Steam System Optimization at Palm Oil Mill: Case Study in Sabah, Malaysia
محورهای موضوعی : Strategic Management
M D Ibrahim
1
(Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, Universiti Malaysia Sarawak (UNIMAS), 94300 Kota Samarahan, Sarawak, Malaysia)
S A Najamudin
2
(Department of Mechanical and Manufacturing Engineering, Universiti Malaysia Sarawak, 94300 Kota Samarahan, Sarawak, Malaysia)
S S Lam
3
(Universiti Malaysia Terenganu, Malaysia)
کلید واژه: Palm Oil Mill, Energy Saving Opportunities, Steam System Optimization, Steam System Tool Suite,
چکیده مقاله :
In this paper, a preliminary study of industrial steam system reveals that most of the industrial steam user especially the palm oil mill did not bother to save energy as long as the mill meets their productions target and is getting profits for the company. The management is not aware that a huge amount of energy is being wasted during the processes of extracting oil from the fresh fruit bunch (FFB). To embark this study, Steam System Scoping Tool (SSST), Steam System Assessment Tool (SSAT) and 3E Plus: Insulation Program Software, provided by the United Nations Industrial Development Organization (UNIDO) are used to assess the efficiency of steam system operations. The tools also assist in preliminary assessments of how efficiently the steam system is operating. After analyses are conducted, the proposed improvement project is recommended to modify the system back to its initial designed best efficiency. The results also show that there were various losses that are contributing to the energy waste and its cost impact to the mill. Meanwhile, the boiler efficiency was only about 68.6%. The findings proposed steam system optimization (SSO) opportunities by installing the feedwater economizer and reducing the blowdown rate of the boiler. The efficiency of the boiler was increased to 77% from its current operating condition. This also improved the steam quality and production output of the mill. Through these SSO, the annual demand saving is around 4.9 MW, with an energy saving of 75,276 GJ/yr., capable of reducing 13,002 metric tons of carbon dioxide emissions per annum and save 598.3 Tph/yr of biomass fuel. Thus, through this steam system optimization the estimated annual net cost savings are around USD 100,000.00. This paper aims at promoting similar system optimization projects at other plants throughout Malaysia, as it benefits to all industrial steam user especially the palm oil mill industries in Malaysia.
Available at: https://escholarship.org/uc/item/3m1781f1
Available at:f http://www.mpoc.org.my/Malaysian_Palm_Oil_Industry.aspx
Awalludin, M., Sulaiman, O., Hashim, R. and Nadhari, W. (2015). An overview of the oil palm industry in Malaysia and its waste utilization through thermochemical conversion, specifically via liquefaction. Renewable and Sustainable Energy Reviews, 50, pp.1469-1484
Barma, M., Saidur, R., Rahman, S., Allouhi, A., Akash, B. and Sait, S. (2017). A review on boilers energy use, energy savings, and emissions reductions. Renewable and Sustainable Energy Reviews, 79, pp.970-983
Cengel, Y. and Boles, M. (2015). Thermodynamics. 7th ed. New York: McGraw-Hill Education, 216.
Chong, C., Ni, W., Ma, L., Liu, P., & Li, Z. (2015). The Use of Energy in Malaysia: Tracing Energy Flows from Primary Source to End Use. Energies, 8(4), 2828-2866. doi: 10.3390/en8042828
Chowdhury, J., Hu, Y., Haltas, I., Balta-Ozkan, N., Matthew, G. and Varga, L. (2018). Reducing industrial energy demand in the UK: A review of energy efficiency technologies and energy saving potential in selected sectors. Renewable and Sustainable Energy Reviews, 94, pp.1153-1178.
Department of the Environment (UK). The Economic Thickness of Insulation for Hot Pipes; 1994.
Einstein, D., Worrell, E. and Khrushch, M. (2001). Steam System in Industry: Energy Use and Energy Efficiency Improvement Potentials. Lawrence Berkeley National Laboratory.
https://doi.org/10.2298/TSCI091014046S.
https://www.industrialenergyaccelerator.org/wp-content/uploads/Final_SSO_case-study.pdf
https://www.nrel.gov/docs/fy09osti/44660.pdf
https://www.nrel.gov/docs/fy09osti/44660.pdf
Idrees, A. (2014). One of The World's Largest Palm Oil Exporter.
IOI Pan Century Oleochemical Sdn.Bhd. (2014). Industrial Energy Efficiency Improvement: Steam Project - Malaysia A Success Story of Steam System Optimization. Retrieved from http://documents.rec.org/offices/news/316_case_study_no_3_sso_pan_century.pdf
Kalogirou, S. (2004). Solar thermal collectors and applications. Progress in Energy and Combustion Science, 30(3), pp.231-295
Madhav, D., Ramesh, L., & Naveen, M.(2013) Heat recovery through boiler blow down tank. Int J Eng Trends Technol;4:1597–600.
Mohammadi, A., Ahmadi, M., Bidi, M., Ghazvini, M. and Ming, T. (2018). Exergy and economic analyses of replacing feedwater heaters in a Rankine cycle with parabolic trough collectors. Energy Reports, 4, pp.243-251
National Renewable Energy Laboratory, U.S Department of Energy, Tool to Boost Steam System Efficiency, 2008. pp. 1
National Renewable Energy Laboratory, U.S Department of Energy, Tool to Boost Steam System Efficiency, 2008. pp. 2
Nevena Iordanova, Ven V. Venkatesan & Michael Calogero (2000) Steam System Optimization: A Case Study: Armstrong Service, Inc. USA, Energy Engineering, 97:6, 43-66
Palmoilmills.org. (n.d.). Palm Bunch Sterilization Station - Palm Oil Mill Machine Leading Manufacturers and Suppliers. Available at: http://www.palmoilmills.org/products/palm-oil-mill-plant/palm-bunch-sterilization-station.html
Papar, R., Harrel, G., & Venkatesan, V. (2012). Industrial Steam System Optimization Expert Training. UNIDO International Energy Expert Steam, 2012, 9
Saidur, R. (2011) Energy Savings and Emission Reductions in Industrial Boilers.THERMAL SCIENCE, Vol. 15, No. 3, pp. 705-719
U.S. Department of Energy Washington (2012). Minimize Boiler Blowdown: Advanced manufacturing Office, pp.1-2. Available at: https://www.energy.gov/sites/prod/files/2014/05/f16/steam9_blowdown.pdf, Accessed 9 Nov. 2018
United Nations Industrial Development Organisation, UNIDO-Malaysia (2020) Efficiency Solutions for Industrial Heat Case Study. Retreved from
Ven V. V., (2012) Steam System Improvement: A Case Study, Energy Engineering, 96:1, 16-29
Worrell, E. and Price, L. (2001). Policy scenarios for energy efficiency improvement in industry. Energy Policy, 29(14), 1223-1241.
Worrell, E., Price, L., & Martin, N. (2001). Energy efficiency and carbon dioxide emissions reduction opportunities in the US iron and steel sector. , 26(5), 513–536. doi:10.1016/s0360-5442(01)00017-2
Yoon, Y.K. (2020). U.S Patent No. 10,364,979. Torrance, California: U.S. Patent and Trademark Office.
