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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