Utilities Optimized will guarantee
to document and assist with the implementation of at least one initiative that will provide greater than 100% pay-back of the evaluation cost, or the evaluation fee will be waived.

 

BOILER SYSTEM WATER MASS BALANCE REVIEWS:

The operating cost profile of any heating or cooling system is directly related to understanding the thermal losses in the plant and also the utilization of water. It is critical that every component of the system maximize its usage of the water before it is directed to the next user or discharged to sewer.

By performing a detailed study of the impurities in the various water streams, cycles of concentration can be monitored and more importantly, scale forming impurities tracked to ensure they are at their maximum concentrations before water is released from the system.

Utilities Optimized utilizes and independent water testing laboratory to track the impurity loadings in various treated water streams to ensure that maximum concentrations are achieved and adequate chemical inhibition treatments are present.

Through this study process, simple cross checking of routine water treatrment field test processes can be applied to ensure their accuracy and a focus of continual improvement is realized.

BLOWDOWN HEAT RECOVERY
AND BOILER FEEDWATER SYSTEM MODIFICATION
IMPROVE ACCESSIBILITY AND REDUCE OPERATING COSTS

A major feedmill operation in South Western Ontario needed to improve their Boiler Room layout to improve accessibility to major equipment. Utilities Optimized was retained to redesign the boiler feedwater system and install a Blowdown Heat Recovery system.

The existing horizontal boiler feedwater tank was replaced with a vertical stainless steel unit. Boiler feedwater pumps were relocated from underneath the existing tank to grade level beside the new feedwater tank. All electrical panels were mounted on the wall behind the pumps, allowing easy access to all components. The Blowdown Heat Recovery system was installed in place of the existing blowdown flash chamber and well water cooling system. Flash steam from the Blowdown Heat Recovery system was routed to the new boiler feedwater tank and injected below the normal water level with a stainless steel steam muffler system.

Picture illustrates initial boiler feedwater system and blowdown flash chamber. Boiler feedwater pumps were located underneath existing tank with electrical panels in front making accessibility extremely difficult.

Second picture shows new layout of the boiler feedwater system and Blowdown Heat Recovery system. All components are on grade level with ample open space around each section for easy access and maintenance. Flash steam comes off top of Blowdown Heat Recovery unit via 1-inch line to steam muffler.

Make-up water is routed through storage section of Blowdown Heat Recovery tank, picking up thermal energy normally lost to sewer.

Make-up water temperature has increased from 55oF to over 110oF, consistently. Boiler feedwater temperature has increased and average of 30oF with less steam flow from the steam heater system. Blowdown water going to sewer averages 75 - 80oF with no additional water consumption.

Overall savings have been calculated to be greater than $11,000 annually as a result of the Blowdown Heat Recovery system. (BHR-15)

CASE HISTORY

Water Mass Balance Evaluation – Utility Plant

Utilities Optimized personnel were request by a regional natural gas supplier to provide a detailed water mass balance evaluation of a Utility Plant in the Niagara area. The gas supplier would be responsible for detailed combustion studies and a third consulting engineer was responsible for electrical and gas consumption evaluation and compiling the final report.

The plant utilizes Welland Canal water, which is essentially considered “free”. An arbitrary “pumping cost” of $0.10 per cubic meter was assessed to provide a basis for evaluating subsequent treatment costs.

Utilities Optimized was charged with determining the flow pattern through the site, document operating costs associated with each aspect of treatment and provide a concise evaluation of water consumption, system losses, current boiler blowdown losses and projections on savings initiatives.

Based on the treatment process and associated losses, for regeneration, chemicals, leaking pump seals etc., the cost of boiler feedwater was determined to be 146% more expensive than the “free” influent canal water. This increase in cost provided justification for what was considered minor/insignificant repairs and also more appropriately designed heat recovery. Additional savings initiatives in regenerant water recovery were identified for future consideration.

The attached schematic roughly defines the steam plant water path. Utilities Optimized personnel also performed a thermal evaluation and several heat recovery initiatives were further documented. The final report was incorporated into a detailed Project Study Report. This report is being utilized as part of the basis for determining whether this site is a candidate for co-generation and also a Utility Site, selling both steam and electrical power to the main site user.