Food and Dairy. Special Working Group Project Report

Transcription

1 Food and Dairy Special Working Group Project Report

2 Food & Dairy Special Working Group Project Report Preface The Sustainable Energy Authority of Ireland (SEAI) was set up by the Government in 2002 as Ireland s national energy agency. Its mission is to promote and assist the development of sustainable energy in Ireland. This includes implementing important aspects of the Energy White Paper, Delivering a Sustainable Energy Future for Ireland, and the National Climate Change Strategy ( ), as provided for in the National Development Plan ( ). In this work, key goals include: Improving energy efficiency Advancing the development and competitive deployment of renewable sources of energy and combined heat and power Reducing the environmental impact of energy production and use, particularly in respect of greenhouse-gas emissions The Energy Demand Management Department is one of the five departments in SEAI. It is responsible for implementing both Ireland s National Energy Efficiency Action Plan (NEEAP 2009) and SEAI s industry programmes. These programmes offer a range of support services to industry and the wider business sectors of the Irish economy. The emphasis is on supporting companies to address their energy use rationally so as to improve their competitiveness and reduce their environmental impact. The SEAI Energy Agreements Programme is aimed at the largest energy users which are committed to taking a strong, strategic and systematic approach to energy management. Firms agree to implement the new energy management standard IS EN 16001:2009 and to pursue an aggressive programme of energy-efficiency action and investment. (IS EN was developed using the former energy management standard IS 393 as a blueprint. IS 393 was developed by SEAI in consultation with the National Standards Authority of Ireland and with industry.) SEAI offers relationship support, advice, networking support and financial supports. It has an additional role of developing initiatives that stimulate or drive action over and above business as usual. One such initiative is the development of the Special Working Groups (SWGs). These groups provide a focus for investigating energy-management techniques and best practice in individual technology areas. They are made up of representatives of companies participating in the Energy Agreements Programme, SEAI and in some cases engineering design companies. 1

3 Food & Dairy Special Working Group Project Report The Food and Dairy SWG was established in September The aim of the SWG is to offer solutions to stimulate further investigations and energy-efficiency projects across the sector. The long-term objective is to stimulate and promote the implementation of energy-efficient solutions. The Food and Dairy SWG was composed of SEAI members from SEAI s Energy Agreements Programme, with technical support from a technical panel of consultants. The SWG members were: Abbott Ireland Foyle Food Group Glanbia Bulmers Ireland HJ Heinz Arrow Group Cadbury Ireland Nutricia Green Isle Foods Kerry Group Dairygold Connacht Gold The technical panel of consultants consisted of: Eirdata FDT Consulting Engineers Viegand & Maagoe PM Group Industrial Utilities Ltd BTEC Jacobs Engineering RPS Group DPS Engineering SEAI is particularly grateful to the Energy Agreements Programme members who made an invaluable contribution to the success of the Food and Dairy SWG. This initiative will be successful to the extent that it stimulates energy-efficiency activity within the Food and Dairy Sector and strides are made in achieving energy reduction across the sector 2

4 Food & Dairy Special Working Group Project Report Contents Executive Summary 5 Glossary of terms Introduction Background to the Food and Dairy Sector Food and Dairy Sector Analysis Formation of Food and Dairy Special Working Group Key Objectives of Working Group Initial Analysis of the Sector Areas of Focus Stakeholder Engagement Study SEAI Energy Aspects Gap Analysis Findings Agreed Technical Areas of Focus Approach to Site Investigations Auditing Approach to Developing Member Site Investigation Opportunities Integration of Auditing Methodology into Existing Management Systems Site Investigations Findings Analysis of Conclusions and Recommendations from Site Investigations Sample of Site Recommendations Generic Analysis of Key Technical Areas of Focus Opportunities Lists & Findings Conclusions from Generic Analysis: Strategic Studies Study 1: Steam Reduction Programme Food and Dairy Sector SWG Study 2: Process Integration and Heat Recovery in the Irish Food Industry Monitoring and Targeting Metering and KPI Structure for the Food Industry Application of Overall Equipment Effectiveness (OEE) Energy Master Planning Linkages to Other Special Working Groups Key Conclusions 74 Appendices 76 Appendix 1: Steam Reduction Programme Food and Dairy Sector SWG 76 Appendix 2: Process Integration and Heat Recovery in the Irish Food Industry 91 Appendix 3: KPI Structure Nutricia Macroom 109 Appendix 4: CIP Optimisation Bulmers Ireland Clonmel 112 Appendix 5: Heat Recovery Green Isle Foods Portumna 116 Appendix 6: Process Integration Study Arrow Group 121 Appendix 7: Process Integration Workshop Dairygold Mitchelstown 126 Appendix 8: Steam Optimisation Diageo 133 Appendix 9: PINCH Analysis Lakeland Dairies 135 Appendix 10: Refrigeration Heat Recovery Kerry Ingredients Listowel 144 Appendix 11: Refrigeration Kerry Ingredients Charleville 147 Appendix 12: Overall Equipment Effectiveness (OEE) Connacht Gold 150 3

5 Food & Dairy Special Working Group Project Report List of Tables Table 3.1: The six highlighted areas 15 Table 3.2: The typical major saving initiatives in food industries 18 Table 3.3: Areas of focus presenting best energy efficiency opportunities 19 Table 5.1: Snapshot of recommendations arising from site investigations 25 Table 6.1: Scoring of recommendations 30 Table 6.2: Colour coding of recommendations 30 List of Figures Figure 1.1: Members of the LIEN, by sector 9 Figure 1.2: The Food & Dairy share of Ireland s TPER (2009) 9 Figure 1.3: Energy efficiency performance by sector ( ) 10 Figure 1.4: Change in output, by sector ( ) 10 Figure 1.5: Change in TPER, by sector ( ) 11 Figure 1.6: Energy savings by category (2009) 11 Figure 3.1: Areas of main interest, as indicated by group members 14 Figure 3.2: Collated areas of focus 16 Figure 3.3: Gap Analyis 17 Figure 3.4: Key areas for energy efficiency opportunities 20 Figure 4.1: Energy Venn Diagram 21 Figure 4.2: Application of Energy Venn Diagram to a milk drying process 22 Figure 5.1: Site investigations breakdown of technical areas 24 Figure 6.1: Rating range of best-practice recommendations across focus areas 63 Figure 6.2: Best-practice recommendations rating breakdown 63 Figure 8.1: COPs for chilled water plant 67 Figure 8.2: OEE over 3 months for spray dryer in food ingredients plant 68 Figure 8.3: Use of OEE to monitor evaporator performance target versus achievement 69 4

6 Food & Dairy Special Working Group Project Report Executive Summary In September 2009, the Sustainable Energy Authority of Ireland (SEAI) established the Food and Dairy Special Working Group (SWG). Its membership consisted of members of the SEAI s Energy Agreements Programme. The Food and Dairy industry in Ireland represents approximately 20% of the total industrial energy consumption in Ireland. Strong opportunities exist for energy-efficiency improvements across the sector. The sector has performed positively in terms of energy efficiency despite reductions in output. Results over the past four years ( ) demonstrate this performance. The level of potential energy-efficiency improvements achievable is estimated to be in the 10% to 30% range, from current consumption levels. Such savings would translate into 550 to 1,650 GWh and cost savings of 40 million to 120 million across the sector. The role of this working group is to support the members of the Energy Agreements Programme (EAP) in their efforts to constantly improve energy performance through continuous improvement. Conducting special investigations on an ongoing basis into potential areas of energy savings has proven successful across all energy sectors in highlighting areas for improvement. The focus of this SWG is to highlight areas for further investigations and energy-efficiency projects across the Food and Dairy industry. The SWG specific outputs contained in this report, which will encourage the uptake of efficiency projects across the sector, consist of: Sector analysis findings detailing the areas of focus that present the best opportunities for energy savings. These technical areas of focus include: o o o o o o o o Clean In Place (CIP) Water use Refrigeration/cold plant Boilers, including steam generation and distribution Drying/evaporation processes Pasteurisation processes Process integration/heat recovery Data-collection / M&T Opportunity lists in each of the key technical areas that present the best opportunities for energy-efficiency improvements A number of commissioned member site investigation reports Strategic studies, including the Steam Reduction in Ireland Programme and Process Integration & Heat Recovery in the Irish Food Industry A guide to energy monitoring and targeting, in particular the establishment of KPI structures for plants An introduction to site Energy Master Planning for sites considering establishing the correct energy management strategies in the medium to long term Using the information as listed above, the intention of this SWG is to facilitate the identification of new investigation opportunities that are most appropriate to the particular needs of the SWG members. The site investigation reports indicate that there is substantial scope for energy reduction across almost every element of the Food and Dairy production process. The Food and Dairy industry in general is progressive and innovative and has not been slow to research alternative approaches to producing food products. 5

7 Food & Dairy Special Working Group Project Report Almost every site visited as part of this SWG had potential to reduce process and utility energy requirements through the use of the following energy-reduction techniques: Using a lower-grade heating medium or a higher-grade cooling medium to achieve the process heating or cooling requirements Heat recovery Part-load operation and setback control Training of operators on the opportunities to increase the efficiency of their processes Fundamental to this working group, and in line with other SWGs, was the auditing approach taken, based on the Energy Venn Diagram. This approach facilitates the application of a consistent methodology in carrying out a technical audit at a site. The methodology applied is analogous to the Challenge and Analyse phase of the Energy Efficient Design (EED) methodology, as developed by the EED Special Working Group. This approach complies with the requirements of the EN Energy Management Standard, specifically with regard to identifying opportunities that can be added to the Register of Opportunities, as the standard requires. Opportunities presented in this report are categorised in the layers of the Energy Venn Diagram. In conclusion, it is estimated that energy savings of up to 30% are possible in the sector. The outputs from the SWG described in this report present the key opportunities for energy reduction across the sector and should be used by industry to stimulate the identification of new opportunities that should be investigated. 6

8 Food & Dairy Special Working Group Project Report Glossary of terms CIP EED (Energy Efficient Design) Energy Master Planning Energy service Energy Venn Diagram KPI LPHW M&T OEE QA Register of Opportunities Clean In Place (CIP) a method of cleaning the interior surfaces of pipes, vessels, process equipment, filters and associated fittings, without disassembly A methodology that facilitates the design, construction and management of projects so that they consume the minimum quantity of energy during subsequent operation Taking a medium to long-term approach to investment in energy efficiency by analysing the impact of future requirements on future energy and utility systems, and by taking a holistic approach to energy streams that flow through a facility The desired outcome that necessitates the consumption of energy. Examples: Comfort is the desired outcome of an office air-conditioning system; killing and removing bacteria is the desired outcome of a CIP process; clean manufacturing space is the desired outcome of a cleanroom HVAC system. Illustrates the layers that contribute to energy consumption. At the core of the Venn diagram is the energy service. This is followed by Process, then Equipment, etc. The challenge of energy consumption should start from the inside and work out. Key Performance Indicator a measure used on its own, or in combination with other KPIS, to monitor how well a business is achieving its quantifiable objectives Low-Pressure Hot Water usually refers to hot water generated in a boiler or by steam heat exchanger and used for space heating in a HVAC system Monitoring and targeting equipment for effectively monitoring energy usage onsite Overall Equipment Effectiveness a methodology or tool to monitor the effectiveness of a particular unit operation through focused monitoring of parameters such as availability, performance and efficiency, in order to identify with the objective of identification of inefficiencies in plant. Quality assurance is the systematic monitoring and evaluation of the production facility to maximize the probability that minimum standards of quality are being attained by the production process Live register of energy-saving opportunities identified in operational facilities, as required by the EN Energy Management System 7

9 Food & Dairy Special Working Group Project Report 1.0 Introduction 1.1 Background to the Food and Dairy Sector The Food and Dairy industry in Ireland represents about one-fifth of the total industrial energy consumption in Ireland. The sector is characterized by the following features in relation to energy efficiency: Many medium-sized companies and few large companies. Some medium-sized companies are organized in groups while others operate in smaller entities. In general, food companies have strict requirements for return on investment. Most projects require a payback period of less than two years to secure capital funding. Many plants are relatively old often 25 to 30 years. In general, investment in energy-efficient technologies has been limited historically but has improved in the past five years. In general, management in Food and Dairy companies puts the emphasis on energy efficiency in accordance with the energy cost and the impact on the short-term business bottomline margin. Companies in the sector can seldom obtain the funding to implement longer-term initiatives to improve efficiency. In certain sub-sectors (nutritional ingredients, beverage, dairy, meat) QA-departments have a strong influence on operational parameters (e.g. CIP, air-change rates, temperatures, quality of nitrogen). There can be a tradition of replacing equipment like-for-like without considering if a more energyefficient design could lead to lower life-cycle costs. There is limited involvement by external technical consultants in design projects, even though they may be most aware of opportunities to incorporate EED. Many of the companies in the Food and Dairy sector are members of the Large Industry Energy Network (LIEN). This is a voluntary network, facilitated by the Sustainable Energy Authority of Ireland (SEAI), of companies that work together to develop and maintain robust energy management. Over 135 of Ireland s largest energy users are members of the LIEN. Over 80 of these companies are also members of the Energy Agreement Programme and are implementing the Energy Management Standard EN The network accounts for over two-thirds of Ireland s total industrial energy use. The LIEN has continuously improved its energy performance since it was formed; some companies have improved their energy efficiency by over 30% over the last decade. Of the 135 members of LIEN, 42 companies are from the Food and Dairy sector the largest group from any one sector. 1 1 SEAI Large Industry Energy Network Annual Report

10 Food & Dairy Special Working Group Project Report Figure 1.1: Members of the LIEN, by sector 1.2 Food and Dairy Sector Analysis The pie chart below indicates the breakdown of industrial sectors that made up Ireland s Total Primary Energy Requirement (TPER) for It highlights the Food and Drinks sector as a major user of energy. The sector represents approx.. 3,900 GWh of TPER. Figure 1.2: The Food & Dairy share of Ireland s TPER (2009) 9

11 Food & Dairy Special Working Group Project Report Further historical analysis of the sector, available in the LIEN 2009 Annual Report (covering ), reveals that it has, overall, performed in a positive manner. Its performance may be summarized under three headings: Energy efficiency The sector has achieved 15% cumulative savings in energy in , with consistent savings year on year. Figure 1.3 shows the increase in energy efficiency. Figure 1.3: Energy efficiency performance by sector ( ) Output There was a 2% cumulative contraction in output in the sector in (Figure 1.4). Figure 1.4: Change in output, by sector ( ) TPER There was a 16% cumulative contraction in TPER in the sector in (Figure 1.5). This would be expected because of reductions in output activity in addition to energy-efficiency measures. 10

12 Food & Dairy Special Working Group Project Report Figure 1.5: Change in TPER, by sector ( ) It is important to highlight that energy efficiency generally is negatively affected when output falls. However, the sector has performed positively in terms of energy efficiency against the backdrop of a decline in output. The energy-saving potential in the sector is acknowledged to be substantial. Based on the sector analysis and taking into account the views of technical experts, the level of potential energy savings that can be achieved ranges from 10% to 30%, from current consumption. It has been determined that pursuing opportunities across the key identified technical areas could account for a large proportion of the potential energy savings achievable in the sector. The extent of savings achievable over the medium term will vary from site to site apart from the barriers to energy efficiency that prevail in many parts of the Food and Dairy industry. Energy savings across the Irish industrial sector were categorised for 2009, using the Energy Venn Diagram, to gain an understanding of project activity for the year. Challenging the energy service requirements accounted for the greatest amount of project activity. This activity offers the strongest opportunity for step-change reductions in energy requirements. Figure 1.6: Energy savings by category (2009) 2 2 Refer to section 4.1 of this report for an explanation of the Energy Venn Diagram. 11

13 1.3 Formation of Food and Dairy Special Working Group Food & Dairy Special Working Group Project Report The SEAI Food and Dairy Sector (F&D) Special Working Group (F&D SWG) was established in September Born out of the SEAI Special Working Groups Initiative, it provides a focus for stimulating activity to identify energy efficiency projects across the Food and Dairy sector. It aims to achieve some of the objectives that the wider Energy Agreements Programme (EAP) strives to achieve. Many of the SWG s member companies have committed themselves to taking a strong, strategic and systematic approach to energy management through the EAP. The SWG programme of work, as determined by the group, was envisaged as combining desktop studies, stakeholder workshops, special investigations identifying energy-saving projects, bestpractice initiatives, demonstration projects and feasibility studies. A key objective is to focus on key technologies that present the best opportunities for energy efficiency across the group and wider sector. The objectives of the F&D SWG support the overall objective of the Energy Agreements Programme, specifically in line with the IS EN 16001:2009 energy management standard and the carrying-out of special investigations. Through the energy management standard, firms agree to implement and pursue an aggressive programme of energy-efficiency action and investment. Stimulating additional activity in identified technical opportunities allows for the successful integration of these into a company s energy management system via the Register of Opportunities and operation control procedures. SEAI recommends and facilitates an energy management systems approach in the Food and Dairy sector as a means to continuous improvement and control of energy. 12

14 Food & Dairy Special Working Group Project Report 2.0 Key Objectives of Working Group The objectives of the Food and Dairy Special Working Group are to: Focus and identify key common areas for energy reduction that offer the greatest opportunity for replication across the industry Offer solutions to help stimulate further investigations and energy efficiency projects in the Food and Dairy sector Increase knowledge and awareness of identified energy-efficiency solutions Facilitate specific company onsite assessments and special investigations for group members and develop a list of opportunities that arise from the Food and Dairy sector Challenge both the technical consultants panel and industry group members to identify opportunities using the applied Energy Venn Diagram methodology Provide a source of opportunities for companies in the Energy Agreements Programme to identify energy-efficiency improvement projects and special investigations that can be integrated into energy management systems via the Register of Opportunities Apply learnings from other SEAI SWGs that relate to this sector i.e. the Energy-Efficient Design, Refrigeration, and Alternative Methodologies SWGs 13

15 Food & Dairy Special Working Group Project Report 3.0 Initial Analysis of the Sector Areas of Focus As part of the initial stages of the working group, two approaches were initiated in order to establish the areas of focus: o Stakeholder Engagement Study (see section 3.1 below) o GAP Analysis Review (3.2) 3.1 Stakeholder Engagement Study This approach consisted of three separate streams of work: An industry workshop meeting took place to determine the views of industry participants about the opportunities for energy efficiency. A desktop study of information available on best-practice initiatives was carried out to identify the potential opportunities for energy saving across the sector. A technical review within the sector was carried out as part of the overall study process. The analysis below shows the trend in terms of each of the sources from which information was gathered, but also shows where various sources agree. The findings from each source are described below Member Wishlist In general the areas that were of most interest were Monitoring &Targeting (M&T), Energy Audits and Surveys, and Managing Hot and Cold Process Streams. Figure 3.1: Areas of main interest, as indicated by group members M&T Tariffs Staff Motivation Energy Audits and Surveys Pasteurisers and Sterilisers Evaporators and Dryers Cleaning Packaging Boilers and steam distribution systems Compressed Air Motors and Drives Refrigeration and Cold Stores Lighting Space Heating and Ventilation Water Heating Managing Hot and Cold process streams 3 The LHS axis shows the number of suggestions made in the specific area; it shows the emphasis of the group in a particular area as expressed during the meeting. 14

16 Food & Dairy Special Working Group Project Report Desktop Information Review In general the areas most often highlighted as having potential for energy savings were Evaporators and Dryers, Compressed Air, Refrigeration and Cold Stores, and Managing Hot and Cold Process Streams (see Figure 3.2) Technical Panel Review In general the areas most often highlighted by the technical expert panel as having potential for energy savings were Evaporators and Dryers, Cleaning, Boilers and Steam Distribution, Refrigeration and Cold Stores, and Managing Hot and Cold Process Streams (see Figure 3.2) Collated Areas of Focus Combining the suggested focus areas indicates that areas are common to all three of the information sources (i.e. the group, the desktop study information and the technical expert panel). Figure 3.2 plots the percentage of total suggestions for each information source in each of the identified areas. For example, the circle highlighting Area 1 demonstrates that 17.5% (approx.) of the suggestions from the group, 5% of the findings of the desktop study information and 5% of suggestions from the expert panel related to M&T. The six areas highlighted in Figure 3.2 that present opportunities for further investigation are either areas where all three source groups are strongly represented (such as Area 6: Managing Hot and Cold Process Streams) or areas where the group was particularly strong (such as Area 2: Energy Audits & Surveys) (see Table 3.1) Table 3.1: The six highlighted areas Area 1: Monitoring & Targeting (Key Performance Indicators) Area 2: Energy Audits and Surveys Area 3: Equipment Optimisation (including Cleaning) Area 4: Boiler and Steam Distribution Area 5: Refrigeration and Cold Streams Area 6: Managing Hot and Cold Process Streams 15

17 Figure 3.2: Collated areas of focus 4 Food & Dairy Special Working Group Project Report

18 Food & Dairy Special Working Group Project Report 3.2 SEAI Energy Aspects Gap Analysis Findings Since 2006, SEAI-appointed consultants have participated in a number of site visits for Food and Dairy companies, to conduct technical reviews of energy aspects with the aim of performing GAP analysis according to the requirements of EN and IS 393. The results of the analysis are summarised below. Figure 3.3: Gap Analysis Overview of energy consumption o o Several companies lack accurate information on total energy consumption on site. Energy management performance is often tracked based on cost rather than on a consumption basis (kwh). This is not a true indicator of energy management performance. Data collection o o o No comprehensive metering plans identifying existing meters and proposed future meters, as required by EN 16001, were presented on any of the sites visited. The standard of energy metering and monitoring on sites visited was variable, with more focus on electrical sub-metering than thermal, although thermal energy consumption (hot and cold) is high on most Food and Dairy sites. There is significant scope on all of the sites to use data from existing process, utilities/building management and manufacturing computer systems, as well as information from existing manual meters, to monitor energy usage with little or no expenditure. Break-down of energy consumption for end-users o o o The sites show varying levels of success in identifying areas of significant energy consumption, as required by Clause of EN (Identification and Review of Energy Aspects). It is important that some estimation of utilities energy usage, as well as direct process energy use, is allocated to the main areas of the plant to indicate where focus and investment is most appropriate. In some of the sites visited, some of the largest energy users were poorly metered, while smaller users had a good standard of metering. Energy balances and Sankey diagrams 17

19 Food & Dairy Special Working Group Project Report o o A small proportion of sites have used detailed analysis tools such as energy balances or Sankey diagrams to highlight areas of significant energy consumption. Some of the sites have done substantial work on process modelling. - A significant differential between design energy usage and actual usage highlights optimisation opportunities, indicating the appropriateness of energy balances. EPIs and energy management o o o o There is scope for improvement in EPI generation and monitoring on all of the sites visited. Energy performance indicators (EPIs), detailing total energy consumption per quantity of product (kwh/ton or kwh/l), are used typically at total plant level (management EPI) for comparison with other plants. A small number of companies had detailed EPIs by plant area (operational EPI); these are much more useful than indicators at full site level. More focus tends to be put on electrical usage (as cost/kwh is higher), even on sites with high thermal load. It is common for some food companies to track performance in energy management by cost and not in kwh, thus not gaining a true indicator of performance in energy management. Savings opportunities o o A limited number of sites have a formal energy team with energy management responsibilities and objectives, while some lack a formal Register of Opportunities. Expenditure based on simple payback only can have huge implications for plant operating costs in the future. Projections for energy cost increase and carbon-tax projections should be built into this analysis as well as life-cycle costing and equipment energy use. A number of opportunities were identified for retrofit/upgrade projects to address high energy usage. The typical major saving initiatives in food industries are listed in Table 3.2. Table 3.2: The typical major saving initiatives in food industries Replacement of steam with hot water for sub 100 C thermal users Installation of economisers on boilers, improvements to condensate recovery Generating a heat and mass balance to look for internal process integration opportunities Review of CIP procedures Steam pressure reduction and network rationalisation Improved operations scheduling to minimise peak loads on all utilities Waste heat recovery for hot-water production Review of refrigeration plants Optimisation of HVAC and process extract operation 18

20 Food & Dairy Special Working Group Project Report 3.3 Agreed Technical Areas of Focus Before carrying out any special investigations, the panel of consultants engaged in an interactive workshop to evaluate, discuss and confirm the final choice of focused technical areas for the SWG that presented the greatest potential for energy efficiency improvements. Taking into account the identified areas (section 3.1) and the opportunities presented in the GAP analysis reports (section 3.2), the final areas of focus that were deemed to present the best opportunities for energy efficiency are highlighted in Table 3.3. This table highlights the transition from the member-identified areas to those areas agreed following the technical consultants workshop. Table 3.3: Areas of focus presenting best energy efficiency opportunities Member-identified key areas Area 1: Monitoring & Targeting (Key Performance Indicators) Area 2: Energy Audits and Surveys Area 3: Equipment Optimisation (including Cleaning) Area 4: Boiler and Steam Distribution Area 5: Refrigeration and Cold Streams Area 6: Managing Hot and Cold Process Streams Areas of focus agreed following technical consultants workshop Data Collection / M&T Removed site-wide audits considered too general for purposes of SWG Pasteurisers Evaporators and Dryers Clean In Place Water Use Boilers & Steam Refrigeration Process Integration 19

21 Food & Dairy Special Working Group Project Report Figure 3.4 shows the key areas graphically. Figure 3.4: Key areas for energy efficiency opportunities Based on the above key areas, the SWG planned the following scope of group outputs: Generation of theoretical opportunity lists in the key technical areas of CIP, Water Use, Refrigeration, Steam, Pasteurisation & Dryers/Evaporators A number of member site investigations across the key areas of focus, in particular CIP, Water Use, Refrigeration, Steam, Pasteurisation & Dryers/Evaporators, Process Integration Strategic studies such as Steam Reduction in Ireland Programme and Process Integration & Heat Recovery in Irish Food Industry A Site Investigation relating to Energy Monitoring and Targeting, and in particular the establishment of KPI structures for plants A Site Investigation relating to Energy Monitoring and Targeting, in particular the application of Overall Equipment Effectiveness (OEE) on an evaporator Review of Energy Master planning an important exercise for sites to establish the correct strategies for energy management in the medium to long term A number of case studies relating to the focus areas 20

22 Food & Dairy Special Working Group Project Report 4.0 Approach to Site Investigations 4.1 Auditing Approach to Developing Member Site Investigation Opportunities A consistent approach in carrying out the technical audit at member sites has been used to deliver special investigations. The methodology applied is based on the Challenge and Analyse phase of the Energy Efficient Design (EED) methodology, as developed by the EED Special Working Group. In particular, the Energy Venn Diagram, shown in Figure 4.1, presents the approach taken in carrying out this Challenge and Analyse phase as it illustrates the different categories that should be considered when seeking to implement the optimum energy-efficient solution. The principle of the methodology of the Venn Diagram is to challenge and examine the various layers that comprise the overall energy usage. Figure 4.1: Energy Venn Diagram The Energy Venn Diagram illustrates the layers that contribute to the energy requirement. At the core of the diagram is the Energy Service. Working outwards, this is followed by Process, Equipment, Control, Operation & Maintenance, and finally Housekeeping. Thus the challenge of minimising the energy requirement starts from an exercise to minimise the Energy Service requirements and works outwards through each layer with the aim of selecting the most energy-efficient solution. 21

23 Food & Dairy Special Working Group Project Report As this SWG entails member sites that are currently in operation, the approach to auditing used on the sites is consistent with an official EED Operations Optimisation Process being devised as part of the EED SWG. This operational audit process incorporates an EED review of a system or process when already in operation. In particular, the audit approach applied in the Food and Dairy SWG is consistent with Phase 2 Challenge, Identify & Quantify at SEU level of this four-phase operational audit process. The following represents an example of the application of the Energy Venn Diagram within the Food and Dairy industry, specifically to a milk drying process. Figure 4.2: Application of Energy Venn Diagram to a milk drying process 22

24 Food & Dairy Special Working Group Project Report 4.2 Integration of Auditing Methodology into Existing Management Systems The IS EN 16001: 2009 Energy Management Standard is the European energy management standard. It applies a PDCA (Plan Do Check Act) approach. It is targeted at organizations and provides a framework for developing an ongoing energy management strategy. It involves carrying out an Energy Aspects review which highlights the opportunities to reduce energy consumption onsite. The EED Operational Audit approach and methodology being used in this working group can be used as a tool to generate the Energy Aspects document. The auditing approach used in this working group involves consultation with site personnel to understand and challenge plant and process operations. During this analysis, the operational control procedures and practices are interrogated and challenged using the Energy Venn Diagram. This exercise leads to the identification of opportunities which helps to meet the energy standard requirement to maintain a register of opportunities for energy saving. 23

25 Food & Dairy Special Working Group Project Report 5.0 Site Investigations Findings 5.1 Analysis of Conclusions and Recommendations from Site Investigations In line with the work outlined in sections 3 and 4 above, a number of special investigations were carried out at member sites as part of the work of the Food and Dairy SWG: Abbott Ireland Cootehill Foyle Food Group Glanbia Ballyragget Bulmers Ireland Cadbury Ireland Connacht Gold Nutricia Macroom Kerry Ingredients Charleville Kerry Ingredients Listowel Dairygold Dawn Meats Naas Figure 5.1 shows the approximate split in technical areas of focus relating to the special investigations carried out across the member sites. Figure 5.1: Site investigations breakdown of technical areas Number of Site Investigations - Technical Area Breakdown Clean In Place (CIP) Refrigeration & Cooling Boilers & Steam Water Data Collection/M&T Process Integration Drying/Evaporation Processes Pasteurisation Processes The site investigation reports indicate that there is significant scope for energy reduction across all layers of the Energy Venn Diagram. While addressing the energy service is the first step and can have the most impact on energy consumption, the opportunities to reduce energy consumption substantially have been difficult to flush out. The Food and Dairy industry in general is a progressive and innovative industrial sector and has not been slow to research 24

26 Food & Dairy Special Working Group Project Report alternative approaches to producing food products. Very significant opportunities in the process, equipment and control areas have been identified across the entire spectrum of technical areas focused on during this working group. Almost every site had potential to reduce process and utility energy requirements through using the following energy reduction techniques: Use a lower-grade heating medium or a higher-grade cooling medium to achieve the process heating or cooling requirements A central heating medium (usually high-pressure steam) often meets all site heating demands and quite often one centralised cooling medium meets all cooling demands. Very few of the cooling or heating loads on the sites investigated have a utility which is a good match from an energy viewpoint. Heat recovery Almost every site report concluded that heat recovery was possible through the integration of processes and utilities. Energy costs and developments in heat exchange technologies have been proven to make heat recovery more viable than when plants were designed or installed. Part-load operation and setback control Another common theme was the opportunities to retrofit efficient controls to processes and utilities to increase efficiency, particularly during periods of low load operation. Variable-speed drives (VSDs), sequencers, weekend setback controls and intelligent control systems to initiate process step changes have again featured extensively in the site investigation reports. Significant savings in Housekeeping and Operation & Maintenance have not been frequently highlighted in the site investigations, but some lack of awareness about the energy implications of some activities in the industry was noted. The need to train operators on the opportunities to increase the efficiency of their process was identified. 5.2 Sample of Site Recommendations Table 5.1 gives a snapshot of the recommendations delivered through the site investigations carried out throughout the SWG. As the site investigations are specific to companies, this information cannot be disclosed in its totality. The recommendations are listed according to the Energy Venn Diagram layer. Table 5.1: Snapshot of recommendations arising from site investigations Energy Venn Layer Energy Service Savings Opportunities Replace hot caustic cleaning with cold caustic cleaning Achievable Energy Saving Technical Area Why the Opportunity is Viable 2,298,611kWht Clean In Place As a chemical sterilant is currently in use it may be possible to carry out cold caustic cleaning. This would provide a considerable reduction in the steam requirements. 25

27 Food & Dairy Special Working Group Project Report Energy Venn Layer Energy Service Energy Service Energy Service Process Savings Opportunities Consider free cooling opportunity using local water source for periods of the year Consider alternative heating methods of producing air at extreme high temperatures for milk drying, rather than current use of HP steam Reduce or eliminate time spent running dryers on water instead of product Use cooling-tower water as a precooling step before more expensive chilled water in pasteurising process Achievable Energy Saving Thermal Thermal Technical Area Refrigeration & Cooling Steam Generation and Distribution Why the Opportunity is Viable As all the site water is taken from river/wells and ultimately heated, there is potential to do highgrade cooling with the incoming water and pick up some heat. The incoming water can offset cooling-tower water and chilled-water usage and reduce steam input to heating the ingredient water. Using indirect-fired gas air heaters to produce hightemperature air for drying can be more efficient than producing highpressure steam for the entire site just to satisfy one or a few high-pressure users. Thermal Drying Running on water effectively keeps the system operational and at process temperatures while no product is flowing. There is a considerable energy penalty which can be reduced or eliminated by planning batch runs. Electrical Refrigeration System Cooling-tower systems typically carry out high-grade cooling applications at a cost of less than 20% of that of chilledwater systems. It makes sense from both an energy and financial perspective to use tower water as a first step to process cooling where the 26

28 Food & Dairy Special Working Group Project Report Energy Venn Layer Savings Opportunities Achievable Energy Saving Technical Area Why the Opportunity is Viable product temperatures allow it. Process Heat recovery from refrigeration to preheat water for washing should be further investigated Thermal Refrigeration System Medium-grade waste heat is available from industrial refrigeration systems from the oil-cooling circuit and from desuperheating the discharge gas before the condensers. In most cases this heat can be used for washing water in food production spaces which also only require mediumgrade heat, and displaces fuel consumed in boilers. Process Consider replacing steam boilers with direct-fired industrial hot-water generation equipment with heat recovery from adjacent refrigeration condenser plant Thermal Steam Generation & Distribution The use of steam to service what are ultimately low to medium-grade heating demands is wasteful. Greater efficiency can be achieved with hotwater generation equipment coupled with heat recovery. Process Review requirement for current temperature levels during process and consider reducing the operating temperature set point by 5 0 C tonnes of steam Data Collection / M&T By challenging the operating parameters of processes, it is often possible to reduce the overall operating temperatures; a large reduction in fuel input is possible. Process Heat recovery from air compressors 494,784 kwht Heat Recovery Opportunities A huge portion of the energy used by air compressors is rejected in the form of low-grade heat. This heat can be used to pre-heat water for heating or processing purposes. 27

29 Food & Dairy Special Working Group Project Report Energy Venn Layer Equipment Equipment Control Control Control Savings Opportunities Consider a VSD screw compressor to allow setback on low plant loads Consider using biomass boilers as a replacement for heavy fuel oil boilers Consider sequencing of compressors on fixed-speed compressors Assess the feasibility of installing chilledwater controls to prevent the excessive use of energy in overcooling milk during periods of low chilled-water demand Investigate using torque-based control of process end point to replace current defined time-based control Achievable Energy Saving Technical Area Why the Opportunity is Viable Electrical Refrigeration The use of VSDs with screw compressors allows the compressors to operate at or close to maximum efficiency for a longer periods. Thermal Electrical Refrigeration System Modern biomass boiler plants can be an effective method of generating steam for processing plants using heavy fuel oil or diesel. Any carbon allowances will have a big impact on feasibility. Having compressors load and unload based on local parameters is less desirable than having a sequencing system selecting the optimum number and capacity of compressors to match demand. Thermal Pasteurisation Even though quality and operations personnel may like product to be cooled as much as possible, there is an energy penalty for overcooling beyond the required setpoint. This can be avoided by installing appropriate control technology. 51,850 KWhe Data Collection / M&T Process steps can be initiated or stopped based on feedback on the product conditions rather than waiting for a pre-set safe time to elapse. This can be the case for heating, cooling, mixing, proving or 28

30 Food & Dairy Special Working Group Project Report Energy Venn Layer Savings Opportunities Achievable Energy Saving Technical Area Why the Opportunity is Viable any other process step that requires a significant energy input. O&M O&M Housekeeping Focus on pressure drops and flowrates through CIP sprayballs Consider using EPIs to monitor the performance of the pasteuriser. The pasteuriser appears to be one of the driving forces of energy usage at the facility. It is highly recommended that automated performance measurement becomes part of normal operations onsite. Install insulation across all pipework in plantroom Electrical/Thermal Clean In Place Checking the flowrate through sprayballs used for cleaning the internals of vessels can reduce the likelihood of blockages, thus reducing pump power and the volume of heat energy required to properly clean the vessel. Thermal Pasteurisation Having online EPIs can highlight any process issues with equipment. In energyintensive operations such as pasteurisation or drying the EPI should be relatively consistent so that any deviations can be identified and resolved quite quickly. 0??? Steam Generation & Distribution Housekeeping such as replacing defective insulation or fixing a leak can address energy issues at source. 29

31 Food & Dairy Special Working Group Project Report 6.0 Generic Analysis of Key Technical Areas of Focus To re-emphasise, the technical areas of focus are: o o o o o o o o Clean In Place (CIP) Water use Refrigeration/cold plant Boilers, including steam generation and distribution Drying/evaporation processes Pasteurisation processes Process integration/heat recovery Data-collection / M&T The following tables present best-practice guides to achieving energy efficiency. These tables are based on using the Venn Diagram 5 as a tool in challenging and analysing the energy requirements. 6.1 Opportunities Lists & Findings The following pages present the opportunities lists, detailing the recommendations within each Energy Venn Diagram layer, with the corresponding ratings. Analysis of each opportunity list provides an overview of how well an opportunity rates in terms of potential savings and ease of implementation. Rating in the form of low, medium and high are presented graphically for each; the scoring for each recommendation is shown in Table 6.1. Table 6.1: Scoring of recommendations Potential savings Ease of implementation 1 Low 1 Difficult 3 Med 3 Med 5 High 5 Easy Colour coding of each recommendation, based on its rating, is as in Table 6.2. Table 6.2: Colour coding of recommendations Ranking scoring basis (0-25) 0 to 5 6 to to 25 5 Use of the Venn Diagram concept in the cases below, and in particular in the Energy Service and Process layers, to display the recommended options for energy efficiency, is made in a slightly loose fashion. For example, relating to milk pasteurisation, strictly speaking the energy service is the killing of bacteria in the milk, and the process is thermal pasteurisation. However, for killing bacteria in the dairy industry there are many applications, so it was deemed appropriate to refer to pasteurisation of milk as the energy service. Similar examples can be found throughout the spreadsheets However, this was these were built for ease of use. 30

32 Food & Dairy Special Working Group Project Report Clean In Place (CIP) Clean In Place (CIP) Venn Diagram Layer Investigation Opportunity Reason Why Potential Savings 1 Low 3 Med 5 High Ease of Implement ation 1 Difficult 3 Med Opportunity Rating 5 Easy Energy Service 1 Investigate the potential for the elimination of sterilant and/or final rinse steps in CIP. Carry out a calculation of Energy Impact of Steam Sterilisation vs. Liquid Sterilant. Extra sterilant steps based on perceived risks. Savings on pumping of sterilant and water for final rinse step Review CIP temperatures and consider a reduction of Reducing temperature will reduce thermal energy caustic temperature e.g. from 80 to 40 0 C. Consider different requirement. CIP temperatures in different plant areas It is recommended to confirm the definition of "clean" as agreed with all site stakeholders, e.g. Micro Reduction, Sterile, Sterile and Dry. Cleaning requirements not accurately defined and plant often being cleaned to a level above what the process actually requires Define CIP process steps to achieve cleanliness with minimum energy input, based on type of equipment to be cleaned, etc. Eliminate any unnecessary steps. CIP requirements different for tanks, vessels, hoses, etc, and depending on production processes. Often CIP recipes can be based on historical requirements or perceived requirements. Copying of CIP & rinse times from one area of plant to another is common, even if system volumes are much lower