Greening Sri Lanka’s industries through Steam System Optimization

The Government of Sri Lanka is spearheading carbon reduction in key industries through its partnership with the EU-funded Accelerating Industries’ Climate Response in Sri Lanka project, implemented by the United Nations Industrial Development Organization (UNIDO). As part of this, training on Steam System Optimization (SSO) was delivered to 29 industry professionals. The SSO training will equip them to spot and implement opportunities to improve energy use and reduce emissions.

Sri Lanka’s first SSO Capacity Building and Implementation Programme kicked off in May-June 2023, with the trainees completing their final exam on 5 February 2024. Employees in pivotal sectors like tourism, fisheries, tea plantations and agriculture took the training. As a key producer and exporter of tea, natural rubber and finished rubber products, as well as apparel and textiles to the global market, many of Sri Lanka’s industries fall into the heavy steam user category. Therefore, steam usage is a vital stepping stone in Sri Lanka’s aspirations for a cleaner and greener future.

Sri Lanka aims to reduce industry greenhouse gas (GHG) emissions by 7 per cent by 2030, and become entirely carbon-neutral by 2050. Steam systems have great capacity to enhance energy efficiency and help propel Sri Lanka towards those goals, as well as saving money. “The SSO trainers introduced techniques and tools for measuring and assessing energy wastage in our steam lines, providing more accurate quantitative values,” said trainee Pulasthi Nammuniarachchi, of Associated Motorways (Pvt) Ltd. “Following the implementation of improvements at our plant, I estimate potential annual savings of up to US$5,000.”

Trainees also learned from hands-on assignments at working factories. “The opportunity to visit a manufacturing plant was extremely beneficial,” Kalana Siriwardhana, from MAS Fabric Intimo, said. “It allowed us to put the theories we had learned into practice. The hands-on experience proved invaluable in recognizing and understanding real-world industrial scenarios.”

Industrial growth in Sri Lanka has meant a surge in energy demand, with the resulting emissions posing a significant challenge. Switching to renewable energy sources, and controlling residential energy uses, are crucial, but an often-overlooked clean energy source for industry is steam systems. UNIDO has developed its SSO training course over the past decade.

Steam is an exceptionally efficient heating source, with the ability to maintain a constant temperature and high heat transfer coefficients. With the highest amount of transferable energy per unit mass, steam is inherently flexible as an energy transfer medium, for process heating and power generation. Industry data shows that steam energy use could account for as much as 35-40 per cent of on-site energy consumption, so the effectiveness of steam systems already in use is clear. Optimization is crucial to reduce operating costs, but how this happens depends on each unique system and its function.

The training programme comprised two elements: SSO User Training and SSO Expert Training. The first part instructed participants on assessing industrial steam systems, pinpointing opportunities for performance enhancements and savings in terms of energy, emissions and cost. These could be achieved via operational methods, maintenance, and efficient steam use. The Expert component brought in international experts: Riyaz Papar from UNIDO and the US Department of Energy, and Alfred Hartzenburg, an International Resource Efficiency Consultant & Trainer.

The trainees were given in-depth technical instructions on assessing performance, troubleshooting, and improving steam systems, as well as pitching skills to bring energy-efficient ideas to management. One trainee has already brought improvements to their workplace, Michelin Lanka Private Limited: “After the SSO training equipped me with the skills to pinpoint energy wastage in our systems, I successfully garnered management support to initiate an insulation project. This project will include a steam distribution system with automated steam valves for greater overall efficiency,” said Vidya Wijethunga. Another participant, Darshana Guruge, of Teejay Lanka PLC, spotted an opportunity to reduce fossil fuel use: “I gathered information that was valuable to the ongoing project aimed at phasing out coal usage at Teejay. I was able to determine an optimal boiler configuration and explore alternative energy-saving opportunities.”

The trainees completed classroom sessions, on-site hands-on training, personalized coaching, and training via a web-based simulation developed by the US Department of Energy. They were also given tools and guidelines developed by UNIDO, and sent in groups to practice what they’d learned at manufacturing plants. Individuals and teams completed assessment reports, which were reviewed and approved by the international SSO experts.

Sri Lanka has been identified as one of the world’s most vulnerable nations to the impacts of climate change. The transition to renewables could alleviate strain on government finances by reducing dependence on fuel imports. It has plenty of other benefits, too, including the creation of jobs and opportunities for women, improving the economy, and allowing further industrial growth without negative environmental impact.