ECCJ / Text for Training Courses / METI / Energy conservationin Japanese factory(2006.7) / Thailand

ECCJ / Text for Training Courses

Thailand

Improvement of operation at Heating furnace (fuel gas combustion)
In this case, the cause of high energy intensity is due to high air ratio combustion: <action> To change air ratio: 1.6(before) to 1.3(after) Gas unit consumption (average): target 0.31 (Nm³/piece) result: 0.34 (Nm³/piece) to 0.30(Nm³/piece)
Energy conservation rate in the heating furnace: 12% (cost reduction 1milion yen/year)

How to increase energy efficiency?

Basic methodology of management

To repeat “P-D-C-A” circle is very effective and important.

Flow of Management circuit (production, cost, energy consumption, etc.)

Energy audit (Factory audit) for energy conservation

< Energy audit is one of very effective tools for energy conservation activity in a factory. >

Objectives:

Fact-finding (energy loss, management state ) and study of cause & measures and advise for improvement

Type of audit:
<Utility audit> Common energy / Utilities:
Usually audited by In-house auditors (Energy managers/ Energy engineers) or out sourcing audit.
	* Out sourcing audit (a part of ESCO, Audit consultant, ECCJ service, etc.) --- Specialists As for utility energy, it should be considered as an common issue for the whole factory, thus the results of the utility audit (boilers, steam, blowers, compressors, ) at Line A can easily be transferred for Line B and other lines.
<Process audit> Energy consumed in process:
Usually audited by In-house auditors (Process engineers and Energy engineers/Energy managers).
	* It is difficult to audit without special knowledge and experiences about the manufacturing process/line (technology, facilities, systems). * Process audit (energy) is usually implemented as a comprehensive audit (productivity, quality, cost, maintenance, etc.). It can obtain bigger results.

Management (organization, target, standard, operation-manual, maintenance, measurement, record, etc.)
Energy loss (heat, steam, electricity — compressed air etc., idling time, shut-down time, etc.)
Energy efficiency (energy unit consumption, 1-loss/input, etc.)--- by equipment, line, factory

<How to audit> Document review, walk-through check, on-site inspection with measuring devices,
<Advice/recommendation of counter measures, Estimation of E-C effect: potential/cost saving >

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