Energy auditing and energy savings for Tanzania and Italian petroleum oil refinery (TIPER)

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University of Dar es Salaam
Industry is the key to economic development in which several inputs are required to run the industries. One of the inputs is energy and is among the major consumed input in the sector. Revelation show that energy can serve a country well if wisely utilized. Energy uses in Tanzania energy sectors are still inefficient and for a long time little effort have been attempted to arrest the situation. This is evidenced by little activities associated with industrial energy management. This has been mainly prompted by lack of awareness and financial support. Faced with finiteness of energy resources and global environment problems many industries worldwide have engaged themselves in energy conservation activities. The same has been the trend in refinery industries where the potential for energy serving is promising. The potential for energy servings and the measure to affect it should be the overall goal of the industrial energy management. This report is about aspects of industrial energy management at Tanzanian and Italian Petroleum Refining Co. (TIPER). Here energy auditing was conducted which involved analysis of Historical data and Plant survey. These required measurements of the energy related data, such as gas analysis, temperature, and flow of fluids, power factor and electric current. Historical data analysis for the year under study revealed inconsistent energy usage for plant studied. This was due to poor processing and/ or malfunctioning plant/ equipment. Result on flue gas analysis showed that proper control of excess air can save the factory up to TShs 90 million per annum. Water analysis records revealed that actual boiler down at16.5% was 12.3% higher than recommended value. A saving of up to T.Shs 71 million can be realized through boiler blow down control. The overall plant power factor was found to be 0.8 which is low and subject to TANESCO penalty. Installation of a capacitor bank will improve power factor to 0.95 resulting into a saving into a saving of up to T,Shs 91 million per annum. Flue gases temperatures were found to be high, 408, 250 and 588oc for the two boilers and furnace analyse. Through regular sootblowing and use of combustion air preheater and/ or economiser to the above boilers and furnace it will be possible to save up to Tshs 91 million per annum. Reduction of thermal losses by eliminating sream leakage and improving insulation to the processing lines, and other equipment can save up to TShs 100 million per annum for the Topping plant and power Station. Replacement of inefficient with more efficient lights and disconnection of the burnt ballast can result can result into a saving of up to Tshs 4.2 million per year. The above is not exhaustive and more work is needed in the area of petroleum chemistry, in particular to the premium former former plant where catalytic chemical reactions reform naphtha to high quality gasoline. This is a high temperature process using extensive direct heat and account to nearly 10% of the total energy usage in a refinery.
Available in print form, East Africana Collection, Dr. Wilbert Chagula Library, Class mark (THS EAF TP690.3.M69)
Fossil fuels, Petroleum, Energy conservation, Energy industries, Tanzania
Mnyone, J. (1997) Energy auditing and energy savings for Tanzania and Italian petroleum oil refinery (TIPER), Master dissertation, University of Dar es Salaam