Success Story
Heat Recovery Reduces Steam Consumption in Tunnel Wash System
Today, Natural Factors is one of the largest manufacturers of nutritional products in North America.
Their origins reach back to the 1950s, and right from day one, they’ve always been fully committed to making products right. Natural Factors is not a public company with shareholders to impress. Instead, they care about impressing you. They have close to 700,000 square feet of space across nine locations in North America housing offices, manufacturing and production facilities, laboratories, distribution centres, and extensive warehouses. The head office is in Coquitlam, British Columbia.
Marc Giron, Chief Engineer at the Coquitlam plant was interested in reducing his plant steam consumption. His company’s success was taxing his boiler capacity fast and a project was being developed to add an additional boiler. In the meantime he was looking for cost effective projects with quick paybacks to assist him in his goal – reduce steam consumption but maintain factory output. Mark called Andrew Reynolds to have a conversation to discuss his options. After walking the plant and in learning about the production processes and the various areas of steam consumption a proposal was made. Reclaim the waste heat from the tunnel and cart washers. A detailed cost analysis was made looking at the number of Btu’s that would be recaptured including the installation and equipment costs. The result was a unique energy saving heat exchanger system that was installed and reduced overall steam consumption by 50% for the washing systems. The cold water makeup was now 100% preheated during normal operation. This success was achieved by recapturing valuable heat content from the overflow rinse water.
This type of heat recovery system is now standard with many tunnel and cart washer manufacturers. Marc’s project earned a 6 month payback. Natural Factors installation of an additional boiler went ahead the next year. The heat recovery system continues to this day to save the company money with reduced steam demand for cart and tunnel washing.
Did You Know?
Consider Installing a Condensing Economizer
Boilers equipped with condensing economizers can have an overall efficiency that exceeds 90%. A condensing economizer can increase overall heat recovery and steam system efficiency by up to 10% by reducing the flue gas temperature below its dew point and improves the effectiveness of waste heat recovery and fall under 2 categories. An indirect contact condensing economizer removes heat from hot flue gases by passing them through one or more shell-and-tube or tubular heat exchangers. A direct contact condensing economizer consists of a vapor-conditioning chamber followed by a countercurrent spray chamber. In the spray chamber, the cool liquid come into direct contact with the hot flue gas, providing a non-fouling heat transfer surface
