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Case StudySeptember 2017
ChallengeMaking spirits at the Jeptha Creed Distillery starts with
creating the mash. The cooking process begins with grinding
the corn, which is then heated in water to get the starches
accessible, before adding a combination of wheat, rye and
barley to convert the starches to sugars. Yeast is added to
the product during fermentation, after which the product is
distilled, a process which heats the product to a vapor in order
to separate the alcohol from the flavor components. With large
amounts of heat and steam used in the distillation process,
the distillery had a great need for chilled water to cool the
vapor to convert it back into liquid. “Our challenges were not
so much with the HVAC needed for comfort cooling, but with
the chilled water required for the distillation process,” said
Joyce Nethery, owner, CEO and master distiller, Jeptha Creed
Distillery. “We had some really big chilled water needs. We
were looking for an economical way to cool the mash, and we
needed to do it quickly, which meant a lot of BTU load.”
SolutionKnowing of Trane’s extensive work on the process cooling
side of the distillery market and experience using thermal
storage, the mechanical engineer working on the Jeptha Creed
Distillery building design introduced Trane to the project. The
Trane team began the process of selecting the right equipment
to handle the distillery's process cooling needs, adhering to
industry-specific process cooling requirements.
A family-owned craft distillery, Jeptha Creed Distillery was born out of the owners' background in farming and chemical engineering, and their desire to build a legacy. Holding true to its motto, “Don’t Forget Where You Came From,” the distillery uses old-fashioned brewing methods and locally-sourced ingredients, such as its signature Bloody Butcher corn, as well as berries, apples and mint grown on the 64-acre property. For more information, visit JepthaCreed.com.
Built from the ground up, the 15,500 sq ft Jeptha Creed Distillery includes a production area, a warehouse for raw materials and finished goods, office space, a gift shop, and a cocktail bar.
Jeptha Creed DistilleryThermal storage system answers process cooling needs; shifts demand load; results in energy savings of more than $20,000 a year • Shelbyville, Kentucky
Determining the right equipment
Unlike an office building, hospital or school, in the distillery
environment, Trane knew special consideration must be given
to electrical classifications because of the product's potential
flammability. In addition, the Trane team evaluated the facility’s
chilled water demand needs, which fluctuate throughout the
day due to the batch loading of the distillery process. With 40
to 60 percent of the distillery’s electricity bills coming from
demand costs, Trane engineers sought to spread out the peak
electrical loads of the chilled water system, instead of having
30-60 minute spikes throughout the day. Rather than looking
at a single day of the distillery process, Trane analyzed an
entire week to determine the right equipment sizing.
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Shifting demand to reduce energy cost
A thermal storage system was implemented to shift demand
from peak-load production process times to lower-cost, off-
peak hours, significantly reducing energy demand costs. The
system includes a Trane CGAM air-cooled chiller, two CALMAC®
IceBank® energy storage tanks, and a custom-designed ice
completion module with an all stainless steel pipe pump
package. Running with glycol for freeze protection, the system
converts from glycol to a chilled water system to serve distillery
processes. The Trane chiller operates loaded most of the time
when the distillation process is not running, building up ice in
the storage tanks to provide capacity to handle the operation’s
needs throughout the week. The ice cools the distillation
process for one or two mashes a day, after which the tank
is recharged. Instead of using a 200 to 250-ton chiller to
handle the load that the process might require over a one-
hour period, the thermal storage system spreads out demand
loads, allowing the use of a smaller 40-ton chiller. The high-
efficiency Trane CGAM chiller not only helps to lower energy
use, but delivers the lowest noise levels in its class, providing a
comfortable environment for workers and guests.
Commissioning for optimal flow
A Trane® Tracer™ SC building automation system (BAS) and a
Tracer UC600 programmable unit controller were installed as
part of the ice completion module. With remote access, Trane
used the Web-enabled controls system during the start-up and
commissioning phases to make small adjustments to frequency
drives and differential pressure settings to balance the systems
and get proper flows through the equipment, as the owners
were going through initial production runs. Ongoing, the
controls system will provide the distillery with visibility into
chilled water process temperatures and pressures.
ResultsImplementing a thermal storage system for process chilled
water cooling has resulted in significant energy savings for the
Jeptha Creed Distillery. The system has enabled the distillery
to shift demand, allowing the use of a smaller 40-ton chiller
combined with ice storage, instead of a larger 200 to 250-
ton chiller to serve the distillery’s process needs. The result is
an energy savings of $20,000-$30,000 a year. “The system
provides the chilled water we need, when we need it, at the
temperature we set," said Nethery. "There have been no delays
in the process because we didn’t have chilled water. I don’t
have to think about my chilled water; it is just there.”
(Trane, the Circle Logo, and Tracer are trademarks of Trane in
the US and other countries. Calmac and Ice Bank are registered
trademarks of CALMAC Manufacturing Corp. All trademarks
referenced are trademarks of their respective owners.)
The thermal storage system is located outside, so as not to occupy floor space needed for the production process or other business functions.
©2017 Ingersoll Rand CASE-SLX470-EN September 18, 2017