Difference between revisions of "Energy efficiency in milk products"
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!colspan="6"|Low-cost / short term opportunities | !colspan="6"|Low-cost / short term opportunities | ||
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|1. Switch off whenever possible. | |1. Switch off whenever possible. | ||
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!colspan="6"|Higher cost / longer term opportunities | !colspan="6"|Higher cost / longer term opportunities | ||
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|1. Fit a standard heat recovery unit. | |1. Fit a standard heat recovery unit. | ||
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!colspan="6"|Design measures | !colspan="6"|Design measures | ||
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|1. Group refrigeration cells according to temperature. | |1. Group refrigeration cells according to temperature. | ||
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!colspan="6"|Low-cost / short term opportunities | !colspan="6"|Low-cost / short term opportunities | ||
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|1. Switch off lights, fans, pumps. etc., when not required. | |1. Switch off lights, fans, pumps. etc., when not required. | ||
+ | |7. Use load rescheduling (e.g. cool at night) where maximum-demand tariffs are in operation. | ||
|- | |- | ||
|2. Repair damaged insulation/seals. | |2. Repair damaged insulation/seals. | ||
+ | |8. Minimise cooling space by installing removable plastic screens or panels or by filling cooling space with polystyrene foam blocks | ||
|- | |- | ||
|3. Check for refrigerant contamination. | |3. Check for refrigerant contamination. | ||
+ | |9. Switch off evaporator fans when compressor is off | ||
|- | |- | ||
|4. Check for scaling on condenser and evaporator surfaces. | |4. Check for scaling on condenser and evaporator surfaces. | ||
+ | |10. Regulate condenser pressure (and therefore temperature) | ||
|- | |- | ||
|5. (Multi-compressor systems); set controls to activate minimum number of compressors. | |5. (Multi-compressor systems); set controls to activate minimum number of compressors. | ||
+ | |11. Delayed start-up of compressors. Initially, only start-up of ventilation. | ||
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|6. Monitor timing and duration of defrost cycles. Defrost on demand rather than at fixed intervals. | |6. Monitor timing and duration of defrost cycles. Defrost on demand rather than at fixed intervals. | ||
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|12. Increase the evaporation temperature. | |12. Increase the evaporation temperature. | ||
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!colspan="6"|Higher cost / longer term opportunities | !colspan="6"|Higher cost / longer term opportunities | ||
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− | | | + | !colspan="6"|Energy Saving Opportunity |
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|1. Install kWh meters and instrumentation to monitor equipment and cold room. | |1. Install kWh meters and instrumentation to monitor equipment and cold room. | ||
+ | |7. Install frequency control (i.e. VRF) on chiller compressor. | ||
|- | |- | ||
|2. Install an energy management system which analyses operation of the whole | |2. Install an energy management system which analyses operation of the whole | ||
refrigeration system. | refrigeration system. | ||
+ | |8. Install high efficiency or 2-rev electromotor on evaporation fan | ||
|- | |- | ||
|3. Use effective insulation and sealing. | |3. Use effective insulation and sealing. | ||
+ | |9. Build a cooled front space for refrigeration units. | ||
|- | |- | ||
|4. Install efficient electronic expansion valves. Avoid “head pressure control” where possible. | |4. Install efficient electronic expansion valves. Avoid “head pressure control” where possible. | ||
+ | |10. Use hot refrigerant gas from the compressor for the initial stages of the defrosting cycle. | ||
|- | |- | ||
|5. Recovery of waste heat at the condenser | |5. Recovery of waste heat at the condenser | ||
+ | |11. Use excess heat from other production processes for the production of cooling using | ||
+ | adsorption/absorption cooling. | ||
|- | |- | ||
|6. Automatic bleeding of refrigerant to remove any penetrated air | |6. Automatic bleeding of refrigerant to remove any penetrated air | ||
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{| class="wikitable" | {| class="wikitable" | ||
− | | | + | !colspan="6"|Energy Saving Opportunity |
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|1. Use the most efficient lamps consistent with required illumination levels and colour rendering. | |1. Use the most efficient lamps consistent with required illumination levels and colour rendering. | ||
+ | |8. Replace lamps which have exceeded their rated life. | ||
|- | |- | ||
|2. Use the light output from lamps efficiently. | |2. Use the light output from lamps efficiently. | ||
+ | |9. Use “switch-off” and “save-it” stickers as a tool of good housekeeping. | ||
|- | |- | ||
|3. Maintain lamps and fixtures clear of light-blocking dust and dirt. | |3. Maintain lamps and fixtures clear of light-blocking dust and dirt. | ||
+ | |10. Consider new technologies in order to reduce installation cost, such as infrared switching. | ||
|- | |- | ||
|4. Switch off lights where lighting is not needed. | |4. Switch off lights where lighting is not needed. | ||
+ | |11. Divide the lighting system of a large space into several independent lighting groups. | ||
|- | |- | ||
|5. Consider automatic control of lighting (time clocks and/or photo cells). | |5. Consider automatic control of lighting (time clocks and/or photo cells). | ||
+ | |12. Use presence detection switches | ||
|- | |- | ||
|6. Make the best use of daylight. | |6. Make the best use of daylight. | ||
+ | |13. Use a lighting system that is continuously variable (e.g. high-frequency fluorescent lighting). | ||
|- | |- | ||
|7. Avoid the absorption of light by the surroundings (light-coloured wall, ceilings, and floors). | |7. Avoid the absorption of light by the surroundings (light-coloured wall, ceilings, and floors). | ||
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{| class="wikitable" | {| class="wikitable" | ||
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|1.Thermal insulation of floor | |1.Thermal insulation of floor | ||
+ | |3.Thermal insulation of roof | ||
|- | |- | ||
|2.Thermal insulation of walls | |2.Thermal insulation of walls | ||
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|4. Use of double-glazed or solar | |4. Use of double-glazed or solar | ||
shading glass windows | shading glass windows | ||
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!colspan="6"|Low-cost / short term opportunities | !colspan="6"|Low-cost / short term opportunities | ||
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|1. Use a weather dependent control to regulate the temperature | |1. Use a weather dependent control to regulate the temperature | ||
of the boiler water in relation to the outside temperature. | of the boiler water in relation to the outside temperature. | ||
+ | |3. Insulate pipework | ||
|- | |- | ||
|2. Install an advanced timer for the boiler operation schedule. | |2. Install an advanced timer for the boiler operation schedule. | ||
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|4. Insulate hot water storage tanks | |4. Insulate hot water storage tanks | ||
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!colspan="6"|Higher cost / longer term opportunities | !colspan="6"|Higher cost / longer term opportunities | ||
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|1. Divide large interior spaces into smaller areas. | |1. Divide large interior spaces into smaller areas. | ||
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{| class="wikitable" | {| class="wikitable" | ||
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|1. Heat recovery of exhaust air using a rotary wheel. | |1. Heat recovery of exhaust air using a rotary wheel. | ||
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|1. Use local exhaust ventilation systems. The purpose of a local exhaust system is to remove the contaminants (dust, fume, vapour etc.) at the source. | |1. Use local exhaust ventilation systems. The purpose of a local exhaust system is to remove the contaminants (dust, fume, vapour etc.) at the source. | ||
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{| class="wikitable" | {| class="wikitable" | ||
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|1. Use thermal energy storage systems (i.e. ice banks) | |1. Use thermal energy storage systems (i.e. ice banks) |
Revision as of 13:00, 23 January 2015
Back to EFFICENCY FINDER OF FOOD INDUSTRY
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 | |||||
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1. Plant insulation | 6. Ensure plant at high load factor | ||||
2.Local burner efficiency | 7. Eliminate uneconomic “hot standby” periods | ||||
3. Maximise heat transfer rate | 8. Recycle waste heat to process | ||||
4. Improve controls (e.g. thermostats) | 9. Recover heat, for use elsewhere | ||||
5. Consider alternative energy source | 10. 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 | 6. Check condensate traps | ||||
2. Set thermostats to minimum for comfort | 7. Vent air from hot water systems | ||||
3. Minimise loss of hot air | 8. Time switches | ||||
4. Clean and effective heaters | 9. Manual controls where appropriate | ||||
5. Maintain pipe insulation in unheated areas |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Install more/more efficient thermostats | 4. Change energy source | ||||
2. Use motorised valves to divide building into
different zones |
5. Change heating system – where:
Insulation: Good or Poor Ventilation: High or Low Use: Radiant Heat or Convective Heat | ||||
3. Air curtains | 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. |
4. Install variable speed drives | ||||
2. Install motor controllers (voltage, power
factor and fixed speed controllers). |
5. Install high efficiency motors | ||||
3. Build in “soft-start” facilities. |
Compressed Air
Low-cost / short term opportunities | |||||
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Energy Saving Opportunity | |||||
1. Switch off whenever possible. | 5. Use lowest air intake temperature 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. |
6. Fit 2-speed motors. | ||||
3. Clean air intake filters regularly | 7. Fix leaks | ||||
4. Use lowest possible operating pressure. Reduce pressure
locally if possible. |
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. | 6. Air pre-cooling. | ||||
2. Duct air intake to ensure coolest possible. | 7. If some users are using low pressure air (2.5 – 3 bar), install two separate systems. | ||||
3. Fit air flow and kWh meters to monitor power and air use. | 8. Use frequency control for compressor. | ||||
4. Install modern controls on multi-compressor installations. | 9. Use an individual compressed air supply for special applications. | ||||
5. Fit a standard heat recovery unit. | 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 |
Refrigeration
Design measures | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Group refrigeration cells according to temperature. | |||||
2. Use an integrated plant layout – optimise use of
evaporators or condensers (i.e. remove obstacles) | |||||
3. Limit energy losses through open doors |
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Switch off lights, fans, pumps. etc., when not required. | 7. Use load rescheduling (e.g. cool at night) where maximum-demand tariffs are in operation. | ||||
2. Repair damaged insulation/seals. | 8. Minimise cooling space by installing removable plastic screens or panels or by filling cooling space with polystyrene foam blocks | ||||
3. Check for refrigerant contamination. | 9. Switch off evaporator fans when compressor is off | ||||
4. Check for scaling on condenser and evaporator surfaces. | 10. Regulate condenser pressure (and therefore temperature) | ||||
5. (Multi-compressor systems); set controls to activate minimum number of compressors. | 11. Delayed start-up of compressors. Initially, only start-up of ventilation. | ||||
6. Monitor timing and duration of defrost cycles. Defrost on demand rather than at fixed intervals. | 12. Increase the evaporation temperature. |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Install kWh meters and instrumentation to monitor equipment and cold room. | 7. Install frequency control (i.e. VRF) on chiller compressor. | ||||
2. Install an energy management system which analyses operation of the whole
refrigeration system. |
8. Install high efficiency or 2-rev electromotor on evaporation fan | ||||
3. Use effective insulation and sealing. | 9. Build a cooled front space for refrigeration units. | ||||
4. Install efficient electronic expansion valves. Avoid “head pressure control” where possible. | 10. Use hot refrigerant gas from the compressor for the initial stages of the defrosting cycle. | ||||
5. Recovery of waste heat at the condenser | 11. Use excess heat from other production processes for the production of cooling using
adsorption/absorption cooling. | ||||
6. Automatic bleeding of refrigerant to remove any penetrated air |
PRODUCTION BUILDINGS
Lighting
Energy Saving Opportunity | |||||
---|---|---|---|---|---|
1. Use the most efficient lamps consistent with required illumination levels and colour rendering. | 8. Replace lamps which have exceeded their rated life. | ||||
2. Use the light output from lamps efficiently. | 9. Use “switch-off” and “save-it” stickers as a tool of good housekeeping. | ||||
3. Maintain lamps and fixtures clear of light-blocking dust and dirt. | 10. Consider new technologies in order to reduce installation cost, such as infrared switching. | ||||
4. Switch off lights where lighting is not needed. | 11. Divide the lighting system of a large space into several independent lighting groups. | ||||
5. Consider automatic control of lighting (time clocks and/or photo cells). | 12. Use presence detection switches | ||||
6. Make the best use of daylight. | 13. Use a lighting system that is continuously variable (e.g. high-frequency fluorescent lighting). | ||||
7. Avoid the absorption of light by the surroundings (light-coloured wall, ceilings, and floors). |
Building skin
Energy Saving Opportunity | |||||
---|---|---|---|---|---|
1.Thermal insulation of floor | 3.Thermal insulation of roof | ||||
2.Thermal insulation of walls | 4. Use of double-glazed or solar
shading glass windows |
Central Heating
Low-cost / short term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Use a weather dependent control to regulate the temperature
of the boiler water in relation to the outside temperature. |
3. Insulate pipework | ||||
2. Install an advanced timer for the boiler operation schedule. | 4. Insulate hot water storage tanks |
Higher cost / longer term opportunities | |||||
---|---|---|---|---|---|
Energy Saving Opportunity | |||||
1. Divide large interior spaces into smaller areas. | |||||
2. Use radiation heating in cases where large ventilation rates are required. | |||||
3. Use displacement ventilation in the case where the heated indoor areas are
higher than 6 meters. |
Ventilation system
Energy Saving Opportunity | |||||
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1. Heat recovery of exhaust air using a rotary wheel. | |||||
2. Reduce the amount of ventilation air as much as possible by the installation of:
Timer switch; sensor; Air quality; Frequency control on the fan motor | |||||
3. Prevent infiltration through door openings with:
|
Exhaust systems
Energy Saving Opportunity | |||||
---|---|---|---|---|---|
1. Use local exhaust ventilation systems. The purpose of a local exhaust system is to remove the contaminants (dust, fume, vapour etc.) at the source. | |||||
2. Some options for improving the efficiency of exhaust systems are:
|
Air-conditioning
Energy Saving Opportunity | |||||
---|---|---|---|---|---|
1. Use thermal energy storage systems (i.e. ice banks) | |||||
2. Use shading devices for windows. |