Energy Management inCommercial BakeriesEnergy Management
inCommercial Bakeries269 Sheffield Street Mountainside, NJ 08628
Ph: 908-233-2882 Fax: 908-233-1064
www.csmworldwide.comThepriceofnaturalgasisSOARING! And because of
this, the price of electricalpowerisclimbingaswell.
Sinceutilitycostsinthebakerymustbemanaged,ourindustryislookingtowardrealworldimplementation
ofENERGY MANAGEMENT.Frankly, its the right thing to do.As always,
the baking industry is very practical
andassuchmustlookforpracticalwaystomanageenergy.Thebakeryislookingforstraightforward,cost
effective ways to conserve energy and to reclaimenergy for further
use.Bakeryengineersandmanagementmustfindandimplement efficiency
improvements wherever eithernatural gas or electricity can be
saved.To this end, the bakery must implement conservationplans to
minimized heat losses.And,thebakerymustimplementWasteHeatRecovery,
transferring the reclaimed heat to anotherpart of the bakery where
it can be put to good
use.Equallyimportant,however,istheneedtoimplementarealtimeFacilityEnergyMonitoringSystem(FEMS).
Thisprovidesarealtimedisplayprofilingthebakerysenergystatus.Bakeryengineersknowthattomanageit,youmustfirstmeasureit.WhenFEMSisimplemented,instrumentationisinstalledthroughoutthebakerytotakekeymeasurementsofenergyparameters.
Forexample,FEMSmeasuresthetemperature of all air flows entering and
leaving thefacility;itmeasuresandrecordsambientconditionsPage
1Energy Management in Commercial Bakeries CSMWorldwide, Inc. Energy
Management inCommercial BakeriesBy: Donald CiccolellaVice
President, Sales &
MarketingToday,itspossible,itsaffordable,anditsbeing
done.Itisbesttobegin,however,withsimpler,easytoimplementprojectsthatgetresultsfast.
Asstatedearlier,thebakingindustryisverysmartandvery practical.Begin
by calling in the Energy Experts.Contract for an energy audit.Then
make a list of recommended improvementsand get
going.Thenextgasandel ectri cbi l l i sj
ustaroundthecorner.withinthebakery;itrecordsnaturalgasusagebyeach
oven, boiler or combustion device; and it
notestheseparametersonthesamerealtimedisplay.FEMS is also
smart.When a measured
parameterstraysfromacceptablebounds,analarmalertsthebakery to check
it
out.ExaminingWasteHeatRecovery,CSMrecognizesthattheprimarysourcesofrecoverableheatinthebakeryareexhaustsfrom:ovens,boilersand
Catalytic Oxidizers (CatOx).Recovered heat from these sources can
be transferredtoalternatelocationsinthebakeryforanyofthefollowing
uses:make hot water, pre-heat boiler feedwater, generate steam, and
heating
air.Theparticulareconomicsforeachoftheseprojectsdiffer,butasthepriceofnaturalgashasrisenthereturn
on investment has improved significantly!Listing only a few uses
for recovered heat, consider: Making steam for use in the bakery
including, perhaps, the proofer room. Using a gylcol coil to
transfer heat to theproofer room. Making hot air for comfort heat
in the bakeryshipping area or offices. Pre- heat i ngt hemake- upai
rcomi ngi nt o t hebakery. Making hot water for the wash room or
for sanitary cleanup. Pre-heating the boiler feed water.The
objective is to evaluate each of the major energyusing components
in the bakery and deciding whichpractical improvements should be
considered.Withthis in mind, look first at the baking
ovens.Itiscommonknowledgeinthebakerythatsomeoftheovenburnerelementsjustdontlight.Theseshould
be detected, repaired or shut down.No
longerisiteconomicaltobleednaturalgasthroughunlitburners.Unburnedmethanegoingtoatmospheresimply
costs too much!Tuni ngt hebur ner sf or opt i mumcombust i oni
snowaverysmart t hi ngt odo, andpre- heat i ngt heai ri nl et t ot
heovenbyrecl ai mi ngheat f romt heovenexhaust shoul dbeconsi
dered.Oneofthesimplestandsmartestthingstodoistocalibratetheovensthermocouplesandinstrumentation.CSMWorldwide,
Inc.Energy Management in Commercial BakeriesPage 2 Page 5Energy
Management in Commercial Bakeries CSMWorldwide, Inc.
Also,itisimportanttoinstallagasflowmeteroneachovenandrecordgasusage.Remember,letsmanage
it!MostbakeryovenstodayhaveaCatalyticOxidizeror CatOx installed to
destroy ethanol
emissions.TheCatOxalreadyusesanair-to-airheatexchangetorecoverheatforreuseintheCatOx.But,thereismore
that can be done.CatOxburneroptimizationisrequired.
Again,unburnedmethanetoatmosphereisnotaffordable.The combustion air
to fuel ratio of the CatOx burnercan be modified and
optimized.CatOxthermocouplesandinstrumentationshould be calibrated
on a scheduled
basis.Semi-annualoverallmaintenance,conductedbytheCatOxmanufacturer,isanimperative.Theexpertsystem
tune-up has a
payback!CantheCatOxbeoperatedatalowercatalysttemperature?Sometimesitcanandthemanufacturer
should be charged with finding out!Ag a i n , a g a s me t e r b e
l o n g s o n t h eCat Oxme as ur e andmanage
!AdditionalWasteHeatRecoverycanbeappliedtotheclean,hotairexhaustoftheCatOx.TheCatOxexhaust,evenafterprimaryheatrecovery,stillhasheat
to give back to the bakery!Boiler optimization is so practical and
so
necessary.Again,semi-annualmaintenancebyaqualifiedtechnicianisrequired.Theburnercontrolsystemwithassociatedthermocouplesandinstrumentationmust
be calibrated and
checked.Boilerexhaustcangiveupheatviauseofaneconomizer to pre-heat
the boiler feed water, and gasmeters are needed here as well.Should
the boiler be upgraded to a more efficient andmodern system?What
are the ramifications of suchincluding emission requirements?Can
the bakery dobetter by installing small boilers and perhaps more
ofthem?Bakerywideconservationshouldincludechecking and improving,
where appropriate
andeconomical,insulationofducts,stacksandsteam/hotwaterpiping.
And,especiallyinolderfacilitieswithdecadesofmodifications,eliminatingthedeadlegsinsuchpiping.Whileatit,remember
to check and maintain condensate traps.Electric power must be
conserved as
well.Lookforopportunitiestoeconomicallyupgradetopremium efficiency
motors and to install VFDs.Inspect and clean blower air intake
filters.Install timers where
applicable.Lookupwardandexaminethelighting.Canhighefficiency
fluorescent lighting be used?Find every heater used in the
bakery!Must it run allthe time?Is it the right size?And, what about
refrigeration?Is it time to
upgrade?Aretheunitssettotherighttemperatureandarethey performing
well?ReturningtoabakingFacilityEnergyMonitoringSystemorFEMS.Itslikelytobeethernetbasedusingthermocouplesandinstrumentationthroughoutthebakerytoprovidedataforrealtimedisplay.FEMSdi
spl aysthetemperatureoneachexhaust andal l make- upai r. Thet emper
at ureof eachcr i t i cal l ocat i onthroughoutthebakeryi sal sodi
spl ayed.Observethepositionofeachgasvalveateachcombustion point in
the bakery.Each gas flow
meterreportstotheFEMS.Beingcreativeanthorough,abevyofotherusefulcalculatedenergyparametersshould
be displayed as
well.FEMSissmart!Alarmswilldisplaywhereverandwheneveracriticalparameterstraysoutofbounds;
the range of acceptable values are set by
thebakerymaintenancepersonnelorperhapsthePlantManager.Eachexcursionisdocumentedandquantified.Moreimportantly,thebakeryinvestigates,findstheproblem
and corrects it.Can more be
done?Absolutely.Someoftheadditionalenergymanagementoptionsare much
more complex and still others may not yetbe affordable.How about
installing a highly efficient,
naturalgasfiredCOGENSystemusingoneormorereciprocatingenginesoramicroturbine,theexhaustofwhichfeedsasteamboiler.Hotwater
can be made at the same time!Page 3Energy Management in Commercial
Bakeries CSMWorldwide, Inc.CSMWorldwide, Inc. Energy Management in
Commercial Bakeries Page 4
