energy savings in dairy applications

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Enery Savings in Dairy Applications

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Opportunities

• Milk Cooling at Collection centre

• Dairy Plant level

• Chilling centre level

• Cold Stores at Plant & Warehouse

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Milk Cooling system

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Replace the Piston Technology with Scroll

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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

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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

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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

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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

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Reciprocating (Piston) v/s Scroll

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Multiple Condensing Units

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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.

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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

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How does it look?

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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

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Can be built on Condensing Unit

Heat R

ecovery

Heat R

ecovery

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Some Practical Opportunities

• Ventilation

• Clean Condenser

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Condensing Unit Installation

Allow Free Air Flow on CDU

Ensure good ventilation

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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

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Keep Condenser CleanRISK: Shorter compressor life; high power bill; longer cooling time

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RGE/XGE Fan speed regulators

Condenser Fan speed Regulation

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DANFOSS VLT

®

YOUR PARTNER IN DAIRY

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Fixed AC Input

(3ph,415v,50hz)

Variable AC Output

( 0-415v,0-x Hz)

What is a Variable Frequency Drive ( VFD) ?

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VFD APPLICATION RESULT

Variable speed control:

•50% energy savings when

the fan or pump speed is

reduced from 100% to 80%

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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

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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

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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

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• 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

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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

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HOW CAN DANFOSS VLT DRIVES

BE YOUR PARTNER

TO REDUCE YOUR

OPERATING COST ??

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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