ODA-UNESCO Project:

” Promotion of Energy Science Education for Sustainable Development in Laos:”

Prepared by: Assoc. Prof. Sengratry KYTHAVONE

Department of Mechanical Engineering, Faculty of Engineering

National University of Laos

Case Study:

Energy Efficiency and CDM Project

in Lao Brewery Co.Ltd,.

Production Energy Efficiency in Lao Brewery Co.,Ltd.

ISO 9001:2008

ISO 14001:2004

Electrical Energy Consumption: 14million kWh

Fuel Oil Consumption: 2.8 million Tons

Production: 160 million liters

(Year 2009)

Process Diagram

The proposed project aims at improving energy efficiency and will be

implemented at a single industrial facility, i.e., the LB’s beer brewery in

Vientiane. The project consists of two components as follows:

☆Project Component #1: Installation of Vapour Re-Compression

(VRC) system in brewhouse and heat-pump system in pasteurizing

process

☆ Project Component #2: Installation of biogas boiler

The VRC system and heat-pump system in the pasteurizing system

would reduce fuel consumption by recycling waste heat with advanced

technology. On the other hand, the biogas boiler that utilizes biogas

(methane) coming from the wastewater treatment system displaces fuel

consumption of the existing boilers.

Energy Efficiency Project in Lao Brewery Co.,Ltd.

Energy Utility Equipments

Transformer : 6,900 kVA

Cooling system plant : 2,768,700 kcal /hr. 3,220 kW

Boiler plant : 26 ton /hr. (9 ton/hr Stand by) 192 kW

Air compressor plant : 1960 Nm3/hr. 223 kW

CO2 plant : 905 kg /hr 138 kW

Air conditioning system : 3,071,000 Btu/hr

Diesel Generator : 1,000 kVA

Water treatment : 172 m3/hr 155 kW

Waste water plant : 3200 m3/day 315 kW

Brew house : 350*2 hl/brew 188 kW

Filtration plant : 300 hl/hr 101 kW

Packaging line 1 : 20.000 bph 320 kW

Packaging line 2 : 24.000 bph 424 kW

Packaging line 3 : 24.000 bph 1,038 kW

Drinking Water : 24.000 bph 886 kW

Energy Saving System : VRC , Heat pump, Biogas 250 kW

Energy Efficiency Facilities Installation in Lao

Brewery Co., Ltd.

8

Vapor Recompression System

Project activity :

Saving steam by reusing the discharged steam

※ This system was developed for energy saving with the aid from Japanese Government

Boiler steam Drain

HL:Heat Loss

Exhaust steam

Steam compressor

1/10~1/15

COP=10~15

Vapor Re-Compression system

Drain

Conventional heat recovery system VRC system

WP WP

Exhaust steam

HL:Heat Loss

Heat Recovery

Baseline: Discharging the Exhaust Steam

9

VRC System

M

ST ST EAM

40 40 ℃ ℃

Hot water

recovery from

vapor drainage

Wort Kettle

Vapor

76 C 95 C

99 C

80 C

Wort supply

25 C

85 C Waste Vapor

from Wort kettle

Vapor scrubber wash

the vapor and

recover heat for Wort

Pre-heater

Hot water

storage Tank at

99C

100 C

Waste Vapor is

recompressed by

Steam compressor.

Energy Input is

1/10~1/20

Pre-heater

10

VRC System

VRC

11

Heat Pump Efficient Pasteurising System

Hot Water

P P P P P P P P P

No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9

Heat Pump System

Flow of Hot Water

Project activity : Saving steam by heat pump system for Pasteuriser

12

Efficient Pasteurising System

14

Biogas Plant system

Gas Holder

Bio-gas

Boiler 2 ton

Anaerobic Waste Water

Treatment System

Project activity :

Saving Fuel oil usage by Biogas Boiler

Baseline :

Flaring the biogas

15

Biogas Boiler system

Biogas Plant

16

Synergies in treatment

ANAEROBIC

PRE-TREATMENTBREWERY

AEROBIC

POST-TREATMENT

DISCHARGE

PIPE

MUNICIPAL

WASTE WATER

TREATMENT PLANTCITY

BIOGAS

UTILISATION

RIVER

Biogas Plant

1. Average fuel consumption before energy saving system was installed :

3.13 kg – oil / hl ( average Jan – Oct / 2006 )

2. Expected consumption rate in year 2007

2.39 kg – Oil / hl ( average Jan – May / 2007 )

3.Prouction volume in year 2007 : 1,300,000 hl / year

4.Fuel saving : 1,300,000 hl *( 3.13 – 2.39 )kg –oil / hl = 962,000 kg – oil/year

a) Fuel Cost Saving : 962,000 / 0.99 * 4,700 /10,600 = US $ 430,856

b) Running Cost : USD 2.572 ( average Jan – May)*12M *0.9( 90% ) = US $ 27,778

( 70 % Power factor )

c) Broken bottle saved : US $ 21.083 ( average Jan – May ) *12 M * 0.9( 90% ) = US $ 227,696

d) Water Saving : US$ 1.648 ( average Jan – May ) * 12 M * 0.9( 90% ) = US $ 17,798

Annual saving : a) + c) + d) – b) = US $ 648,572 / year

Payback period : US $ 1,829,600 ( total investment ) / US $ 648,572 = 2.8 year

Production volume and Estimated Energy Saving System.

18

0

20000

40000

60000

80000

100000

120000

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

2,000,000

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Pro

fit(

US

D)

Pa

yb

ack P

erio

d(U

SD

)

Graph 1 ESS Year 2007 Report

Payback Period $

VRC+BIOGAS +Heating Pump(Saving cost) $

Profit $

0

1000

2000

3000

4000

5000

6000

7000

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

2,000,000

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Opera

ting R

unnin

g S

yste

m C

ost (U

SD

) / F

uel cost (k

ip/little)

Payb

ack P

eriod (

US

D)

Graph 2 ESS Year 2007 Report

Payback Period $

Operating Running System Cost $

Fuel cost kip/liters

Payback Period of Three Facilities of Saving Energy

19

0

20000

40000

60000

80000

100000

120000

140000

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

900,000

1,000,000

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Pro

fit(

US

D)

Pa

yb

ack P

erio

d(U

SD

)

Graph 1 ESS. Year 2008 Report

Payback Period $

VRC+BIOGAS +Heating Pump(Saving cost) $

Profit $

0

1000

2000

3000

4000

5000

6000

7000

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

900,000

1,000,000

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Op

era

tin

g R

un

nin

g S

yste

m C

ost

(US

D)

/ F

ue

l co

st (k

ip/little

)

Pa

yb

ack P

erio

d (

US

D)

Graph 2 ESS. Year 2008 Report

Payback Period $

Operating Running System Cost $

Fuel cost kip/liters

Payback Period of Three Facilities of Saving Energy

20

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

1 2 3 4 5 6 7 8 9 10 11 12

kW

h/h

l

monthly

Energy Consumption Yearly 2008 Report

Energy year 2007

Energy year 2008

Target Year

2008

27 kwh/hl

-7% -2%

2%

-1%

Monthly energy consumption before and after installation

energy saving facilities

21

Target

Year 2007

27 kWh/hl

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

1 2 3 4 5 6 7 8 9 10 11 12

kW

h/h

l

monthly

Energy Consumption Yearly 2008 Report

Energy year 2007

Energy year 2008

-7% -2% 2%

-1%