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OVERVIEW OF STEEL; PAPER; FOOD AND GARMENT INDUSTRY – ENERGY SAVING POTENTIAL. Nguyen, Thi Ngoc Tho, Energy Efficiency and Conservation Center of Ho Chi Minh City January 14, 2013. Table of Contents. Energy-using structure Potential energy saving Current status of technologies - PowerPoint PPT Presentation
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OVERVIEW OF STEEL; PAPER; FOOD AND GARMENT INDUSTRY – ENERGY SAVING POTENTIAL
1. Energy-using structure2. Potential energy saving3. Current status of technologies4. Business opportunity5. Case study
Table of Contents
Steel Sector consumed 4.67 billion kWh / year - 5.2% of total electricity consumption
Pulp and Paper sector consumed 251.3 million kWh, accounting for 0.29% of the total power consumption
Energy-using Structure
Source: Energy Institute Vietnam and Vietnamese economic and financial community – 2012-2010
Energy-using Structure in Garment Sector
Source: ECC-HCMC
Energy-using Structure in Food Sector
Source: ECC-HCMC
Electric Consumptions of Equipment Food Sector
Energy-using Structure in Food Sector
Source: ECC-HCMC
Energy using in food sector
Energy-using Structure in Paper Sector
Source: ECC-HCMC
Electric Consumptions of Equipment Paper Sector
Energy-using Structure in Paper Sector
Source: ECC-HCMC
Energy using in paper sector
Energy-using Structure in Steel Sector
Source: ECC-HCMC
Energy using in steel sector
Potential Energy Saving by Sectors
Source: Statistics data from Vietnam National Energy Efficiency Program, 2000
Current status of technologies in steel sector
- Steelmaking technology: 95% of steel production facilities are using electric arc furnace technology EAF. The rest are medium frequency induction furnace IF and blowing oxygen furnace
BOF. Worldwide, the amount of steel produced by the EAF accounts for about 34%, the
remaining comes from LD / BOF
Source: Vietnam Steel Association, 2012
Current status of technologies in steel sector
- Steel rolling technologies are divided into 3 groups: Group of modern plants, using modern technology and equipment from EU,
accounting for about 20% to 25% of the total capacity. Average group of plants, use of technology and equipment from countries such as
China, Taiwan, accounting for about 55% to 65% of the total capacity. Group of very small-scale plants, using domestic technologies, accounting for 15%
to 20% of the total capacity.
Source: Vietnam Steel Association, 2012
Current status of technologies in steel sector
No. Material Unit Europe Vietnam
1 Iron and steel scrap kg/t 1.080 – 1.130 1.135 – 1.200
2 Cast iron bar kg/t 0 - 250
3 Liquid cast iron kg/t 0-600
4 Lime kg/t 30 - 80 50 - 80
5 Coal kg/t 13 - 15 0 - 20
6 Graphite electrode kg/t 1,5 – 4,5 2,9 – 6,8
7 Material inside the EAF kg/t 1,9 – 25,1 17 - 30
8 Total energy Mj/t 6.000- 7.000 7.000 – 10.000
9 Electric kWh/t 350 - 500 420 - 800
10 Oxygen m3/t 24 - 27 30 - 50
11 Cooling water m3/t 0 (circulation) 4 -7
12 Rate of recovery of steel ingots
% 90 - 93 86 - 88
Current status of technologies in steel sector
Source: UNIDO – 7/2011
GJ/ton
EEI standard from USA
Best practice from USA
- The technological level: 42.5% (based on pulp production) using cold alkaline technology, no
chemical recovery; 24.4% use technology to cook pulp by caustic technology, the rest is using sulphate technology for pulp cooking with chemical
recovery.
- Quality of Vietnamese paper products is mainly to meet domestic demand.
Current status of technologies in pulp and paper sector
Source: Vietnam Paper Association 2012
Current status of technologies in pulp and paper sector
No Material Unit Vietnam India North Europe
1 Fiber (output) % 44 - 45 40 - 44 55
2 Chemical Kg/t 80 - 150 71 - 135 75
3 Heat Kcal/t 3x106 – 8x106
3x106 – 5x106
1x106 – 4,6x106
4 Coal Kg/t 575 – 1500 575 - 1000
192-880
5 Oil Kg/t 294 -784 294-490 98-450
6 Electric kWh/t 900 - 1900 855 - 980 700 - 850
7 Water M3/t 175 - 350 180 - 280 20 - 40
Current status of technologies in food and garment sector
Food Sector
Energy saving potential for food processing industry is up to 20%
EE motors and variable speed drive (VSD) are promising products.
The market size for EE lighting and EE equipment such as freezing machine, ice making machine, boiler…; insulation materials; inverter; heat pump; solar water heater are expected to be high.
Garment Sector
Energy saving potential for garment industry is up to 30%
Energy cost accounts for 10-15% of production cost whereas energy waste is up 20-32% due to old technologies and outdated energy management systems.
EE motors and variable speed drives are promising products as SMEs are willing to invest.
The sewing saver also has a lot of potential
Current status of technologies in food sector (beer processing)
No Material Unit Traditional Tech.
Average Tech.
High Tech.
Viet nam
1 Malt Kg 18 16 15 16 – 18
2 Heating MJ 390 250 150 250 – 350
3 Fuel (FO) Lit 11 7 4 4 – 8.5
4 Electric kWh 20 16 8 – 12 10 – 30
5 Water m3 2 – 3.5 0.7 – 1.5 0.4 0.6 – 2
6 NaOH Kg 0.5 0.25 0.1 0.2 – 0.4
7 The other g 570 255 80 100 - 400
•These data for 1000 liters of beer• Source: CPEE project – Jan 2012
Business opportunity in steel sector
The system to supply hot ingost from steelmaking process to roller process
Business opportunity in pulp and paper sector
High efficiency boiler
High efficiency pulp processing
Automatic control the flow of pulp and steam
Business opportunity in food and garment sector
Fluorescent lamps
Energy saving
Ventilation Fans
Energy saving
Inverter
Energy saving
Energy saving up to
Source: Meet-Bis
Boiler System
Business opportunity in food and garment sector (cont.)
electronic sewing machine
Energy saving up to
Heat pump
Fuel saving
Solar Water Heater
Energy saving up to
fuel saving to
Source: Meet-Bis
Sew saver
Business opportunity in food and garment sector (cont.)
Sewsaver
Energy saving up to
IQF
Energy saving up to
IQF (individually quick frozen) Freezer
Refrigerator with screw compressor
Business opportunity in energy efficiency
Energy managerment system and ISO 50001
Wastewater treatment
Introduce the hi-tech to Vietnam enterprise Implement pilot projects Build a financial mechanism for change new technology:
ESCO, leasing financial, …. Cooperate with a Vietnam’s agency for taking the
technology transfer to reduce the investment cost
How to develop EE products in Vietnam
Case study in energy efficiency – Hoa phat group
- Hoa Phat Group produce coke with capacity is 700,000 ton/year.
- In Phase 1: Hoa phat already recovered waste heat for electric gerneration with capacity is 15 MW
- in Phase 2: Hoa phat would like to recover the waste heat from coke making with flow is 166,000 Nm3/h and temperature is 950 -1100oC. Electric capacity of phase 2 is 22 MW
Case study in energy efficiency – Hoa phat group
The chimney of coke making process and the pipe of recovery waste heat
The boiler of electric gerneration system
Hung Tri company produce pulp and paper with small scale – 40 ton carton/day
Install a pulp store to reduce energy cost at peak hours
Case study in energy efficiency – Hung Tri pulp and paper company
Case study in energy efficiency – Hung Tri pulp and paper company
- Install a equipment to neutralize the impurities
Reduce 30% energy consumption
Case Study: energy saving at Hung Long Garment & Service JSC
Company Overview Hung Long Garment & Services (Hung Long) was established in 2001 with
540 workers for the start. Over 10 years of operation and development, Hung Long now has over 2400 workers with 29 production lines in 10 factories. Its products are mainly exported to USA (70%), Europe (10%), Japan (5%), Korea (5%), and others (10%)
The company’s power consumption is very large, about 270,000 kWh/month , in which lighting systems consumes the most with more than 5400 kinds of bulbs
Energy Saving at Hung Long Installed 500 power-saving devices for sewing machine system, saving
12.5% on energy cost
Installed condensate recovery pump in the boiler, saving 25% on fuel costs
Case Study: Energy saving at Hung Long Garment & Service JSC (Cont.)
Energy Saving at Hung Long (cont.) Installed elevator system integrated inverter that helps to reduce energy
costs by 15% for the elevator system
Invested in 2900 sets of T8 fluorescent lamps with electronic ballasts, saving 18% energy costs for lighting.
Replaced 900 sets of T10 to T5, saving 25% energy cost for lighting
Outputs from Applying Energy Efficiency Total energy cost reduces 21%, from $180,000/year to $142,000/year
Electrical energy saving: 100 TOE/year
Fuel energy saving: 250 TOE/year
Case Study: Energy saving at Hung Long Garment & Service JSC (Cont.)
Energy Saving at Hung Long (cont.) Installed elevator system integrated inverter that helps to reduce energy
costs by 15% for the elevator system
Invested in 2900 sets of T8 fluorescent lamps with electronic ballasts, saving 18% energy costs for lighting.
Replaced 900 sets of T10 to T5, saving 25% energy cost for lighting
Outputs from Applying Energy Efficiency Total energy cost reduces 21%, from $180,000/year to $142,000/year
From electrical energy saving: reduced 100 CO2e /year
From fuel energy saving: reduced 250 CO2e /year
Case Study: Energy saving at Investment Commerce Fisheries Corporation
Company OverviewFounded in 1999, Investment Commerce Fisheries Corporation (Incomfish) specializes in frozen seafood processing with a designed capacity of 15,000 MT a year. Its products are mainly exported to USA, Europe, and Japan
Equipment used in IncomfishThree IQF lines with a combined capacity of 1,250 kg/hour
Two Contact Freezers with a total capacity of 1,500 kg/batch
Three Air-Blast Freezers with a capacity of 375 kg/bach/each
An Air Blasting Freezer with a capacity of 2,500 kg/batch
A Refrigeration system with a capacity of 3.7 Million kCal/hour
Two Boilers with a total capacity of 1,000 kg/hour
Two Power Generators with a total capacity of 2,500 KVA and other equipments
Case Study: Energy saving at Investment Commerce Fisheries Corporation (Cont.)
Energy Saving at Incomfish Installed 2 inverters for two water cooling pumps => energy saving of 12,000
kWh/year (energy saving 27%).
Installed 2 inverters and 4 motor soft starters for 6 water pumps => energy saving of 13,500 kWh/year (energy saving 41%).
Installed 2 inverters for 4 condenser fans => energy saving of 89,100 kWh/year (energy saving 30%).
Installed solar water heater for the water supplied to the boiler => DO saving of 4%, pay back in 1.2 years.
Other energy saving solutions applied: used T8 Fluorescent lamps with electronic ballasts to replace Incandescent and Halogen lamps, better demand side management etc.
