Difference between revisions of "Energy efficiency in fruits/vegetables/herbs"

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Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]]
 
Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]]
  
−
*Case studies
+
== PRODUCTION PROCESSES ==
−
**[[Media: BPE_Kernel_Export.pdf|Kernel Export]]
+
 
−
**[[Media: D3.2_factsheet_Dannenberg_english.pdf| Dannenberg]]
+
 
−
**[[Media: D3.2_factsheet_Skrzatusz_english.pdf | Skrzatusz ]]
+
=== Thermal energy ===
 +
==== Heat generation ====
 +
 
 +
 
 +
{| class="wikitable"
 +
!colspan="6"| 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.
 +
| -
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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.
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 =====
 +
 
 +
{| class="wikitable"
 +
|''' 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 =====
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
{| class="wikitable"
 +
| ''' 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 ====
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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.
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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.
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
{| class="wikitable"
 +
| ''' 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 ====
 +
 
 +
{| class="wikitable"
 +
|''' 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 ====
 +
 
 +
{| class="wikitable"
 +
!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.
 +
|-
 +
|2. Install an advanced timer for the boiler operation schedule.
 +
|-
 +
|3. Insulate pipework
 +
|-
 +
|4. Insulate hot water storage tanks
 +
|}
 +
 
 +
{| class="wikitable"
 +
!colspan="6"|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 ====
 +
 
 +
{| class="wikitable"
 +
|''' 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 ====
 +
 
 +
{| class="wikitable"
 +
| ''' 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 ====
 +
 
 +
{| class="wikitable"
 +
| ''' Energy Saving Opportunity '''
 +
|-
 +
|1. Use thermal energy storage systems (i.e. ice banks)
 +
|-
 +
|2. Use shading devices for windows.
 +
|}
 +
 
 +
 
 +
 
 +
 
 +
== Case studies ==
 +
 
 +
*[[Media: BPE_Kernel_Export.pdf|Kernel Export]]
 +
*[[Media: D3.2_factsheet_Dannenberg_english.pdf| Dannenberg]]
 +
*[[Media: D3.2_factsheet_Skrzatusz_english.pdf | Skrzatusz ]]
  
 
Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]]
 
Back to [[Subsection DA food|EFFICENCY FINDER OF FOOD INDUSTRY]]

Revision as of 15:26, 11 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
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.



Case studies

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