Difference between revisions of "Energy efficiency in baby food"
Line 165: | Line 165: | ||
|8. Recover heat, for use elsewhere | |8. Recover heat, for use elsewhere | ||
|- | |- | ||
− | |9. Train all staff to operate manual controls and to watch for energy saving opportunities. | + | |9. Train all staff to operate manual controls and |
+ | to watch for energy saving opportunities. | ||
|} | |} | ||
Line 201: | Line 202: | ||
|1. Install more/more efficient thermostats | |1. Install more/more efficient thermostats | ||
|- | |- | ||
− | |2. Use motorised valves to divide building into different zones | + | |2. Use motorised valves to divide building into |
+ | different zones | ||
|- | |- | ||
|3. Air curtains | |3. Air curtains | ||
Line 224: | Line 226: | ||
| ''' Energy Saving Opportunity ''' | | ''' Energy Saving Opportunity ''' | ||
|- | |- | ||
− | |1. Try to ensure that motor capacity is not more than 25% in excess of full load. | + | |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). | + | |2. Install motor controllers (voltage, power |
+ | factor and fixed speed controllers). | ||
|- | |- | ||
|3. Build in “soft-start” facilities. | |3. Build in “soft-start” facilities. | ||
Line 244: | Line 248: | ||
|1. Switch off whenever possible. | |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. | + | |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 | |3. Clean air intake filters regularly | ||
|- | |- | ||
− | |4. Use lowest possible operating pressure. Reduce pressure locally if possible. | + | |4. Use lowest possible operating pressure. Reduce pressure |
+ | locally if possible. | ||
|- | |- | ||
|5. Use lowest air intake temperature possible. | |5. Use lowest air intake temperature possible. | ||
Line 276: | Line 283: | ||
|6. Air pre-cooling. | |6. Air pre-cooling. | ||
|- | |- | ||
− | |7. If some users are using low pressure air (2.5 – 3 bar), install two separate systems. | + | |7. If some users are using low pressure air (2.5 – 3 bar), install |
+ | two separate systems. | ||
|- | |- | ||
|8. Use frequency control for compressor. | |8. Use frequency control for compressor. | ||
Line 294: | Line 302: | ||
|1. Switch off whenever possible. | |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; | + | |2. Regular maintenance is necessary to maintain pump |
+ | efficiency and prevent breakdown, especially when the | ||
+ | vacuum-space contains condensing vapours; | ||
|- | |- | ||
|3. Fix leaks | |3. Fix leaks | ||
Line 307: | Line 317: | ||
|1. Fit a standard heat recovery unit. | |1. Fit a standard heat recovery unit. | ||
|- | |- | ||
− | |2. Use a central vacuum system with several delivery points | + | |2. Use a central vacuum system with several |
+ | delivery points | ||
|} | |} | ||
Line 319: | Line 330: | ||
|1. Group refrigeration cells according to temperature. | |1. Group refrigeration cells according to temperature. | ||
|- | |- | ||
− | |2. Use an integrated plant layout – optimise use of evaporators or condensers (i.e. remove obstacles) | + | |2. Use an integrated plant layout – optimise use of |
+ | evaporators or condensers (i.e. remove obstacles) | ||
|- | |- | ||
|3. Limit energy losses through open doors | |3. Limit energy losses through open doors | ||
Line 361: | Line 373: | ||
|1. Install kWh meters and instrumentation to monitor equipment and cold room. | |1. Install kWh meters and instrumentation to monitor equipment and cold room. | ||
|- | |- | ||
− | |2. Install an energy management system which analyses operation of the whole refrigeration system. | + | |2. Install an energy management system which analyses operation of the whole |
+ | refrigeration system. | ||
|- | |- | ||
|3. Use effective insulation and sealing. | |3. Use effective insulation and sealing. | ||
Line 379: | Line 392: | ||
|10. Use hot refrigerant gas from the compressor for the initial stages of the defrosting cycle. | |10. Use hot refrigerant gas from the compressor for the initial stages of the defrosting cycle. | ||
|- | |- | ||
− | |11. Use excess heat from other production processes for the production of cooling using adsorption/absorption cooling. | + | |11. Use excess heat from other production processes for the production of cooling using |
+ | adsorption/absorption cooling. | ||
|} | |} | ||
Line 409: | Line 423: | ||
|10. Consider new technologies in order to reduce installation cost, such as infrared switching. | |10. Consider new technologies in order to reduce installation cost, such as infrared switching. | ||
|- | |- | ||
− | |11. Divide the lighting system of a large space into several independent lighting groups. | + | |11. Divide the lighting system of a large space into several independent lighting groups. |
|- | |- | ||
|12. Use presence detection switches | |12. Use presence detection switches | ||
Line 419: | Line 433: | ||
{| class="wikitable" | {| class="wikitable" | ||
− | ''' Energy Saving Opportunity ''' | + | |''' Energy Saving Opportunity ''' |
− | 1.Thermal insulation of floor | + | |- |
− | + | |1.Thermal insulation of floor | |
− | 2.Thermal insulation of walls | + | |- |
− | + | |2.Thermal insulation of walls | |
− | 3.Thermal insulation of roof | + | |- |
− | + | |3.Thermal insulation of roof | |
− | 4. Use of double-glazed or solar shading glass windows | + | |- |
+ | |4. Use of double-glazed or solar | ||
+ | shading glass windows | ||
+ | |} | ||
Line 432: | Line 449: | ||
{| class="wikitable" | {| class="wikitable" | ||
− | Low-cost / short term opportunities | + | !colspan="6"|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. | + | | '''Energy Saving Opportunity''' |
− | 2. Install an advanced timer for the boiler operation schedule. | + | |- |
− | 3. Insulate pipework | + | |1. Use a weather dependent control to regulate the temperature |
− | 4. Insulate hot water storage tanks | + | of the boiler water in relation to the outside temperature. |
− | + | |- | |
+ | |2. Install an advanced timer for the boiler operation schedule. | ||
+ | |- | ||
+ | |3. Insulate pipework | ||
+ | |- | ||
+ | |4. Insulate hot water storage tanks | ||
+ | |} | ||
{| class="wikitable" | {| class="wikitable" | ||
− | Higher cost / longer term opportunities | + | !colspan="6"|Higher cost / longer term opportunities |
− | Energy Saving Opportunity | + | |- |
− | 1. Divide large interior spaces into smaller areas. | + | | ''' Energy Saving Opportunity ''' |
− | 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. | + | |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 ==== | ||
{| class="wikitable" | {| class="wikitable" | ||
− | Energy Saving Opportunity | + | |''' 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: | + | |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; | |
− | 3. Prevent infiltration through door openings with: | + | 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 ==== | ||
{| class="wikitable" | {| class="wikitable" | ||
− | Energy Saving Opportunity | + | | ''' 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: | + | |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 ==== | ||
Line 482: | Line 518: | ||
{| class="wikitable" | {| class="wikitable" | ||
− | Energy Saving Opportunity | + | | ''' Energy Saving Opportunity ''' |
− | 1. Use thermal energy storage systems (i.e. ice banks) | + | |- |
− | 2. Use shading devices for windows. | + | |1. Use thermal energy storage systems (i.e. ice banks) |
+ | |- | ||
+ | |2. Use shading devices for windows. | ||
+ | |} |
Revision as of 15:16, 11 January 2015
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 |
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 |
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. | |||||
2. Repair damaged insulation/seals. | |||||
3. Check for refrigerant contamination. | |||||
4. Check for scaling on condenser and evaporator surfaces. | |||||
5. (Multi-compressor systems); set controls to activate minimum number of compressors. | |||||
6. Monitor timing and duration of defrost cycles. Defrost on demand rather than at fixed intervals. | |||||
7. Use load rescheduling (e.g. cool at night) where maximum-demand tariffs are in operation. | |||||
8. Minimise cooling space by installing removable plastic screens or panels or by filling cooling space with polystyrene foam blocks | |||||
9. Switch off evaporator fans when compressor is off | |||||
10. Regulate condenser pressure (and therefore temperature) | |||||
11. Delayed start-up of compressors. Initially, only start-up of ventilation. | |||||
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. | |||||
2. Install an energy management system which analyses operation of the whole
refrigeration system. | |||||
3. Use effective insulation and sealing. | |||||
4. Install efficient electronic expansion valves. Avoid “head pressure control” where possible. | |||||
5. Recovery of waste heat at the condenser | |||||
6. Automatic bleeding of refrigerant to remove any penetrated air | |||||
7. Install frequency control (i.e. VRF) on chiller compressor. | |||||
8. Install high efficiency or 2-rev electromotor on evaporation fan | |||||
9. Build a cooled front space for refrigeration units. | |||||
10. Use hot refrigerant gas from the compressor for the initial stages of the defrosting cycle. | |||||
11. Use excess heat from other production processes for the production of cooling using
adsorption/absorption cooling. |
PRODUCTION BUILDINGS
Lighting
Energy Saving Opportunity |
1. Use the most efficient lamps consistent with required illumination levels and colour rendering. |
2. Use the light output from lamps efficiently. |
3. Maintain lamps and fixtures clear of light-blocking dust and dirt. |
4. Switch off lights where lighting is not needed. |
5. Consider automatic control of lighting (time clocks and/or photo cells). |
6. Make the best use of daylight. |
7. Avoid the absorption of light by the surroundings (light-coloured wall, ceilings, and floors). |
8. Replace lamps which have exceeded their rated life. |
9. Use “switch-off” and “save-it” stickers as a tool of good housekeeping. |
10. Consider new technologies in order to reduce installation cost, such as infrared switching. |
11. Divide the lighting system of a large space into several independent lighting groups. |
12. Use presence detection switches |
13. Use a lighting system that is continuously variable (e.g. high-frequency fluorescent lighting). |
Building skin
Energy Saving Opportunity |
1.Thermal insulation of floor |
2.Thermal insulation of walls |
3.Thermal insulation of roof |
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. | |||||
2. Install an advanced timer for the boiler operation schedule. | |||||
3. Insulate pipework | |||||
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:
Thermal insulation Draught curtains Air cushion Automatic door Slip door Rubber seal between door and doorpost instead of brushes or no sealing. |
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:
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
Energy Saving Opportunity |
1. Use thermal energy storage systems (i.e. ice banks) |
2. Use shading devices for windows. |