Energy Savings in Dairy Applications

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This Dairy Toolkit from Danfoss shown energy saving technologies and its application in dairy industries. It was used in the context of energy auditor training in Nepal in 2012 that was supported GIZ NEEP Programme.

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Energy Savings in Dairy Applications

  1. 1. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 1 Enery Savings in Dairy Applications
  2. 2. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 2 Opportunities • Milk Cooling at Collection centre • Dairy Plant level • Chilling centre level • Cold Stores at Plant & Warehouse
  3. 3. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 3
  4. 4. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 4 Milk Cooling system
  5. 5. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 5 Replace the Piston Technology with Scroll
  6. 6. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 6 Recip v/s Scroll Details Reciprocating Scroll Displacement 100 70 COP / EER MODERATE - HIGH HIGH Serviceability YES NO Reverse Rotation No issue Need protection Range … to 13.5 HP 1.5 to 30 HP Liquid Handling capability OK… within compressor charge limit OK… within compressor charge limit Applied cost MODERATE HIGH System service / maintenance MODERATE CRITICAL Pump down control Scavenging pump down allowed Only static pump down allowed Sensitivity to load variations and working conditions MODERATE HIGH
  7. 7. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 7 0,4 0,45 0,5 0,55 0,6 0,65 0,7 0,75 0,8 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 ISENTROPICEFFICIENCY PRESSURE RATIO Built-in pressure ratio (geometrical) (EXAMPLE) In scroll compressors the isentropic efficiency depends on the shape of the scrolls, that means on which pressure difference it has been optimised. Technologies specificities : Scrolls Vs. Recip Optimization point :Scrolls Vs. Recip
  8. 8. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 8 Design The refrigerant vapor is compressed by a piston that is located inside a cylinder. The piston is connected to the crankshaft by a rod. As the crankshaft rotates (by a motor), it causes the piston to travel back and forth inside the cylinder. Suction valve and the discharge valve, are used to trap the refrigerant vapor within the cylinder during this process. Compressors- Working Principle Reciprocating Compressor
  9. 9. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 9 Design It works on the principle of trapping the refrigerant vapor and compressing it by gradually shrinking the volume of the refrigerant. The scroll compressor uses two scroll to perform this compression process. The stationary scroll contains a discharge port. The driven scroll is connected to a motor by a shaft and bearing assembly. Compressors- Working Principle Scroll Compressor
  10. 10. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 10 Reciprocating (Piston) v/s Scroll
  11. 11. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 11 Multiple Condensing Units
  12. 12. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 12 Heat Recovery from Condenser The Cool New Way To Heat Water Real power savings for every business using a refrigeration plant and generating Hot Water.
  13. 13. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 13 Heat recovery Up to 60% power savings – (AgResearch Field Tested on a dairy farm application) Can generate upto 85 Hot Water Return on investment – From within 12-24 Months (application dependent - Tariff - Volume of Hot water etc.) No CO2 emissions
  14. 14. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 14 How does it look?
  15. 15. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 15 Heat Recovery from Condenser REFRIGERATION & AIR CONDITIONING DIVISION April 2009  Unitech visit – June 15th 2010 Special demand :Heat Recovery system REFRIGERATION & AIR CONDITIONING DIVISION April 2009  Unitech visit – June 15th 2010 Special demand :Heat Recovery system
  16. 16. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 16 Can be built on Condensing Unit HeatRecovery HeatRecovery
  17. 17. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 17 Some Practical Opportunities • Ventilation • Clean Condenser
  18. 18. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 18 Condensing Unit Installation Allow Free Air Flow on CDU Ensure good ventilation
  19. 19. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 19 Ensure GOOD ventilation The Hot air should go out of the room and NOT recycle into the condenser. RISK: Increase in Power bill, longer cooling time, shorter compressor life
  20. 20. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 20 Keep Condenser Clean RISK: Shorter compressor life; high power bill; longer cooling time
  21. 21. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 21 RGE/XGE Fan speed regulators Condenser Fan speed Regulation
  22. 22. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 22 DANFOSS VLT ® YOUR PARTNER IN DAIRY
  23. 23. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 23 Fixed AC Input (3ph,415v,50hz ) Variable AC Output ( 0-415v,0-x Hz) What is a Variable Frequency Drive ( VFD) ?
  24. 24. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 24 VFD APPLICATION RESULT Variable speed control: •50% energy savings when the fan or pump speed is reduced from 100% to 80%
  25. 25. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 25  Homogenisers (Control via. Flow or Level)  Separators / Clarifiers (Speed Control)  Silo Agitators (Control via. Level)  Filtration Plants Pumps (Control via. Flow & / or Pressure)  Size range 1.1kW – 50kW MILK Standardization – VFD applications
  26. 26. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 26 BUTTER Manufacturing – VFD Applications • Silo Agitators (Control via. Level) • Cream Pumps (Positive pumps) (Control via. Level or Flow) • Separators / Clarifiers (Speed Control) • Butter churns • Size range 1.1kW – 50kW
  27. 27. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 27 Cheese Manufacturing VFD Applications • Transfer Lobe Pumps (Control via. Level or Flow) • Cheese Machine Drive Motors • Rapid Cool Storage • Stirrer Motors • VSD Size Range 1.1kW – 90kW
  28. 28. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 28 • film movement control through Danfoss MCO + Drives • Sealing tool positioning • Precise side roller movements for continuous sealing of film • VFD control for all motors HFFS • Precise film movement coordinated with product drop • Weigher synchronization with Bagging machine • Motor control by VFD for vertical, weigher & roller assembly VFFS FOR HORIZONTAL ROLLER FOR CUT LENGTH SEALING JAWS FC 300 Series MCO MCO FOR ROLL UNWINDING WEIGHER CONTROL PACKAGING
  29. 29. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 29 We Understand: NEED OF MODERN DAIRY • Drives capable of operating under wash down conditions • Compatible to CIP application, which is a standard for most Dairy equipments • Compact & optimum utilization of space • Energy Savings operation • High operational efficiency • Drives which cover wider range of motor KW ratings • Operation in high ambient temperature • Higher uptime & service support • Low set up & replacement cost
  30. 30. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 30 HOW CAN DANFOSS VLT DRIVES BE YOUR PARTNER TO REDUCE YOUR OPERATING COST ??
  31. 31. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 31 OPERATIONAL EFFICIENCY DAIRY REQUIREMENT DANFOSS VALUE  Energy savings operation  Low transmission losses  Low initial cost of drive (over designing)  Back channel cooling translates to 5-10% savings  Danfoss VLT drives do not require output reactors<150 m cable length  savings of 5% on output choke of total project cost  Reduces transmission losses by 0.5% due to output reactors  No de rating required due to 50 deg.c rated temperature
  32. 32. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 32 OPERATIONAL EFFICIENCY DAIRY REQUIREMENT DANFOSS VALUE  Faster payback period for critical application  Low heat loss  With Danfoss drives having less heat loss and Highest Efficiency you can achieve the same .  Danfoss offers Savings in lakhs /year on heat loss against its competitors
  33. 33. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 33 Innovative cooling • Two cooling possibilities: • Back cooling - Air ducted in and out the back • Duct work cooling - Air ducted in the bottom – out the top • 85 % of the heat will not enter control room – saves on a/c • Takes less space • Cooling air for “power part” is separated from the electronics
  34. 34. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G Upper exhaust Back exhaust Back inlet Bottom inlet Heat sink fan Heat sink IP54 Seal  Two cooling possibilities  Back cooling – Air ducted in and out the back  Duct work cooling – Air ducted in the bottom, out the top  85% of the cooling air volume never enters the controls area  Separate path makes heat sink cleaning easy  Pre-engineered, thermally tested cooling kits available for Chassis enclosuresPower component cooling Control component cooling Innovative Cooling
  35. 35. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 35 VLT DRIVE IP66 CONSTRUCTION DAIRY CONDITIONS DANFOSS VALUE  Heavy water jets  Continuous water contact  Heavy fouling condition  Space constraints for MCC & PCC panel in plant  IP 66 Drive from Danfoss is ideally suited for heavy wash down application  IP 66 drive coated with strong epoxy paint  No SS Panel required for IP 54/66 rating drives  Owing to 50 deg.c operating temp & back channel cooling, Danfoss drives are sized optimally
  36. 36. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 36 BENEFIT TO DAIRY DAIRY REQUIREMENT DANFOSS VALUE  Compatibility to third party Automation / PLC  Drives to operate in corrosive condition  Drives covering wider range of KW ratings  Danfoss drives interface with device net /profi bus / Ethernet and all universal bus protocols  Danfoss drive with Special 3C3 coated PCB & casing with IP 66 ensures adaptation to harsh rusting application  Micro advanced – 0.18 to 22kW  VLT 2800 – 0.37 to 18.5 KW  FC 300 Series – 0.37 to 1.4 MW  IP 66 enclosed – Up to 90KW
  37. 37. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 37 BENEFIT TO DAIRY DAIRY REQUIREMENT DANFOSS VALUE  Strong service network, and minimum time for problem redress  Spare parts availability  Specialists for dairy equipments  Danfoss has dedicated regional service engineers to provide service within 24 hrs.  Danfoss maintains safety stock which are delivered 24 hrs  Danfoss has over 32 dedicated partners for drives business nationwide offering core expertise
  38. 38. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 38 DAIRY RANGE FROM DANFOSS IP 66 Enclosed VLT drives  Range from 0.37 to 90KW  All cast Aluminum parts with epoxy coating.  Unique cooling concept with no ambient air flow over electronics  All screws in SS  Fan designed to withstand corrosion FC 300 Series  Range from 0.25 kw to 1.4 MW  Rugged drives ,Built in DC Chokes low cost of ownership  Built in 6 line Graphical Display with KWH Meter FC 300 series with MCO gives supreme performance with accurate positioning
  39. 39. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 39 DAIRY RANGE FROM DANFOSS VLT 2800  Range from 0.37 to 18.5KW  Easy set up and low installation cost , long life capacitor .  Ease of repairing under breakdown,  Versatile drive covering all fan & pump motor application typical to dairy Micro Advanced series  Range from 0.25 to 22 KW  LCD Detachable display with copy function  Extremely rugged drives with plug & play operation  Economical solution
  40. 40. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 40 TOTAL SAVINGS DANFOSS ADVANTAGE VALUE  Inbuilt DC choke (% of drive cost) 15%  Heat loss (certified) Vs competitor per year 15%  Output reactor cost (% of project cost) 5%  Back channel cooling (savings/year) 2%  SS MCC panel cost (% of drive cost) 30%  Over designing cost due to de rating at higher temp of 50 deg.c as compared to other makes Initial cost of higher rating drive Sample calculation for IP 66 90 KW Drive CAN RESULT IN 2-3 Paise saving/litre of milk produced
  41. 41. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 41 DANFOSS ADVANTAGE A Savings of 20% on the SS panel cost Heat loss saving upto 35% in heat dissipation 15% savings on inbuilt DC choke 90% plant uptime with Danfoss service Rated design operating temp. at 50deg.c TRUST DANFOSS
  42. 42. R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G / 42 OEM SUPPORT  Dedicated partner for drives in separators, decanters, homogenizers  Danfoss part of standard equipment  products in line with their technology  Inherent part of separators manufactured  Worldwide technology partner  Other equipments include butter churning, cleaning equipment  Work closely to understand their technology needs  Joint up gradation of products  strong application partners

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