Process Heating & Cooling

Drying

• Check dryer performance regularly
  
  
• Set energy consumption targets for dryers
  
  
• Check dryer instrumentation is working properly
  
  
• Keep dryers well maintained and ensure preventive maintenance
  
  
• Automatic end-point detectors should be fitted to batch dryers
  
  
• Investigate drying time reduction through de-watering the product in a previous process
  
  

Recycling waste heat

• Using any process that generates uncaptured heat is wasteful of energy. Attempt to capture this heat (where feasible) - specialist companies / consultants can help.
  
  

Kilns and furnaces

• Existing furnaces should: monitor energy consumption regularly; set consumption targets for each furnace; benchmark performance; shorten holding times through altering production schedules; undertake a detailed energy audit; look into waste heat recovery.
  
  
• Refurbished / new furnaces should design plant to use the most efficient burners and the optimum insulation.
  
  

Flows controls

• Steam, water and other fluids should be monitored at several locations around their distribution networks for pressure and flow. Following this, a programme should be implemented comprising of: monitoring and targeting to identify any leaks; regular inspection of flow controls; regular calibration of flow meters.
  
  

Waste steam

• Such waste can be ducted to an area where it can be condensed back to water by spraying cold water over it. The hot water is then collected and reused.
  
  
• Energy recovery from high temperature steam or waste gases from kilns using heat exchangers, for example.
  
  

Industrial cooling

The checklist below should be used to identify energy wastage:

• Are products being over cooled?
  
  
• Are cold store doors left open?
  
  
• Are door seals in place and in good condition?
  
  
• Do blast freezer fans stop when the line stops?
  
  
• Could strip curtains be used on doors?
  
  
• Is the condenser regularly checked for dirt and leaves?
  
  
• Has the defrost cycle been optimised?
  
  
• Could electronic expansion valves be fitted?
  
  

Plant insulation

• Specialist advice should be sought as insulation materials vary greatly.