Melhoria da eficiência energética em sistema de evaporadores: uma análise de custos com variações de parâmetros

Abstract

This study addresses the optimization of energy efficiency in evaporator systems used in the production of Valine, an essential amino acid obtained by fermentation and evaporation. The process evaporators, formed by Falling Film Evaporators (FFE) and Forced Circulation Evaporators (FCE), are crucial in this process, used for concentration and purification of compounds generated during fermentation. The high steam consumption in evaporators results in high operating costs. The company, due to its segmented production and high turnover between campaigns, faces challenges in maintaining efficient operating conditions, which leads to a waste of resources and inefficiency in the production process. To solve these problems, it is proposed to change the vacuum parameters of the evaporator system, evaluate the operating conditions and implement an action plan that aims to optimize the use of steam, thus reducing the associated costs, carried out in the work through changing the vacuum setpoints of the evaporator control system. Data extraction techniques, mass and energy balance calculations, and analysis under different vacuum conditions are used to identify adjustments that can improve operational efficiency and reduce costs. Lean Six Sigma tools, such as the <5 whys=, are applied to identify inefficiencies, root causes and promote continuous improvements in industrial processes. With the application of the chosen solution, a 10% reduction in steam consumption is expected and, consequently, a 10% decrease in operational costs related to the use of steam. The study aims not only to increase industrial competitiveness and reduce energy consumption, but also to contribute to the mitigation of environmental impacts by minimizing carbon emissions.