J02 Summary Workshop

PROMOTION OF ENERGY EFFICIENCY AND CONSERVATION

SOME-METI WORK PROGRAMME 2005-2006

Summary of Local Workshops and

Follow-up Surveys in Major Industries
at
Brunei Darussalam, Cambodia,
Indonesia and Philippines

January, 2006
Hideyuki TANAKA

ECCJ The Energy Conservation Center, Japan 1

Contents
1. Outline of Phase-1 & 2 Activities
2. Outline of Phase-2 PROMEEC Activities in 2005
3. Activities in 4 Countries in 2005
(1) Brunei a. Follow up Energy Audit
(2) Cambodia b. New Factory Energy Audit
(3) Indonesia c. Topics in Seminar
(4) Philippines
4. Presentation Items from ASEAN Countries
Lao PDR - Hydro-Power
Malaysia - Food, Glass, Iron/Steel, Textile
Thailand - Co-Generation and ESCO
Philippines - Chemical, Food, Iron/Steel and Power
Vietnam - Porcelain, Brick and Energy Audits
5. Topics at Seminar
6. Summary of Follow up on PROMEEC Activity
7. Barriers and Possible Measures
8. General Overview of PROMEEC Activities in Industry, 2005
2
ECCJ

1
 1. Outline of Phase-1 & 2 Activities
Country
Industry Brunei Cambodia Indonesia Lao PDR Malaysia Myanmar Philippine Singapore Thailand Vietnam
1. Country Condition
- Area (km2) 5,765 181,000 1,890,000 240,000 330,000 680,000 299,404 699 514,000 329,241
- Population (x103) 350/‘03 13,500/ ‘02 215,000/‘00 5,609/‘05 25,580/‘04 52,170/ ‘02 81,500/'03 4,240/ ‘04 61,970/‘04 82,060/ ‘04
- GDP(US$) per capita 13,418/ ‘03 291/‘02 954/‘03 402/’03-04 4,372/‘04 180/‘03 1,050/‘03 25,191/ ‘04 2,236/‘03 483/‘04
2. Industry & Time of Energy Audit
2000
(1) Cement F. 5~9, ‘01
(Dec.2005)
(2) Textile 2000
F. 15～ 19, '01

2001
(3) Pulp / Paper J. 22~26, ‘01
(Dec.2005)
(4) Oil Refinery 2001
D. 18～22, '01

(5) Ceramics / 2001

Porcelain D. 18～22, '01

(6) Hydropower 2001

J. 28～F. 1, '02

2002
D. 9~13, ‘02
(7) Garment F. 17~21,’03
(Aug.2005)
2002
(8) Iron & Steel F. 10~14,‘03
(Sep.2005)
2003
(9) Food N. 24～28
J.12～15

(10) Chemical 2003

D. 1～ 5, '03
(Caustic Soda) J. 6～9, '04
3
ECCJ

2. Outline of Phase-2 Activities in FY2005

Follow-up of Energy Audits and Seminar-Workshop Presentations
Country
Brunei Cambodia Indonesia Philippines
Items Time Dec. 13～17 Aug. 22～26 DEC. 5～12 Aug. 29～Sep.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.
2) EE&C Activit ies

Garment (Cambodia) F-up: MIME/ECCJ

Food (Singapore) Malaysia - PTM
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) What are the Barriers & Measures on the Implementation of EE&C [ECCJ]
3) Way Forward 2) Development of Technical Directory, DB/BM/GL for Industry [ECCJ &4 ACE]

ECCJ

2
3-(1) Activities in Brunei Darussalam
1. Schedule: December 14 - 17, 2005
2. Energy audits at Cement Factory and Food Processing Factory
1) Butra Heidelberg Cement Sdn. Bhd. (December 14)
2) Kingston Beverage & Creamery Sdn. Bhd. (December 15)
3. Seminar-Workshop: December 17 at Centrepoint Hotel, BSB
Participants: Over 100 (Including Foreigners: 6, ACE: 2)
Presentations:
1) Overview of EE&C Programs of ASEAN (ACE)
2) Energy Overview in Brunei Darussalam (DES, Brunei)
3) Initiatives and Programs of ECCJ in Industry in Japan (ECCJ)
4) EE&C Best Practices in Industries:
- Cement (Mr. Widjaja – Butra H. Cement, Brunei Darussalam)
- Pulp and Paper (Mr. Subagyo - PT Kertas Leces, Indonesia)
- Porcelain and Brick Industry (Mr. Khoa - Institute of Technology,
Electricity of Vietnam)
- Glass and Textile Industry (Mr. Hishamudin - PTM, Malaysia)
- Hydro Power and Steel Industries (ECCJ)
5) Barriers/Measures for EE&C (ECCJ)
Discussion:
Technical Directory, D/B-B/M-G/L (ECCJ/ACE)
5
ECCJ

3.
3. (1)
(1) Brunei
Brunei Darussalam
Darussalam
aa.. Follow up Energy Audit at Butra
Heidelberg Cement Sdn. Bhd.

Phase 1 Energy Audit: Feb. 5 ~ 9, 2001

Phase 2 Follow up : Dec. 14, 2005
Audit Participators: DES = 8, University = 3, ECCJ = 3

Production: Cement, Less than 250kt/y (Capacity = 500kt/y)

Energy: Electricity only
Employee: 110
Process: Mixing of Clinker and Gypsum, Crushing and Grinding
Storage and Packing
Recommended items at phase 1: 6 items
Finished items = 2
Studied, but unavailable (Quality & not wanted) = 2 3
Studied, but un-adopted (Expensive) = 1
Remaining items = 1
Achievement ratio = (2+3)/6 83%
6
ECCJ

3
3. (1) Brunei Darussalam - a.

- Cement Factory and Energy Conservation

Clinker and Gypsum
from oversea Hoppers
Countermeasures
to clinker chute Separation of air
and gas ducts room in slide
(Not yet) (No-needed)

Clinker
Crushing silo
Application of & Blending Gypsum
dirty air to storage Preparation of check
separator Cement mill sheets and manuals
second air for maintenance
(No, by QA) (Yes)
Packer
Modification of Cement silos
cement
transportation Operation Maintenance of
(No, expensive) room sensors, meters
Cement (Yes)
Energy: Storehouse tanks
Electricity Maintenance
100% yard
Office
ECCJ
Gate 7

3. (1) Brunei Darussalam - a.

- Results of Follow up Energy Audit

Year Improvement
Items
2000 2004 (2004/2001)
Production Cement (t/y) 232,174 247,733 1.07
Energy Electricity
consumption (MWh/y) 14,723 16,675 1.43
Energy 63.4 67.3
Electricity 1.06
Intensity (kWh/t) For production: For production:
53.3 56.7
Energy Electricity
0.043 (B$0.07) 0.043 (B$0.07) 1.0
price (US$/kWh)

1) Frequent shut down in 2004

2) High quality cement (Higher % of clinker)

8
ECCJ

4
 3. (1) Brunei Darussalam - a.

- EE&C activities in Butra Heidelberg Cement

Top management’s awareness for EE&C is good!
They strive for EE&C under rigid economic conditions.
1. Preparation of answers for questionnaires
2. Acquirement of ISO-9000 (2003) and ISO14001 (2004)
3. Installation of reactive capacitor bank
4. Use of grinding aid for steel balls in mill
5. Preparation of Standard Operating Procedure (SOP) for after
maintenance
6. Improvement of clinker unloading period from 7 to 4 days by
vessel selection and improving transportation equipment
7. Installation of electric timer to turn off exterior lighting in the
daytime
- Recent situation: Cement demand is less than 250,000t/y in Brunei,
and Brunei Darussalam started to import cement from China since
July of 2005. Company operation rate is always less than 50%, and
now going down gradually.
9
ECCJ

b. Energy Audit at Kingston Beverage &
Creamery Sdn. Bhd.
Company Profile
- Food Processing Industry
Only 1 factory in BD
producing Soft Drinks and
Ice-cream
(50~60k-Carton/monyh)
- Operation at new factory:1994~
- Employees: 150
- Diesel oil: Boiler, 5t/h-150PSI - To gather the electricity consumption for
Transportation cars
- Power: 11kVA, 1000A
(1 Generator: 350kVA for Em.)
- Line operation: 3 lines & PET
Bottle molding machine
- Compressor: Air, Ammonia
- Chiller
- Audit participator:
DES = 5, ACE = 1, ECCJ = 3
ECCJ
ECCJ
3.
3. (1)
(1) Brunei
Brunei Darussalam
Darussalam
EE&C Activities
There are no data of the energy consumption!
Power: Invoice from supplier
(= Government)
Only one KWH meter at receiving
point
Diesel oil: Invoice from Oil supplier
(No meter)
each process, each device, etc.
Setting the KWH meters or preparation of
portable type meter
- To check the diesel oil consumption for
boiler
Setting the flow meter
- To analyze the energy intensity by
product or shipment value
Now is just the beginning of EE&C activity!
10

5
 3. (2) Activities in Cambodia
1. Schedule: August 22 – 26, 2005
2. Energy audits at Garment Factories
1) June Textile Co. Ltd. (August 22 & 23)
2) Berry Apparel Co. Ltd. (August 23)
3) M & V International Manufacturing Ltd. (August 24 & 25)
3. Seminar-Workshop: August 26 at Phnom Penh Hotel, Phnom Penh
Participants: 58 (MIME + Company: 50, Foreigners: 7, ACE: 1)

Presentations:
1) Overview of EE&C Activities in Cambodia (MIME, Cambodia)
2) EE&C Case Study:
- Glass Industry (Mr. Nor - PTM, Malaysia)
- Hydro Power (Mr. Vanthong - Num Ngum Hydro Power Plant, Lao PDR)
- Pulp and Paper (Mr. Subagyo - PT Kertas Leces, Indonesia)
- Ceramics (Mr. Phong - MOI, Vietnam)
3) Follow up of Energy Audit Findings at Garment Factories
(MIME/ECCJ)
4) Barriers/Measures for EE&C (ECCJ)

Discussion:
Technical Directory, D/B-B/M-G/L (ACE/ECCJ)
11
ECCJ

3.
3. (2)
(2) Cambodia
Cambodia
a. Follow up Energy Audit at June Textile Co., Ltd.

Phase
Phase 11 Energy
Energy Audit:
Audit: Dec. 12, 2002 & Feb. 18, 2003
Phase 2 Follow up : Aug. 22 & 23, 2005
Audit Participators: MIME = 5, ECCJ = 3

Production: Casual wear

Energy: Fuel oil, Diesel oil and Electricity
Employee: 5,000
Process: Cloth cutting, sewing and ironing

Recommended items at phase 1: 3 items

Finished items = 2
Remaining items = 1

Achievement ratio = 2/3 67%

12
ECCJ

6
3. (2) Cambodia - a.

- Garment (Casual) Production Process and

Energy Consumption
Original cloth By 3 recommendations, Actual EE&C:
EE&C = - 4% Fuel = -29.6%
Paper matrix Elect. = -11.6%

Cutting Sewing First Putting on Ironing Second

(49%) inspection buttons & inspection
fasteners
Heat
insulation
(Yes) Labels &
Compressed Air Packing
Lighting air Condi-
(19%) 75kW×1 tioning Steam
37kW×2 (9%) (18%) Boiler:
300, 500, Shipping
782kg/h

To lower Number
position control Water Fuel oil
(No) Electricity
(EDC, IPP)
(Yes)
13
ECCJ

3. (2) Cambodia - a.

- Results of Follow-up Energy Audit

Year Improvement
Items
2001 2004 (2004/2001)
Casual wear 2,110,000×0.8=1,688,000
Production (Dozens/y) 1,170,000 1.443
(By subcontract: 20%)

Fuel for Diesel Oil: 30,000

Diesel Oil: Fuel Oil: 171,000
Boilers (L/y) 1.015
198,000 Total = 201,000
Energy
consumption Electricity IPP: 1,676,000 IPP: 1,356,000
1.275
(kWh/y) EDC: 2,170,000 EDC:3,549,000
Total = 3,846,000 Total = 4,905,000

Energy Fuel 0.169L/Dozen 0.119L/Dozen 0.704

Intensity Electricity 3.287kWh/Dozen 2.906kWh/Dozen 0.884

No. of Workers 4,400 Person 5,000 Persons 1.136

Skill up of Output per
workers 266Dozens 338Dozens 1.27
Person/y
Energy Fuel Diesel oil Diesel oil
1.71
price US$0.35/L US$0.60/L

Electricity US$0.122/kWh US$0.15/kWh 1.23

14
ECCJ

7
3. (2) Cambodia - a.

- EE&C activities in June Textile Co.

Top management’s awareness on EE&C is Good!

1. Replacement of air compressor (37kW×2 75kW Inverter

type)
2. Steam drain recovery Boiler supply water
3. Heat insulation reinforcement for steam system
4. New type of air conditioning
5. Replacement of sewing machines to efficient ones every
4~5years
6. Skill up of workers

1. Furthermore heat insulation!

2. Lighting with reflectors and clean up!
15
ECCJ

3.
3. (2)
(2) Cambodia
Cambodia
b. Follow up Energy Audit at M & V International
manufacturing Ltd.

Phase
Phase 11 Energy
Energy Audit:
Audit: Dec. 11, 2002 & Feb. 19, 2003
Phase 2 Follow up : Aug. 24 & 25, 2005
Audit Participators: MIME = 5, ACE = 2, ECCJ = 3

Production: Knit wear (Sweater)

Energy: Fuel oil, Diesel oil and Electricity
Employee: 3,200
Process: Knitting yarn, dyeing, washing, knitting, ironing

Recommended items at phase 1: 3 items

Finished items = 2
Remaining items = 1

Achievement ratio = 2/3 67%

16
ECCJ

8
3. (2) Cambodia – b.

- Garment (Sweater) Production Process

By 3 recommendations: Actual EE&C:
Oil = - 2%, Elect. = -1.5% Fuel = -24%

Knitting yarn Dyeing & Washing

(Warehouse) Washing & Drying
Knitting &
Heat Linking
insulation
(Yes) Lighting

To lower Knitting
Steam position Electricity
(Turn off: Yes)
& Check
Boilers Diesel
Heat
Fuel oil recovery Generator
Repair
(No) and EDC

Shipping QA & Ironing &

17
ECCJ Packing Check

3. (2) Cambodia – b.

- Results of Follow-up Energy Audit *1

Year Improvement
Items
2001 2004 (2004/2001)
Knit wear
Production (k Pieces/y) 5,100 8,300 1.65

Fuel Oil for

928,000 1,152,000 1.24
Boilers (L/y)
Energy Diesel Oil for
480,000 592,000 1.23
consumption Generator (L/y)
Electricity *2
214,000 Unknown Unknown
(EDC) (kWh/y)
Fuel Oil
182 139 0.763
Energy (L/k-pieces)
Intensity Diesel Oil
(L/k-pieces) 94 71 0.758

No. of Workers 3,000 Persons 3,200 Persons 1.07

Skill up of
workers Output per
Person/y 1,700p’ces 2,594p’ces 1.53
Fuel Oil US$0.25/L
Energy
Diesel Oil US$0.35/L US$0.60/L 1.71
price Electricity US$0.152/kWh
*1: It was difficult to survey in detail because of poor cooperation. *2: Power for security at night
18
ECCJ

9
 3.
3. (2)
(2) Cambodia
Cambodia
c. Energy Audit at Berry Apparel Co.
Company Profile EE&C Activities
- Garment Industry
Sister company of June
Textile Co., Ltd. (JT) Almost new factory
- New factory: - Intake air in room is cooled down directly
Operation start at May, 2005 by water
- Employees: 4,000 - Inverter type air compressor
(In near future, 10,000)
- To recover the steam drain and to use it
- Fuel oil: Boiler, 1t/h for boiler supply water.
- Power: - To check the lighting type for high
- Line operation: Same as JT ceiling
- Compressor: Same as JT
- Air conditioning: Same
system as JT

- Audit participator:
MIME = 1, JT = 1, ECCJ = 3
19
ECCJ
ECCJ

3. (3) Activities in Indonesia

1. Schedule: December 5 – 12, 2005
2. Energy audits at Pulp/Paper and Textile Factories
1) PT Kertas Leces, Pulp/Paper Factory (December 5-7, 9)
2) Industri Sandang Nusantara, Unit Patal Grati Spinning Factory
(December 8)

3. Seminar-Workshop: December 12 at Gran Mahakam Hotel, Jakarta

Participants: 60 (Including Foreigners: 7, ACE: 5)
Presentations:
1) Overview of EE&C Programs of ASEAN (ACE)
2) Initiatives and Programs of ECCJ in Industry in Japan (ECCJ)
3) EE&C Best Practices in Industries:
- Pulp and Paper (Mr. Djoko - PT Kertas Leces, Indonesia)
- Hydro Power (Mr. Vanthong - Num Ngum Hydro Power, Lao PDR)
- Glass and Textile Industry (Mr. Phubalan - PTM. Malaysia)
- Steel (Mr. Domingo - DOE, Philippines)
- Co-Generation and ESCO (Mr. Arthit - EEICL, Thailand)
4) Barriers/Measures for EE&C (ECCJ)
Discussion:
Technical Directory, D/B-B/M-G/L (ECCJ/ACE)
20
ECCJ

10
3.
3. (3)
(3) Indonesia
Indonesia
a. Follow up Energy Audit at PT Kertas Leces
Phase 1 Energy Audit: Jan. 22~26, 2001
Phase 2 Follow up : Dec. 6 & 7, 2005
Audit Participators: MOE = 2, PLN = 1, ECCJ = 3

Production: Pulp and Paper

[Corrugating medium, writing,
printing, duplex board, tissue and Newsprint]
Energy: Fuel oil, N-Gas, LPG and Electricity
Employee: 3,145

Recommended items at phase 1: 34 items

Finished items = 28
Studied, but un-adopted (Expensive) = 2
Studied and tested, but had troubled = 1
Studied, but un-adopted because of machine structure = 1
Equipment stopping = 2
ECCJ Achievement ratio = (28+6)/34 100% 21

3. (3) Indonesia -a.

- EE&C activities in PT Kertas Leces

Top management’s awareness on EE&C is excellent!
PT Kertas presented their EE&C activities at all seminar-
Workshop of PROMEEC.
1. Trigger for energy conservation
1) Energy cost is 24% of production cost! ( 17% (2004) 23% (2005))
2) Decreased the subsidy of the fuel oil since 2001
2. Cost down measures on energy Recent pending problem
1) Fuel changing from oil to gas for short term (2003)
2) Fuel from gas to coal for long term (2006~)
3. EE&C activities
1) Boiler: Increasing boiler performance by re-tubing, boiler operation from 4 to 3,
additional economizers, lowering of steam pressure, etc.
2) Turbine: Increasing turbine performance by clean up of tubes and overhaul
3) Electricity: Repair the old capacitors, Installation of new capacitors
4) Replacement of new air compressor
5) Maintenance of utility devices and instrument, preventive & predictive mainte.
6) Reinforcement of production management 22
ECCJ

11
 3. (3) Indonesia -a.

- Results of Follow-up Energy Audit

Year Improvement
Items
2000 2004 2005 (2005/2001)
Bagasse Pulp 14,876 2,682 823
Production DIP pulp 42,863 2,870 -
Paper (t/y) 135,717 152,482 114,273 0.84
Fuel Oil for 1,019 5,184
Boilers (kL/y) 147,832
Energy LPG (kg/y) 267,290 0 0
consumption
N-Gas (kNm 3/y) 0 122,478 95,149
Fuel total (toe/y) 143,693 105,851 86,492 0.60

Electricity (MWh/y) 219,628 190,936 143,669 0.65

Energy Fuel (toe/t-paper) 1.059 0.694 0.757 0.71

Intensity Elect. (kWh/t-paper) 1,618 1,252 1,257 0.78

Energy Fuel Oil 0.0428/L 0.1776/L 0.3937/L 9.2

Price (US$) LPG 0.1479/kg
N-Gas 0.1179/Nm3 0.1228/Nm3
Electricity 0.0216/kWh 0.0478/kWh 0.0501/kWh 2.3

Recent situation (Main problems): Shortage of bagasse,

ECCJ
Newspaper market, Gas Supply and Increasing fuel price! 23

3. (3) Indonesia -a.

US$0.37/L
2.3 times of 2004
FUEL PRICE
10 9.66
9
8
US$/MMBTU

7
6
5
4.18 4.36
4 3.67
3.2 3.3
3 2.67 2.96
2 1.32 2.2 1.9
1.4 1.6 1.7
1 1.07
0
2001 2002 2003 2004 2005
YEAR

Oil Gas Coal

24
ECCJ

12
 3.
3. (3)
(3) Indonesia
Indonesia
b. Energy Audit at Unit Patal Grati,
PT Industri Sandang Nusantara
Factory Profile EE&C Activities
- Textile (Spinning) Industry Energy team (Section) in factory organized
Operation start at expanded since 1996
factory: 1996 - Checking of energy usage on process
- Employees: 536 machines and utility equipment, then
promotion of the efficient energy use
- Power: 2770kVA from PLN 1996: 950kWh/B,
(3 Generator: 300kW and 2 of 2002: 850kWh/B, (B: Bale = 181kg
1,250kW for Emergency) of textile thread)
2005: 750kWh/B
- Line operation: - Electricity cast: 47% of total cost!
Blowing, carding, drawing,
speed, ring spinning, cone - To collect the necessary energy data
winding - To analyze the energy intensity by
- Compressor: Air, 30kW×4 process (each line) or area
- Chiller: Turbo type 800RT×2 - To check the relation between equipment
- Air conditioning, lighting specifications and actual load
- Audit participator: - To keep the equipment efficiency by
MOE = 1, ECCJ = 3 proper maintenance 25
ECCJ
ECCJ

4. Activities in Philippines
1. Schedule: August 29 – September 2, 2005
2. Rolling Mill Factory visits for energy audit
1) Steel Asia Manufacturing Corporation (August 29, 30)
2) Primary Steel Corporation (August 31, September 1)
3. Seminar-Workshop: September 2 at Dusit Hotel Nikko, Metro Manila
Participants: Approx. 40 (: DOE & DOST and private
companies 33, Foreigners: 6, ACE:1)
Presentations:
1) EE&C Promotion Activities in the Philippines (DOE, Philippines))
2) EC Activities in Industries in Japan (ECCJ)
3) EE&C Best Practices in Industries:
- Overview of Wholesale Electricity Spot Market (Mr. Fernandez –
DOE, Philippines)
- Chemical Industry (Mr. Veloso - R. I. Chemicals Co., Philippines)
- Food Industry (Mr. Erestain - Universal Robina Co., Philippines)
- Iron and Steel, and Food Industry (Mr. Talib - PTM. Malaysia)
- Pulp/Paper Factory (Mr. Subagyo - PT Kertas Leces, Indonesia)
- Ceramic Industry (Mr. Van Long - MOI, Vietnam)
4) Findings of Follow Up Energy Audit at Iron and Steel Industry in
the Philippines (DOE, ECCJ)
5) Barriers/Measures for EE&C (ECCJ)
Discussion:
ECCJ
Technical Directory, D/B-B/M-G/L (ECCJ/ACE) 26
ECCJ

13
3.
3. (4)
(4) Philippines
Philippines
a. Follow up Energy Audit at Steel Asia Mfg. Co.

Phase 1 Energy Audit: Feb. 12~13, 2003

Phase 2 Follow up : Aug. 29 & 30, 2005
Audit Participators: DOE = 2, DOST = 1, ACE = 2, ECCJ = 3

Production: Steel bar

Energy: Fuel oil and Electricity
Employee: 450

Recommended items at phase 1: 4 items

Finished items = 2
Under study = 1
Remaining items = 1

Achievement ratio = 2/4 50%

27
ECCJ

3. (4) Philippines - a.

- Rolling Mill Process and Energy Conservation

By Re-generative burner,
Fuel EE&C = - 10% Heat recovery from
Fuel oil exhaust gas
Recuperator: 20%
(Yes, Re-generative
Billet Furnace burner: No study)
Lighting
Air conditioning
Others
Demand control
(Under study)

Electricity Air
compressor

Improvement of Water Number control

power factor in service (No)
(Yes)
Rod & Bar

Rolling mill 28
ECC
ECC
JJ

14
 3. (4) Philippines - a.

- Results of Follow-up Energy Audit

Year Improvement
Items
2002 2004 (2004/2001)
Steel Bar 212.1
Production (kt/y) 173.7 1.22

Fuel for 5,413 6,776 1.25

Energy Furnace (kL/y)
consumption
Electricity 14,613 20,877 1.43
(MWh/y)
Energy Fuel (L/t) 31.16 31.95 1.025
Intensity
Electricity 84.12 98.43 1.17
(kWh/t)
Fuel oil 0.21 1.4
Energy (US$/L)
0.15 1.6
0.24 (2005)
price
Electricity 0.086 0.095 1.10
(US$/kWh 0.122 (2005) 1.42
1) Many small size products in 2004
2) Much loss time by many kinds of
products
29
ECCJ

3. (4) Philippines - a.

- EE&C Activities in Steel Asia

Top management’s awareness for EE&C has become good in

the wake of the EE&C training course on June, 2005, in Japan!

1. Establishment of “Energy Management Team” in factory

Leader: QA Senior manager (Trainee in EE&C training course)
Member: Staffs from all section/department of factory
Object/Action: Systematic EE&C activity, once a week meeting
Theme: a. Minimization of energy usage at idle time
b. Promotion of worker’s awareness for EE&C

2. Reinforcement of recuperator maintenance and furnace insulation

3. Installation of capacitors
4. Installation of KWH meters
30
ECCJ

15
 3.
3. (4)
(4) Philippines
Philippines
b. Energy Audit at Primary Steel Corporation
Company Profile EE&C Activities
- Iron & Steel Industry Plant manager has a good awareness for
Steel bar production EE&C!
(110~134kt/y (Capa.=240kt/y)) (Plant manager is a member of EE&C
- Operation at new factory:1998 training course on June 2005 in Japan,
- Employees: 200 and received the JETRO inquiry
commission for EE&C in 2004 and 2005.)
- Fuel oil: Furnace (Capa.=40t/h) - Organization of Energy Conservation
- Power: Approx. 4,000kW Groups (2004)
- Line operation: 1 line Maintenance, Production, Materials and
Cross country type total Administration group
15stands tandem mill - Replacement of recuperator of reheating
- Air Compressor furnace (2004)
- Water treatment equipment - Air leak check and maintenance
- Lighting and air conditioning - Installation of baby compressor for
- Audit participator: maintenance
DOE = 2, DOST = 2, - To keep the equipment efficiency by
ACE = 1, ECCJ = 3 maintenance 31
ECCJ
ECCJ

4. Presentation Items from ASEAN Countries (1/2)

(1/2)

Country Industry EE&C Activities

Lao PDR Hydro-power Industry Same presentation done in 2004
Food Industry 1. Installation of economizers to LP boilers
2. Waste heat recovery from hot water boilers
Malaysia (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)
Glass Industry Same presentation done in 2004
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
Power saving = 25% compared to throttle valve
Mill: 550kt/y
Power saving = 1.7%, Fuel saving = 13.7%
Total cost down = 3%
Textile Industry Same presentation done in 2004
1. 10 key success factors for EE project
Thailand Co-Gene & ESCO 2. Cogeneration system by biogas, biomass and
N-gas
3. ESCO investment option and government support
32
ECCJ

16
 Presentation Items from ASEAN Countries (2/2)
(2/2)
Country Industry EE&C Activities
Chemical Industry 200RT refrigeration system is changed from vapor
RI Chemical Corp. compression type to vapor absorption type, that is
available in where there is waste heat and there is
need for chilled water. Effect on productivity: +3.6%
Food Industry Power saving examples with high efficiency motors
Philippines Universal R. Ind. and lighting (By verbal explanation & no paper)
Introduction of outline of Philippines’ steel industry
and “2005 Don Emilio Abello EE Awards”
Iron/Steel Industry [Rolling Mill Co. saved fuel oil 580kL/y by heat
(By DOE) recovery from furnace, etc. and Steel sheet coating
Co. saved 107kL/y of oil]
Power Industry The concept and history of WESM (Wholesale
(By DOE) Electricity Spot Market): WESM is a market for fair
and competitive trading of electricity in real time.
Porcelain Industry Much improvement of percent complete after 2004
(By MOI) follow up. Similar presentation at last Summary-W
Brick Industry Energy audit at brick factory: Fuel saving = 3%.
(By MOI) Power saving = 13% by insulation strengthening, etc.
Vietnam
Energy Audits at 12 Main measures identified by audit:
industrial factories VSD, Boiler improvements, Condensate collection
(By Institute of Energy) system, Maintenance method, Compressed air
systems, etc. Saving: Fuel = 0~38%. Power = 5~40%
33
ECCJ

5. Questions at Seminar (1/2)

1. Brunei Darussalam
1) Is there any subject to punishment in Japanese Energy
Conservation Law? Yes.
2) What kind of measuring instrument is good for energy
conservation? Only one is enough? No.
3) Request to government to stop the cement import
2. Cambodia
1) Who do support the Finance of Malaysia-PTM? Government
2) How to select the equipment, cost or performance?
3. Indonesia
1) How is the method to request the energy audit to
ECCJ in a factory? ECCJ is not liberty to work for
the energy audit by the request from third parties.
Please ask to your government.

34
ECCJ

17
 Questions at Seminar (2/2)

3. Indonesia
2) How to do joining the JETRO’s energy audit program
in January 2006? Please ask to your government.
3) N-gas supply Shortage: Some information of nuclear
power plant in ASEAN came up in conversation.

4. Philippines
1) Does ECCJ work for energy audit of power supplier?
ECCJ activities are limited in user side, not supply
side. Power suppliers in Japan can assess energy
usage by themselves.
2) Many questions from private sector were threw to
government side.

35
ECCJ

6. Summary of EE&C Activities

(1)
(1) Achievement
Achievement Ratio
Ratio in
in Recommended
Recommended Items
Items by
by Follow-up
Follow-up
Energy
Energy Audit,
Audit, 2004
2004 &
& 2005
2005
Items Numbers and Ratio (%)
Country Company Name Non-
(Industry) Recommended Finished Under
by ECCJ or Studied Study activity
Brunei Butra Heidelberg Cement 5 0 1
6 17%
(Cement Industry) 83% 0%
M&V International Mfg 2 0 1
3 33%
(Garment Industry) 67% 0%
Cambodia
2005

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
2004 + Presen tation

(Ceramics Industry) 91% 0% 9%

Num Ngum Hydropower 4 4 0 0
Lao PDR
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) 62 40 (64.5%) 7 (11.3%) 15 (24.2%)
36
ECCJ

18
 Summary of EE&C Activities
(2) Numbers
(2) Numbers of
of Energy
Energy Audit
Audit members
members and
and Seminar
Seminar Participants,
Participants, 2004
2004 &
& 2005
2005

Energy Audit Participants Seminar-Workshop

Country Host Country + ASEAN/Others + ACE + ECCJ = Host Country + ASEAN + ACE + ECCJ =
Total Total

Brunei Cement: 11 + 0 + 0 + 3 = 14 92 + 3 + 2 + 3 = 100

Food: 5 + 0 + 1 + 3 = 9
Garment A: 5 + 0 + 0 + 3 = 8
Cambodia Garment B: 1 + 1 + 0 + 3 = 5 52 + 4 + 1 + 3 = 60
2005

Garment C: 5 + 0 + 2 + 3 = 10
Indonesia Paper: 2 + 1 + 0 + 3 = 6 48 + 4 + 5+ 3 = 60
Textile: 1 + 0 + 0 + 3 = 4

Philippines Iron/Steel A: 4 + 0 + 2 + 3 = 9 34 + 3 + 1 + 3 = 41
Iron/Steel B: 4 + 0 + 1 + 3 = 8

Lao PDR Hydro Power: 1 + 0 + 1 + 4 = 6

Garment: 1 + 0 + 1 + 4 = 6 42 + 1 + 1 + 4 = 48

Malaysia Textile: 3 + 0 + 0 + 3 = 6 84 + 1 + 2 + 3 = 90
2004

Myanmar Oil refinery A: 2 + 1 + 0 + 2 = 5 45 + 2 + 2 +2 = 51

Oil refinery B: 2 + 0 + 1 + 2 = 5

Vietnam Porcelain: 1 + 1 + 1 + 3 = 6 115 + 4 + 1 + 3 = 122

Glass (Lighting F’s): 1 + 1 + 0 + 3 = 5
37
ECCJ Ave. = 3 Ave. = 64

7. Barriers and Possible Measures (1/2)

(1/2)

Barriers Possible Measures Remarks

- Laws & Regulations - Government
1) Policy - Awareness of Top Management policy is
- Commitment of Top Management clear.
2) Human - Top-level Decision
Resources - Education & Training, OJT - Self-study,
prep actively
3) Technology - Seminar/Workshops - ASEAN
- Study Tour PROMEEC
- Technical Directory Project
4) Finance - Feasibility Studies and
Economic Justification
- Economic Instruments
(Incentives, Subsidies,
Soft Loans, etc.)
- Availability of Funding Facility
38
ECCJ

19
 Barriers and Possible Measures (2/2)
(2/2)

Barriers Possible Measures Remarks

- Seminar / Workshops - ASEAN

5) Information PROMEEC
- Technical Directory
Project
- Seminar / Workshops
6) Inadequate
- Capability Building
Local
- Investment Promotion &
Manufacturing
Facilitation
Capability
- Technical Directory
- Education - ASEAN
7) Society &
- Awareness Campaign PROMEEC
Culture
- Reward System Project
8) Business - Awareness of Top Management
Condition /
Energy Price
39
ECCJ

8. General Overview of PROMEEC Activities in

Industry, 2005
PROMEEC is becoming actively year by year at factories in
ASEAN countries, and many companies challenging EE&C
issues can get the profits!
1. Start of PROMEEC in Factories:
By the stimulus of
- Government policy (New policy or revision)
- Cost down
- EE&C training by METI-ECCJ, etc.
- Efficiency up, production increase
- Exterior help, etc.
2. Effects of PROMEEC
- Profit increase
- Bringing up of EE&C awareness
- Good Image as a Green company
The “Management’s supports and all in activities together”
are important to get the good results in EE&C.
40
ECCJ

20
 Thank You
We
We appreciate
appreciate your
your cooperation
cooperation in
in
PROMEEC
PROMEEC activities
activities in
in ASEAN.
ASEAN.

The Energy Conservation Center, Japan41

21