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Case Study:

Reduce Energy Consumption in a Cocoa Plant


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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