||Energy Analysis and Optimization in Pectin Production
||Nielsen, Daniel Rønne
||Elmegaard, Brian (Thermal Energy Systems, Department of Mechanical Engineering, Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark)
Bang-Møller, Christian (Thermal Energy Systems, Department of Mechanical Engineering, Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark)
||Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
||The big manufacturer of gelling and texturizing agents for the food industry, CPKelco in Lille Skensved is close to an expansion of the production, but also process enhancements, which will reduce the energy consumption significantly. The expansion has major impact on the energy integration and heat recovery at the factory. For this reason CPKelco has requested a mapping of the energy consumption in the factory in order to estimate the consumption after the expansion, but also in order to prepare and identify new potentials for energy savings.
The CPKelco factory contains five production lines and utilities such as the process water system, distillation setup and central heating system, which all have been described and mapped. The steam consumption has been determined and validated, and only deviating 10-15% from the actual consumption. The majority of this deviation is explained by losses and improper operation of the distillation process.
Waste heat and heat recovery has been analyzed and respective amounts clarified. The expansion and changes of the energy integration implies a large amount of heat recovery, especially for heating of the process water. Unfortunately, it turns out that close to 25% of the recovered heat in the process water system is lost due to heat losses on its way to the storage tanks, from which the processes are supplied by hot water. The lacking utilization of the recovered heat implies major saving potentials due to an execution of an intensive insulation program. The potentials entail gas savings above DKK 2 million per year.
The CPKelco factory contains plenty of other potentials such as utilizing the waste heat for the central heating system and other flows in the production that need to be heated. Some of the respective potentials have been investigated and extensive energy savings implies payback time less than a year. Together, they imply total gas savings above DKK 6 million per year.
||The thesis is confidential
||DTU Mechanical Engineering
Creation date: 2011-12-14
Update date: 2011-12-14