Pinch

A Blue-Chip Food company came to us and requested a Pinch analysis across all processing lines on one of their sites to assess their energy usage and to help them find possible areas for heat recovery or energy usage reduction.

(1) Process Integration of a Snack manufacturing process:

A Blue-Chip Food company came to us and requested a Pinch analysis across all processing lines on one of their sites to assess their energy usage and to help them find possible areas for heat recovery or energy usage reduction.

The design with the best performance gave a payback of 2.7 years with gas and steam savings of 790 kW equating to approximately £125,000 a year savings.

A Pinch analysis is a method for optimising and maximising heat recovery systems across industrial processes and minimising energy consumption.

The information needed to conduct the analysis was queried from site databases where available with onsite measurement used to identify outstanding information. This allowed the sites hot and cold streams to be mapped, minimum hot and cold utility requirements to be found and multiple heat exchanger networks modelled to recover heat.

pinch

With the heat recovery networks kept focused on individual lines at site requests, the performance of the networks was evaluated based on a payback calculated from the capital cost, operational cost and savings generated. The least thermally efficient line gave the best paybacks from the multiple heat recovery systems.

(2) Process Integration of a brewery keg washing facility:

We were also approached by a large brewery in Scotland which had an interest in optimising their plant performance for their keg washing facility. A large amount of water and steam is used to clean and wash the kegs but generating a large amount of waste water. We carried out a pinch analysis and evaluated how to reduce waste water and optimise energy usage. The most cost effective solution was to use a number of flat plate heat exchangers, 3 way valves and additional water pump. The estimated payback was just under 2 years.