Energy efficiency in baby food
From Efficiency Finder
PRODUCTION PROCESSES
Thermal energy
Heat generation
low-cost / short term opportunities | |||||
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Energy Saving Opportunity | Action to Check | ||||
1. Reduce excess combustion air to minimum | 1. CO2/O2 measurement | ||||
2. Maximise completeness of combustion | 2. Soot/CO measurement | ||||
3. Maintain boiler cleanliness (soot/scale) | 3. Monitor for rise in flue gas temperature | ||||
4. Repair (replace) boiler insulation | 4. Periodic inspection of boiler insulation condition. | ||||
5. Insulate feedwater tank – cover tank | 5. Check possible feedwater temperature losses | ||||
6. Insulate condensate return lines | 6. Check possible heat loss from condensate return lines. | ||||
7. Optimise quality of make-up water and feedwater | 7. Monitor quality of make-up water and feedwater: hardness, acidity, O2. | ||||
8. Minimise blowdown | 8a. Monitor concentration of dissolved solids in boiler water.
8b. Improve blowdown controls | ||||
9. Maintain nozzles, grates, fuel supply pressure/temperature at manufacturers’ specifications | 9a. Ensure specifications are available and in use.
9b. Regular check and resetting/maintenance. | ||||
10. Maximise combustion air temperature | 10. Draw air from highest point in boilerhouse. | ||||
11. Reduce steam pressure where it exceed system/process requirements. | 11. Check system/process needs; adjust controls. | ||||
12. Use duct for intake of warmer combustion air | 12. Install duct from combustion air intake to higher parts of room. | ||||
13. Install an automated gas leakage detector. | - | ||||
14. Repair leaks in steam pipework. | - |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | Action to Check | ||||
1. For rapidly varying demand, convert one or more boilers to live accumulator (buffer tank). | 1. Monitor/evaluate demand change patterns. | ||||
2. Alter controls to “High-Low-Off” or “modulating-Low-Off” | 2. Monitor/evaluate demand change patterns. | ||||
3. Install flash steam heat recovery | 3. Consider in large capacity situations with high (continuous/frequent) blowdown. | ||||
4. Improve combustion controls. | 4a. Provide adequate heat input to meet demand.
4b. Minimise fuel/pollution. 4c. Protect personnel/equipment. | ||||
5. Waste heat recovery | 5a. Economiser
5b. Air heater (recuperator)? | ||||
6. Install boiler blowdown heat recovery. | 6. Consider in large capacity situations with high (continuous/frequent) blowdown. | ||||
7. Use process integration | 7. Couple process units that have significantly different heat requirements (i.e. low-pressure
steam leaving a high-pressure steam consuming production process can be used for a process requiring low-pressure steam). |
Heat Distribution
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | Action to Check | ||||
1. Repair/replace faulty insulation | 1. Pipework insulation – especially around valves. | ||||
2. Repair inefficient steam traps/drains. valve spindles etc. | 2. Regular checks for leaks throughout the system. | ||||
3. Insert valves to isolate “periodic-use” items in system. | 3. Check system for periodic (e.g. seasonal, nightly) items (e.g. space heaters). | ||||
4. Remove/isolate “dead-legs” and redundant Pipework. | 4. Check for dead-legs and redundant piping. |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | Action to Check | ||||
1. Replace steam traps/drains with more efficient designs. | 1. Monitor efficiency of, and heat losses from existing traps. | ||||
2. Replace or increase insulation | 2. Check existing insulation; estimate heat losses in system. | ||||
3. Maximise condensate returns. | 3. Measure “discarded” heat from condensate. | ||||
4. Redesign system to minimise pipe runs. | - | ||||
5. Generation pressure reduction. | - |
Heat Utilisation
Process
Energy Saving Opportunity |
1. Plant insulation |
2.Local burner efficiency |
3. Maximise heat transfer rate |
4. Improve controls (e.g. thermostats) |
5. Consider alternative energy source |
6. Ensure plant at high load factor |
7. Eliminate uneconomic “hot standby” periods |
8. Recycle waste heat to process |
8. Recover heat, for use elsewhere |
9. Train all staff to operate manual controls and to watch for energy saving opportunities. |
Space heating
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Use heat only when area is occupied | |||||
2. Set thermostats to minimum for comfort | |||||
3. Minimise loss of hot air | |||||
4. Clean and effective heaters | |||||
5. Maintain pipe insulation in unheated areas | |||||
6. Check condensate traps | |||||
7. Vent air from hot water systems | |||||
8. Time switches | |||||
9. Manual controls where appropriate |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Install more/more efficient thermostats | |||||
2. Use motorised valves to divide building into different zones | |||||
3. Air curtains | |||||
4. Change energy source | |||||
5. Change heating system – where:
Insulation: Good or Poor Ventilation: High or Low Use: Radiant Heat or Convective Heat | |||||
6. Improve building insulation |
Electrical Energy
Motors
Energy Saving Opportunity |
1. Try to ensure that motor capacity is not more than 25% in excess of full load. |
2. Install motor controllers (voltage, power factor and fixed speed controllers). |
3. Build in “soft-start” facilities. |
4. Install variable speed drives |
5. Install high efficiency motors |
Compressed Air
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Switch off whenever possible. | |||||
2. Install low-cost solenoid valves on air supply lines to individual machines. Switch off compressed air supply as soon as machine is switched off. | |||||
3. Clean air intake filters regularly | |||||
4. Use lowest possible operating pressure. Reduce pressure locally if possible. | |||||
5. Use lowest air intake temperature possible. | |||||
6. Fit 2-speed motors. | |||||
7. Fix leaks | |||||
8. Check on correct pressure setting regularly. |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Fit a small (jockey) compressor to meet off-peak demand. | |||||
2. Duct air intake to ensure coolest possible. | |||||
3. Fit air flow and kWh meters to monitor power and air use. | |||||
4. Install modern controls on multi-compressor installations. | |||||
5. Fit a standard heat recovery unit. | |||||
6. Air pre-cooling. | |||||
7. If some users are using low pressure air (2.5 – 3 bar), install two separate systems. | |||||
8. Use frequency control for compressor. | |||||
9. Use an individual compressed air supply for special applications. | |||||
10. Replace pneumatic tools be electrical tools |
Vacuum
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Switch off whenever possible. | |||||
2. Regular maintenance is necessary to maintain pump efficiency and prevent breakdown, especially when the vacuum-space contains condensing vapours; | |||||
3. Fix leaks |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Fit a standard heat recovery unit. | |||||
2. Use a central vacuum system with several delivery points |