Problems & solutions Heat transfer Cutting process cooling costs by a quarter


Problem: Technical plastic injec- tion moulder, OGM, manufac- tures technical and clean-room plastic injection mouldings and assemblies for companies in the medical and electronic indus- tries. Due to an increase in demand, the company built a facility in Yarnton, and required a process cooling system. Solution: OGM has invested in IsoCool’s IsoFC packaged heat exchanger, designed for use within dual circuit systems. Installed in October 2011, the IsoFC is on target to reduce cool- ing costs by over 25%, providing a payback period of 2.5 years. Stuart Wilson, engineering manager at OGM, explained why he choose the IsoCool system: “Our manufacturing processes


Increased capacity


Problem: Blackburn Chemicals, a manufacturer of antifoam and speciali- ty surface-active chemicals, is expand- ing production at its Lancashire site. However, the existing heater had insuf- ficient capacity to meet the new requirements. Solution: Having explained its require- ments to Babcock Wanson, an HEB Hot Water Boiler was recommended due to its efficiency and compact size. The boiler has been supplied with plate heat exchangers for indirect batch heat- ing of process water used in the pro- duction of wax and silicone based emulsion technology, that is primarily for products in the paper and pulp industries. The boiler is serving two plants: the Silicone Plant heating 15,000l from 5 to 80˚C over an eight hour period; and the Paper Plant heat- ing 3,000l from 5 to 80˚C per hour. Nicola John, factory manager at Blackburn Chemicals, said of the new boiler: “It has increased our capacity for hot water and also speeded up pro- duction and we are very happy with our purchase.” Babcock Wanson T: 0208 953 7111


Enter 211 www.babcock-wanson.co.uk


are required to meet exacting standards, and IsoCool’s propos- als and approach inspired us with the highest level of confi- dence. They were also the only company to offer an attractive energy-saving solution like the IsoFC. Because we operate a policy of continuous improve-


ment goals, it fits perfectly with our drive to improve efficiency.” IsoCool installed a Eurochiller AX-A chiller with cooling capac- ity 110kW, a pump and tank system, and bespoke pipework into the new factory. To min- imise the initial investment required, as well as the carbon footprint of the extension, IsoCool utilised existing equip- ment wherever possible. The IsoFC indirectly links mould and hydraulic cooling cir- cuits through a high-efficiency packaged heat exchanger, and facilitates energy transfer via intelligent software between the systems without them mixing. IsoCool T: 01376 328455 www.isocool.ltd.uk


Enter 208 A sparkling solution


Problem: A. G. Barr, the UK’s largest independent soft drink maker, required heat exchangers to cool carbonated drinks prior to bottling. Solution: HRS Heat Exchangers has sold three units from the MI55 series to the company. The MI series heat exchanger is suited to food applications involving fluids of low to intermediate viscosities. Corrugated tubes are used to increase heat transfer rates, which is said to make the MI series more efficient than normal smooth tube heat exchang- ers. The carbonated drinks flow through the interior tubes to bring the tempera- ture down. Corrugated tubes create extra turbulence, increasing heat transfer compared to smooth tube exchangers. The exchangers have been vertically mounted to fit into a relatively small plant footprint.


HRS Heat Exchangers T: 01923 336312


Enter 209 www.hrs-heatexchangers.com Chocolate producer solves trap failure problem


Problem: Founded in 2007 by parent company Ferrero Group, Energhe develops energy effi- cient projects and financial sav- ings for Ferrero. The company was looking for a replacement for inverted bucket steam traps installed at Ferrero Group sites in Europe. The traps normally had to be replaced every 12 months, and sometimes they would fail, but the 24/7 process could not be stopped, resulting in steam wastage. Solution: Energhe conducted a trial by replacing a steam trap with an appropriately sized ven- turi orifice GEM steam trap from


Thermal Energy. The trial, car- ried out on a process toaster with a 9-bar pressure, was monitored by a flow meter over a 12-month period to verify the steam con- sumption. It established that the GEM steam trap was totally reli- able and that it had achieved steam savings of 15%.


In addition to replacing its failed mechanical traps with GEM, Energhe now ensures that the venturi design is used in all of Ferrero’s new plants and during shutdown for mainte- nance. The project manager at Energhe, said: “GEM steam traps solved our problem of trap fail- ure and steam leakage...In addi- tion, we also like the fact that Thermal Energy International offers a 10-year guarantee on the GEM, which is backed by fast response and excellent service.” Thermal Energy International T: 0117 917 7010


Enter 210 www.thermalenergy.com Steam boiler supply is a strictly local affair


Problem: Imperial Tobacco was looking for a cost-effective solu- tion to supply heating and hot water for its headquarters in Bristol. Solution: The solution ended up being a local affair as factory maintenance engineer, Gary Withey, explained: “The new skid-mounted steam boiler pack- age was specified by our Bristol- based consulting engineers Hoarlea, built in Bristol by Fulton and installed by Spie Matthew Hall, also based in Bristol.”


Even though the old boiler house had been decommissioned and the factory demolished, the original offices remained, and still featured the original steam


8


coils and site services. It was therefore decided that a replace- ment steam boiler package was the cheapest solution for supply- ing domestic hot water and heat- ing, rather than opting for a new hot water boiler, which would have required a new HVAC system for the offices. The Fulton gas-fired, skid-mounted system con- tains two 60J boilers – to ensure duty backup for planned/unplanned main- tenance procedures – and features all the necessary ancillaries to integrate with Imperial Tobacco’s HVAC services.


Carl Knight from Fulton, said that the com-


JULY 2012 Process & Control


pany’s knowledge of steam sys- tems and the fact that the new skid-mounted boiler system was connecting to existing site ser- vices, kept downtime to a mini- mum during the switch. Fulton T: 0117 977 2563 www.fulton.co.uk


Enter 212


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36