KTMW PRELIMINARY

ENERGY AUDIT REPORT

[Document subtitle]
 TABLE OF CONTENTS
EXECUTIVE SUMMARY.........................................................................................................................2
TABLE OF CONTENTS............................................................................................................................3
TABLE OF TABLES..................................................................................................................................4
1. INTRODUCTION...............................................................................................................................5
1.1 About KTMW(Iganga)......................................................................................................................5
1.2 Main Objective of Preliminary Energy Audit....................................................................................5
1.3 Specific Objectives of Energy Audit.................................................................................................5
1.4 Scope of Preliminary Energy Audit.............................................................................................5
2 METHODOLGY.................................................................................................................................6
2.1 Training Workshop............................................................................................................................6
2.2 Walk through.....................................................................................................................................6
2.3 Data Collection..................................................................................................................................6
2.4 Data Analysis....................................................................................................................................6
2.5 Report Writing...................................................................................................................................6
3. FINDINGS..........................................................................................................................................7
3.1 Energy Management..........................................................................................................................7
3.2 Energy profile....................................................................................................................................8
4. RECOMMENDATIONS...................................................................................................................10

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EXECUTIVE SUMMARY
KTMW is a collection of individual maize mill owners with their respective mills who are billed
as a cluster in order to obtain a better tariff from UMEME. Each mill however, has its own sub-
meter. A training workshop was held with these mill operators and owners on energy efficiency.
One mill was selected, and a preliminary energy audit was carried out. Historical production data
of this mill together with data on daily meter readings were collected. This data was then used to
come up with different statistics such as total production, total and specific energy consumed. On
analysis of this data, recommendations were drawn on how to improve on the energy efficiency
of the selected mill and all the millers as a whole.

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 TABLE OF CONTENTS
Figure 1; A maize mill in operation.................................................................................................6
Figure 2; Belts on the maize mill.....................................................................................................6
Figure 3; Pie-chart showing consumption during billing periods...................................................8

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 TABLE OF TABLES
Table 1 Production Data Over A Year............................................................................................8
Table 2; Annual Production Quantities...........................................................................................8
Table 3; Data from Utility Bill........................................................................................................8

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 1. INTRODUCTION
1.1 About KTMW(Iganga)
KTMW was started in 2011 and consists over 20 maize mill owners who grouped themselves
together in one cluster to be billed as one by Umeme. Their main business is maize milling
which produces mainly 3 categories; pure flour, broken flour and maize bran. Electrical energy is
simultaneously their only source of energy and biggest cost of production. The rate and volume
of production are different for each maize mill. Each individual maize mill has a sub-meter from
which daily readings are recorded and there’s one general meter belonging to the utility
(UMEME) for the whole group from which billing is done.

1.2 Main Objective of Preliminary Energy Audit

The main objective of the preliminary energy audit was to identify ways in which energy could
be conserved and utilised efficiently.

1.3 Specific Objectives of Energy Audit

The specific objectives of the preliminary energy audit include;
 Identify areas of energy loss/wastage.
 To recommend measures in which energy usage can be improved.
 To sensitize mill owners and operators on better energy consumption practices.

1.4 Scope of Preliminary Energy Audit

The preliminary energy audit was carried out on only one of the 20 maize mills for a day.
Specifically looking at Electrical power and energy management practices in the maize mill.

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2 METHODOLGY
The preliminary energy audit was carried out in the following stages; training workshop, walk
through, data collection, data analysis and report writing.

2.1 Training Workshop

A training workshop was carried out with all the maize mill operators and owners present on
energy efficiency. They were sensitized on simple techniques in which they can save energy. The
maize mill operators and owners also aired out the challenges they face as they go about
production.

2.2 Walk through

A walk through began with an introduction meeting where the audit planning was done with the
mill staff. This walkthrough was conducted to physically identify operator behaviors, machine
conditions and other relevant parameters that influence energy consumption in this mill.
Observations were made and used to support the findings in this document.
2.3 Data Collection
Data from one maize mill was collected and included;
 Production data in kilograms over one year.
 Electrical units consumed over one month from daily sub-meter readings.
 Energy consumption data such as power factor, maximum demand, frequency, voltages,
and current.

2.4 Data Analysis

The data collected was analyzed using Microsoft Excel. This data was graphed showing the
demand profile and power factor variation over one hour. The total production of the mill over
one year was also compiled. Specific energy consumption for each kilogram produced was also
compiled.
2.5 Report Writing
A report was compiled detailing and explaining all the information that was obtained and
appropriate recommendations and conclusions drawn.

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 3. FINDINGS
3.1 Energy Management.
A walkthrough was carried out of the facility and observations from what was seen were made.
 The facility keeps records of daily energy consumed and the daily production data which
is a very good practice. An observation made of this data is the thorough analysis and use
of the data to make decisions.
 Maize is manually fed into the mill as seen in figure 1 below thus leading to losses from
human error and weakness.
 Most of the belts on the machines were observed to be sagging as seen in figure 2 thus
leading to overworking of the motor hence energy loss.
 The facility was generally not well maintained with dust from the maize grain clogging
terminals and old motors haphazardly piled.
 The machines were not well covered thus posing a risk to those operating them.
 The motors used in the mills once they need replacement are instead rewound and this
occurs many times over the lifetime of the motor.

Figure 1; A maize mill in operation

Figure 2; Belts on the maize mill

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3.2 Energy profile
This chapter includes data collected on production of the sample maize mill and on the energy, it
consumes. The maize mill produces three different categories of product and these are; pure
flour, broken flour and maize bran. The production of the sample maize mill in the three different
categories is shown in figure below.
Table 1 Production Data Over A Year

Month Pure (kg) Broken (kg) Bran (kg)

July-2016 296585 8723 49430
August-2016 198130 5827 33022
September-2016 83307 2450 13885
October-2016 201956 5940 30878
November-2016 213943 6292 35878
December-2016 185562 5458 30927
January-2017 341590 10047 56932
February-2017 174159 5122 29027
March-2017 218808 6436 36468
April-2017 315230 9271 52538
May-2017 202131 5954 33689
June-2017 202691 5962 33781
Total 2634092 77482 436455

As can be observed from the table, pure flour has the largest quantities produced with the months
of January, April and July having the highest production.
Table 2; Annual Production Quantities

Produc Quantity(kg)
t
Pure 2634092
Broken 77482
Bran 436455
Total 3148029

Data from the utility bill for the whole cluster was analyzed and tabulated as below.
Table 3; Data from Utility Bill

Item Units Used Rate (Ushs) Amount (Ushs)

Off-peak 488 244.5 119,316
Energy-shoulder 29563 388.5 11,337,411
Peak 5619 498.2 2,799,386
Demand(kW) 284 11,096 3,151,264
Reactive Charge 15655 40 626,200

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From the utility bill data in table 3, it can be observed that the reactive charge is high thus
indicating a poor power factor.
The demand charge is also observed to be high.
It can also be observed that the demand charge is high.

Units Used Durong Billing Periods

Off-peak Energy-shoulder Peak

Figure 3; Pie-chart showing consumption during billing periods

From the pie-chart in figure 3, it can be seen that most units are used during off-shoulder,
followed by off-peak and then peak periods.
In the month of June 2017, the mill used a total of 5,739 units with a total production of
242,434kg. The specific energy consumption for the sample mill is thus, 0.024 units per
kilogram of product produced.

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 4. RECOMMENDATIONS
For each of the observations made in the findings, below are the recommendations drawn;
 The data collected by the mill operators should be used to influence decisions in
production and pricing per kilogram.
 A system should be designed and fabricated where maize is mechanically fed into the
mill with as little human intervention/contact as possible. This will help to reduce loss of
grain.
 New belts with higher tension should be procured and the supplier could also be changed.
 A proper and frequent cleaning system should be created to reduce the amount of dust
around the facility to prevent clogging of the terminals.
 Wooden or metallic covers should be placed over exposed parts of the maize mills.
 Motors should be replaced with new ones that have better efficiency other than rewinding
old motors which leads to lower efficiency.
 Power factor correction should be done by installing capacitor banks so as to reduce the
reactive charge charged by the utility company.
 The mill operators can reduce on the demand charge by sequencing operation of the mills
such that the highest kilowatt demand throughout the thirty days is low.
 The maize mill operators should switch their production hours such that more production
is done during off-peak and shoulder-peak hours.

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