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OPTIMISING THERMAL ENERGY RECOVERY

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OPTIMISING THERMAL ENERGY RECOVERY ( optimising-thermal-energy-recovery )

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4.1 Energy Consumption in Crisp Manufacturing Process As mentioned above, crisp manufacturing is an energy-intensive process. Processes such as the hot washing and peeling require hot water and steam respectively, while the packing hall is required to be heated. Space heating accounts for about 20% of the total energy and is produced using boilers, which makes use of boiler fuels (Hardcastle and Ward, 1984). The frying operation is the most energy-consuming unit operation and consumes more than 65% of the total energy use (in the form of electrical energy). This comprises the electrical energy used in driving the conveyor systems, foul gas fans, pumps and other auxiliaries. Figure 4-3 shows a typical day’s hourly electrical energy consumption in the KP Billingham crisp manufacturing plant. The graph shows that the average hourly electricity usage stands at 65.90 kW for the processes up to the fryer and 124.40 kW in the fryer. This results in a total daily average electricity usage of 190.30 kW. 250 200 150 100 50 0 0 1 2 3 4 5 6 7 8 9 101112131415161718192021222324 Time (h) Electricity Consumption up to Fryer Electricity consumption in the Fryer Total Electricity Consumption Figure 4–3: Electricity Consumption in Crisp Manufacturing 95 Electricity Consumption (kWh/h)

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