A study of energy use and saving opportunities at a tobacco green leaf threshing plant

Abstract

This study was carried out to analyze the energy use patterns at a Tobacco Green Leaf Threshing Plant (GLT) in order to understand energy consumption trends and patterns. The main aim of this was to identify energy conservation opportunities (ECO) and respective energy conservation measures (ECM) that can be put in place where possible to conserve energy and in relation to best practice in this type of industry. Energy costs in the GLT are a major manufacturing cost contributing up to 22% of total manufacturing costs. With the GLT already operating at higher costs than projected plan, the finding of this study will greatly help the GLT to reduce its operational costs and be competitive. In the assessment of energy use it was observed that the GLT has been consuming energy at higher rates of 4MJ of heavy furnace oil and 1.1MJ of electricity per kilogram of production compared to target benchmarked standards of3.3MJ and 0.84MJ per kilogram of production. Also observed was that even as the GLT has been putting in measures to conserve energy such measures were not well planned and coordinated. Observations and measurements were made on process behaviors of energy distribution and user systems. Several ECO' s were identified and respective ECM's recommended with estimate investments required and expected payback periods It was found that the proposed ECM's have potential to save the GLT 114,971 kWh per year equivalent to Ksh 1,429,412 per year, which is a 2% reduction from 2010 total electricity usage with an estimate investment of Ksh 2,204,400 and 270,4851itres of HFO per year equivalent to Ksh 11,623,835 which is a 17% reduction from 2010 total HFO usage with an estimate investment of Ksh 6,862,200. Other recommendations were also made on what else can be done as future projects to further reduce energy use.