Difference between revisions of "Energy efficiency in baby food"
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+ | Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]] | ||
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== PRODUCTION PROCESSES == | == PRODUCTION PROCESSES == | ||
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{| class="wikitable" | {| class="wikitable" | ||
− | !colspan= | + | !colspan="6"| low-cost / short term opportunities |
|- | |- | ||
− | |Energy Saving Opportunity | + | |''' Energy Saving Opportunity ''' |
− | |Action to Check | + | |''' Action to Check ''' |
|- | |- | ||
|1. Reduce excess combustion air to minimum | |1. Reduce excess combustion air to minimum | ||
|1. CO2/O2 measurement | |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 | + | |2. Maximise completeness of combustion |
− | 4. Repair (replace) boiler insulation 4. Periodic inspection of boiler insulation condition. | + | |2. Soot/CO measurement |
− | 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. | + | |3. Maintain boiler cleanliness (soot/scale) |
− | 7. Optimise quality of make-up water and feedwater 7. Monitor quality of make-up water and feedwater: hardness, acidity, O2. | + | |3. Monitor for rise in flue gas temperature |
− | 8. Minimise blowdown 8a. Monitor concentration of dissolved solids in boiler water. | + | |- |
+ | |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 | 8b. Improve blowdown controls | ||
− | 9. Maintain nozzles, grates, fuel supply pressure/temperature at manufacturers’ specifications 9a. Ensure specifications are available and in use. | + | |- |
+ | |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. | 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. | + | |10. Maximise combustion air temperature |
− | 12. Use duct for intake of warmer combustion air 12. Install duct from combustion air intake to higher parts of room. | + | |10. Draw air from highest point in boilerhouse. |
− | 13. Install an automated gas leakage detector. - | + | |- |
− | 14. Repair leaks in steam pipework. | + | |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. | ||
+ | | - | ||
|} | |} | ||
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{| class="wikitable" | {| class="wikitable" | ||
− | !colspan= | + | !colspan="6"|Higher cost / longer term opportunities |
|- | |- | ||
− | |Energy Saving Opportunity | + | |''' Energy Saving Opportunity ''' |
− | |Action to Check | + | |''' Action to Check ''' |
|- | |- | ||
|1. For rapidly varying demand, convert one or more boilers to live accumulator (buffer tank). | |1. For rapidly varying demand, convert one or more boilers to live accumulator (buffer tank). | ||
|1. Monitor/evaluate demand change patterns. | |1. Monitor/evaluate demand change patterns. | ||
|- | |- | ||
− | 2. Alter controls to “High-Low-Off” or “modulating-Low-Off” 2. Monitor/evaluate demand change patterns. | + | |2. Alter controls to “High-Low-Off” or “modulating-Low-Off” |
− | 3. Install flash steam heat recovery 3. Consider in large capacity situations with high (continuous/frequent) blowdown. | + | |2. Monitor/evaluate demand change patterns. |
− | 4. Improve combustion controls. 4a. Provide adequate heat input to meet demand. | + | |- |
+ | |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. | 4b. Minimise fuel/pollution. | ||
4c. Protect personnel/equipment. | 4c. Protect personnel/equipment. | ||
− | 5. Waste heat recovery 5a. Economiser | + | |- |
+ | |5. Waste heat recovery | ||
+ | |5a. Economiser | ||
5b. Air heater (recuperator)? | 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 | + | |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 ==== | ==== Heat Distribution ==== | ||
{| class="wikitable" | {| class="wikitable" | ||
− | !colspan= | + | !colspan="6"|Low-cost / short term opportunities |
|- | |- | ||
− | |Energy Saving Opportunity | + | |''' Energy Saving Opportunity ''' |
− | |Action to Check | + | |''' Action to Check ''' |
|- | |- | ||
|1. Repair/replace faulty insulation | |1. Repair/replace faulty insulation | ||
|1. Pipework insulation – especially around valves. | |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). | + | |2. Repair inefficient steam traps/drains. valve spindles etc. |
− | 4. Remove/isolate “dead-legs” and redundant Pipework 4. Check for dead-legs and redundant piping. | + | |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. | ||
|} | |} | ||
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− | |||
{| class="wikitable" | {| class="wikitable" | ||
− | !colspan= | + | !colspan="6"|Higher cost / longer term opportunities |
|- | |- | ||
− | |Energy Saving Opportunity | + | |''' Energy Saving Opportunity ''' |
− | |Action to Check | + | |''' Action to Check ''' |
|- | |- | ||
|1. Replace steam traps/drains with more efficient designs. | |1. Replace steam traps/drains with more efficient designs. | ||
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| - | | - | ||
|} | |} | ||
+ | |||
==== Heat Utilisation ==== | ==== Heat Utilisation ==== | ||
===== Process ===== | ===== Process ===== | ||
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+ | {| class="wikitable" | ||
+ | !colspan="6"|Energy Saving Opportunity ''' | ||
+ | |- | ||
+ | |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 ===== | ===== Space heating ===== | ||
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+ | {| class="wikitable" | ||
+ | !colspan="6"|Low-cost / short term opportunities | ||
+ | |- | ||
+ | !colspan="6"| 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 | ||
+ | |} | ||
− | === | + | {| class="wikitable" |
+ | !colspan="6"|Higher cost / longer term opportunities | ||
+ | |- | ||
+ | !colspan="6"| 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 ==== | ==== Motors ==== | ||
− | Energy Saving Opportunity | + | |
− | 1. Try to ensure that motor capacity is not more than 25% in excess of full load. | + | {| class="wikitable" |
− | 2. Install motor controllers (voltage, power factor and fixed speed controllers). | + | !colspan="6"| Energy Saving Opportunity |
− | 3. Build in “soft-start” facilities. | + | |- |
− | + | |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 ==== | ==== Compressed Air ==== | ||
− | Low-cost / short term opportunities | + | |
− | Energy Saving Opportunity | + | {| class="wikitable" |
− | 1. Switch off whenever possible. | + | !colspan="6"|Low-cost / short term opportunities |
− | 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 | + | !colspan="6"|Energy Saving Opportunity |
− | 4. Use lowest possible operating pressure. Reduce pressure locally if possible. | + | |- |
− | + | |1. Switch off whenever possible. | |
− | + | |5. Use lowest air intake temperature possible. | |
− | + | |- | |
− | 8. Check on correct pressure setting regularly. | + | |2. Install low-cost solenoid valves on air supply lines to individual machines. Switch off compressed air supply |
− | Higher cost / longer term opportunities | + | as soon as machine is switched off. |
− | Energy Saving Opportunity | + | |6. Fit 2-speed motors. |
− | 1. Fit a small (jockey) compressor to meet off-peak demand. | + | |- |
− | 2. Duct air intake to ensure coolest possible. | + | |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. | |
− | 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. | + | {| class="wikitable" |
− | 10. Replace pneumatic tools be electrical tools | + | !colspan="6"|Higher cost / longer term opportunities |
+ | |- | ||
+ | !colspan="6"|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 ==== | ==== Vacuum ==== | ||
− | Low-cost / short term opportunities | + | |
− | Energy Saving Opportunity | + | {| class="wikitable" |
− | 1. Switch off whenever possible. | + | !colspan="6"|Low-cost / short term opportunities |
− | 2. Regular maintenance is necessary to maintain pump efficiency and prevent breakdown, especially when the vacuum-space contains condensing vapours; | + | |- |
− | 3. Fix leaks | + | !colspan="6"|Energy Saving Opportunity |
− | Higher cost / longer term opportunities | + | |- |
− | Energy Saving Opportunity | + | |1. Switch off whenever possible. |
− | 1. Fit a standard heat recovery unit. | + | |- |
− | 2. Use a central vacuum system with several delivery points | + | |2. Regular maintenance is necessary to maintain pump efficiency and prevent breakdown, especially when the |
+ | vacuum-space contains condensing vapours; | ||
+ | |- | ||
+ | |3. Fix leaks | ||
+ | |} | ||
+ | |||
+ | {| class="wikitable" | ||
+ | !colspan="6"|Higher cost / longer term opportunities | ||
+ | |- | ||
+ | !colspan="6"|Energy Saving Opportunity | ||
+ | |- | ||
+ | |1. Fit a standard heat recovery unit. | ||
+ | |- | ||
+ | |2. Use a central vacuum system with several delivery points | ||
+ | |} | ||
+ | |||
==== Refrigeration ==== | ==== Refrigeration ==== | ||
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− | + | {| class="wikitable" | |
+ | !colspan="6"|Design measures | ||
+ | |- | ||
+ | !colspan="6"|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 | ||
+ | |} | ||
+ | |||
+ | {| class="wikitable" | ||
+ | !colspan="6"|Low-cost / short term opportunities | ||
+ | |- | ||
+ | !colspan="6"|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. | ||
+ | |} | ||
+ | |||
+ | {| class="wikitable" | ||
+ | !colspan="6"|Higher cost / longer term opportunities | ||
+ | |- | ||
+ | !colspan="6"|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 == | == PRODUCTION BUILDINGS == | ||
==== Lighting ==== | ==== Lighting ==== | ||
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− | 12. Use presence detection switches | + | {| class="wikitable" |
− | 13. Use a lighting system that is continuously variable (e.g. high-frequency fluorescent lighting). | + | !colspan="6"|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 ==== | ==== Building skin ==== | ||
− | Energy Saving Opportunity | + | |
− | 1.Thermal insulation of floor | + | {| class="wikitable" |
− | + | !colspan="6"|Energy Saving Opportunity | |
− | + | |- | |
− | 4. Use of double-glazed or solar shading glass windows | + | |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 ==== | ==== Central Heating ==== | ||
− | Low-cost / short term opportunities | + | |
− | Energy Saving Opportunity | + | {| class="wikitable" |
− | 1. Use a weather dependent control to regulate the temperature of the boiler water in relation to the outside temperature. | + | !colspan="6"|Low-cost / short term opportunities |
− | 2. Install an advanced timer for the boiler operation schedule. | + | |- |
− | + | !colspan="6"|Energy Saving Opportunity | |
− | 4. Insulate hot water storage tanks | + | |- |
− | Higher cost / longer term opportunities | + | |1. Use a weather dependent control to regulate the temperature of the boiler water in relation to the outside temperature. |
− | Energy Saving Opportunity | + | |3. Insulate pipework |
− | 1. Divide large interior spaces into smaller areas. | + | |- |
− | 2. Use radiation heating in cases where large ventilation rates are required. | + | |2. Install an advanced timer for the boiler operation schedule. |
− | 3. Use displacement ventilation in the case where the heated indoor areas are higher than 6 meters. | + | |4. Insulate hot water storage tanks |
+ | |} | ||
+ | |||
+ | {| class="wikitable" | ||
+ | !colspan="6"|Higher cost / longer term opportunities | ||
+ | |- | ||
+ | !colspan="6"|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 ==== | ==== Ventilation system ==== | ||
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− | + | {| class="wikitable" | |
+ | !colspan="6"|Energy Saving Opportunity | ||
+ | |- | ||
+ | |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: | ||
+ | *Thermal insulation | ||
+ | *Draught curtains | ||
+ | *Air cushion | ||
+ | *Automatic door | ||
+ | *Slip door | ||
+ | *Rubber seal between door and doorpost instead of brushes or no sealing. | ||
+ | |} | ||
+ | |||
+ | |||
+ | |||
==== Exhaust systems ==== | ==== 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. | + | {| class="wikitable" |
− | 2. Some options for improving the efficiency of exhaust systems are: | + | !colspan="6"|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: | ||
+ | *Frequency control on the electromotor of the fan | ||
+ | *Close exhaust points that are not in use. | ||
+ | *Start up the exhaust system with all exhaust points closed. | ||
+ | |} | ||
+ | |||
+ | |||
==== Air-conditioning ==== | ==== Air-conditioning ==== | ||
− | Energy Saving Opportunity | + | |
− | 1. Use thermal energy storage systems (i.e. ice banks) | + | {| class="wikitable" |
− | 2. Use shading devices for windows. | + | !colspan="6"|Energy Saving Opportunity |
+ | |- | ||
+ | |1. Use thermal energy storage systems (i.e. ice banks) | ||
+ | |- | ||
+ | |2. Use shading devices for windows. | ||
+ | |} | ||
+ | |||
+ | |||
+ | Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]] |
Latest revision as of 13:31, 23 January 2015
Back to EFFICENCY FINDER OF FOOD INDUSTRY
PRODUCTION PROCESSES
Thermal energy
Heat generation
low-cost / short term opportunities | |||||
---|---|---|---|---|---|
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 | 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 | |||||
---|---|---|---|---|---|
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 | |||||
---|---|---|---|---|---|
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. |