Case Study:

Reduce Energy Consumption in a Cocoa Plant


Food

Download as a PDF

FM_CaseStudyDetailBreadcrumb

Home / Case Study / Reduce Energy Consumption in a Cocoa Plant

Customer Details
A cocoa plant in Indonesia
Problems
Condensate not being recovered

Low feedwater temperature

Low steam to fuel ratio
Objective
To identify savings opportunities and bring down the annual energy bill.
Solution
Forbes Marshall conducted a detailed survey of the plant to identify avenues to reduce energy consumption by 15%. The plan was implemented in two phases :

Phase 1: Stop Wastage
- Proper steam trap management
- Feedwater management
- Recovery of blowdown heat
- Redundant steam lines
- Improvement in condensate recovery factor

In this phase uptime was improved by 5.6%, with 4.8% reduction in energy wastage.

Phase 2: Optimise Efficiency
- Proper capacity utilisation of the boiler; avoiding part loads
- Improvement in boiler efficiency
Benefits
Overall energy saving of 17%

- Operating only one boiler at full load, instead of 3 boilers at part load

47 Dec C rise in feedwater temperature

Condensate recovery factor 40%

Improvement in steam to fuel ratio by 3.95 Kg steam/m3 gas

1.5 million tonnes per annum of CO2 emissions reduced

18975  m3/year water saved