Energy Analysis of a Large-Scale Plastic Industry: A Case Study of Panar Limited, Kano Nigeria

Abstract

The study analyzed the energy consumption pattern of a large-scale plastic manufacturing facility in Kano, Nigeria, over five years (2017-2021). The objective was to identify inefficiencies, establish an energy baseline, and estimate potential savings, along with the corresponding CO₂ emissions. Results showed electricity consumption of 8,730,673.30 kWh and diesel use of 661,613.93 liters, representing 71% electricity cost and 29% diesel cost respectively, amounting to ₦ 540,808,037 with a production output of 88,014,099.58 kg (2017-2021). The industry’s capacity is 63,000 metric tons/year. The extrusion section was the highest energy consumer (36%), while the administrative block was the lowest energy consumer (5%). The calculated energy intensity was 1.16 GJ/m², confirming high energy use, while the Normalized Performance Indicator (NPI) (0.93 GJ/m²) was rated “Satisfactory”. Carbon emissions were dominated by diesel use, highlighting environmental challenges. The study concludes that improved energy management, retrofitting, and integration of renewable energy could yield average cost savings of ₦ 108,666,877.8 per year with an average four-year payback period while reducing the industry’s carbon footprint. Findings underscore the economic and environmental benefits of energy conservation in Nigeria’s plastic sector.