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Energy‐Saving Audit Project
in Malaysia


JAPAN EXTERNAL TRADE
ORGANIZATION (JETRO)

Satoshi Kubota, Abubakar Rasol, Daisuke Arai,
Yuki Kyozuka
                           June,2011
Overview
1.   Background
2.   About Energy-Saving Audit Project
3.   Process
4.   Model Company
5.   Request for MGTC
6.   Ending
1.Background
 1.Needs
  (1)Malaysia
     ~ National Green Technology Policy
       (From July-2009~)

  (2)Japan
     ~ International Cooperation
     ~ Technology Transfer
1.Background
 2.Potential
   Energy efficiency saving potentials identified in MIEEIP
   (Malaysia Energy Efficiency Improvement Program)

                                    GLASS, 4.0%
                   CERAMIC, 6.0%
                                                        PULP&PAPERS,
                RUBBER, 6.3%                               31.4%



            IRON&STEEL,
               10.5%




         CEMENT, 13.4%

                                                        FOOD, 14.5%

                   WOOD, 14.0%


     Source: MIEEIP Final Completion Report, PTM,2007
2.About Energy‐Saving Audit Project

1. Purpose
   (1) Implement more high level energy-saving
        to model company.

  (2) Share energy-saving technology
      in Malaysia.
Energy-Saving                                                                                                           Heat




Technology e.g.
                                                                                                                        shielding




                                                                                     Monitor energy consumption
                                                                                             on the Web
                                                        Factory Energy
                                                          Management
                                                        System(FEMS)
                             Exhaust                                     Gas turbine cogeneration system
                              steam                                                                                  Heat shield painting
                                       Exhaust steam
                                       heat exchanger
                                                        Purchased         Fuel for in-house      Lighting and
                                                        electricity       power generation       office equipment
        Steam                             Warm water
                        Recovery
         trap             tank
                                Drain
                               recovery Cold water
Exhaust heat recovery System
                                                              Factory energy that can be saved                       Highly-efficient lighting
                                                                                                                     ・Inverter fluorescent light
                                                                                                                     ・Highly-efficient mercury lamp
                                                                                                                     ・LED lighting
Energy recovery by
micro-hydro system                                                           Boiler and          Air conditioning
                                                         Power
                                                                              furnace              and freezing

                  Commercial
                   electricity
                     supply

 Frequency command


                  Inverter
                   Rotation speed:
                    70-100%
       Inverter
Cooling control unit
water                                                                                                                               Inverter air
   Temperature sensor                   Turbo freezer                                                                               conditioning
                                                            Heat-retention by insulator            Water recycling
 Introduction and utilization of inverter
Report e.g.
                 Plant & Proposal                Investment            Field of Improvement            Savings in   CO2 Emission

                                                   Group                                                 US$/y      Reduction t/y
 1. Flow Meter Installation                          B        Cost & Energy Management                     -             -

 2. Boiler blow down heat recovery (Case 1)          B        Energy saving                              6.042          38,5

 3. Economizer Installation                          C        Energy saving                             52.777         335,1

 4. Steam Main Line Layout                           C        Steam system reliability & Maintenance       -              -

 5. Proper Trapping of the Steam Main Line           C        Steam system reliability & Maintenance       -              -

 6. Support of Steam Main Line                       C        Steam system reliability & Maintenance       -              -

 7. Air venting of the Steam Main Line               C        Steam system reliability & Maintenance       -              -

 8. Steam leaks in the Steam Main Line               B        Energy saving                             114.473        730,4

 9. Clean Hot Water Generation                       B        Product Quality & Maintenance                -              -

 10. Steam Separators                                B        Product Quality                              -              -

 11. Proper Trapping of Scalders                     B        Energy saving & Reliability               19.533         124,6

 12. Proper Trapping of Horno Fessmann               B        Productivity & Reliability                   -              -

 13.   Stall at Air condition Heat exchanger         A        Productivity & Reliability                   -              -

 14. Long-lasting energy efficient steam traps       B        Energy saving, Maintenance                   -              -

                                                                                              Total     192,.825       1.228,6
2.About Energy‐Saving Audit Project

                             CHILE                   CHINA                 MEXICO            MEXICO
           Period                    2009                    2010           2008-2009            2011

            Field                    Food            Water Treatment          Steel            Chemical


  Number of companies                  3                      2                 3                 3

    Total CO2-Savings
                                             15.1                   46.6              38.5                6.7
    (1,000 Ton / Year)
    Total Cost-Savings
                                               2.5                  20.4              53.7                1.1
    (Million MR / Year)
  Source: Each Project Report,
           J-file(http://www.jetro.go.jp/world/),
           Applied 5-May-2011 currency rate
2.About Energy‐Saving Audit Project

                        Japanese
    Cooperation      Technology and   Support of
  from Malaysian       know-how       JETRO and
     Company                            MGTC




             Development of Green
             Technology in Malaysia
3.Process
   1. Select model companies

      2. Decide specialist

        3. Field survey

            4. Proposal

              5. Feedback seminar
4.Model Company
1. Merits
   (1) Grasp the hidden energy-savings potential
       in the plant
   (2) Share the solutions using advanced technology
       and technique
   (3) Complement energy-savings by no cost proposal

 Moreover…the audit fee is free!
4.Model Company

2. Conditions
   (1) Target field : Processed food, beverage
   (2) Number of companies : 2~3
                            (1 plant per 1 company)
   (3) Scale : Having a large scale and energy
               consuming factory
   (4) Other: completely cooperative for an audit
               and a feedback seminar
5.Request for MGTC
  1. Suggest a recommendation of 2-3 model
     company.

  2.Cooperating in feedback seminars.

  3. Linking the Energy-Saving Audit project to
     GTFS.(Green Technology Financing Scheme)
6.Ending
  Thank you for listening our presentation.
  I’m available for any questions you may
   have.

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Energy saving audit project( mgtc)

  • 1. Energy‐Saving Audit Project in Malaysia JAPAN EXTERNAL TRADE ORGANIZATION (JETRO) Satoshi Kubota, Abubakar Rasol, Daisuke Arai, Yuki Kyozuka June,2011
  • 2. Overview 1. Background 2. About Energy-Saving Audit Project 3. Process 4. Model Company 5. Request for MGTC 6. Ending
  • 3. 1.Background 1.Needs (1)Malaysia ~ National Green Technology Policy (From July-2009~) (2)Japan ~ International Cooperation ~ Technology Transfer
  • 4. 1.Background 2.Potential Energy efficiency saving potentials identified in MIEEIP (Malaysia Energy Efficiency Improvement Program) GLASS, 4.0% CERAMIC, 6.0% PULP&PAPERS, RUBBER, 6.3% 31.4% IRON&STEEL, 10.5% CEMENT, 13.4% FOOD, 14.5% WOOD, 14.0% Source: MIEEIP Final Completion Report, PTM,2007
  • 5. 2.About Energy‐Saving Audit Project 1. Purpose (1) Implement more high level energy-saving to model company. (2) Share energy-saving technology in Malaysia.
  • 6. Energy-Saving Heat Technology e.g. shielding Monitor energy consumption on the Web Factory Energy Management System(FEMS) Exhaust Gas turbine cogeneration system steam Heat shield painting Exhaust steam heat exchanger Purchased Fuel for in-house Lighting and electricity power generation office equipment Steam Warm water Recovery trap tank Drain recovery Cold water Exhaust heat recovery System Factory energy that can be saved Highly-efficient lighting ・Inverter fluorescent light ・Highly-efficient mercury lamp ・LED lighting Energy recovery by micro-hydro system Boiler and Air conditioning Power furnace and freezing Commercial electricity supply Frequency command Inverter Rotation speed: 70-100% Inverter Cooling control unit water Inverter air Temperature sensor Turbo freezer conditioning Heat-retention by insulator Water recycling Introduction and utilization of inverter
  • 7. Report e.g. Plant & Proposal Investment Field of Improvement Savings in CO2 Emission Group US$/y Reduction t/y 1. Flow Meter Installation B Cost & Energy Management - - 2. Boiler blow down heat recovery (Case 1) B Energy saving 6.042 38,5 3. Economizer Installation C Energy saving 52.777 335,1 4. Steam Main Line Layout C Steam system reliability & Maintenance - - 5. Proper Trapping of the Steam Main Line C Steam system reliability & Maintenance - - 6. Support of Steam Main Line C Steam system reliability & Maintenance - - 7. Air venting of the Steam Main Line C Steam system reliability & Maintenance - - 8. Steam leaks in the Steam Main Line B Energy saving 114.473 730,4 9. Clean Hot Water Generation B Product Quality & Maintenance - - 10. Steam Separators B Product Quality - - 11. Proper Trapping of Scalders B Energy saving & Reliability 19.533 124,6 12. Proper Trapping of Horno Fessmann B Productivity & Reliability - - 13. Stall at Air condition Heat exchanger A Productivity & Reliability - - 14. Long-lasting energy efficient steam traps B Energy saving, Maintenance - - Total 192,.825 1.228,6
  • 8. 2.About Energy‐Saving Audit Project CHILE CHINA MEXICO MEXICO Period 2009 2010 2008-2009 2011 Field Food Water Treatment Steel Chemical Number of companies 3 2 3 3 Total CO2-Savings 15.1 46.6 38.5 6.7 (1,000 Ton / Year) Total Cost-Savings 2.5 20.4 53.7 1.1 (Million MR / Year) Source: Each Project Report, J-file(http://www.jetro.go.jp/world/), Applied 5-May-2011 currency rate
  • 9. 2.About Energy‐Saving Audit Project Japanese Cooperation Technology and Support of from Malaysian know-how JETRO and Company MGTC Development of Green Technology in Malaysia
  • 10. 3.Process 1. Select model companies 2. Decide specialist 3. Field survey 4. Proposal 5. Feedback seminar
  • 11. 4.Model Company 1. Merits (1) Grasp the hidden energy-savings potential in the plant (2) Share the solutions using advanced technology and technique (3) Complement energy-savings by no cost proposal Moreover…the audit fee is free!
  • 12. 4.Model Company 2. Conditions (1) Target field : Processed food, beverage (2) Number of companies : 2~3 (1 plant per 1 company) (3) Scale : Having a large scale and energy consuming factory (4) Other: completely cooperative for an audit and a feedback seminar
  • 13. 5.Request for MGTC 1. Suggest a recommendation of 2-3 model company. 2.Cooperating in feedback seminars. 3. Linking the Energy-Saving Audit project to GTFS.(Green Technology Financing Scheme)
  • 14. 6.Ending Thank you for listening our presentation. I’m available for any questions you may have.