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|ESA-195 Public Report (J.R. Simplot, Moses Lake)|
|Written by USDOE Energy Efficiency & Renewable Energy|
|Friday, 15 July 2011 09:50|
ESA-195 Public Report
This J.R. Simplot facility produces French fries and other potato products in Moses Lake, Washington. The plant operates a primary boiler that burns a combination of natural gas and hydrogen. The hydrogen is piped to the boiler room from a neighboring facility. The plant uses saturated steam to peel, blanch, and cook the potato products.
Objective of ESA:
The purpose of the steam energy saving assessment was to train this facility’s and neighboring facilities’ engineering groups to use the Department of Energy steam tools, to create a model of the plant steam system, and to identify projects that will save energy.
Focus of Assessment:
The plant generates steam to be used in the production of French fries and other potato products. The J.R. Simplot Company operates three plants in the Moses Lake area and several plants in the neighboring state of Idaho. Neighboring plants participated in the ESA to gain knowledge regarding the use of the Department of Energy’s steam tools. If ways can be identified to improve the plant steam system operation, the cost of energy use at the facilities can be reduced (i.e., primarily reduce the amount of natural gas consumed).
Approach for ESA:
J.R. Simplot was serious about gaining as much as possible from the Department of Energy-sponsored ESA; eight people were involved in the training audit, including two corporate engineering representatives. The assessment began by reviewing the Department of Energy’s Steam System Scoping Tool (SSST). Information obtained from the SSST and other specific information from the evaluation team was used to begin the modeling process. Jeff Breiling, the plant lead for the assessment, was very well prepared with the data previously requested. A plant tour was conducted to collect flue gas samples from the boiler, to observe the operation of the blowdown heat recovery equipment, and the deaerator, feed water economizer, and the condensate recovery system.
3E Plus software was used to build a metric for determining the heat loss in portions of the plant distribution system that have bare or poorly insulated pipe.
By the end of the first day of work, Jeff Breiling was manipulating the Steam System Assessment Tool (SSAT) model to develop a comprehensive list of steam system improvement opportunities. On the second day, significant time was spent computing steam turbine isentropic efficiencies, demonstrating the use of the 3EPlus software, and adjusting the SSAT model to ensure that all of the training audit team members were satisfied that the SSAT model represented the current plant operation.
General Observations of Potential Opportunities:
To enhance the accuracy of the SSAT model, the facility needs to record the steam generated from each boiler each day, the makeup water used in the boilers each day, and the amount of low pressure process steam used each day.
The following opportunities were evaluated using a fuel cost of $5.35/MMBtu and electric cost of $0.017/kWh. Some projects were modeled to determine the marginal cost of steam for the plant and the value of return condensate. The values are listed below.
Potential fuel savings from above improvements:
Management Support and Comments:
We did not meet with the plant manager but J.R. Simplot dedicated personnel from three plants to the training audit for three days, including corporate engineering representatives.
DOE Contact at Plant/Company:Alan ChristieCorporate Engineer