Computer-based monitoring system of retort processes for energy efficiency and carbon emission reduction

• A Computer -based system for monitoring of a retort without intelligent systems. • Investigating carbon emissions based on a real retort. • Main sources of carbon emissions were air compressors, boilers, and natural gas. • The cooling system reduces energy consumption by 20.4 %. • The cooling system reduces total carbon emissions by 15.68 %. Retort sterilization is critical in the food industry. However, retorts are not smart enough to fully monitor and calculate their energy usage to reduce their carbon emissions. In this project, sensors and network equipment were installed in a retort, and a PC-based system was used to process the collected data. To monitor the sterilization status and energy consumption, we added flow sensors and electricity meters and built a visual identification system. Carbon emissions were calculated, and energy conservation and carbon emission reduction strategies were explored. According to the monitoring data, the electricity consumption of the air compressor, boiler, and natural gas combustion accounted for 80 % of the total carbon emissions. If the equipment cannot be changed, the cooling water system can be stopped in noncooling stages to conserve energy. This strategy reduced the energy consumption of the cooling system by 70 % and was the most effective strategy for this project.