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 exchangers Saves money by reducing the amount of water needed to heat up for 140 and 180 potable water Will 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 solids Acid is used to help separate water and tallow Phosphoric acid cost: $323,169/year

Tests Na 2 SO 4 NaNO 3 Lactic Acid Acetic Acid Sulfuric 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 motors Determine cost to run motor About $190,000/year for a 700 hp motor About $70,000/year for a 250 hp motor Is 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 top Energy is lost due to using too much water

New 180 System Reduces water usage Energy efficient $125,000 in estimated savings per year

Rendering P&ID Mapped out entire boiler/cooker operation Located key areas of improvement Designed a procedure for start up/shut down of cookers

Engineering Principles Fluid dynamics PLC ’ s Pumps Thermodynamics Refrigeration Cycle Separations Heat Transfer

Recommendations Sharing a project with a full time engineer More interns/engineers More interaction with upper management Visit other plants