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COLD INTELLIGENCE
Brewing Sector
Brewing Sector
INDUSTRIAL REFRIGERATION FACTS
Accounts for 30 – 50 % of Electricity Spend
Upto 50% More Than Is Required
The GOOD NEWS ?
Refrigeration Plants Can Be Optimised For Significant Savings With Little CAPEX
Brewing Sector Refrigeration Facts
INDUSTRIAL REFRIGERATION FACTS
• Plants are typically set up for ambient conditions which occur for less than 2 weeks of the year
• Maintenance contractors are incentivised to get plants up and running quickly, minimise call out frequency and duration – at the expense of energy efficiency
• Site facilities staff are typically not refrigeration experts
• Maintenance contractors rarely take ‘whole system’ view and their energy impact is rarely monitored
• There is typically minimal plant monitoring in place so the effects of sub par maintenance or process changes go unnoticed
• Process loads and conditions typically change over time and the plant is never recommissioned to optimally handle new loads and profiles
Why So Inefficient ?
INDUSTRIAL REFRIGERATION FACTSTypical Brewery Shock Loads
INDUSTRIAL REFRIGERATION FACTS
• Fermentation Typically Beer cooled kept at circa 21 deg CCooled before exit of FV’s to 8-14 deg C
• Wort Cooling Typically wort cooled to 12-14 degrees C
• Beer Chilling before final packing Typically -1 to -2 deg C
• Large central plants installed to meet all cooling loads Lowest common denominator = -4 deg C glycol
• Refrigeration plants are not typically controlled dynamically For example they typically do not ramp up glycol temperature when only Fermentation cooling is occurring
Typical Brewing Sector Cooling Loads
INDUSTRIAL REFRIGERATION FACTSReducing / Removing Shock Load Variability
• Many plants are controlled on a glycol exit setpoint
• Driving compressors to do whatever is required to maintain this set point– Calls for lag compressors when not necessarily required – only to
quickly drop out again
• This leads to excessive energy consumption in the plant
• Optimum compressor efficiency is achieved via dynamic control of both suction & discharge pressures to meet ambient & process need conditions - 1 bar reduction in discharge pressure = 7.5% reduction in electricity consumption
• Use the glycol infrastructure to manage & reduce shock load changes:– Utilise large distribution pipework infrastructure as a buffer – Hot and cold buffer tanks – Cold glycol spill back
INDUSTRIAL REFRIGERATION FACTSChilled Water for Wort Cooling
▪Often refrigeration plant is used to cool incoming towns water from ambient (5-22 deg C) to 6-10 deg C
▪6 deg C CHW is used to cool wort to target temp of 14 deg C before Fermentation
▪Cooling load varies by 300% winter to summer as ambient water temp varies
INDUSTRIAL REFRIGERATION FACTSChilled Water Optimisation
▪Possible to use returning “warm” to cool CHW for wort cooling
▪This will have the effect of:▪Widening glycol delta T – by up to 1 deg C in summer
time ▪Reducing energy consumption on compressors
▪Additional Optimisation Opportunities:▪use incoming borehole water to drop temp of towns water
in summer – this will in turn heat borehole water by circa 7 deg C i.e. circa £32k in gas savings ▪Use “warm” glycol to vapourise CO2 or N2
INDUSTRIAL REFRIGERATION FACTSEfficient Refrigeration Control Best Practices
• Dynamically control and vary suction and discharge setpoints based on ambient and process conditions versus fixed setpoints
• Ensure compressors are controlled for optimal loading:– Screw Compressors are loaded in excess of 70% on
average – Reciprocating Compressors acting as Trim compressors
• Ensure stable & efficient operation of distribution pumps – Optimised via intelligent pump VSD control
• Track energy consumption vs production and ambient conditions
• Track impact of operations & maintenance
INDUSTRIAL REFRIGERATION FACTS
CONTROL is Key
Cynergy Dynamically Optimises The ‘Whole’ Industrial Refrigeration System
Production Needs
Ambient Conditions
Compressors
Condensers
Evaporators
EEVs & Pumps
Introducing ..
INDUSTRIAL REFRIGERATION FACTS
Next-Generation Industrial Refrigeration Control
Solution
Real-Time Adjustment & Balancing of Refrigeration
Plant
Production Needs OPTIMALLY MET – ALWAYS
Removes 20 – 50% Energy Costs
No Cost To Client – Fully Paid Via Guaranteed
Savings
Immediate Positive Cashflow & Control To You at No
Risk
WIDESPREAD REFRIGERATION PERFOMANCE & EFFICIENCY ISSUES ACROSS SECTOR
90%
70%
60%
% of Our Client Base
Had …
Energy Savings
Delivered15 – 40%15 – 30%10 – 30%
Inefficient Distribution System
Inefficient Compressor Start / Sequencing / Type
Additional Typical Inefficiencies Incorrect Condenser Piping – No Liquid
TrapsNo Utilisation of Free Heat
Decentralisation of Plant / Inefficient PACKsManual Energy Consumption Monitoring
Refrigerant Choice / Secondary Refrigerant Concentration
Inefficient or No Real-Time Control vs Production Needs &
Ambient Conditions
INEFFICIENCY DRIVEN BY LACK OF CONTROL & NO PRODUCTION CONTEXT
Impact
• Fixed / Semi-Fixed Discharge & Suction Pressures
• No Ambient Condition Linkage• No Process Load Prediction Control • No VSDs on Condenser & Evaporators• No EEVs• No Defrost Optimisation
Inefficient Distribution System
Inefficient Compressor Start / Sequencing / Type
Inefficient or No Real-Time Control vs Production Needs &
Ambient Conditions
Root Cause
• No Flow vs Process Load Control• No VSDs on Pumps
• Inefficient Load Sharing • No Part Load Optimisation• No VSDs• No Smart Starting and Trimming• No Compressor vs Secondary Pump
Control
INDUSTRIAL REFRIGERATION FACTS
INDUSTRIAL REFRIGERATION FACTS
SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM
PRODUCTION FACILITY
CLOUD / INTERNET
• CUSTOM DASHBOARD
• ‘SPARK’ ALERTS• SAVINGS
PERFORMANCE
MASTER
INDUSTRIAL REFRIGERATION FACTS
EFFICIENCY + PERFORMANCE = WINNNG STRATEGY
SECURE CLOUD-BASED REAL-TIME OPTIMISATION ENGINE & REPORTING PLATFORM
Inspired By Real-Time Formula 1
Data-Driven Decision Making
Technology
~300 Sensor Inputs
Car Sensor Data (Telemetry)
Sent For Remote
Analysis & Processing
Energy Conservation &
Performance Optimisation Instructions
Returned to Car
INDUSTRIAL REFRIGERATION FACTS
CLOUD-BASED Cynergy FAR EXCEEDS TRADITIONAL LOCAL PLC FUNCTIONALITY ..
Plant Data Collected:
Ambient Conditions,
Production Needs & Refrigeration
Plant Status
Telemetry Sent For Remote
Processing by Cloud-based
Cynergy Logic Engine
200 Control Rules C.O.P.
£££
C.O.S.P.
Optimised Refrigeration
System Setpoints Sent Back to Plant, Monitored & Monetised
..i.e PREDICTIVE PRODUCTION REFRIGERATION OPTIMISATION, TARIFF REDUCTION
INDUSTRIAL REFRIGERATION FACTS
DIGITISE INSTALL M/C INTERFACES,VSDs, EEVs, AMBIENT CONDITION MONITOR etc BASED ON COST BENEFIT ANALYSIS
OPTIMISE
MONETISE
CUSTOMISE LOGIC ENGINE TOWARDS PLANT OPTIMISATION
ESTABLISH SAVINGS BASELINE MODEL
CUSTOMISE DASHBOARD & REPORTING
3 MONTH ROLL-OUT JOURNEY(TYPICAL OVERALL IMPLEMENTATION TIMESCALE WITH LIMITED ONSITE WORK)
£££
£££s FLOW
INDUSTRIAL REFRIGERATION FACTS
DRAMATIC & IMMEDIATE CONTROL & EFFICIENCY IMPACT£££
Major Project Undertaken
INDUSTRIAL REFRIGERATION FACTS
CUSTOMISED CONSUMPTION vs PRODUCTION DASHBOARDS£££ Major Project
Undertaken
INDUSTRIAL REFRIGERATION FACTS
TRACK ENERGY CONSUMPTION vs PRODUCTION RATIO£££
INDUSTRIAL REFRIGERATION FACTS
Existing Plant
Existing M/C
Control
Existing Plant
Existing M/C
Control
!
COMMS FAULT ? CONTROL AUTOMATICALLY UNCOUPLED & DEFAULT MAINTAINED
Cynergy ONLY ADVISES – DRIVER (Existing Plant Control) STILL IN COCKPIT !
INDUSTRIAL REFRIGERATION FACTS
TRACK REAL-TIME SAVINGS£££
INDUSTRIAL REFRIGERATION FACTS
HOW ARE SAVINGS CALCULATED ?£££ We have extensive experience optimising refrigeration
systems across the Brewing Sector, amongst others
We have developed sophisticated models which predict energy consumption using up to 3 influencing factors
We then check the predictive model against historical usage data to establish a correlation or confidence factor - must be > 80%
Tracking Three Influencing
Factors
INDUSTRIAL REFRIGERATION FACTS
TRACK REAL-TIME SAVINGS & COSTED ALERTS (SPARKS)£££
INDUSTRIAL REFRIGERATION FACTS
ADDITIONAL SAVINGS - RED ZONE PEAK CHARGE AVOIDANCE£££
INDUSTRIAL REFRIGERATION FACTS
OUR STRAIGHTFORWARD OFFERING
£OLD ENERGY COST NE
W ENERGY COST
SAVING
FEE
GAURANTEED SAVINGS
PLUS CONTROL
INFRASTRUCTURE
PLUS REAL-TIME VISIBILITY
PLUS REAL-TIME ALERTS
NO COST TO CUSTOMER
MONTHLY FEE FROM SAVING
THIS IS NOT BUSINESS AS USUAL – WE ASSUME ALL RISK
IMMEDIATE POSITIVE CASHFLOW£
-£
Vendor Profits
TRADITIONAL PURCHASE MODEL
£
-£
You Get Immediate Cash Savings
We Assume All Risk
tAt Your Expense
t
TYPICAL FEE : £2,000/mth
BASED ON £250K ANNUAL REFRIGERATION SPEND20% REDUCTION IN ENERGY = £4,167/mth
TRUSTED CLIENTS OF
Bernard MatthewsCranswick Group
Linden FoodsTennents Lager
Johnson & JohnsonGE Healthcare
Direct Table FoodsAliaxis Group
Emrill
COLD INTELLIGENCE
NEXT STEPSIf you would like to
understand the savings potential of Cynergy
applied to your refrigeration plant,
please contact Crowley Carbon to book a free
initial Opportunity Assessment
www.crowleycarbon.com
+353 1 274 8880
COLD INTELLIGENCECOLD INTELLIGENCECOLD INTELLIGENCE