Cadbury Adams Thailand Report English

Demonstration Project for Energy Saving Case Study

Department of Alternative Energy Development and Efficiency, Ministry of Energy

Liquid Desiccant Dehumidification (Nov., 6, 2009) / 39

Liquid Desiccant Technology in

Dehumidification

Demonstration Project for Energy Saving

Department of Alternative Energy

Development and Efficiency

Ministry of Energy




Description

Technology Demonstration for Energy Saving

Technology “Liquid Desiccant Dehumidification”

Content

Page

Principal of Technology

Replacing the Existing Technology

Energy Saving Potential

Suitable Conditions for the Technology

Target Group for Adopting the Technology

The Cost of This Technology

Payback Period of This Technology

Environmental Impact

Case Study: Cadbury Adams (Thailand) Co., Ltd.

Appendix

Appendix A Energy Consumption Index Calculation before Implementation

Appendix B Energy Consumption Index Calculation after Implementation

3

4

5

6

6

7

7

7




Liquid Desiccant Dehumidification

1. Principal of Technology

Liquid Desiccant Dehumidification Technology uses liquid desiccant solution to remove the moisture out of

the air. It5s capable to control humidity lower than 40 % RH within the temperature range of 22 + 1 oC. The

system consists of 3 major parts, Collection Section, Regeneration Section and Heat Pump Section, as

shown in Figure 1.1.

Figure 1.1: Principal Operation of Liquid Desiccant Technology

= Collection Section > This section absorbs moisture out of the room air. The room air flows into this

section. In this section, Lithium Chloride Solution flows through the cold side heat exchanger, which

cools down the Lithium Chloride Solution. The LiCl solution will be sprayed, when the air contacts LiCl,

LiCl will absorbs moisture as well as cools down the air. Thus, the air will be dry and cool Then, LiCl

will drop into the reservoir and be pumped to the regeneration section.




= Regeneration Section > This section will blow out the moisture out of the liquid desiccant. The LiCl

solution is pumped to the hot heat exchanger, which heat up the LiCl solution. Then, the hot LiCl is

sprayed in this section. At the same time, the outside air is drawn in through the Pre-Heat Coil of the heat

pump (and flow into this section). The hot air will carry out the moisture from the hot LiCl solution. Thus,

the LiCl will become more concentrated and flows back to the collection side (for absorbing the moisture).

= Heat Pump Section > This section controls the flow of the R22 refrigerant, which transfers heat

between hot and cold heat exchanger. Thus, the LiCl solution is heated up and cooled down by this

process. Most of the electrical power is consumed in this section, Therefore the wisely used of both hot

and cold energy is the key that make this technology consume less energy than others.

2. Replacing The Existing Technology

In the past, the system, which controls the humidity below 40%RH at 22 + 1 oC, was designed by using

desiccant dehumidifying unit to control the required room humidity. The normal air conditioning unit is not

capable to extract moisture out of the air at this required condition. So, the air conditioning provides only

the sensible heat of the room, all the latten heat is absorb only by desiccant dehumidifier unit only.

The well-known desiccant dehumidifying unit is Desiccant Wheel, figure 2.1. It uses the LiCl or Silica gel

as the desiccant, and use the electric heater or steam heater to heat up the air for blowing out the

humidity from the desiccant, which consumes lots of energy. The disadvantage is the process (room) air is

heat up 15 > 20 oC, the air is hot and dry. The room air conditioning unit should be larger to compensate

with the heat load produced by the desiccant dehumidifying process. Therefore this technology uses lots of

energy to maintain room air to the required condition.

Figure 2.1: Desiccant Wheel Dehumidifier Using Electric Heater




Figure 2.2: Psychrometric Chart Comparing Different Types of Dehumidifier(3)

At present, the dehumidifying technology for the dehumidifier and dehumidifying equipment for air

conditioning are well developed, to consume far less energy. This new mentioned technology is liquid

desiccant technology. The liquid desiccant dehumidifier uses LiCl solution to extract moisture as well as

reduce the temperature of the air. The major advantage of this technology approach is using the heat

pump design, which can reduce the energy consumption to one third of the former desiccant

dehumidifying technology. The processed air is cool and dry, the temperature is reduced by 5 > 7 oC.

Therefore, the size of air conditioning unit can be reduced, which leads to less energy consumption. The

overall energy consumption of the system is much more reduced.

3. Energy Saving Potential

From the case study in Thailand, the liquid desiccant technology can reduce the energy by 50%

comparing to desiccant wheel dehumidifier which used electrical heater or steam heater to throw out the

moisture from the desiccant wheel.

From the data of the distributor of this technology, there was the installed liquid desiccant technology for

the dry food packing process which the food was dry by vacuum freeze drying process. The packing

room should have very low humidity, 30% at 22.5 oC. The investment and energy saving calculation




between the air conditioning with the desiccant wheel and the new liquid desiccant dehumidifier is shown

in the following table.

Investment Description Liquid Desiccant Desiccant Wheel Differences

System System

1. Air-Cooled Split Type (Baht) 1,250,000 (25 tons) 1,750,000 (35 tons) 500,000

2. Desiccant Dehumidifier (Baht) 1,500,000 1,350,000 - 150,000

Total Investment (Baht) 2,750,000 3,100,000 350,000

1. Air Conditioning System

Cooling Capacity (Ton) 25 35 10

Electrical Power (kW) 38 53 15

One Month Power Consumption (kW.Hr/Month) 27,000 37,800 10,800

One Month Electrical Expense (Baht/Month) 74,500 103,950 29,700

2. Desiccant Dehumidifier

Electrical Power (kW) 25 70 45

One Month Power Consumption (kW.Hr/Month) 18,000 50,400 32,400

One Month Electrical Expense (Baht/Month) 49,500 138,600 89,100

Total Electrical Expense (Baht/Month) 123,750 242,550 118,800

Total Electrical Expense (Baht/Year) 1,485,000 2,910,500 1,425,600

Remarks : The electrical cost is 2.75 Baht per kW-Hr., 24 Hours/Day, 30 Days/Month, 1.5 kW/Ton

From the table, it showed that the liquid desiccant dehumidifier can reduce the initial investment by 10 >

15% and be capable to reduce the energy consumption as much as 50%.

4. Suitable Condition for This Technology

The liquid desiccant dehumidification technology is suitable for factory or air conditioned building which

requires less than 40% relative humidity in production line or particular area. This technology is to

replace the energy hungry desiccant wheel dehumidifier.




5. Target Group for Adopting This Technology

The factory groups which can apply this technology are as the following.

• Food Factory and Dry Food Packing Factory

• Frozen Food Factory

• Diary Factory

• Pharmaceutical Factory

• Plastic Injection Factory

• Electronic Factory

• Chemical Factory

• Etc.

6. The Cost of This Technology

The investment cost of the liquid desiccant system will depend on the size of the system and the type of

installation. For the case study in Thailand, the system investment cost would be around 400,000 >

600,000 Baht per 1,000 CFM of air flow.

7. Payback Period of This Technology

From the case study in foreign country and case study in Thailand, the liquid desiccant dehumidification

system has the payback period of 3 > 5 years.

8. Environmental Impact

The liquid desiccant dehumidification system has low environmental impact, which is in the same level as

the air conditioning system. The liquid desiccant, LiCl solution, has low toxic to environment, almost the

same level as Sodium Chloride.




Case study of Dehumidification using Liquid Desiccant Technology

Name of Business: Cadbury Adams (Thailand) Co., Ltd.

Type of Industry: Food Industry-Chewing Gum and Candy

Technology: Dehumidification using Liquid Desiccant

Former Technology: Desiccant Wheel Dehumidifier using heat from Electric

Heater

Implementation of Technology: Replace former technology with a DuCool Liquid Desiccant

Dehumidification unit

Controlled Air Condition: Temperature 20+-1 ⁰C Humidity 45+- 1% % RH

Installation Period: 6 months

Type of Energy Reduced: Electricity

Energy Reduction: 2,395,061.76 Mega Joule/year

Energy Expenses Reduction: 817,314.83 Baht/year

Installation Cost: 1,930,000 Baht

Pay-back Period: 2.36 years




Case Study: Cadbury Adams (Thailand) Co., Ltd.

1) Background and Basic Information

Cadbury Adams (Thailand) Co., Ltd. has joined Demonstration Technology for Energy Saving Project and

managed to install Liquid Desiccant Dehumidification Technology to condition air transmitted into gum

production area of the factory. This technology is to replace the former dehumidifying technology using

solid desiccant and using electric heater to dry out the solid desiccant. The details of procedures are as

following.

2) Procedure before and after the replacement

2.1 Former Process (before the replacement)

The former process to put fresh air and recondition the air into gum production area in the factory of

Cadbury Adams (Thailand) Co., Ltd. consisted of three main equipments; Fresh Air Unit (FAU),

Dehumidifying unit using solid desiccant and heat from electric heater (DH) and Air Handling Unit (AHU).

The outside air was drawn into FAU which installed cooling coil inside. Then preliminary conditioned air

flew into dehumidifying unit which used solid desiccant to draw moisture out of the air. The air, flowing

through solid desiccant, had lower humidity but higher temperature. This was because solid desiccant had

to use heat from electric heater to blow away the humidity. Therefore, the temperature of solid desiccant

was high. As a result, the air flew through solid desiccant got higher temperature. To cool down the air to

proper temperature, AHU with cool coil inside had to be installed for final air conditioning before it was

supplied to the production area (See following diagram).




• Diagram of former equipments

• Details of Former Equipments

The air in the gum production area was controlled both temperature and humidity by FAU, AHU and

dehumidifier using solid desiccant which need electric heater in the dehumidifying process. The details of

FAU, AHU and dehumidifying unit are as following;

1. FAU with no Desiccant

Equipment Capacity 84.142 Btu/h

Wind quantity 800 CFM

2. FAU with dehumidifying unit using solid desiccant/Heater (DH-G002)

Equipment Capacity 57,154 Btu/h

Electric Heater 46 kW

Air Flow Rate 1,470 CFM

Supplied Air Temperature/Humidity 45*C/8.2% RH

Enthalpy of the Air 32.46 Btu/lb*F

3. AHU with no Desiccant





• Picture of machine and supplementary equipment before improvement

Picture No. 1 FAU code number FAU-G001

Picture No. 2 Dehumidifying unit code number DH-G002




Picture No. 3 AHU code number AHU-G004




2.2 Baseline Energy Index before Improvement

Air conditioning and dehumidifying system for gum production area in the factory of Cadbury Adams

(Thailand) Co., Ltd mainly uses electrical energy. The FAU uses electricity for cooling the air by passing it

through cooling coil running with chilled water from the factory5s chiller, FAU fan consumes electricity to

supply cool air to dehumidifying unit.

Electric Heater in Dehumidifying unit uses electricity to produce heat to blow away humidity from solid

desiccant after drawing humidity from the air. It also uses electricity for a fan to blow low humidity but

high temperature air to AHU.

AHU uses electricity for cooling through cooling coil running with chilled water from chiller of the factory. It

also uses electricity for a fan to supply the conditioned air; temperature and humidity, to gum production

area.

Since all the machines in the system work relatively, to calculate the baseline energy index before

improvement, the energy used by all the machines in three units has to be considered. This is to find out

the energy consumption per hour for conditioning air for gum production area. The index will be used to

compare with the one made after the improvement.

Summary of energy consumption in FAU before improvement

Equipment Electrical Energy Consumption

kWh/h

Preliminary Energy

MJ/h

Heat Energy

MJ/h

Total

Electrical Energy Consumption of FAU A GOO1

FCU-GOO1 6.35 50.76 - 50.76

Electrical Energy Consumption of DH A GOO2

DH-GOO2 46.48 371.84 - 371.84

Electrical Energy Consumption of AHU A GOO4

AHU-G004 16.72 133.76 - 133.760

Total 69.55 556.36 - 556.36

Remarks: To convert electrical energy to preliminary energy, efficiency value in transforming heat energy

to electrical energy of 0.45 is used in calculation.

Energy index before improvement = 558.36 MJ/h

(Details of index of energy consumption calculation is provided in Appendix A)




Energy Consumption Determining Factors (Before Improvement)

Energy Consumption Determinant Before Improvement

- Temperature and Humidity in the Gum Production Area

(Air from FAU)

- Humidity Ratio

18*C/34% RH

4.24g/kg(a)

-Temperature and Humidity in the FAU Room (before

passing through FAU)

- Humidity Ratio

30.8*C/43.20%RH

12.06 g./kg(a)

Capability of Chiller (kW/ton) 0.88

Baseline Energy Consumption before Improvement

Electrical energy consumed by air conditioning and dehumidifying system is mainly used by AHU, DH and

FAU. Total energy and expense for total energy before improvement are shown below;

Table 1: Summary of Energy Consumption before Improvement

Details Electricity

(Kilo Watts HR./y)

Energy used per

year (MJ/y)

Electrical energy consumption

1. FAU-G001

2. DH-G002

3.AHU-G004

45,415.20

332,424.96

119,581.44

163,494.72

1,196,729.86

430,493.18

Total energy consumption 487,421.60 1,790,717.76

Preliminary Energy Consumption before Improvement

Final electrical energy before improvement = 1,790,717.76 MJ/y

Preliminary energy = 1,790,717.76/0.45 MJ/y

= 3,979,372.80 MJ/y

Total preliminary energy consumption before improvement = 3,979,372.80 MJ/y




Table 2: Total Energy Expense before Improvement

Details Energy Expense(Baht/year)

Expense for electricity of the system

1. FAU-G001

2. DH-G002

3. AHU-G0041.

123,983.50

307,520.14

326,457.33

Total energy expense 1,357,960.97




2.3 Improvement Process and details of new machines and equipments

• Improvement Concept

To improve air conditioning and fresh air handling system in the factory, The Cadbury Adams (Thailand)

decided to replace the old system with one set of fresh air unit with heat pipe and dehumidifying unit using

liquid desiccant. The existing AHU could still be used. Using new dehumidifying technology, the energy

used by electric heater is reduced. The energy used by AHU is also reduced since the air from new

dehumidifying unit is cool and dry. Therefore, the work of connected AHU is reduced. Details of new

machines and equipments are as following.

• Details of machines and equipments in the new system

1. Fresh Air Unit with Heat Pipe(FAU-G001-WHP)

Cooling capability 80,000 Btu/h

Air Flow Rate 800 CFM

2. Dehumidifying Unit using Liquid Desiccant DT-2400 (DH-G0002N)

Electricity consumption 11.4 KW


3. Air Handling Unit (AHU-G0004) The existing unit.




• Diagram of New Equipments

Installation

Cadbury Adams (Thailand) Co., Ltd improved Fresh Air and re-circulating conditioning system for the gum

production room using dehumidifying technology with liquid desiccant since February 2009. The

installation and implementation period took about 6 months.

After the improvement, the new system performs same function as before. The change is that liquid

desiccant dehumidifier is used to replace solid desiccant dehumidifier.

LIQUID DESICCANT DEHUMIDIFIER

EXISTING AHU

FRESH AIR UNIT WITH HEAT PIPE

NEW EQUIPMENT




Picture No. 4 New dehumidifying and air conditioning units: Consists of Fresh air unit,

Dehumidifying unit using liquid desiccant (DHG002N) (in the back) and air handling unit

Picture No.5 Dehumidifying unit using liquid desiccant (DH-G002N)




2.4 Energy Consumption Index after improvement (Post Energy Index) and Energy Consumption

Reduction of Technology

After the installation of new dehumidifying unit, the electricity consumption in part of using heat to blow

away humidity in solid desiccant is reduced. And since the temperature of conditioned air from

dehumidifying unit is already cool, the electricity used in AHU is also reduced. Summary of energy

consumption after improvement is shown below.

Summary of energy consumption after improvement


kWh/h

Preliminary Energy

MJ/h

Total


FCU-GOO1 6.35 50.76 50.76


DH-GOO2 12.42 99.36 99.36


AHU-G004 8.92 71.36 71.36

Total 27.69 221.48 221.48

Remarks: To convert electrical energy to preliminary energy, efficiency value in transforming heat energy

to electrical energy of 0.45 is used in calculation.

Therefore,

* Energy Consumption Determinant after improvement

- Temperature and humidity in gum production room 18.1*C/34.5 %RH

- Humidity Ratio in gum production room 4.44 g/kg(a)

- Temperature and humidity of air before entering FAU 31.9*C/49.6%RH

- Humidity ratio of air before entering FAU 14.81 g/kg(a)

- Chiller efficiency 0.88 kW/tonr

(Details of index of energy consumption calculation is provided in Appendix B)

Energy Consumption Index (after improvement) = 221.48 MJ/h




2.5 Energy consumption and energy expense reduction after improvement (Post Energy

Consumption)

Energy Consumption after improvement (Post Energy Consumption)

After improvement, the new units in factory of Cadbury Adams (Thailand) Co., Ltd still mainly use

electricity. FAU uses energy for blowing air through cooling coil running with chilled water from chiller of

the factory. It is also used fan to blow cool air into dehumidifier using liquid desiccant unit.

Dehumidifying unit using liquid desiccant uses electricity to re-circulate liquid desiccant and for heat

pump.

Existing AHU uses electricity to cool down the temperature and blowing cool and dry air into process

area. The energy consumed in this unit significantly decrease comparing to the former technology. This is

because air from new dehumidifying unit is cooler than the former one using electric heater.

Details of energy consumption of the three units after improvement are shown in the following tables.

Table no. 4: Energy Consumption after Improvement

Details Electricity

(kW-h/y)

Energy Consumption/year

(MJ/y)

Electricity Consumption

1. FAU-G001

2. DH-G002N

3. AHU-G004

45,415.20

88,827.84

63,795.84

163,494.72

319,780.22

229,665.02

Total Energy Consumption 198,038.88 712,939.97

Primary Energy Consumption after Improvement

Final Electrical Energy after Improvement = 712,939.97 MJ/y

Primary Energy = 712,939.97/0.45 MJ/y

= 1,584,311.04 MJ/y

Total Preliminary Energy Consumption after

Improvement = 1,584,311.04 MJ/y




Table no. 5: Energy Expense after improvement

Details Energy Expense(baht/year)


1. FAU-G001

2. DH-G002

3. AHU-G0041.

123,983.50

242,500.00

174,162.64

Total energy expense 540,646.14

Table No. 6: Energy Saving

Details Electricity

(kW/y)

Total Energy

(MJ/y)

Total Expense

(Baht/y)

Energy

Consumption

Index (MJ/y)

- Energy Consumption

before Improvement

- Energy Consumption after

Improvement

497,421.60

198,038.88

3,979,372.80

1,584,311.04

1,357,960.97

540,646.14

556.36

221.48

Saving 299,382.72 2,385,061.76 817,314.83 334.88

Energy Saving by Technology

Energy Consumption Index = 556.36 MJ/y

Before Improvement

Energy Consumption Index = 321.48 MJ/y

After Improvement

Percentage of saving is

= Energy Consumption Index before Improvement > Energy Consumption Index after Improvement * 100

Energy Consumption Index before Improvement

= 556.36 > 321.48 x 100

556.36

= 60.19%

• Payback Period and Return on Investment

Investment expense 1,930,000 Baht

Expense reduction/year 817,314.83 Baht/y

Payback Period 2.36 Years




Appendix A

Details of Energy Consumption Index Calculation (before Improvement)

Air conditioning and dehumidifying system for gum production area in the factory of Cadbury Adams

(Thailand) Co., Ltd mainly uses electrical energy. The FAU used electrical energy for passing air through

cool coil running with chilled water from the chiller of the factory and for the fan of unit to handling cool air

to dehumidifying unit.

Electric Heater in Dehumidifying unit uses electrical energy to produce heat to blow away humidity from

solid desiccant after drawing humidity from the air. It also uses electrical energy for a fan to blow low

humidity but high temperature air to AHU.

AHU uses electrical energy for cooling using cooling coil running with chilled water from chiller of the

factory. It also uses electrical energy for a fan to supply the conditioned air; temperature and humidity, to

gum production area.

Since all the machines in the system work relatively, to calculate the baseline energy index before

improvement, the energy used by all the machines in three units has to be considered. This is to find out

the energy consumption per hour for conditioned air for gum production area. The index will be used to

compare with one made after the improvement. To calculate the baseline index, following information of

energy consumption are used.

Result of Measured Electric Power Consumption in Fresh Air System

- Electric power consumed by fan in FAU G001 0.81 kW

- Electric power consumed by DH G002 46.48 kW

- Electric power consumed by fan in AHU G004 4.12 kW

- Average Cooling Efficiency of Chiller 0.88 kW/tonr




Picture A.1 Energy Consumption of DH G002 and AHU G004 (Fan)

Energy Consumption of Fresh Air Unit (FAU-G001) with no Desiccant

Inspection date: 18-20/02/09

Inspection Method

Measured all determining factors involved in energy consumption of Fresh Air Unit. Measured electrical

energy used by fan, temperature of supply and return chilled water and flowing rate of chilled water used

by the unit in order to calculate energy consumption to produce chilled water running in the cooling coil of

Fresh Air Unit.

Inspection result




Summarized Measured Result of Fresh Air Unit with no Desiccant (FAU-G001)

- Electric power consumed by fan in FAU (PfanFAU) 0.81 kW

- Chilled water flow rate 1.48 kg/s

- Supply chilled water temperature 4.89 *C

- Return chilled water temperature 8.46 *C

Calculation of Refrigeration Ton of Fresh Air Unit (HIJKLIMNOPIQMIRSTMKNIUVWXM)

Qt = mcw x 4.186 x (T1-T2)

When

mcw = flow rate of chilled water kg/s

T1 = supply chilled water temperature*C

T2 = return chilled water temperature *C

Refrigeration ton (tonr) = Qt x 3,600/(1.055 x 12,000)

Therefore

Actual refrigeration = 1.48 x 4.186 x(8.46-4.89) x 3,600/(1.055 x 12,000)

= 6.29 refrigeration ton

Electrical power used = 6.29 (tonr) x 0.88 (kW/tonr)

= 5.54 kW

Total Electrical power = Electrical power used for chilled water production + Electrical power used

by fan

= 5.54 + 0.81

= 6.35 kW




Dehumidifier using Solid desiccant and Electric Heater (DH-G0002)

Measuring Method

The following determining factors of energy consumption in dehumidifying unit are measured : electrical

consumption of fan and electric heater, temperature and humidity of in and out air from the unit and in and

out air flow rate from the unit. These are to be used as reference value comparing with one after

improvement.

Inspection result

Summarized Measured Result of Dehumidifying Unit (DH-G002)

- Electricity consumption by dehumidifying unit (PDH) 46.48 kW

Electricity consumption by Air Handling Unit AHU-G004

Measuring date: 18-20/02/09

Measuring Method

The following determining factors of energy consumption in air handling unit are inspected: electricity

consumption of fan, temperature of supply and return chilled water and flow rate of chilled water running in

the unit. This is to calculate energy using in producing chilled water for the cooling coil of the unit.




Measured Result

Summarized Measured Result of Air Handling Unit(AHU-G004)

- Electrical power consumed by fan in FAU (PfanFAU) 4.12 kW

- Flow rate of chilled water 1.94 kg/s

- Supply chilled water temperature 4.0 °C

- Return chilled water temperature 11.20 °C

Actual cooling size = 1.94 x 4.186 x (11.20-5.0) x 3,600 (1.055 x 12,000)

= 14.32 Cooling Ton

Therefore,

Electric power consumed in chilled water production (PChilled AHU) = 14.32 (tonr) x 0.88 (kW/tonr)

= 12.60 kW

Total Electrical power consumed = Electrical power consumed in chilled water production +

Electrical power used by fan

= 12.60 + 4.12

= 16.72 kW




Baseline Energy Calculation

Electric Power Consumption

Calculate working hour (OH) 1 hour

Fresh Air Unit (FAU-G001) with no Desiccant

Electrical Power Consumption = (PfanFAU+PChilledFAU) OH x 100%

= (0.81 + 5.54) x 1 x 100%

= 6.35 kW/h

Final Energy = 6.35 x 3.6

= 22.84 MJ/h

Preliminary Energy Consumption = Final Energy/0.45

Preliminary Energy = 50.76 MJ/h

Dehumidifying Unit using Solid desiccant/Electric Heater Coil (DH-G002)

Electrical power Consumption = PDH x OH x 100%

= 46.48 x 1 x 100%

= 46.48 kW/h

Final energy = 46.48 x 3.6

= 167.33 MJ/h

Preliminary energy consumption = Final Energy/0.45

Preliminary energy = 371,84 MJ/h

Air Handling Unit (AHU-G004)

Electrical power Consumption = PFanAHU +PChilledAHU x OH x 100%

= (4.12 + 12.60) x 1 x 100%

= 16.72 kW/h


= 60.19 MJ/h


Preliminary energy = 133.76 MJ/h

Summary of Energy Consumption of Fresh Air




System before improvement


kWh/h

Preliminary Energy

MJ/h

Heat Energy

MJ/h

Total


FCU-GOO1 6.35 50.76 - 50.76


DH-GOO2 46.48 371.84 - 371.84


AHU-G004 16.72 133.76 - 133.760

Total 69.55 556.36 - 556.36

Total energy consumption = preliminary electrical power

= electrical power consumption of FAU+DH+AHU

= 50.76+371.84 + 133.76 MJ/h

= 556.36 MJ/h

Therefore

* Determining Factors for Baseline Calculation

- Temperature in gum production area 18°C / 34%RH

- Humidity ratio in gum production Area 4.24 g/kg(a)

- Temperature and humidity of fresh air before 30.8°C / 43.20%RH

passing through FAU

- Humidity ratio of fresh air before passing 12.06 g/kg(a)

through FAU

- Capacity of chilled water production unit 0.88 kW/ton

Energy consumption index = 556.36 MJ/h




Baseline Energy Consumption before Improvement

Air conditioning and dehumidifying system before improvement mainly consumes electric power by fresh

air unit, dehumidifying unit and air handling unit. Total energy and expenses for total energy are shown

below.

Details of information for calculation are;

- Number of working hour: 24 hours/day

- Number of working days: 298 days/year

- Cost of electricity: 2.73 baht/unit

Electrical energy of fresh air unit (FAU-G001)

Electrical power used by fan = 0.81 kW

Electrical power used in chilled water production = 5.54 kW

Electrical energy consumption per year = (0.81+5.54)x24x298

= 45,415.20 kW/h/y

Electrical expense per year = 45,415.20 x 2.73

= 123,983.50 baht/y

Electrical Energy of Dehumidifying Unit (DH-G002)

Total electrical power of DH-C002 = 46.48 kW

Electrical energy consumption per year = 46.48x24x298

= 332,424.96 kW/h/y


= 907,520.14 baht/y

Electrical Energy of Air Handling Unit (AHU-G004)

Electrical power consumed by fan = 4.12 kW

Electrical power consumed by chilled water production = 12.60 kW

Electrical energy consumption per year = (4.12+12.60) x24x298

= 119,581.44 kWh/y

Electrical expense per year = 326.457.33 baht/y

Total electrical energy consumption = electrical energy of FAU-G001+electrical energy of DH-G002

+ electrical energy of AHU G-004




= 45,415.20 + 332.424.96 +119,581.44

= 497,421.60 kWh/y

Total electrical expense = electrical expense of FAU-G001+electrical expense of DH-

G002 + electrical expense of AHU G-004

= 123,983.50+907,520.14+326,457.33\

= 1,357,960.97 baht/y

Summary of energy consumption and energy expense calculation (before improvement) is shown in the

following table A.1 and A.2.

Table A.1 Summary of energy consumption (before improvement)

Details Electricity

(Kilo Watts -h/y)

Energy used per year

(MJ/y)

Electrical Energy Consumption

1. FAU-G001

2. DH-G002

3. AHU-G004

45,415.20

332,424.96

119,581.44

163,494.72

1,196,729.86

430,493.18

Total energy used 497,421.60 1,790,717.76

Preliminary Energy Consumption before Improvement

Final electrical energy before improvement = 1,790,717.76 MJ/y

Preliminary energy = 1,790,717.76/0.45 MJ/y

= 3,979,372.80 MJ/y

Total preliminary energy consumption before improvement = 3,979,372.80 MJ/y

Table A.2: Total Energy Expense before Improvement



1. FAU-G001

2. DH-G002

3. AHU-G0041.

123,983.50

307,520.14

326,457.33

Total energy expense 1,357,960.97




Appendix B

Details of Energy Consumption Index Calculation (after Improvement)

After improvement, the new units in factory of Cadbury Adams (Thailand) Co., Ltd still mainly use electrical

energy. The FAU uses electricity for cooling the air by passing it through cooling coil running with chilled

water from the factory5s chiller and for machine fan to supply cool air to dehumidifying unit.

Dehumidifying using liquid desiccant unit uses electrical energy to circulate liquid desiccant and for

heat pump.

Existing AHU uses electric energy to cool down the temperature and blowing cool and dry air into

process area. The energy consumed in this unit is decrease comparing to the former technology. This is

because air from new dehumidifying unit is cooler than the former unit using electric heater.

Details of energy consumption of the three units after improvement are shown below.

Summary of the measurement of energy consumption after improvement

Date of measurement:

10:00 o5clock of 10/08/09 to 16:30 o5clock of 11/08/09

Measured result of electrical power consumed by fresh air system

Electric Power Consumption in Fresh Air System

- Electric power consumed by fan in FAU G001 0.81 kW

- Electric power consumed by DH G002 12.42 kW

- Electric power consumed by fan in AHU G004 3.30 kW

- Average cooling efficiency of Chiller 0.88 kW/tonr

(refers to one before improvement)

Remarks: Information of electrical power of fan in FAU-G001 (0.81kW) is the information before

improvement. After the improvement, the factory has also improved the fresh air unit FAU-G001 and

additionally installed new heat pipe into the FAU to reduce energy consumption.




Picture B.1 Measured result of electrical power consumed by DH-G002N

Picture B.2 Measured result of electrical power of fan in AHU-G004

Energy consumption of Fresh Air Unit (FAU-G001)

In energy consumption calculation of fresh air unit after improvement, the value of electric power before

improvement is used, which equals 5.54 kW. This is because after improvement, the factory installed

additional heat pipe system which reduced electric power consumption for cooling to only 2.73 kW.




Power used for air cooling by fresh air unit (FAU-G001)

Actual Cooling Load = 1.48 x 4.186 x(8.46-4.89) x 3,600/(1.055 x 12,000)

= 6.29 cooling ton

Electrical power used for chilled water production (PChilled FAU) = 6.29 (tonr) x 0.88 (kW/tonr)

= 5.54 kW

Total energy consumption = electrical power for chilled water + electrical power of fan

= 5.54 + 0.81

= 6.35 kW

Energy Consumption of Dehumidifying Unit using Liquid Desiccant (DH-G002N)

Date of measurement : 10-11/08/09

Measured Result

Summary of measured result of dehumidifying unit (DH-G002N )

- Electrical power of dehumidifying unit 12.42 kW

- Percentage of load duty cycle during operation 100 %




Energy Consumption of Air Handling Unit (AHU-G004)

Date of inspection: 10-11/08/09

Inspection Result

Summary of Measured Result of Air Handling Unit (AHU-G004)

- Electrical power consumption of fan in AHU (PFanAHU) 3.30 kW

- Chilled water flow rate 1.65 kg/s

- Chilled water supply temperature 5.09 °C

- Chilled water return temperature 8.34 °C

Actual refrigeration size = 1.65 x 4.186 x (8.34 -5.09) x 3,600/(1.055 x 12,000)

= 6.38 tonr

Capacity of chiller producing chilled water is 0.88 kW/tonr (refers to baseline information before

improvement)

Therefore,

Electrical power consumption for chilled water production (PChilled AHU) = 6.38 (tonr) x 0.88 (kW/tonr)

= 5.62 kW

Total electrical power consumption = electrical power consumed by chilled water production +

electrical power consumed by fan

= 5.62 + 3.30

= 8.92 kW




Energy Consumption Index Calculation (after Improvement)

Calculation was made from 1 working hour (OH) for comparing energy consumption to energy

consumption baseline index (before improvement).

Energy Consumption of Fresh Air Unit (FAU-G001)

Electrical power Consumption = PFanFAU + PChilledFAU x OH x 100%

= (0.81 + 5.54) x 1 x 100%

= 6.35 kW/h


= 22,84 MJ/h



Energy Consumption of Dehumidifier Unit (DH-G002N)

Electrical power Consumption = PDH x OH x 100%

= 12.42 x 1 x 100%

= 12.42 kW/h

Final energy = 12,42 x 3.6

= 44.71 MJ/h



Energy Consumption of Air Handling Unit AHU-G004

Electrical power Consumption = PFanAHU + PChilledAHU x OH x 100%

= (3.30 + 5.62) x 1 x 100%

= 8.92 kW/h


= 32.11 MJ/h


Preliminary energy = 0 71.36 MJ/h




Summary of Energy Consumption of Fresh Air System After Improvement


kWh/h

Preliminary Energy

MJ/h

Total


FCU-GOO1 6.35 50.76 50.76


DH-GOO2 12.42 99.36 99.36


AHU-G004 8.92 71.36 71.36

Total 27.69 221.48 221.48

Total energy consumption = preliminary electrical power

= electrical power consumption of FAU+DH+AHU

= 50.76 + 99.36 + 71.36 MJ/h

= 221.48 MJ/h

Therefore

* Determining Factors for Baseline calculation

- Temperature and humidity in gum production area 18.1 °C / 34.5% RH

- Humidity ratio in gum production Area 4.44 g/kg(a)

- Temperature and humidity of fresh air before 31.9 °C / 49.6%RH

passing through FAU

- Humidity ratio of fresh air before passing 14.81 g/kg(a)

through FAU

- Capacity of chilled water production unit 0.88 kW/tonr

Energy consumption index = 221.48 MJ/h




Energy Consumption of the System after Improvement

Electrical energy of fresh air unit (FAU-G001)



Electrical energy consumption per year = (0.81+5.54) x 24 x 298

= 45,415.20 kW/h/y


= 123,983.50 baht/y

Electrical energy of dehumidifying unit (DH-G002)

Total electrical power of DH-C002 = 12.42 kW

Electrical energy used per year = 12.42 x 24 x 298

= 88,827.84 kW/h/y

Electricity expense per year = 88,827.84 x 2.73

= 242,500 baht/y

Electrical Energy of Air Handling Unit (AHU-G004)



Electrical energy consumption per year = (3,30+5.62) x 24 x 298

= 63,794.84 kWh/y

Electricity expense per year = 63,794.84 x 2.73

= 174,162.64 baht/y

Total electrical energy consumption = electrical energy of FAU-G001+electrical energy of DH-G002 +

electrical energy of AHU G-004

= 45,415.20+88,827.84+63,795.84

= 198,038.88 kWh/y

Total electricity expense = electricity expense of FAU-G001+electricity expense of DH-

G002 + electricity expense of AHU G-004

= 123,983.50+242,500+174,162.64\

= 540,646.14 baht/y




Summary of energy consumption and energy expense calculation (after improvement) is shown in

the following tables A.1 and A.2.

Table A.1 Summary of energy consumption (after improvement)

Preliminary Energy Consumption after Improvement

Final electric energy before improvement = 712,939.97 MJ/y

Preliminary energy = 712,939.97/0.45 MJ/y

= 1,584,311.04 MJ/y

Total preliminary energy consumption after improvement = 1,584,311.04 MJ/y

Table A.2: Total Energy Expense after Improvement


Expense for electricity of the whole system

1. FAU-G001

2. DH-G002

3. AHU-G0041.

123,983.50

242,500.00

174,162.64

Total energy expense 540,646.14

Details Electricity

(kWatts -h/y)

Energy consumption

per year (MJ/y)

Electrical Energy Consumption

1. FAU-G001

2. DH-G002

3. AHU-G004

45,415.20

88,827.84

63,795.84

163,494.72

319,780.22

229,665.02

Total energy consumption 198,038.88 712,939.97




Reference

(1) American Society of Heating, Refrigerating and Air Conditioning Engineer, 1996 ASHRAE Handbook HVAC System and Equipment, Chapter 22, pp 22.2-22.3, I-PEdition, Atlanta, Georgia, 1996

(2) Natural Green Innovation Co., Ltd, OEnergy saving in air conditioning and dehumidifying system with new technologyP supporting document.

(3) Department of Alternative Energy Development and Efficiency, Ministry of Energy, Case study027

Liquid Desiccant Dehumidifier, first edition, Bangkok, Thananat Business, September 2003

(4) Drykor Inc. Dry-Cooling News, Volume III, Spring 2004

Cadbury Adams Thailand Report English

Documents

Transcript of Cadbury Adams Thailand Report English