M D Ibrahim - Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, Universiti Malaysia Sarawak (UNIMAS), ۹۴۳۰۰ Kota Samarahan, Sarawak, Malaysia
S A Najamudin - Department of Mechanical and Manufacturing Engineering, Universiti Malaysia Sarawak, ۹۴۳۰۰ Kota Samarahan, Sarawak, Malaysia
S S Lam - Universiti Malaysia Terenganu, Malaysia

In this paper, a preliminary study of industrial steam system reveals that most of the industrial steam user especially the palm oil mill did not bother to save energy as long as the mill meets their productions target and is getting profits for the company. The management is not aware that a huge amount of energy is being wasted during the processes of extracting oil from the fresh fruit bunch (FFB). To embark this study, Steam System Scoping Tool (SSST), Steam System Assessment Tool (SSAT) and ۳E Plus: Insulation Program Software, provided by the United Nations Industrial Development Organization (UNIDO) are used to assess the efficiency of steam system operations. The tools also assist in preliminary assessments of how efficiently the steam system is operating. After analyses are conducted, the proposed improvement project is recommended to modify the system back to its initial designed best efficiency. The results also show that there were various losses that are contributing to the energy waste and its cost impact to the mill. Meanwhile, the boiler efficiency was only about ۶۸.۶%. The findings proposed steam system optimization (SSO) opportunities by installing the feedwater economizer and reducing the blowdown rate of the boiler. The efficiency of the boiler was increased to ۷۷% from its current operating condition. This also improved the steam quality and production output of the mill. Through these SSO, the annual demand saving is around ۴.۹ MW, with an energy saving of ۷۵,۲۷۶ GJ/yr., capable of reducing ۱۳,۰۰۲ metric tons of carbon dioxide emissions per annum and save ۵۹۸.۳ Tph/yr of biomass fuel. Thus, through this steam system optimization the estimated annual net cost savings are around USD ۱۰۰,۰۰۰.۰۰. This paper aims at promoting similar system optimization projects at other plants throughout Malaysia, as it benefits to all industrial steam user especially the palm oil mill industries in Malaysia.

Palm Oil Mill, Energy Saving Opportunities, Steam System Optimization, Steam System Tool Suite