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Energy efficiency improvement is a vital action to overcome the problem of energy crisis.
In Ethiopia, industrial parks are becoming vast energy demanding and consuming sector.
Bole Lemi I industrial park (BLIP I) comprises twenty factory sheds focused on the textile
and garment industry. However, series attention is not given to energy efficiency
improvement. Energy audit is not done for this IP starting from its operation, Therefore,
Jay-Jay Textile Factory PLC, which owns three factory sheds inside BLIP is selected as a
case study. The major objective of the study is to conduct an energy audit and energy
efficiency improvement for Jay Jay textile factory without affecting the quality and the
production. For the energy audit and data analysis, As-built drawings, energy bills, years
of data records for major energy-intensive equipment, and lighting data are collected. SLD
is modeled using ETAP 12.6 software and load flow analysis of the factory distribution
network is simulated with MATLAB. Finally, energy efficiency improvement measures
are recommended. Accordingly, the thesis finding shows that, the possibility of an annual
energy saving of 380 MWh, which is around 10.28% of the total annual energy
consumption. Energy intensity analysis is done in comparison with the benchmark showing
there is an opportunity of saving 2,237,059.09 ETB/year by implementing energy
efficiency improvement practices. By minimizing air leakage of the compressor and using
an outside air system, the factory can save 45,403.86 kWh/year of energy or a cost saving
of 47,873.84 ETB/year. Improving the factory lighting as per the required lux for the
specific workstation results in an energy saving of 113,880.00 kWh/year. However, by
using energy efficient lighting 311,433.60 kWh/year of energy or 328,687.02 ETB/year
can be saved. Replacing magnetic ballast with electronics ballast 23,148 kWh/year of
energy or 24,430.39 ETB/year can be saved. MATLAB simulation result shows that the
distribution network active power loss reduced from 68.43 kW to 39.77 kW. On the other
hand, installing an automatic centralized 484 kVAr shunt capacitor bank improves the PF
from 0.75 to 0.9 and results a percentage loss reduction of 30.5 %. PF correction, using
energy efficient lighting technologies, and air compressor leakage prevention found the
main mitigating methods to save energy.
Keywords: - Energy audit, Energy efficiency improvement, Garment industry |
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