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Abbreviation EE&C TD DB/BM/GL Energy Efficiency and Conservation Technical Directory Database / Benchmark / Guideline ACE METI ECCJ ASEAN Center for Energy Ministry of Economy, Trade and Industry The Energy Conservation Center, Japan Cambodia MIME Ministry of Industry, Mines and Energy, Cambodia EE&S Office EDC Electricite du Cambodge DET Philippines DOE Department of Energy DOST Department of Science and Technology RE Renewal Energy MERALCO Manila Electric Company (Old Name: Manila Electric Railroad and Light Company) ECPH Energy Conservation for the Philippines (2005 6 ) FAS Factory Automation System WESM Wholesale Electricity Spot Market Indonesia MEMR Ministry of Energy and Mineral Resources DIP BIO Biotechnology PM Paper Machine PLN KONEBA PT Konservasi Energi Abadi (Persero) Brunei Darussalam DES Department of Electrical Services BHC Butra Heidelberg Cement Malaysia PTM Pusat Tenaga MalaysiaMalaysia 1

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Original cloth Cutting Sewing Paper matrix Compressed air Electricity First inspection Lighting Putting on buttons fasteners 4 Water Ironing Steam Fuel oil Second inspection Labels & Packing Shipping

Productions (k Dozens) 2,000 1,500 1,000 500 0 2001 2004 Year 7

Fuel consumption (kl) 250 200 150 100 50 0 198 171 0 30 2001 Year 2004 Heavy oil Diesel oil Power consumption (MWh) 8 6,000 5,000 4,000 3,000 2,000 1,000 0 2,170 3,549 1,676 1,356 2001 2004 Year Fuel (L/Dozen) 0.200 0.150 0.100 0.050 0.000 Electricity Fuel 2001 2004 Year 4.000 3.000 2.000 1.000 0.000 Electricity (kwh/dozen) EDC IPP

Original cloth (Knitting yarn) Dying & Washing Diesel oil Knitting & Linking First inspection Electricity Washing & Drying Lighting Putting on buttons fasteners 17 Water Ironing Steam Fuel oil Second inspection & Repair Ironing Labels & Packing Shipping

Productions (k pieces) 10,000 8,000 6,000 4,000 2,000 0 2001 2003 2004 Year Fuel (KL) 1,500 1,000 500 0 Heavy oil Diesel oil 2001 2003 2004 Year 0.200 0.100 Heavy oil (L/piece) 0.150 0.100 0.050 Diesel oil Heavy oil 0.080 0.060 0.040 0.020 Diesel oil (L/piece) 0.000 2001 2003 2004 Year 0.000 20

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50 120 Heavy oil (L/t) 40 30 20 10 0 Heavy oil Electricity 115 110 105 100 Electricity (kwh/t) 2002 2003 2004 2005(to July) Year 20

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5 10 US$0.5/L US$0.05/kWh 2

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Production Boiler Aux. Facility Boiler Aux. Facility Boiler Aux. Facility Fan and Fan and Fan and 90t/h Pumps 90t/h Pumps 90t/h Pumps #1 Boiler #2 Boiler #3 Boiler Steam 50t/h 50t/h 50t/h 150t/h Turbine 20

91 90 Efficiency(%) 89 88 87 86 85 10 20 30 40 50 60 70 80 90 100 Load Factor(%) 21

Items Present Improved Number of Units in Operation 3 2 Load Factor of the Boiler (%) 56 83 Pumps and Fan Power Consumption Rate (%) 65* 90* Power Consumption per Unit (kw) 458.3 634.5 Total power Consumption (kw) 1,375 1,269 (: ) 22

Pressure (P) S Surging point Mechanical vibration Narrow working region C Stonewall point Sharp decrease of pressure Air- flow (Q) Turbo type compressor: Base load operation Screw type compressor: Load/unload operation depends on demand Large volume air-demand Turbo Screw Screw (Base load) (Load) (Load/unload) Low volume air-demand Turbo Screw Screw (Load/unload) (Stop) Minimum volume air-demand Turbo Screw Screw (Stop) (Load/unload) (Stop) 23

Power 25,000 Consumption (kwh/d) 20,000 15,000 10,000 Vacant zone?? 1 4 7 10 13 16 19 22 25 28 31 Day 2 Power Consumption in May and July on 2005 100 80 Suction Vane Control Around 70% 60 40 20 Load/Unload Control Inverter Control Ideal Control 0 0 20 40 60 80 100 Load Factor (%) 24

Power Consumption Vacant zone 1st M/C 2nd M/C Air flow 25

Power Consumption Power Saving Screw M/C Turbo M/C Screw M/C Air flow 26

Efficiency, Power factor, Current (%) 120 100 80 60 40 Efficiency Power factor Current 25 50 75 100 125 150 Load factor (%) 400V 100.0 Efficiency (%) 80.0 60.0 40.0 20.0 Motor Pump Fan 25 50 75 100 125 Load factor (%) 27

701B Capacity Desigin Design Actual Actual/ Fan/Pump kw Volt. Amp. Amp. Design 1.FOP 11 380 22.5 14.5 0.64 2.BFP 315 6,000 36.5 29.5 0.81 3.DFP 75 380 131 67.4 0.51 4.FDF 315 6,000 36.6 17.5 0.48 Estimation of the Air leakage L: Air leakage (%) t1 L= 100 (%) t1+t2 0.7 0.6 0.5 0.4 0.3 Pressure ascent Small leakage Small leakage Large leakage Time (min) Pressure descent Pressure Change in Air Compressor t2 Setting pressure p1 = Specified pressure Working pressure range p1 p2 = 0.05~0.1MPa p2 = Specified pressure t2 28

High voltage line 6kV Static Condenser Low voltage line 380V M M S.C S.C P 200kW5 200kW 5 P 63kvar 5 63kvar5 30

800RT COP 35

110 Motor Power (%) 100 90 80 70 100 96 92 85 Inlet Temp. of Cooling Water () 32 30 28 26 5 7 9 11 Outlet Temp. of Chiller () -3-1 -3-1 -3-2 36

Outlet Outlet Temperature() (ºC) 35 30 25 20 15 5 4 3 8 10 12 14 16 18 20 22 24 26 28 30 Wet Wet Bulb Temperature (ºC) -3-2 30kW 37

-3-3 Material loss Energy loss Effective Energ y Energy loss Machine problems Trouble Waiting time Defect -3-3 Patal Grati 38

3 VIP Soekanar Ms. Maryam Dr. Weerawat 42

ODA 1996 1 ODA 1998 2

Mill & related facilities 6.6kV 11kV 6.6kV 11kV MOF CB 7,500kVA Mill & related facilities 7,500kVA MOF 1,000kVA 380V Other facilities 750kVA 380V Other facilities 9

1.1 1 0.9 0.8 0.7 0.6 18% Base pressure: 0.7MPaG 0.5 0.4 0.3 0.4 0.5 0.6 0.7 0.8 Discharge pressure (MPa) 11

Compressor Pi Qi Pi Po P Pipe line Loss P Q Air power at terminal system Pressure loss Q Terminal system Po Qo Leakage loss 0 Qo Qi 12

Estimation of the Air leakage L: Air leakage (%) t1 L= 100 (%) t1+t2 0.7 0.6 0.5 0.4 0.3 Pressure ascent Small leakage Small leakage Large leakage Time (min) Pressure Change in Air Compressor t2 Setting pressure p1 = Specified pressure Working pressure range p1 p2 = 0.05~0.1MPa p2 = Specified pressure t2 Pressure descent 13

200HP Water at dew point (g/m 3 ) Compressor 100 10 1-50 -30-10 10 30 50 0.1 0.01 Dryer (Chiller type) Compressor yard Heatless dryer Dew point () Factory To M/C 14

Efficiency, Power factor, Current (%) 120 100 80 60 40 Efficiency Power factor Current 25 50 75 100 125 150 Load factor (%) 16

100.0 Efficiency (%) 80.0 60.0 40.0 20.0 Motor Pump Fan 25 50 75 100 125 Load factor (%) Capacity Design Design Actual Actual/ Motor kw Volt Amp Amp Design Mill motor 2800 6,000 300 263 0.88 Separator 90 380 152 35 0.23 Bag filter fan 400 6,000 43 29 0.68 120 100 80 60 40 20 0 Suction damper Speed control Damper Ideal curve 0 20 40 60 80 100 Air Flow (%) 17

Circular Plate Direction of the rotation Mark 23

Time (hour) 25

Energy Consumption fixed Energy Consumption changing fixed Production 26 Production

Plan: To find the loss and waste of energy consumption and find countermeasures to minimize them. Do: Carry out the countermeasures Energy audit Check: Evaluate the result Action: Reform the process Making Improving improvements through PDCA using the cycle PDCA cycle 100.0 Efficiency (%) 80.0 60.0 40.0 20.0 Motor Fan Pump 25 50 75 100 125 Load factor (%) 27

1.1 1 0.9 0.8 0.7 0.6 18% Base pressure: 0.7MPaG 0.5 0.4 0.3 0.4 0.5 0.6 0.7 0.8 Discharge pressure (MPa) 28

Load Unload 29

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Country Brunei Cambodia Indonesia Philippines Items Time Dec. 1317 Aug. 2226 DEC. 512 Aug. 29Sep.2 Cement & Food 3 Garment Pulp/Paper and 2 Rolling Mill 1. Follow-up / Energy Audit Processing Factories Factories Textile Factories Factories 2. Seminar-Workshop Brunei - MOE Cambodia-MIME ACE Philippines - DOE 1) EE&C Policy ACE ECCJ ECCJ ECCJ Cement (Brunei) Brunei - BHC Ceramics (Vietnam) Vietnam - MOI Vietnam - MOI Vietnam - MOI Chemical (Caustic Soda) Philippines - (Thailand) R.I. Chemicals Co. Garment (Cambodia) F-up: MIME/ECCJ Malaysia - PTM Food (Singapore) Philippines- URC F-up: DOE/ECCJ Iron/Steel (Philippines) (ECCJ) Philippines - DOE Malaysia - PTM Oil Refinery (Myanmar) Power (Lao PDR) (ECCJ) Lao PDR-MIH Lao PDR-MIH Power - DOE Pulp/Paper (Indonesia) Indonesia - Indonesia - Indonesia - Indonesia - PT Kertas Leces PT Kertas Leces PT Kertas Leces PT Kertas Leces Textile (Malaysia) Malaysia -PTM Malaysia -PTM Glass-Malaysia Glass-Malaysia Glass - Malaysia Other Industries Co-Gene & ESCO - Thailand 1) 1) What are are the the Barriers & Measures & for the on the Implementation of EE of & EE&C C [ECCJ] [ECCJ] 3) Way Forward 2) Development of of Technical Directory, Directory, DB/BM/GL DB/BM/GL for Industry for Industry [ECCJ &[ECCJ ACE] & ACE] 2) EE&C Activities - 3

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Item Items Numbers Numbers and and Ratio Ratio (%) (%) Country Company Name (Industry) Recommended Finished Under Nonactivitlmented Not Imp- by ECCJ or Studied Study Brunei Butra Heidelberg Cement 5 0 1 6 (Cement Industry) 83% 0% 17% M&V International Mfg 3 2 0 1 (Garment Industry) 67% 0% 33% Cambodia June Textile Co. Ltd. 2 0 1 (Garment Industry) 3 67% 0% 33% Indonesia PT KERTAS LECES 34 28 34 0 6 0 (Pulp/Paper Industry) 100% 0% 0% Philippines Steel Asia Mfg. Corp. 4 2 1 1 (Iron/Steel Industry) 50% 25% 25% Vietnam Hai Duong Porcelain Co. 11 2 10 0 9 1 (Ceramics Industry) 91% 0% 9% Lao PDR Num Ngum Hydropower 4 4 0 0 Plant (Power Industry) 100% 0% 0% Arab-Malaysia D. B. 4 5 0 Malaysia 9 (Textile Industry) 44% 56% 0% Mann Thanbayakan 2 2 0 Myanmar 4 (Oil Refinery) 50% 50% 0% Total 78 65 (83.3%) 8 (10.3%) 5 (6.4%) (2004) only 62 40 (64.5%) 7 (11.3%) 15 (24.2%) 2005 2004 + Presentation - 6

Country Industry EE&C Activities Food Industry 1. Installation of economizers on LP boilers 2. Waste heat recovery from hot water boilers (Edible Oil Refinery) 3. Process oil cooling by cold feed water 4. Condensate collection system Total fuel saving = 116,703GJ/y (=Approx. 2,920kL/y) Malaysia Iron/Steel Industry 1. 2-stage recuperator (Recovery of flue gas temp.) 2. Air compressor change, from piston type to Capacity: screw type: Power saving = 45% EAF: 700kt/y, 3. VSD for rolling mill cooling water pump process Mill: 550kt/y Power saving = 25% compared to throttle valve Power saving = 1.7%, Fuel saving = 13.7% Total cost reduction = 3% Chemical Industry Change the 200RT refrigeration system from a vapor RI Chemical Corp. compression type to a vapor absorption type, wherever there is waste heat and a need for chilled water. Effect on productivity: +3.6% Philippines Iron/Steel Industry Introduction of outline of Philippines steel industry (By DOE) and 2005 Don Emilio Abello EE Awards [Rolling Mill Co. saved 580kL/y of fuel oil by heat recovery from the furnace, etc. and Steel sheet coating Co. saved 107kL/y of oil] Porcelain Industry Significant percentage improvement after 2004 follow up. (By MOI) Similar presentation at last Summary-Workshop Brick Industry Energy audit at brick factory: Fuel saving = 3%. Vietnam (By MOI) Power saving = 13% by insulation strengthening, etc. Energy Audits at 12 Main measures identified by audit: industrial factories VSD, boiler improvements, condensate collection (By Institute of system, maintenance method, compressed air Energy) system, etc. Saving: Fuel = 0~38%. Power = 5~40% - 7

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Year 2006 2007 Activities Month 4 5 6 7 8 9 10 11 12 1 2 3 Preparation of Detailed (1) Implementation Plan & Preparation for 1st Site Activity Two 1st Site Activity (Follow-up Countries (2) Survey & Workshop (2 Countries)) Analyses of 1st Site Activity (3) Results / Preparation for 2nd Site Activity Two 2nd Site Activity (Follow-up Countries (4) Survey & Workshop (2 Countries)) Analyses of 2nd Site Activity (5) Results / Preparation for 3rd Site Activity 3rd Site Activity (S & P- (6) Workshop, TD disemmination & DB/BM/GL formulation) (7) Report Writing OJT ASEAN ECCJ ECCJACE OJT ECCJ ECCJACE - 10

6 JETROECCJ 46 1 ACEECCJ - 11

Database / Benchmarking / Guideline Database Database ECCJ Database - 12

ECCJ ACE ASEAN Database Database ASEAN - 13

ECCJ Schedule 1