Energetic analysis and optimal design of a CHP plant in a frozen food processing factory through a dynamical simulation model

The proper design of cogeneration plants requires the choice of the technologies that best fits the ratio between heating and power loads. In this paper, a dynamical procedure of selecting and dimensioning a cogeneration plant, using deep and detailed energy, exergy and economic analysis of the entire production process of a frozen food production factory is proposed. The results highlight that a design method, based on a dynamic simulation, optimizes the energy efficiency of the food processing plant involved in the experimental test. Indeed, by considering the overall efficiency of the CHP + National grid system, the energy efficiency is 6% higher in the case of dynamic compared to a static design, resulting in better overall use of resources with a possible lower level of environmental impact. Moreover, the CHP plant designed with the proposed method generates electrical energy which appropriately matches that required by the process, with a surplus/deficit less than 4%, while the classic method never covers the amount required and results in a deficit greater than 20%. Finally, the annual savings of the solution derived from the dynamic method is 12% higher than that obtained with a traditional design technique. Considering the greater absolute cost of the cogeneration plant, this dynamic approach results in more profitable annual investment margins for the company.