How CaTS Reduced Fuel Consumption by 20% and Improve Steam Boiler Efficiency at a Food Production Factory

Introduction:

CaTS, as a leading provider of Industrial Technical Solutions is fully committed to offering sustainable and innovative engineering solutions for manufacturing plants in Nigeria. This case study details how CaTS was able to reduce fuel consumption while optimizing operational efficiency for a Food and Beverage factory in Nigeria.

The Client

Our client is a multinational company with a major market share in the food and beverage industry in Nigeria. Backed with a history of over 250 years in operation in Europe and Africa, they offer a variety of international and local brands that always reflect a deep understanding of their diverse customers culinary tastes.

The Challenge

As one of the biggest food producers worldwide, our client has decided to align its whole value chain (from the product design to its consumption and disposal) with strategies and initiatives that contribute to a better world. Utilizing processes that promote efficient usage of energy is one area our client aligns its business objectives with the Sustainable Development Goals as proposed by the United Nations for a better world. The client needed a solution to reduce energy consumption from its steam boilers while optimizing its performance.

The Solution: Overview

A Condensate Recovery system is a vital component of steam boiler operations, designed to reclaim and reuse condensate – the water formed as steam condenses back into its liquid state. This system is integral to reducing fuel consumption and optimizing boiler performance in several ways. Designed to suit the client's existing layout, a fully automated condensate recovery system was designed to achieve the following results:?

Heat Energy Recovery:

Our calculations indicate that the system recovers 75% of the condensate's heat energy, translating to a 20% reduction in fuel consumption for the boiler system. This translates to huge annual cost savings running into millions of Naira.

Water Conservation:

The closed-loop design of the system eliminated the need for additional make-up water by 50%. This translates to saving millions liters of water annually, along with the associated costs for water treatment.

Reduced Boiler Blowdown:

With the return of condensate to the boiler, the need for boiler blowdown – the process of removing impurities and dissolved solids from the boiler water – is reduced. This leads to decreased water and chemical usage, resulting in cost savings and environmental benefits.

Improved Boiler Efficiency:

By maintaining a consistent water level and temperature within the boiler, condensate recovery systems contribute to improved boiler efficiency. Stable operating conditions help prevent fluctuations in steam pressure and temperature, reducing the risk of boiler cycling and improving overall system performance.

Extended Equipment Lifespan:

Minimizing the introduction of fresh water into the boiler reduces the potential for corrosion and scale formation on internal surfaces. This extends the lifespan of boiler components, reduces maintenance requirements, and enhances system reliability.

Environmental Benefits:

The reduction in fuel consumption associated with condensate recovery systems translates to lower greenhouse gas emissions and environmental impact. By optimizing energy usage and resource efficiency, these systems contribute to sustainability goals and regulatory compliance.

Conclusion:

The condensate recovery system designed and installed by CaTS has demonstrably improved our client's sustainability efforts. By capturing and reusing valuable heat energy and water resources, these systems help reduce fuel consumption, minimize environmental impact, and optimize overall boiler performance. The solution aligns with the client's commitment to responsible manufacturing practices.

Ready to implement result-driven sustainable solutions for your manufacturing plant? Get a Free Consultation with CaTS and discover how we can optimize your manufacturing plant's energy efficiency and resource usage.??