Energy Audit of Sebeta Alcohol and Liquor Factory
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2011-12
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Abstract
Sebeta Alcohol and Liquor Factory is one branch of National Alcohol and Liquor Factory which uses light oil as the only energy source to generate steam for all end use devices which consume steam for their function. Fuel and electricity bills clearly indicate as the energy consumption patterns of the factory end use devices are variable from month to month due to many reasons including seasonal changes. The nine energy systems of the factory were inspected to identify ECOs and major energy consuming systems of the factory. Out of the nine energy systems boiler, distillery columns, and pumps and their prime movers were found to be major energy consuming systems.
The appropriate data for the major energy consuming systems were collected by using different portable measuring instruments, from nameplates (machine specifications), readings from the gauges installed on the energy systems, visual inspection, interview, referring factory log sheets and record books to perform energy analysis which can lead SALF to good results in proper utilization of energy. The proposed ECOs are based on the analyses of wasted costs, saved costs, implementation costs, payback periods, and the best available technologies (BATs) on the market. These analyses allow to find inefficiencies and to propose improvements which would enable the factory a significant reduction of the energy bills and the environmental impact.
Using the collected data audit analysis of furnace oil, combustion performance of the furnace and property of steam were investigated. During the audit analysis the causes for the efficiency loss of the boiler were identified. From the results obtained in the audit, excess air admitted which is greater than the recommended value of 15%, absence of appropriate boiler maintenance, improper water treatment, absence of automatic blowdown control system which leads to excessive blowdown, and mismatch of steam supply and demand in the factory are some of them. Energy conservation measures suggested among various ECOs identified are:
Installing double pipe heat exchanger to the distillery columns to extract heat from the effluent. For this 88,200.00 birr is needed to be invested as implementation cost and can be returned within 2 months and also gives 381,745.25 benefits by saving 43.076kW energy.
Repairing boiler feed water treatment plant with implementation cost 172,725.00 Birr to have a benefit of 257,446.18 from 29.05 saved energy. The return time for this ECM is 6 months.
AAiT 2011
Energy Audit of Sebeta Alcohol and Liquor Factory vi
Replacing motors (alcohol transferring pump motor from rectification column to temporary storage condenser feed water pump motor). For these an average of 11,000.00 Birr is needed as implementation cost and can be returned within 8 months and 1.68 years respectively. The total benefit gained from these measures is 23,662.29 .
Insulating boiler surface to avoid radiation and convection loss from the surface which is relatively very hot than the ambient temperature. For this measure 30583.82 Birr implementation cost is needed and 50,185.53 . The payback period will be 1 month.
Insulating distillery surfaces. To conduct this measure 4097.21Birr is needed with return time of 1 month.
Insulating steam distribution pipe lines to the distillery columns. To perform this, 43,346.34Birr is needed and returned within 7 months.
In addition to these, there are also many housekeeping ECMs which can be done with no or low cost by the factory workers.
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Mechanical Engineering