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Case Study:

A Major Dairy in Western India


Dairy

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Problem
Losses due to improper design of heating and chilling facilities.
Objective
To establish utility loads and provide optimum design to cater to process requirements.
Solution
- Establishing utility generator capacities, selecting relevant utility parameters and applying the reduce-reuse-recycle concept

- Correcting utility pipeline loads suitably for pipe-rack design

- Designing of chilled water distribution network for minimal temperature variation

- Selecting pump, and making appropriate modifications, for chilled water and cooling water networks based on load with specifications to ensure lowest OpEx

- Designing of critical distribution network connecting the biomass fired boiler with the process plant over a distance of 1.2km, including a 25 meter underground section across a national highway
Benefits
- Safety within the utility network

- Distribution losses minimised

- Increase of on 0.4deg C in chilled water distribution network of 250 meters

- Minimum pressure drop within the distribution networks

- Operation of biomass boiler made possible and plant was able to achieve carbon neutrality

- 16% opex reduction in the steam fuel bill