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HEATING AND COOLING QUICK RETURNS ON EFFICIENT EXCHANGERS
Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers, explains how the current high cost of energy means investing in heat exchangers results in an even quicker return on investment
obody likes wasting energy, but for businesses there are large financial and environmental drivers to reduce energy use, and since Russia’s invasion of Ukraine, the financial imperative to lower energy costs has come into sharper focus than ever.
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As with many things in life, the old adage that if you can’t measure something, you can’t manage it holds true for energy. In order to deliver energy savings, you need to know the baseline from which you are working and then have the tools to measure changes in consumption. This could be through the use of smart meters and metrics, or the
development of strategic plans to reduce energy consumption, including investing in energy reducing and energy efficient plant and equipment.
Businesses have access to a number of tools to measure and improve energy use and efficiency, such as ISO 50001, which was created to help
HEATER REPLACES ITS PREDECESSOR AFTER 30 YEARS OF OPERATION! B
abcock Wanson has supplied a new TPC-B Thermal Fluid Heater to Crisp Malt to replace the existing Babcock Wanson heater that has been in operation for 30 years! Crisp Malt, a British malting company, supplies high quality English, Scottish and Organic malts to award-winning breweries and distilleries across the globe. Crisp Malt combines traditional and modern malting techniques at its sites in England and Scotland. An important part of the process is the drying of the malt.
At its Fakenham site, a Babcock Wanson Thermal Fluid Heater has been performing this task for the past 30 years. Having well and truly served its purpose, a replacement was required and the company naturally returned to Babcock Wanson. A new TPC 6000B Thermal Fluid Heater was recommended, based on its reliability, high efficiency and large output. The TPC 6000B is the largest Thermal Fluid Heater in the TPC-B range. These fully automatic coil type, multi-pass heaters come complete with integrated burner, control system and safety devices. They provide optimal distribution of the heat, high fluid velocity in the exchange tubes and continuous flow monitoring to ensure long thermal fluid and system life and the highest level of safety.
The new TPC 6000B Thermal Fluid Heater installed at Crisp Malt offers several advantages over its elderly predecessor, including improved controls, Human Machine Interface and overall efficiency, plus a considerable reduction in emissions to comply with current regulations. The TPC 6000B Thermal Fluid Heater was supplied along with new pumps and valves.
Whilst the new heater was being produced, Crisp Malt took advantage of Babcock Wanson’s Thermal Fluid Heating system rental service. Two ‘plug and play’ TPC 2000B Thermal Fluid Heaters were delivered to site and set up by Babcock Wanson’s commissioning engineers to guarantee production.
Following the installation of the new heaters, a full service agreement has also been implemented.
www.babcock-wanson.com
10 JULY/AUGUST 2023 | PROCESS & CONTROL
Rising energy prices have significantly reduced the payback periods for energy efficient heat
exchangers, such as HRS’s corrugated tube technology
organisations implement Energy Management Systems and deliver continuous improvements in energy efficiency. Reducing energy use will deliver savings to both the business’s carbon footprint, and its bottom line. Heat exchangers exchange energy between two different materials or streams, usually for the purposes of heating or cooling a product. This makes them ideal tools to help maximise energy efficiency within a process or wider business, as they continuously recover and utilise energy which may otherwise go to waste. Because heat exchangers are usually employed for energy intensive operations, the largest operating cost is usually that of the energy, such as the gas, electricity or other fuel used to heat (or cool) the service fluid. This means that energy efficiency is a key factor when choosing a heat exchanger. A difference of 5-10% in thermal efficiency will quickly translate into direct savings in energy or running costs.
One of the key measures of this is to look at the payback period required to cover the capital costs of installing the heat exchanger, or the return on investment (ROI). A doubling or tripling of wholesale energy prices means that the payback period may reduce by half or even more. This payback period is shortest for the most efficient heat exchangers (such as those using corrugated tube technology).
For one recently quoted DTI Series heat exchanger using a waste water stream from a cooker, the payback period was less than 90 days when the system was operated for 8 hours a day. Not only that, but the heat exchanger saved more than 500 kg of CO2e a day. Current high gas and electricity prices mean that, in terms of the time taken to recoup the capital investment, there has never been a better time to invest in heat exchangers.
HRS Heat Exchangers
www.hrs-heatexchangers.com
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