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Boyang Li Advisor: Karl DeWahl On-site Supervisor: Clinton Buchner. Energy Conservation At Kraft Foods, Albany. Plant Overview. Plant: Began in 1929, Albany, MN Square Footage: 84,800 sq. ft. Employees: 69 Production Lines: 3 Spray Dryers (Cheese Powder)

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Boyang li advisor karl dewahl on site supervisor clinton buchner

Boyang Li

Advisor: Karl DeWahl

On-site Supervisor: Clinton Buchner

Energy Conservation At Kraft Foods, Albany


Plant overview
Plant Overview

  • Plant:

  • Began in 1929, Albany, MN

  • Square Footage: 84,800 sq. ft.

  • Employees: 69

  • Production Lines:

    • 3 Spray Dryers (Cheese Powder)

    • 1 Dry Blend (Flavored Powder )

    • 2 Thermal Reactors (Grill)

    • 1 Semi-Soft (Liquid Cheese)


Motivations for change
Motivations for Change

  • Sustainability Project in Kraft

  • Sustainability Team Formed in 2009

  • Rising Energy Costs

  • Energy Curtailment


Reasons for mntap assistance
Reasons for MnTAP Assistance

  • Assist Sustainability Team

  • Benchmarking

  • Compartmentalizing Energy Consumption

  • Compressed Air System Study

  • Efficiency Study (Boiler, Steam Coil, and Burner)

  • Discover Future Improvement Opportunities


Approach
Approach

  • Understand Current Systems

  • Literature Review

  • Data Logging

  • Using PLC to Collect Real Time Data

  • Interaction and Feedbacks from the Operators

  • Vendor Contacts


Process

Condensate

Inlet Air

Process

Cheese Slurry

Air

Steam Coil

Burner

1)

Burner

Steam Coil

Natural Gas

Burner Room

Steam

Cheese Powder

2)

Heated Air

Fig. Schematic Process Diagram


Compressed air system
Compressed Air System

  • 3 Compressor

    • 125 hp

    • 100 hp

    • 40 hp

  • System Pressure: 115±2 psi

  • Annual Electricity Cost on 125 hpCompressor: $29,200

  • Current Efficiency: 28 kw/100 cfm delivered


Compressed air system ctd
Compressed Air System (Ctd.)

1) Repairing the Air Leaks

2) Compressed Air System Pressure Reduction

3) Applying Advanced Control Strategy (VFD retrofitting)


Compressed air system ctd1
Compressed Air System (Ctd.)

Determine Air Leaks

Table. Draw Down Test Result

Helped to Develop Air Leak Preventive Maintenance

Table. Savings for Repairing Air Leaks


Compressed air system ctd2
Compressed Air System(Ctd.)

Supply

Demand

117 psig

Pressure Drop Across Compressor System

+

Regulator

97.5psig

Distribution System Pressure Drop

92psig

RegulatedUses

60 psig

Figure. Current System Pressure Profile


Compressed air system ctd3
Compressed Air System(Ctd.)

Supply

Demand

85 psig

83psig

Distribution System Pressure Drop

80psig

Regulated Uses

60 psig

Figure. Improved System Pressure Profile


Compressed air system ctd4
Compressed Air System (Ctd.)

Fig. Average Power vs. Capacity of compressor with different control


Steam conservation
Steam Conservation

Reduce Unnecessary Steam Use

Preheating

Air Intake

Drum Dryer

Dehumidifier

Spray Dryer

Burner

Dryer room

Figure. Current Preheating System Diagram in Dryer 3


Steam conservation ctd
Steam Conservation (Ctd.)

With Preheating System Turned Off

Preheating

Air Intake

Drum Dryer

Dehumidifier

Spray Dryer

Burner

Dryer room

Figure. Improved Preheating System Diagram in Dryer 3


Steam conservation ctd1
Steam Conservation (Ctd.)

Table. Savings if Preheating System is turned off in the Summer

Future Opportunities

  • Research in the possibility that if preheating system can be turned off in the winter


Future opportunities
Future Opportunities

Reduce Unnecessary Steam Use

Increase Boiler Efficiency

Improve Current Dryer Performance


Approach1
Approach

Programming in PLC, collecting and processing real time data

Figure. Display Panel for Dryer Utility Use


Approach2
Approach

Programming in PLC, collecting and processing real time data

Figure. Display Panel for Boiler Utility Use


Approach3
Approach

1) Collecting Real Time Data to Assist Decision Making

Efficiency (%)

Steam Generation (lb/hr)

Figure. Analysis of Boiler Efficiency vs Boiler Load


Approach4

Condensate

Approach

Inlet Air

2) Understanding the Influence of Moisture Content on Dryer Performance.

Burner

Steam Coil

Natural Gas

Steam


Approach

2) Understanding the Limitation of Steam and Reduce Unnecessary Steam Use

Natural Gas Use (scf)

Temperature (F)

Wasted

Energy

Steam Use (lb/hr)

Steam Use (lb/hr)


Approach5
Approach

3) Computational Model to Assist Decision Making

Operating Cost in $/hr


Approach6
Approach

3) Computational Model to Assist Decision Making

Table. Estimated Maximum Savings in Dryer 3



Personal Benefits

  • Technical Understanding Acquired

  • Industrial Environment Exposure

  • Data Analysis

  • Programming Skills

  • Project Cost Understanding

  • Vendor Contact

  • Working Alone As Well As in Groups


Questions
Questions

Thanks!


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