energy savings in dairy applications
DESCRIPTION
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.TRANSCRIPT
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
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
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
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
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
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 controlScavenging pump
down allowedOnly static pump
down allowed
Sensitivity to load variations and working
conditions MODERATE HIGH
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
ISEN
TRO
PIC
EFFIC
IEN
CY
PRESSURE RATIOBuilt-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
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
DesignThe 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
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
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
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
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.
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
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?
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
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
Heat R
ecovery
Heat R
ecovery
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
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
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
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 CleanRISK: Shorter compressor life; high power bill; longer cooling time
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
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
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) ?
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%
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
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
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
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
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
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 ??
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
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
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
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
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
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
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
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 DANFOSSIP 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
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 DANFOSSVLT 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
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
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
choke90% plant
uptime with Danfoss service
Rated design
operating temp. at 50deg.c
TRUST
DANFOSS
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