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Energy Conservation At Kraft Foods, Albany

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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Energy Conservation At Kraft Foods, Albany

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  1. Boyang Li Advisor: Karl DeWahl On-site Supervisor: Clinton Buchner Energy Conservation At Kraft Foods, Albany

  2. 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)

  3. Motivations for Change • Sustainability Project in Kraft • Sustainability Team Formed in 2009 • Rising Energy Costs • Energy Curtailment

  4. 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

  5. Approach • Understand Current Systems • Literature Review • Data Logging • Using PLC to Collect Real Time Data • Interaction and Feedbacks from the Operators • Vendor Contacts

  6. 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

  7. 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

  8. Compressed Air System (Ctd.) 1) Repairing the Air Leaks 2) Compressed Air System Pressure Reduction 3) Applying Advanced Control Strategy (VFD retrofitting)

  9. 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

  10. 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

  11. Compressed Air System(Ctd.) Supply Demand 85 psig 83psig Distribution System Pressure Drop 80psig Regulated Uses 60 psig Figure. Improved System Pressure Profile

  12. Compressed Air System (Ctd.) Fig. Average Power vs. Capacity of compressor with different control

  13. 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

  14. 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

  15. 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

  16. Future Opportunities Reduce Unnecessary Steam Use Increase Boiler Efficiency Improve Current Dryer Performance

  17. Approach Programming in PLC, collecting and processing real time data Figure. Display Panel for Dryer Utility Use

  18. Approach Programming in PLC, collecting and processing real time data Figure. Display Panel for Boiler Utility Use

  19. Approach 1) Collecting Real Time Data to Assist Decision Making Efficiency (%) Steam Generation (lb/hr) Figure. Analysis of Boiler Efficiency vs Boiler Load

  20. Condensate Approach Inlet Air 2) Understanding the Influence of Moisture Content on Dryer Performance. Burner Steam Coil Natural Gas Steam

  21. 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)

  22. Approach 3) Computational Model to Assist Decision Making Operating Cost in $/hr

  23. Approach 3) Computational Model to Assist Decision Making Table. Estimated Maximum Savings in Dryer 3

  24. Recommendation Summary

  25. Personal Benefits • Technical Understanding Acquired • Industrial Environment Exposure • Data Analysis • Programming Skills • Project Cost Understanding • Vendor Contact • Working Alone As Well As in Groups

  26. Questions Thanks!

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