International Journal of Innovative Research in Engineering & Management (IJIREM) ISSN: 2350-0557, Volume-2, Issue-5, September- 2015 111 ENERGY AUDIT FOR A STEAM PLANT (CASE STUDY PYRETHRUM FACTORY IN NAKURU, KENYA) Ndugi D.S. Department of Energy & Industrial Engineering, Egerton University, P.O Box 536 Egerton Ndiema C.K.W., Omwando T. , Osore, E. A. Department of Mechanical & Industrial Engineering, Masinde Muliro University of Science and Technology Yegon, E. Department of Mechanical & Mechatronics Engineering, Multimedia University of Kenya, P.O Box 15653-00503 Nairobi ABSTRACT Abstract: Energy conservation is an essential step towards overcoming the mounting problems of global energy crisis and related environmental issues. Energy Management is considered the key to effective energy conservation. Present study is dealing with developing an “Energy Management System”, and implementing it in a real situation. A program was established as a continues improvement cycle. It started with formation of an energy management team, data collection, monitoring reports and audits. Hence the performance of a process plant can be improved by monitoring, analysis and adjustment of the appropriate plant operating parameters and in some cases, plant modifications. This involves studies of plant energy distribution and the corresponding losses associated with the various uses of energy, the scope and duration of a study my vary depending on the complexity of a plant and various operational requirements and constraints. Energy auditing has been established as useful tool for identifying energy wastage and opportunities for energy saving in a process industry. Heat recovery system is recommended for installation by retrofitting into existing plant in addition to other good housekeeping measures. Pyrethrum processing can be made profitable if energy losses are minimized. From the energy audit, it is possible for plant managers to differentiate the immediate energy saving potentials from those requiring requiring either some investments or further studies. This paper outlines the methodology and the scope for carrying out an energy audit with the main objective of improving the overall plant energy efficiency. The procedure included plant familiarization, data collection and parameter measurement, analysis of energy consumption and losses in the various sections of a steam plant and recommendation for remedial measures Keywords: Pyrethrum, steam plant, energy audit, heat recovery, energy conservation. 1. INTRODUCTION The last decade has seen a near exponential increase in energy consumption in all the sectors of Kenya’seconomy. The increase demand for the petroleum products in transport industry has resulted in increased price of this energy source. According to statistic, energy remain a primary input in most production processes and accounts for about 20-30% of production cost and in some cases up to 70% out of this about 10 to 30% is wasted as heat in the 2004, energy management measures were initiated by the Kenya government in collaboration with Kenya association of manufacturers to facilitate improvement in energy utilization [1] In general the driving force towards energy conservation is the prospect of saving money.in the long term, saving energy reduces environmental pollution and retards the depletion of non-renewable energy resources. Towards this end, processing industries are encouraged to promote energy efficiency practices. Improvement of the current operating practices and the use of efficient technologies and equipment can help achieve energy saving objectives in the process industries .by virtue of diverse range of processes and process conditions, the industrial sector is the prime target for energy conservation. Identification of the energy saving opportunities in any process plant can be facilitated by undertaking an energy audit [2]. An energy audit is essentially an energy survey aimed at identifying and screening the scope and feasibility of improving the efficiency of a process plant. It is usually focused on the improvement of utility systems and utility equipment such as boilers, steam distribution systems, compressors, dryers and chillers [3]. To perform energy balancing for such equipment, data can be obtained from empirical measurements, thermodynamics tables and well-established correlations in literature. At the end of the energy audit, conservation measures are instated or recommended. These measures can be classified as short-term, medium-term and long-term measures according to the estimated payback period for the investment [4]. 1.1 Energy Audit An energy audit is a technique for identifying energy losses, quantifying them, estimating conservation potential, evolving technological options for conservation and evaluating techno economics for the measure suggested.  Assists industries in reducing their energy consumption.  To promote energy- efficient technology through training programs and workshops.