When it comes to energy managementfinely tuning fuel use can have a dramatic impact on the bottom line.
Maxsysa company based in WalsallEnglandhas developed a novel fuel treatment system based on this and is achieving some notable successes across different industrial sectors.
The Fuel+ fuel treatment system improves combustion by applying a finely calibrated magnetic field directly on the fuel. The unit is installed directly into gas or oil fuel lines and can be installed either horizontally or vertically into the existing pipework. With no moving parts and no electrical supply requirementMaxsys says the design and high standard of engineering guarantee optimum long-term reliability. The technology can be used with high- or low-pressure fuel supplies. In the case of heavy fuel oilsthe systems are designed and manufactured to withstand temperatures up to 140°C.
One of the latest companies to adopt the technology is frozen food specialist Findus. The installation of the Fuel+ system at its Benton Lane plant in Newcastle has reduced by 6.6percent the amount of natural gas consumed by the three boilers there – a payback on the original investment of just 12months (Fig.1).
The plant employs 400 people and frozen food manufacture is its core business. To provide steam generation for both processes and heatingthe plant uses three DanksMOD125 Metric boilers all running with SaackeCG40-4960 burners. Fuelled by natural gasuntil recently annual consumption stood at approximately 2.4mcubicmetres.
Maxsys contacted Findus to describe the service and benefits on offer through the adoption of Fuel+.
"Fuel+ looked to be a ‘win/win’ situationwhere this proven technology offered a saving of at least five per cent typically" said company spokesman Kevin Prior. "As it turns outtrials and calculations conducted before and after the installation of Fuel+ concluded that we had gained a 6.6percent reduction in gas consumption. Naturally we are delighted with this outcome and it will enable us to achieve payback within 12 months. The reduction in carbon dioxide output is also welcome (Fig.2). The site is constantly seeking ways to reduce our environmental impact as part of our Climate Change Levy agreement."
The same solution has also been chosen by DSSmith Specialty Packaging for its plant in LauncestonCornwall. Established for 40yearsthe Launceston facility is part of the £1.7billion DSSmith international group and is a hybrid plant manufacturing both conventional packaging and speciality packs. It claims to be the UK’s foremost corrugated packaging manufacture. Products include high volume cardboard transit cases as well as specialitydecorative and heavy-duty packaging.
"With the cost of energy escalating massively and the increasing need to reduce carbon footprintit seemed sensible to stage a review of our boiler plant" explained quality manager Steve Porter. "I’d retained a mail drop from Maxsys about Fuel+ a few months earlier and I decided to give them a call."
The ISO9001:2000 and ISO14001-accredited company runs two ageing Danks gas-firedsteam-raising boilers at Launcestonwhich are used for both general heating and process heat.
"The results have been fantastic. Not only have we reduced our carbon emissions by cutting gas consumption by 5.8percentwe have also made substantial financial savings in the 12months since installation" said Porter.
A test protocolfor the assessment of the boiler plant performance with and without Fuel+ technology in placewas produced and agreed by both parties. Meter readings were then gathered three times a day by DS Smith Speciality Packaging for the duration of the test protocol period. The evaluation was based on the established CUSUM statistical model with regenerative analysis. The results identified that average gas consumption was 5.8percent lower following installation of the Fuel+ systems.
The new technology also helped the Cornwall plant carry off the top prize in the paper and packaging category of the National Green Apple Awards that recognise environmental achievement. The facility won the prize for reducing emissions to airwater and ground as well as working closely with local residents on environmental issues.
The third site to benefit from this technology is the First Milk Cheese Company's Haverfordwest creamery. Herethe Fuel+ energy saving systems on its three oil fired steam-raising boilers have led to a 7.5percent fuel consumption saving and a return-on-investment in less than one year.
First Milk is the UK’s largest dairy farming co-operative. The £500million turnover business has three operating divisions: milkcheese and ingredients. The First Milk Cheese Company is the largest UK-based cheese supplier with a 35percent share of the Cheddar market.
"We are always looking for ways to improve the efficiency of our operations" said general manager Paul Rowe. "With ever increasing energy costs to satisfy the demand for process steam we looked at installing fuel saving technology at the site."
The Haverfordwest creamery has been operational since 1930 and began cheese production in the 1960s. Currently the site manufactures over 20000tonnes of cheese for a number of major retail customers in addition to 35000tonnes of whey products.
Following a site survey by Maxsys and subsequent receipt of a proposalthe company looked at the advantages of fitting Fuel+ energy saving systems to its three heavy fuel oil fired steam-raising boilers at Haverfordwest.
The Haverfordwest creamery houses one Ruston Thermax boiler rated at 25000lb/h and two fully packaged ByworthYSZ11250 boilers rated at 25000lb/h. All three are fired on heavy fuel oil. The plant operates 24/7 with all of the boilers on-line to cover periods of high demand. Maxsys supplied and fitted three bespoke Fuel+ systems to each of the boilers. Fuel metering was already in place but water meters required installing prior to the project commencing.
Fuel meter readings were gathered three times a day by First Milk for the duration of the project. The results identified that average oil consumption was 7.5percent lower than predicted when the Fuel+ systems were installed.
"The project was put together on the basis that it would provide a significant return on the capital invested and in fact the project paid back in just under a year" said Rowe. "Maxsys guaranteed that First Milk would save a minimum of five per cent on our fuel spendso naturally we are delighted with the actual result of 7.5 per cent and it fully justifies the decision we made to ask Maxsys to work with us. The dairy industry is extremely competitiveand it's crucial that we invest in the lastest technology to maintain our leading position. First Milk is also clearly leading the way in investments to reduce energy and carbon dioxide emissions. We have our own environmental targets to meet and this project has provided a significant boost.
"
