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Spirax Sarco was very professional and managed the whole process for the
steam system while keeping me up to date with every single detail. We're
very pleased with the results."
The new FREME system was supplied as a prefabricated, skid-mounted rig,
comprising a flash separation vessel and two plate heat exchangers.
Pressurised condensate from the production process enters the separator
where it splits into separate streams of condensate and flash steam. Each
stream passes through a separate heat exchanger, where it heats the boiler
feedwater. The two streams are then recombined and sent back to the boiler
feedtank.
Crucially, FREME systems are typically positioned downstream of the boiler
feed pump. This allows feedwater temperatures to be elevated well above
100C, without pump cavitation. In the case of Smurfit Kappa, this has
enabled the company to have heated feedwater entering the boiler at 130
and 140C, rather than the 85 or 90C that was previously possible.
On 3rd November, FREME technology won the energy category at the
prestigious annual Institution of Chemical Engineers' awards event which
rewards excellence and innovation in chemical engineering.
Steam traps and calorifiers too
Steam trap management is another important way of saving energy. Heinz
expects to cut more than four percent from its energy consumption over the
next three years at its Wigan factory in Northern England after signing up for
a steam trap management contract with Spirax Sarco. The decision to opt for
the new contract followed great success with a previous, one-off steam trap
survey, which saved enough energy and treated water to pay for itself in less
than nine months.
The Heinz factory in Wigan is the largest food factory in Europe. The 55-acre
site produces canned soups, baked beans, pasta and puddings for the UK and
European market, and its on-site energy centre generates up to 140 tonnes of
steam per hour to keep the canning lines running.
Under the new deal, Spirax Sarco engineers will survey the site every six
months, highlighting any traps that need maintenance from teams at Heinz.
Spirax Sarco specialists will spend around ten days on site each year,
checking, tagging and recording the condition of each steam trap.
"When Spirax Sarco carried out the original survey they put in a conservative
estimate of savings and we ended up saving much more," says Barry Aspey,
the utilities manager for Heinz. "That helped us decide to opt for the threeyear contract. If the new savings estimates are correct, the contract offers
excellent value for money and should help us reduce our carbon emissions by
200tonnes a year."
Catalent Pharma Solutions is also reaping the rewards, thanks to its decision
to swap old shell-and-tube calorifiers for compact Spirax Sarco EasiHeat
steam-to-hot water systems. Spirax Sarco calculated that Catalent could save
EUR7200 a year in energy costs by replacing a single 540kW calorifier with an
EasiHeat.
Catalent has been gradually replacing its old heat exchangers over that past
five years, and now has nine EasiHeat systems in place. The biggest saving
for Catalent is in downtime and maintenance costs, according to engineering
manager Arthur Burnett: "The main thing is that we now have no summer
shutdown, when it used to take two weeks. Also, we can look after the heat
exchangers with one utility engineer instead of four, so it frees up time for
our maintenance team. Previously, there was so much work involved with the
calorifiers that we sometimes had to bring in contractors to service them,
which was obviously another expense."
Shell-and-tube heat exchangers are pressure vessels and must therefore be
dismantled annually for an insurance inspection. EasiHeat systems instead
rely on stainless steel plate heat exchangers (PHEs), which eliminate the
need for stripping down. PHEs are also extremely compact and energy
efficient.
Catalent's Swindon factory encapsulates various products in soft gel
capsules. Between them, the new heat exchangers serve two hot water
systems, one at 80C for process water and air conditioning, and the other at
60C for hand washing.
"The old calorifiers were over 20 years old," says Burnett. "They were not
very efficient, slow to heat up and caused a bottleneck in the process." In
contrast, he says that the EasiHeat units are more than equal to the task:
"We used to run three large calorifiers for one application and replaced them
with two compact EasiHeat systems. Although we always have one on
permanent stand-by, for safety and maintenance precautions, we've never
even had to use it for an application because they're so efficient."