Page 53 - Materials Chemistry, Second Edition

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Sustainable Industrial Design and Waste Management
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CP opportunities assessment
The cleaner production industrial audit for both factories concluded that
water and energy consumption are very high in both factories. The cleaner
production opportunities assessment for water and energy audits indicate the
following opportunities:

Energy issues:
• Heat losses due to poor insulation of steam lines.
• Leakage of steam from the processes.
• Steam losses from steam traps due to poor maintenance and defective
steam traps (the purpose of a steam trap is to let water that condensates
in steam lines escape while stopping the flow of steam from escaping).
• Condensate is usually discharged to the drain.
• Lack of steam traps in some jacketed equipment.
• Steam losses in the process of can sterilization (done by direct steam
injection in water).
• Power factors were less than 90% (the value of the utility contract
without penalty).

Water issues:

• Water leakage in some of the processes.
• High water consumption due to open cooling cycles.
• High water consumption in vegetable washing.
• High water consumption in floor and equipment washing.
• Taps and hoses left running.
• Lack of cooling water recovery systems.

The CP audit selected a number of cleaner production solutions taking into
consideration the technical, economical and environmental aspects. The energy
audit was responsible for the fuel and steam consumption in both factories.
Their major objective was to decrease energy loss and fuel consumption.

Energy saving measures
Insulation of bare steam pipes: The lack of insulation of the steam pipes
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resulted in significant heat loss. A Rockwool insulation of 80 kg/m density
was used to insulate 1,475 m of bare steam pipes at Edfina and 485 m at Kaha
resulting in the savings shown in Table 2.6.

TABLE 2.6
Annual Savings from Insulating Steam Pipeline
Edfina Kaha
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Steam saving (m /y) 5,394 2,123
Fuel saving (ton/y) 440 162