by load
shedding
๏ Insulation inefficient
๏ Inefficient coal feeding practice
21. Observations
๏ Potatoes and fruits are the main products stored
๏ They consume only electrical energy for cooling
process
๏ The rate of electricity charge is subsidized 50%
by NEA
๏ All units have DG for backup.
๏ Motor loadings are not checked
๏ Power factor is low โ none used capacitor banks
๏ Many incandescent lamps are used
๏ Air curtains are not used
22. Energy Intensity regional VS
Baseline
Sector
Electrical Intensity
Regional (kWh/MT)
Baseline (kWh/MT)
Cement
Limestone Base
105
148.5
Cement Clinker
Base
35
48.68
Pulp & Paper
1175
937.49
Metal
200
149.17
Soap & Chemical
-
111.25
Brick (BTK Fixed
-
21.27 kWh/1000 pcs
Cold Storage
-
283.53
23. Energy Intensity regional VS
Baseline
Sector
Thermal Intensity
Regional (MJ/MT)
Baseline (MJ/MT)
Cement
Limestone Base
3,138
5,411.26
Cement Clinker
Base
-
-
Pulp & Paper
16,412
15,434
Metal
1,500
1,470
Soap & Chemical
-
3,378
Brick (BTK Fixed
2,215 MJ/1000 pcs
3,951 MJ/1000 pcs
Cold Storage
-
-
24. Areas of Potential Savings
๏ Efficient motors
๏ Power factor improvement
๏ Improvement in insulation of the cold pipelines,
storage room walls and ceiling
๏ More efficient belt and pulleys
๏ Partition of cooling areas, installation and
effective use of air curtains
๏ Regular cleaning and maintenance of condenser
pipes
๏ Replacement of incandescent lamps
๏ Minimization of leakages of compressed
ammonia gas
25. Recommendations
๏ Energy audits must be carried out
periodically in all the industries so that
opportunities are known and understood
๏ Awareness & training about EE
๏ Financing for the implementation of energy
saving options โ mobilize financial institutes
and banks
๏ Keeping the record of data and monitoring
26. Recommendations
๏ Institutionalizing energy audit expertise
๏ Focus on best practices and best available
technology on energy
๏ Policy with mandatory periodic energy
audits and reporting
๏ Involve educational institutions for offer
course on EE
๏ Competition and award for improvement in
EE by sector