Energy Audit In Ethiopian Sugar Industry: A Case Of Wonji/Shoa Sugar Factory

Abstract

Energy Audit Is The Systematic Accounting Of All Energy Inputs; It Is Utilized As A Tool For Energy Optimization And Emission Reduction In Different Industrial Units, Especially In Sugar Can industry; Because Sugarcane Is An Essential Crop In The World For Sugar And Renewable Energy Production. The Generation Of Electrical And Thermal Energy From Sugarcane Fiber (Bagasse) Is Highly Significant Due To Its Renewable Nature, Ensuring Energy Security, And The Economic Advantages. The Energy Auditing Was Conducted Based On Data Collected From Site Measurement Of Material And Energy Flows Using Infrared Temperature Guns , Mel timeter, Clamp Meter, Voltmeter, And Based On Data Collected From Auto Record Of Distributed Control System (Dcs) &Control Panels Of Each Unit Operations As Well As By Laboratory Analysis & From Laboratory Log Books . The Assessment And Performance Evaluations Of Wonji/ Shoa Sugar Factory (Wssf)Boiler And Evaporator Efficiency Is 66.9% 74.2 Respectively. The Total Thermal Energy Losses O fWssf Is 111,754.6 Kw, Through Vent Vapor(Steam), Dry Flue Gas, Vent Steam Of Different Areas, Leakage Of Condensate Water And Blow Down. The Total Electrical Energy Lost Due To Absence Of Energy Efficient Motors And Turbine Is 5,803.2 Kw &20,930,690 Kw Respectively. The Higher Thermal And Electrical Energy Consumption Were Found In Boiler Unit With Dry Flue Gas Which Is24,716.81 Kw And Extraction Unit At Roller Mills Which Is 21.15 Tera Joules. The Total Output Crystalline White Sugar In The Selected Audit Year Is 36,812.02 Ton, But The Recoverable Sugar Is34,325.02 Ton (336,385,196.0 Etb/Month). The Lost Crystalline White Sugar With By Products Is2,487 Ton Due To Lack And Wastage Of Thermal Energy. By Recovering Lost Thermal Energy Can Generate 750 Ton And 1,152 Ton Sugar In Filter Cake And Bagasse Respectively And The Lost Mone yWith These Two By Products In The Selected Audit Year Is 16,875,600 Etb/Month. By Integrating Pipeline From Boiler Id Fan To Bagasse Elevator For The Purpose Of Evaporate (Minimize)Moisturized Bagasse, The Loss Of 24,716.81kw Thermal Energy Through Dry Flue Gas Can Generate And Then Increase The Boiler Efficiency As Well As Reduce Carbon Dioxide Emission. Implementing The Proposed Energy-Saving Measures Has The Potential To Significantly Reduce Energy Loss, Reduce Greenhouse Gas (Ghg) Emission, Increase Profitability, And Enhance Sustainability In The Sugar Industry.