Energy performance analysis of pasta and macaroni factory—a case study

Abstract

The great expansion of industries in Ethiopia has significantly increased the demand for the limited energy source of the country. Hence, effective and efficient way of utilizing the available energy is a crucial issue in all industries. This study investigates the energy consumption performance and possible energy saving potentials of Pasta and Macaroni Factory—a case of Africa PLC which is located in Adama city. It is the biggest pasta and macaroni producing factory in the city and consuming a very large amount of energy. The thermal and electrical energy consumption of the factory has been analyzed based on the actual data measured. The thermal performances of the two boilers (steam generators) are analyzed using an indirect method (i.e., calculating the different losses) and the typical boiler efficiency obtained are 81% and 80% for boiler #1 and #2 respectively. It is found that the major heat loss from the boilers is due to the dry exhaust gas. Similarly, water chiller, air compressor, electrical motors, pumps and lighting system equipment energy utilization have been analyzed. The various energy saving measures are analyzed and it is found that the industry can save 2,301 GJ/year of electrical energy by using high efficient motors instead of the existing normal standard motors, 782.6 GJ/year of heat energy can be recovered from the dry exhaust gas by using air preheater and 1,221 GJ/year of heat energy can be recovered by controlling the air to fuel ratio which is a significant energy saving potential. Finally this study reveals that the total possible annual bill saving potential of the factory is 1,676,871 ETB.