Energy Efficiency PotentialFood & Beverage Sector

In Nepal

Food & Beverage Sector

Sub-sectors

Beverage

Biscuit

Dairy

Noodle

Sugar

Vegetable oil & Ghee

Beverage Sub-sector

Observations

Beverage industries consume both electrical and

thermal energy

Boilers are used for generation of steam and in most

of cases boiler fuel is diesel

Use of re-winded motors

Steam leakages are observed

Insulation not satisfactory

Saving Potentials - Beverage

From ESPS studies, the potentials are 9.09% for Electrical and 19.25% for thermal energy.

 The electrical saving potential

= 0.0909 * 15300379 = 1,390,804 kWh

= 1,390.804 MWh

The thermal saving potential

= 0.1925 * 55,623,829 MJ = 10,707,587 MJ

= 10,707.587 GJ

Areas of Potential Savings Improvement in motor loading Replacement of old and rewinded motors by energy efficient

motors Minimization of energy losses by partition of cooling areas,

installation and effective use of air curtains Regular cleaning and maintenance of condenser pipes Improvement in the efficiency of capacitor banks Improvement in combustion efficiency in boilers Minimization of heat losses from the boiler Minimization of steam leakages Insulation of steam pipes, valves and flanges Improvement in steam supply system Condensate recovery Waste heat recovery

Biscuit Sub-sector

Observations

Biscuit industries consume both electrical and

thermal energy

Thermal energy required for baking process and

source of thermal energy is diesel

Use of re-winded motors

Insulation of oven not satisfactory

Waste heat not recovered

Saving PotentialsBiscuit

ESPS studies - saving potential for electrical energy is 29.47% and thermal energy is 15.38%

 The electrical saving potential

= 0.2947 * 3571208 = 1,052,435 kWh

= 1,052.435 MWh

 The thermal saving potential

= 0.1538 * 56584558 MJ = 8,702,705 MJ

= 8,702.705 GJ

Areas of Potential Savings

Improvement in motor loading

Replacement of old and rewinded motors by energy

efficient motors

Improvement in combustion efficiency in furnace

Insulation of oven to minimize heat losses

Waste heat recovery

Dairy Sub-sector

Observations

Dairies use both electrical and thermal energy

Boilers are installed to get steam for different processes and in most of the cases boiler fuel is diesel

Use of re-winded motors

Steam leakages

Insulation of steam distribution system not satisfactory

Improper steam distribution lines

Improper insulation of cold lines

Saving Potentials - Dairy

From ESPS studies, the potentials were 6.31% for Electrical and 13.91% for thermal energy

The electrical saving potential

= 0.0631 * 7996867 kWh

= 504.602 MWh

The thermal saving potential

= 0.1391 * 91913748 MJ

= 12,785.202 GJ

Areas of Potential Savings Improvement in motor loading Replacement of old and re-winded motors by energy efficient motors Minimization of energy losses by partition of cooling areas, installation

and effective use of air curtains Improvement in insulation Introduction of modern/efficient belt and pulleys to the drives of

compressors Regular cleaning and maintenance of condenser pipes Improvement in the efficiency of capacitor banks Improvement in combustion efficiency in boilers Minimization of heat losses from the boiler Minimization of steam leakages Insulation of steam pipes, valves and flanges Insulation of walls and ceiling of incubation room Improvement in steam supply system Condensate recovery

Instant Noodle Sub-sector

Observations

Instant Noodle industries consume both electrical and thermal energy

Boilers are installed to get steam for cooking processes and boiler fuel is rice husk

Use of re-winded motors

Steam leakages

Insulation of steam distribution system not satisfactory

Inefficient steam distribution lines observed

Saving Potentials - Noodle

ESPS studies have shown that the saving potential for electrical energy is 6.15% and thermal energy is 11.38%.

 The electrical saving potential

= 0.0615 * 3,956,752 kWh

= 243,340 kWh

= 243.34 MWh

The thermal saving potential

= 0.1138* 235,382,966 MJ

= 26,786,582 MJ

= 26,786.582 GJ

Areas of Potential Savings

Improvement in motor loading

Replacement of old and rewinded motors by energy efficient motors

Installation of capacitor banks

Load management

Improvement in combustion efficiency in boilers

Minimization of steam leakages

Insulation of steam pipes, valves and flanges

Improvement in steam supply system

Condensate recovery

Sugar Sub-sector

Observations

Sugar mills need both electrical and thermal energy

Installed with steam turbines to generate power for its production process

Sugar mills are installed with high pressure boilers and boiler fuel is bagasse obtained from the crushing of canes

Heavy motors are used for crushing, pumps, fans and compressors

Use of re-winded motors

Capacitor banks are installed

One of the sugar mills has surplus turbine capacity with possibility to supply to central grid by cogeneration

Saving Potentials - Sugar

SEC is not useful due to lower consumption in the country as the mills do not account for use of bagasse

The saving potentials from ESPS are 14.55% for electrical energy and 20.73% of the thermal energy.

 The electrical saving potential

= 0.1455 * 5,386,106 kWh = 783,678 kWh

= 783.678 MWh

The thermal saving potential

= 0.2073* 10,106,898 MJ = 2,095,160 MJ

= 2,095.16 GJ

Areas of Potential Savings

Improvement in motor loading Replacement of old and re-winded motors by

energy efficient motors Improvement in the efficiency of capacitor banks Improvement in combustion efficiency in boilers Minimization of heat losses from the boiler Minimization of steam leakages Insulation of steam pipes, valves and flanges Improvement in steam supply system Condensate recovery Waste heat recovery

Vegetable Oil & Ghee Sub-sector

Observations

Vegetable oil refinery industries consume both electrical and thermal energy

Boilers are installed to get steam for heating of oil at different stages of processing and boiler fuel is rice husk

Use of re-winded motors

Steam leakages

Insulation of steam distribution system not satisfactory

Inefficient steam distribution lines observed

Saving Potentials Vegetable Oil & Ghee

n=16, Qs = 122,034 MT, Eo = 200 MJ/MT or 55.55 kWh/MT, To = 2700 MJ/MT

Σ(Ex-Eo) = 2100 MJ/MT, Σ(Tx-To) = 52442 MJ/MT

 Electrical Saving Potentials

= (Qs/n) * Σ(Ex – Eo) = (122034/16)*2100

= 16,016,963 kWh = 16,017 MWh

 Thermal Saving Potentials

= (Qs/n) * Σ(Tx – To) = (122034/16)*52442

= 399,981,689 MJ = 399,982 GJ

 

Saving PotentialsVegetable Oil & Ghee

 From ESPS studies, the potentials are 5.49% for Electrical and 11.07% for thermal energy.

The electrical saving potential

= 0.0549 * 21,863,604 kWh = 1,200,312 kWh

= 1,200.312 MWh

The thermal saving potential

= 0.1107 * 705,371,030 = 78,084,573 MJ

= 78,084.573 GJ

Areas of Potential Savings

Improvement in motor loading Replacement of old / re-winded motors by energy efficient motors Introduction of Variable Frequency Drives (VFD) Minimization of energy losses by proper insulation of cold rooms,

installation and effective use of air curtains Improvement in insulation of the cold pipelines Introduction of modern/efficient belt and pulleys to the drives Regular cleaning and maintenance of condenser pipes Improvement in the efficiency of capacitor banks Improvement in combustion efficiency in boilers Minimization of heat losses from the boiler Minimization of steam leakages Insulation of boiling pans, steam pipes, valves and flanges Improvement in steam supply system Condensate recovery Waste heat recovery from cooling of oil