Engineering Internship at the Schuyler Beef Plant

Jade Titus

Cargill Meat Solutions

Schuyler, NE

Rendering Heat Exchangers

Poor heat exchange which leads to a waste of energy and resources Build up of minerals on shell side (potable water side)Possible buildup of fat and proteins on tube side (vapor side)

Energy losses

Currently we lose 263 mmbtu/day Equivalent to $2,104/day

$182,000 wasted in poor heat transfer per year

CIP Loop

Would raise the efficiency of the heat exchangersSaves money by reducing the amount of water needed to heat up for 140 and 180 potable waterWill help create a vacuum to lower the temperature needed in the inedible rendering cookers

Payback

$117,000 saved from heating water for nightly sanitation$111,000 saved from preheating 180 degree water$228,000 total savings per year

Vertical Centrifuges

Used to separate tallow, water, and solidsAcid is used to help separate water and tallowPhosphoric acid cost: $323,169/year

Tests

Na2SO4

NaNO3

Lactic AcidAcetic AcidSulfuric Acid

Results

Low pH with a high density is required~$200,000/year Would be saved by switching to Sulfuric Acid

Large Motors

Determine efficiency of motorsDetermine cost to run motor About $190,000/year for a 700 hp

motor About $70,000/year for a 250 hp

motorIs there a payback in purchasing brand new motors?Loading factor on motor plays largest role in high horsepower motors

180 Water Usage

Hottest water flows off the topEnergy is lost due to using too much water

New 180 System

Reduces water usageEnergy efficient$125,000 in estimated savings per year

4

10

10 9

9 8

11+2 9 10

13897

13 Valves

13 Temp. Sensors

184.3

182

194

192.8

189.5

190 191.6

194 196

192190

193

188.7192.2 191 196 188.3

196

189 194.8

195.2 193

189

192

185

192

183190 190.5 192.7

188

185.7 183183

190.3

190.2

189.2

181

185

190.5 186

191

189

Avg. temp.= 189.8

119 Sterilizers

3 groups of 30, one group of 29

Rendering P&ID

Mapped out entire boiler/cooker operationLocated key areas of improvementDesigned a procedure for start up/shut down of cookers

Engineering Principles

Fluid dynamicsPLC’sPumpsThermodynamicsRefrigeration CycleSeparationsHeat Transfer

Recommendations

Sharing a project with a full time engineerMore interns/engineersMore interaction with upper managementVisit other plants