Heavy Oil Makes Way for Liquid Natural Gas
Energy hungry manufacturers reliant on heavy fuel oil now have an alternative to natural gas. Innovations in LNG and burner technology enable off grid industries to increase efficiency, reduce emissions and running costs.
Problem
Our client is a prestigious manufacturer supplying high performance nutrition products to the global market.
At their production facility in Wales, manufacturing demand is 24 hours thus a continuous steam load is critical. Due to location, site could not utilise natural gas, instead the primary fuel was heavy fuel oil (HFO). Site relied on outdated boiler and burner technology, coupled with the increasing costs of HFO resulted in an opportunity to provide considerable savings
Synopsis
Outdated burner technology (rotary cup)
Inefficient boiler (converted coal/twin furnace)
Rising cost of HFO
High sulphur emissions
Poor burner turndown (3.5:1)
Increased maintenance costs
Significant cost and energy losses
Solution
The utilisation of liquid natural gas (LNG) as an alternative for mains gas..
Bringing a cost effective solution the LNG infrastructure consisted of 42tonne capacity facility which was installed on site. JBC then began the two phase project consisting of replacing the boilers and burners.
Phase 1 – Standby boiler retrofitted with dual fuel Oilon GKP-1200-M Monox burner with combustion head optimisation. Ecosafe digital combustion controls and inverter drive.
Phase 2 – Decommission and removal of the redundant coal boiler, replaced with 16T/hr package steam boiler with flue gas economiser, Oilon GKP-1200-M Monox dual fuel burner & Ecosafe digital combustion controls.
The mechanical and electrical elements were completed within a three week window. This swift turnaround ensured disruption to production was minimised and emphasised the refined project management skills of JBC’s install team.
The Results
- Burner turndown improved (8:1) LNG (4:1) diesel
- Electrical savings
- Improved overall operating efficiency
- Reduced maintenance costs
- Significantly reduction in fuel consumption
- Abolished harmful sulphur emissions
- Compliance with BG01 (Arr2)
Conclusion
This versatile solution delivers modern boiler and burner technology within an industry that is heavily geared to meet production demands. The challenge was to implement a new era within industry through LNG as a solution to those manufacturers who are ‘off grid’. Through technology and experience, JBC with the help of its chosen gas supply partner delivered the largest commercial LNG installation in the UK without disrupting critical manufacturing production
It is also predicted that the changes under the Industrial Emissions Directive (IED) for the Medium Combustion Plant Directive (MCP) will make HFO a fuel that is no longer a viable alternative and unable to meet the stringent emissions limits that are likely to be imposed over the next few years, without significant investment.
www.jbcindserv.co.uk 0113 220 3830
