ENERGY EFFICIENCY IN PRODUCTION OF EXTRUDED FEED

Transcription

1 s ENERGY EFFICIENCY IN PRODUCTION OF EXTRUDED FEED GRAINTEC A/S Speaker: Anders F. Haubjerg M.Sc., Process Engineer Industrial PhD Student

2 s GRAINTEC A/S TURN-KEY SUPPLIER OF PROCESS PLANTS FOR THE FEED INDUSTRY, SINCE 1985 Pre-project and feasibility studies Project Viability Project design and general scope definition Safe Base Decision Process design and detailed scope definition Excellent Execution Offices in Denmark, Chile, China and USA A/S 40 Enghavevej DK-7100 Vejle

3 s GRAINTEC A/S YOUR ULTIMATE CHOICE OF A GLOBAL BUSINESS PARTNER - Engineering, contracting and project management - recovery - Environmental improvements

4 s WHY ENERGY EFFICIENCY?

5 s ARGUMENTS FOR ENERGY EFFICIENCY??? Increasing energy prices Emmision taxes Environmental friendly company profiles

6 s ENERGY CONSUMPTION IN EXTRUDED FISH FEED PRODUCTION

7 s ENERGY CONSUMPTION IN EXTRUDED FISH FEED PRODUCTION 250 Accumulated energy consumption 200 Electrical Thermal kwh/ ton Ingredients Extruder Dryer Coater Cooler Water Water Oil

8 s ENERGY CONSUMPTION IN EXTRUDED FISH FEED PRODUCTION ELECTRICAL ENERGY CONSUMPTION THERMAL ENERGY CONSUMPTION 31% 28% 13% 28% 38% 2% 60% Drying Extrusion Grinding Others Dryer Extruder Others The largest savings potential is in the drying process!

9 s balance Heating source Dryer Exhaust air in out Note: Up to 95% of energy in dryer exhaust

10 s ODOUR EMISSION & THE SMART SOLUTION

11 s ODOUR EMISSION FROM FISH FEED FACTORY Process units contribution to total odour emission [odour units / hour] 13 % 72 % 14 % Hammer Mill Exhaust Extruder Air Lift Dryer Exhaust Cooler Exhaust Plant Ventilation

12 s THE SMART SOLUTION CONDENSATION = ODOUR REDUCTION % Odour reduction No condensation Air cooling/condensation effect Condensation

13 s ENERGY RECOVERY SOLUTIONS

14 s ENERGY RECOVERY SOLUTIONS Dry less water, little capital expense Mechanical dewatering Avoid overdrying

15 s ENERGY RECOVERY SOLUTIONS Dry less water, little capital expense Mechanical dewatering Avoid overdrying Increase efficiency of drying air, little capital expense Reduction of air leaks, improve insulation, etc. Increase moisture content in exhaust air Use hot air from cooler Zone-wise temperature control Inlet Outlet

16 s ENERGY RECOVERY SOLUTIONS Simple solutions, little capital expense Mechanical dewatering Avoid overdrying Increase efficiency of drying air, little capital expense Reduction of air leaks, improve insulation, etc. Increase moisture content in exhaust air Use hot air from cooler Zone-wise temperature control recovery, higher capital expense Heat exchangers and heat pumps Recirculation of drying air Dryer Recycled drying air water exhaust air

17 s THE SMART SOLUTION = GRAINTEC RECONDENSING SYSTEM Air to water exchangers, cooling tower and chiller Recirculation of dryer air Condensation of water Odour reduction effect above 85% Up to 20% energy recovery possible Heat exchanger Mesh filter Exhaust from system Drip tray Product in Cyclone or bag filter Dryer with internal recirculation Fines Cooling tower Chiller Product out Fan

18 s BAG FILTER AND RE-CONDENSING BATTERY

19 s MEASUREMENTS FROM ACTUAL PLANT USING GRAINTEC RECONDENSING SYSTEM Cooling energy Cooling energy Air exhaust from dryer 24,000 m³/h 79 C - 30%RH Odour conc.: 11,000 OU/m³ 51 C 30 C 25 C Recirculation air 19,000 m³/h 59 C - 42%RH Odour conc.: 6,400 OU/m³ Condensate water 1,100 kg/h to drain or recycling recovery ~ 215 kw Air exhaust from system 5,500 m³/h 51 C - 92%RH Odour conc.: 6,500 OU/m³ Overall reduction in odour emission: > 85% Thermal energy recovery: ~ 215 kw

20 s OTHER SOLUTIONS: Air/Air Heat exchanger No recirculation of dryer air Some water condensation Odour reduction effect below 50% Up to 50% energy recovery possible HEAT EXCHANGER DRYER

21 s OTHER SOLUTIONS: Air/water heat exchangers No recirculation of dryer air Some water condensation Odour reduction effect below 50% Up to 40% energy recovery possible AIR/WATER HEAT EXCHANGERS DRYER

22 s OTHER SOLUTIONS: Air/water heat exchangers + heat pump No recirculation of dryer air Some water condensation Odour reduction effect above 50% Up to 60% energy recovery possible HP AIR/WATER HEAT EXCHANGERS Waste heat at C Heat pump Use full heat at C DRYER

23 s FOULING IN HEAT EXCHANGERS Moist and dirty exhaust air Microbial growth Avoid by: o High efficiency cyclones o bag and mesh filters o CIP

24 s PRODUCT QUALITY ASPECTS AND SUMMARY

25 s PRODUCT QUALITY ASPECTS Quality Drying process efficiency Environmental performance

26 s PRODUCT QUALITY ASPECTS 3-year industrial PhD Ensuring Technical in Efficient Hot Air Drying of Extruded Fish Feed

27 s SUMMARY recovery of dryer exhaust air kwh/ton Integration of energy and odour reducing technologies are in most cases a very cost effective solution efficiency must not compromise product quality New technology inventions of heat exchangers and heat pumps will bring further possibilities to recover energy and reduce emissions from the feed production industry

28 s THANK YOU! QUESTIONS?