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ommission of the European Communities
energy
An i n te g r ate d design
for a liquid milk plant using ice -bank
te chn ol og y for load spr eading
Commission of the European Communities
An integr ated design
for a liquid milk plant using ice-bank
technology for load spreading
T. Kerkhoff
Premier Dairies Limited
Whitehall Road
Rathfarnhal
Dublin 14
Ireland
Contract No EE/219/87/IR
Final report
P A F L ELR0P. Biblioth.
N.C./COM35.55S
CL
1990
Directorate-General
Energy
EUR 13085 EN
<* ^ s>U5
Published by the
COMMI SSI ON OF THE EUROPEAN COMMUNI TI ES
Dir ector ate-Gener al
Telecommunications, Infor mation Industries and Innovation
L-2920 Luxembourg
LEGAL NOTICE
Neither the Commission of the European Communities nor any person acting on
behalf of the Commission is responsible for the use which might be made of the
following information
Cataloguing data can be found at the end of this publication
Luxembourg: Office for Official Publications of the European Communities, 1990
ISBN 92-826-1768-8 Catalogue number: CD-NA-13085-EN-C
ECSC-EEC-EAEC, Brussels Luxembourg, 1990
Printed in Belgium
SUMMARY
The incorporation of ice storage to a chilled water system
will even out the energy profile by removing the random
switching in and out of refrigeration compressors while
maintaining chilled water temperatures at just over 0C
without the use of anti-freeze solutions. With chilled
water temperatures this low and by extending the heat tra-
nsfer surfaces, the system enables product (in this case
milk) to be cooled to under 2C.
The demonstration project has proved that a dairy process-
ing 300,000 litres of milk per day can reduce its electri-
city consumption for cooling by HQ% and transfer all of
its compressor power to the cheaper off-peak electricity
period.
The maximum electricity demand for the dairy has been re-
duced from 1.5 MW to 1.1 MW and the total night electri-
city consumption is now 50% of that during the day where
previously it was under 25%.
The economic viability of the project is good and for rep-
lication would give a simple payback period for the capi-
tal investment required of between 3 to 4 years. When
considering a new installation or additional capacity, the
payback period would be as low as 1 to 2 years and could
quite possibly be lower dependent on the physical layout
of the plant.
Ill
TABLE OF CONTENTS
1. PROJECT DETAILS 1
2. PROJECT AIM AND GENERAL DESCRIPTION 1
2.1. Aim of the project 1
2.2. Description of the installation 2
3. CONSTRUCTION, INSTALLATION AND COMMISSIONING 3
3.1. Suppliers of equipment and services 3
3.2. Project management 4
3.3. Technical problems and solutions 4
3.4. Modifications and over-runs 5
4. OPERATION AND RESULTS 5
4.1. Operating history 5
4.2. Performance 6
4.3. Success of the project 7
4.4. Operating costs 7
4.5. Future of the installation 7
4.6. Economic viability 7
5. PUBLICITY, COMMERCIALIZATION AND OTHER DEVELOPMENTS 8
5.1. Publicity 8
5.2. Outlook 8
5.3. Lessons learnt/Conclusions 9
V
1 . PROJECT DETAILS
Project Number: EE/219/87/IR.
Title of Project: An Integrated Design for a Liquid Milk Plant using
Ice-Bank Technology for Load Spreading.
Contractor: Premier Dairies Limited.
Name of Person for Technical Enquiries: Mr Theo Kerkhoff.
Address: Whitehall Road
Rathfarnham
Dublin 14
Ireland.
Telephone Number: 01-983033.
Telex Number: 909.37.
Co-proposer & Co-signatory of Contract:
Integrated Energy Systems Limited
11A Lune Street
Preston PR1 2NL
Lancashire England.
Telephone Number: 0772-50707.
Telex Number: 67674.
Contact Name: John A O'Shea.
2. PROJECT AIM AND GENERAL DESCRIPTION
2.1. AIM OF THE PROJECT
To demonstrate a high efficiency refrigeration and heat exchange
system in a 300,000 litres/day Liquid Milk Plant with substantial
energy cost savings by transferring the load onto the cheaper night
rate tariff (35% of the day cost) utilising Ice-Bank/Hydro-Cooler
Technology.
The system will even out the energy profile by removing the random
switching in and out of refrigeration compressors while maintaining
chilled water temperatures at just over 0C without the use of anti-
freeze solutions. In conjunction with extending the surface of the
plant heat exchangers, the system enables product (milk) cooling at
under 2C.
The expected energy saving by creating the ideal operational load
profile i.e. constant during ice building, is 500 MW per annum and
the transfer of units to the night period - 800 MW per annum. Using
Ice-Bank/Hydro-Cooler technology and tight limits on heat exchanger
design, milk temperatures of 2C can be demonstrated with lower
energy costs than previously. For comparison purposes, the conven-
tional system (existing redundant plant) consumes 1,300MWper annum.
2.2. DESCRIPTION OF THE INSTALLATION
Chilling is an essential requirement in all Dairies; as soon as the
milk enters it is cooled and continues to be cooled during the
various processes and on completion in its finished packaged form.
The main areas of chilling are: on reception, after pasteurising and
separation and during the processing into cream and buttermilk.
Table III outlines the actual cooling requirements during the
monitoring period.
All the product cooling is by indirect heat transfer using in the
main plate heat exchangers served by a chilled water system, see
Fig 1. The chilled water system has been replaced by a new high
efficiency plant incorporating ice storage having the following
refrigeration component details (refrigerant Ammonia NH
3
).
Compressors: 2 480kW Recipricating machines based on
condensing at +30C and evaporating at 9C
(average). Input power 125 kW.
Condenser: 1 1150 kW evaporative condenser based on a
condensing temperature of +30C and wet bulb
temperature at +20 C
Ice Bank/HydroCooler: 2 3960kW Storage units (7920kW total
capacity) with ice thickness of 50 mm.
The efficiency of a refrigeration circuit is described in terms of
its Coefficient of Performance (C.O.P.), which is the ratio of the
cooling capacity over the gain in enthalpy due to compression. In
praticai terms the CO.P. can be derived from thermodynamics and is
expressed as:
CO.P. = 0 Te
Tc Te
Where 0 = Motor Efficiency
= Compressor Efficiency
Te = Evaporating Temperature in Absolute
Tc = Condensing Temperature in Absolute.
From this formula it is clear that high evaporating and low condens
ing temperatures increase the performance level.
In most cases, refrigeration plants are designed with condensing
temperatures of +35C and evaporating temperatures, anything down to
15C dependent on the coil surface and chilled water temperature.
CO.P.'s of 2.5 are normal. With this application the CO.P. in the
ice build mode is 38 and when operated as a hydrocooler 4.6; a 50
84% improvement.
The cooling requirements of the dairy are between the hours of 0800
and 1900 hours with a total daily chilling demand of 7,600 kW
(average). The installation has been designed for full storage,
i.e. A system which can generate all of the cooling capacity for the
process during the offpeak electricity periods. The refrigeration
system commences operation at 2300 hours and ice forms on the coil
2
surface of the storage units until a pre-determined thickness is
obtained or on reaching 0800 hours. A sensor then shuts down the
refrigeration compressors which can be at any thickness, in 20%
increments, upto 50 mm. At O8OO hours the chilled water pump circ-
ulates water from the storage unit into the dairy for product cool-
ing. The return water is cooled by the melting ice, and continues
until the daily cooling requirement is satisfied. After the elect-
ricity rates return to the off-peak tariff, a timer permits the
refrigeration compressors to re-start, and the charge of ice is then
rebuilt during the off-peak hours for use in the next cooling
period.
The flow of chilled water from the ice storage units is maintained
at 0.5C throughout most of the ice melt cycle. Should this temper-
ature climb above 1C, then the compressors will automatically
start. This does not occur during the high demand period but only
near the end of the day on certain occasions.
Inconjunction with these low chilled water tempratures the product
plate heat exchanger surfaces have been extended to achieve final
milk temperatures of less than 2C.
To assist in the performance evaluation, the following equipment
were installed:
(i) kWh meter for electricity consumption (day and night units),
(ii) Maximum demand monitor (existing on site),
(iii) Temperature recorder for - Evaporating and condensing
conditions.
- Chilled water flow & return.
- Milk off heat exchangers,
(iv) Product flow meters (existing on site).
Measurements were recorded on a daily basis and summarised on Log
Sheets.
3- CONSTRUCTION, INSTALLATION AND COMMISSIONING
3-1. SUPPLIERS OF EQUIPMENT AND SERVICES
The project design, equipment selection and specification were com-
pleted by Integrated Energy Systems Limited and issued for tendering
to four main contractors. The result was that APV Hall Limited were
chosen for the complete mechancial and electrical installation.
The equipment manufacturers and suppliers selected were as follows:-
EQUIPMENT
Ice Storage Units:
2 Model No TSU 1200
Refrigerant Compressors:
2 Model No RC 611
Refrigerant Components &
Pipework
Chilled water circulating
pumps
Chilled water pipework
Additional plates for heat
Exchangers
Control Panel
SUPPLIER
Baltimore Aircoil International
Heist-Op-Den-Berg
B-3100 Belguim.
Grasso-Stacon BV
5201 AH's - Hertogenbosch
The Netherlands.
APV Hall Limited
Dublin Ireland
Worthington Simpson Ltd
London U.K.
>APV Hall Limited
)Dublin Ireland
The commissioning of the plant was conducted by APV Hall Ltd with
Integrated Energy Systems Ltd in attendance; This included charging
the refrigeration system with ammonia and filling the distribution
system with water.
3.2. PROJECT MANAGEMENT
Integrated Energy Systems Limited (IES), as the Consulting Engineers
and system designers, acted as Project Directer inconjunction with
Premier Dairies Limited. The Project Management group consisted of
an IES Engineer and the Group Engineer from Premier Dairies.
During the Construction Phase of the Project site meetings were held
on a regular basis to ensure that the manufacture and installation
would be completed on time and to programme. The Main Contractor's
Project Engineer attended all meetings.
The project monitoring and performance evaluation was conducted by
IES with the assistance of Premier Dairies.
3-3- TECHNICAL PROBLEMS AND SOLUTIONS
There has been only one slight mechanical problem, and this was
during commissioning, when it was noticed that No2 Refrigerant
4-
compressor's motor appeared excessively noisy. This noise was det-
ected as being from the motor bearings. The motor manufacturer was
contacted and after re-newing the bearings the noise has not recur-
red.
From an operational point, the processing of milk was changed sligh-
tly by the Production Department to an earlier start in the day;
0600 hours in lieu of 0800. As the ice build programme was sched-
uled for between 2300 hours and 0800 hours (off-peak period) this
was changed accordingly to suit i.e. ice build commencing at 2200
hours for completion by 0600 hours. With the maximum demand period
being between 0800 hours and 2100 hours high penalties are not
involved, however, the first hour of ice build is during the higher
unit cost period. The actual day hours run by the compressors are
small.
As the cooling demand of the Dairy can vary from one day to another,
the complete melt down of ice from the coils rarely happens. The
characteristics of the water flow pattern through the units does not
give an even ice melt-off; ice melts from the far end of the units
first and progresses towards the water outlet forming a taper. By
constantly rebuilding, the ice tends to bridge and block the water
flow pattern. It has been found that unless a complete melt-down is
carried out on a regular basis, serious problems occur with ice
bridging. To alleviate the problem a complete ice melt-off is per-
formed once per week over the week-end period while demand charges
do not apply.
3-4. MODIFICATIONS AND OVER-RUNS
The construction phase of the project went extremely well and to pro-
gramme; all delivery dates and installation times proved accurate.
There was a slight overspend of 2.6% during the construction and can
be explained as follows:
- Protection Barrier necessary to ice storage units.
- Greater involvement of proposers staff during commissioning.
The delivery programme for the monitoring and measurement equipment
took slightly longer than anticipated and therefore, the measurement
phase of the project commenced 1 month later than planned. A full
six-monthly monitoring period still took place.
4. OPERATION AND RESULTS
4.1. OPERATING HISTORY
The installation first entered normal service on 14th July 1988 and
since that date has suffered no prolonged stoppages.
Every day for between 7 and 8 hours during the night (off-peak)
period the compressors operate on the storage units accumulating ice
upto the maximum thickness of 50 mm. During the day hours the comp-
ressors are off and the chilled water distribution pumps operate.
As previously explained, once a week (on Sunday's) no ice is accumu-
lated when the storage units operate as conventional hydro-coolers.
The monitoring period commenced on 1st August 1988 and was completed
on 31st January 1989; a 6 monthly period.
4.2. PERFORMANCE
During the monitoring period of the project, the following procedure
applied:
- Metering of the electrical power consumption for the total
plant during day and night periods.
- Monitoring the actual hours run by the refrigerant compressors.
- Recording of the milk quantities and temperatures at reception
and throughout the process.
- Recording of the refrigerant condensing and evaporating
pressures/temperatures also, chilled water flow & return
temperatures.
The data collected was itemised on a Daily Log Sheet, the results of
which are shown in Tables I & II.
As the Dairy cooling demands are during day hours only, Table I
clearly shows the transfer of 328,567 kWh to the off-peak period for
the months of August to January inclusive; 6-monthly period. Based
on historic data the projected electricity transfer for the remain-
ing 6 months would be 380,235 kWh indicating that the annual trans-
fer of electricity from day to night units is approximately 710,000
kWh.
In terms of efficiency and electricity savings for the installation,
this has been determined as follows:
Overall power consumption (excluding pumping)
during the 6 months monitoring period = 359,241 kWh
Projected power consumption for remaining
6 months to form a complete year = M15,732 kWh
Yearly Total Power Consumption: = 77^,973 kWh
With the annual electricity consumption for cooling prior to the
installation being 1-3 million kWh, the electricity saving is
1,300,000 - 77^,973 kWh
= 525,027 kWh/annum.
Table II outlines the milk volumes for the monitoring period and
also the quantities for a similar period in 1986/87. It is clear
that there has been no significant changes which would have reduced
the cooling requirements and subsequent power usage except the impr-
oved performance.
Based on the production data shown in Table II, the plant cooling
requirements have been determined and are shown in Table III. From
the energy output data contained in Table III, the plant co-efficient
of performance is determined. The CO.P. varied from, in the summer
months 3-1 to 3-7 in the month of January.
As an overall check on the results, the Electricity Supply Board's
(E.S.B.) bi-monthly billing data has been summarised and shown in
Table IV where 3 years historic data has been averaged for compari-
son with 1988.
4.3. SUCCESS OF THE PROJECT
The introduction of ice accumulation into a dairy for electrical
load spreading and the selection of high-efficiency components has
been successfully proven. The ice-water from the storage units was
maintained below 1C and for the majority of the melt-down cycle was
below 0.5C. With the use of extended heat exchange surface, prod-
uct cooling to 2C was reached.
The project was a complete technical success where the energy saved
and transferred objectives were achieved as follows ( based on 12
monthly period).
kWh Saved in Total:
kWh Transferred (day to night):
FORECAST
500,000
720,000
ACTUAL (PROJECTED)
525,000
710,000
In terms of load spreading; the installation of the 'cold' storage
system has reduced the dairy electricity maximum demand from 1.5MW
to almost 1MW. A much improved electrical profile now exists which
is most suitable for the self-generation of power.
4.4. OPERATING COSTS
With the new installation there are no additional maintenance costs
over the previous conventional chilled water plant, in fact they
should be less. As the compressors operate on a continuous basis
over a shorter time period and are not switching in and out, the
likelihood of failure is reduced. Continuous operational use and
experience should verify this statement.
4.5. FUTURE OF THE INSTALLATION
The life expectancy of the installation is in excess of 20 years and
it is anticipated that the energy cost saving benefit will increase
through the years.
There is a distinct advantage of this project to the Electricity
Supply Board in a more even load pattern throughout the day and a
reduced capacity during peak hours which will assist with future
capacity/supply demands.
4.6. ECONOMIC VIABILITY
(i) The electrical operational costs for the installation on an
annual basis is as follows:
Night Units - 710,000 kWh at 2.4p/kWh = 17.040
Day Units - 65,000 kWh at 6.8p/kWh = 4,420
Total Annual Operating Cost: 21,460
(ii) The operational cost for the previous conventional plant was
88,400/annum, giving an annual energy cost saving of 66,940.
(iii) Simple Payback Period:
= I_ years
Q
Where: I = Investment cost.
Q = Annual energy saving cost
= 310,000 years
66,940
= 4.63 years
5. PUBLICITY, COMMERCIALIZATION & OTHER DEVELOPMENTS
5.1. PUBLICITY
The installation has not been publicised to any great extent as yet,
however, the Electricity Supply Board in Ireland are promoting and
encouraging the use of ice storage.
52. OUTLOOK
There are no real technical problems outstanding in the use of the
technology demonstrated, the installation has been a complete suc
cess. The technique is ready for replication and is most suitable
for all dairies in terms of energy cost saving and product quality.
The installation clearly demonstrates the cooling of milk to below
2C without subzero secondary refrigerants and using purely water
at 0.5C (constant).
The replication potential for this technology is in all industrial
and commercial refrigeration plants. The economic viability for
each installation will vary from between 3 and 4 years simple pay
back on the capital investment for retrofits. Where new installa
tions are being considered or additional capacities are necessary,
the return on capital could be as low as 1 to 2 years. In some
cases for new installations, there may be nc additional capital
required over and above a conventional plant dependent on the actual
design layout.
The Central Electricity Generating Authorities in all member states
should actively promote this technology as the benefits are consid
erable, namely:
(a) By spreading the load, this reduces the peak demands required to
be met by power stations.
(b) Improves .the efficiency of input energy to electrical power
through a more even load profile.
(c) Reduces the need for additional generating capacity to meet the
ever increasing demand.
(d) Environmentally an improvement through reduced power station
emmissions.
8
5-3- LESSONS LEARNT/CONCLUSIONS
The installation has confirmed the theoretical predictions and pro-
ved that ice storage linked to a chilled water plant in the dairy
industry is a most viable proposition. The energy saving objectives
of the project have been achieved.
The technique can be applied to all cooling circuits even if some
are only partial storage i.e. not 100% storage/transfer, and there-
fore, the potential benefits to industry and commercial buildings in
terms of electricity cost saving are considerable.
TABLE I; ELECTRICITY CONSUMPTION & COMPRESSOR HOURS RUN DURING MONITORING PERIOD
MONITORING
PERIOD
1988/89
1. AUGUST
2. SEPTEMBER
3. OCTOBER
4. NOVEMBER
5. DECEMBER
6. JANUARY
TOTALS
ELECTRICITY CONSUMPTION (kWh)
NIGHT UNITS
62,439
60,720
56,025
46,185
54,049
49,149
328,567
DAY UNITS
25,963
25,947
28,454
28,264
26,419
26,763
161 ,810
TOTAL UNITS
88,402
86,667
84,479
74,449
80,468
75,912
490,377
PUMPING
POWER
21,017
22,908
21,607
20.550
22,079
22,975
131,136
TOTAL LESS
PUMPING
67,385
63,759
62,872
53,899
58,389
52,937
359,241
COMPRESSOR
HOURS RUN
NIGHT
434.3
417.6
402.6
339.5
377-3
382.8
2,354.1
DAY
34.4
20.9
49.2
56.7
3O.3
29.5
221 .0
TABLE II: PRODUCTION DATA COLLECTED DURING MONITORING PERIOD AND HISTORIC
MONITORING
PERIOD
1988/89
1. AUGUST
2. SEPTEMBER
3- OCTOBER
4. NOVEMBER
5. DECEMBER
6. JANUARY
TOTALS
MILK VOLUMES (LITRES)
INTAKE
7,347,659
7,339,613
7,448,144
7,099,566
7,573,809
7,775,869
44,584,660
SEPARATED
1,866,383
1,862,205
1,723,625
1,847,122
1,822,714
1,855,218
10,977,267
CREAM
167,134
167,197
174,375
166,365
168,061
168,716
1,011,848
BUTTERMILK
210,934
132,061
250,485
252,758
218,663
264,123
1,329,024
AVERAGE
INTAKE MILK
TEMPERATURE
(C)
6.56
6.01
4.53
4.08
4.15
4. 13
-
AUGUST TO JANUARY
1986/87
MILK VOLUMES (LITRES)
INTAKE
43,174,326
SEPARATED
8,581,025
CREAM
790,970
BUTTERMILK
126,379
TABLE III: COOLING REQUIREMENTS DURING MONITORING PERIOD
MONITORING
PERIOD
1988/89
1. AUGUST
2. SEPTEMBER
3. OCTOBER
4. NOVEMBER
5. DECEMBER
6. JANUARY
TOTALS
COOLING REQUIREMENTS (KCals 10
6
)
INTAKE
37.20
32.83
21.62
17.08
18.99
18.66
146.38
PASTEURISER
76.65
76.50
77.40
73.90
78.85
80.45
463-75
SEPARATION
18.66
.18.62
17.24
18.47
18.22
18.55
109.76
CREAM
5.01
5.02
5.23
4.99
5.04
5.06
30.35
BUTTERMILK
3.80
2.38
4.51
4.55
3-94
4.75
23-93
DISTRIBUTION
14.13
13.53
12.6
11.9
12.5
12.75
77.41
TOTAL
155.45
148.88
138.60
130.89
137.54
140.22
851.58
TABLE IV: ELECTRICITY DATA DURING MONITORING PERIOD & HISTORIC
DESCRIPTION/
pERIOD
MAXIMUM DEMAND (KW)
JULY/AUGUST
SEPTEMBER/OCTOBER
AVERAGE
NIGHT UNITS (KWh)
JULY/AUGUST
SEPTEMBER/OCTOBER
AVERAGE
DAY UNITS (KWh)
JULY/AUGUST
SEPTEMBER/OCTOBER
AVERAGE
TOTAL UNITS (KWh)
JULY/AUGUST
SEPTEMBER/OCTOBER
AVERAGE
1985
1,414
1,406
170,000
158,000
810,000
748,000
980,000
906,000
1986
1,440
1,516
V
1,434
192,000
172,000
V
181,000
816,000
720,000
760,000
1,008,000
892,000
V
941,000
1987
1,382
1,448
204,000
194,000
742,000
724,000
946,000
918,000
1988
1,072
1,078
1,075
278,000
276,000
277,000
602,000
606,000
604,000
880,000
882,000
881,000
-12-

EVAPORATIVE
CONDENSER
ICE BANK/
HYDROCOOLER
(

MILK (
<
FLOW (
H.E.1.
COMPRESSORS
H.E.2. I
INTAKE COOLERS


" I
4 r

re
<J1
4
m
'PASTEURISERS CREAM ' SKIM
V_/SEPARATORS
4
'BUTTER
IMILK
FIG 1. FLOW DIAGRAM
G e n e r a l View Of Ice Bank I n s t a l l a t i o n
14
G e n e r a l View Of Ice Bank I n s t a l l a t i o n
15
G e n e r a l View Of Ice Bank I n s t a l l a t i o n
-16
European Communities Commission
EUR 13085 An integrated design for a liquid milk plant using
ice-bank technology for load spreading
T. Kerkhoff
Luxembourg: Office for Official Publications of the European Communities
1990 V, 16 pp. fig., tab., ill. 21.0 29.7 cm
Energy series
EN
ISBN 92-826-1768-8
Catalogue number: CD-NA-13085-EN-C
Price (excluding VAT) in Luxembourg: ECU 5
The incorporation of ice storage to a chilled water system will even out the
energy profile by removing the random switching in and out of refrigeration
compressors while maintaining chilled water temperatures at just over 0C
without the use of anti-freeze solutions. With chilled water temperatures
this low and by extending the heat transfer surfaces, the system enables
product (in this case milk) to be cooled to under 2C.
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